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Pneumatic CPS 350-12, CPS 400-7, CPS 450-14 Instruction Manual EnglishInstruction Manual For Portable Compressors CPS 350-12 WUX CPS 400-7 WUX CPS 450-14 WUX Original instructions Printed matter No. 9829 3701 18 Chicago CHICAGO PNEUMATIC - PORTABLE ENERGY DIVISION 02/2023 Pneumatic www.cp.comWarranty and Liability Limitation Use only authorized parts. Any damage or malfunction caused by the use of unauthorized parts is not covered by Warranty or Product Liability. The manufacturer does not accept any liability for any damage arising from modifications, additions or conversions made without the manufacturer's approval in writing. Neglecting maintenance or making changes to the setup of the machine can result in major hazards, including fire risk. While every effort has been made to ensure that the information in this manual is correct, Chicago Pneumatic does not assume responsibility for possible errors. Copyright 2023, Chicago Pneumatic (Wuxi) Compressor Co., Ltd. Any unauthorized use or copying of the contents or any part thereof is prohibited. This applies in particular to trademarks, model denominations, part numbers and drawing. Chicago Pneumatic 4Preface Table of contents 4.5 During operation 29 Please read the following instructions carefully 4.6 Regularly carry out following checks: 29 before starting to use your machine. Follow the 1 Safety precautions 7 instructions in this booklet and we guarantee you 5 Maintenance 30 1.1 Introduction 7 years of troublefree operation. 5.1 1.2 8 Liability 30 General safety precautions Always keep the manual available near the machine. 5.2 1.3 In all correspondence always mention the Safety during transport and installation 9 Service packs 30 5.3 compressor type and serial number, shown on the 1.4 Safety during use and operation 10 Use of service packs 30 data plate. 5.4 Service kits 30 1.5 Safety during maintenance and repair 11 5.5 The company reserves the right to make changes 1.6 Tool applications safety Storage 30 12 without prior notice. 5.6 Preventive maintenance schedule for the 1.7 Specific safety precautions 13 compressor 31 2 Leading particulars 14 5.7 Oil specifications 35 2.1 General description 14 5.7.1 Compressor oil 35 5.7.2 Engine oil 35 3 Main parts 16 5.8 Oil level check 36 3.1 Compressor regulating system 18 5.9 Check engine oil level 36 3.1.1 Overview (load condition) 18 5.10 Check compressor oil level 36 3.1.2 Air flow 20 5.11 Oil and oil filter change 36 3.1.3 Oil system 20 5.11.1 Engine oil and oil filter change 36 3.1.4 Continuous regulating system 21 5.11.2 Compressor oil and oil filter change 37 3.2 Markings and information labels 23 5.12 Coolant specifications 38 5.13 Coolant check 39 4 Operating instructions 24 5.13.1 Topping up without draining from the 4.1 Parking, towing and lifting instructions 24 cooling system 40 4.1.1 Parking instructions 24 5.13.2 Topping up after limited quantity 4.1.2 Towing instructions 25 draining from the cooling system 41 4.1.3 Height adjustment 26 5.13.3 Replacing the coolant 42 4.2 Instructions ball coupling (option) 27 5.14 Cleaning coolers 42 4.2.1 Coupling 27 5.15 4.2.2 Uncoupling 27 Battery care 43 5.15.1 Electrolyte 43 4.3 Lifting instructions 27 5.16 Activating a dry-charged battery 43 4.4 Starting/Stopping 28 5.16.1 Recharging a battery 43 4.4.1 Before starting 28 5.16.2 Battery maintenance 43 5 Chicago Pneumatic5.16.3 Compressor element overhaul 43 11 Preheater (option) 63 11.0.1 Operation 64 6 Adjustments and servicing procedures 44 11.0.2 Problem solving 65 6.0.1 Adjustment of the continuous regulating system 44 12 Technical specifications 66 6.1 Air filter engine/compressor 46 12.1 Torque values 66 6.1.1 Cleaning the dust trap 46 12.1.1 For general applications 66 6.1.2 Recommendations 46 12.1.2 Critical torque values 66 6.1.3 Replacing the air filter element 46 6.2 Air receiver 46 13 Compressor / Engine Specifications 67 13.0.1 Reference conditions 67 6.3 Safety valve 46 13.0.2 Limitations 67 6.4 Fuel system 47 13.0.3 Performance data 68 6.5 Brake (option) adjustment 47 13.0.4 Engine 69 6.6 Brake shoe adjustment 47 13.0.5 Altitude unit performance curves 72 6.6.1 Test procedure of brake cable 13.0.6 Electrical system 74 adjustment 48 6.6.2 Brake cable adjustment 49 14 Data plate 77 6.7 Wheels 50 6.7.1 Wheel check 50 15 Disposal 78 6.7.2 Lubrication 50 15.1 General 78 6.7.3 Wheel bolts check 51 15.2 Disposal of materials 78 6.7.4 Wheel bearing adjustment 52 6.8 Towbar and overrun brake 53 16 Maintenance log 79 6.8.1 Towbar and overrun brake check 53 6.8.2 Lubrication 54 7 Problem solving 56 8 Available options 60 9 Cold start (option) 61 9.1 Ambient temperature limit 61 10 Anti-corrosion (option) 62 Chicago 6 PneumaticSafety precautions Personal protective equipments To be read attentively and acted accordingly before towing, lifting, operating, performing maintenance or repairing the unit. INTRODUCTION The policy of Chicago Pneumatic is to provide the These safety precautions are general and some An electrical technician is trained and has the same users of their equipment with safe, reliable and statements will therefore not always apply to a qualifications as both the operator and the mechanical efficient products. Factors taken into account are particular unit. technician. In addition, the electrical technician may among others: Only people that have the right skills should be carry out electrical repairs within the various - the intended and predictable future use of the allowed to operate, adjust, perform maintenance or enclosures of the unit. This includes work on live products, and the environments in which they are repair on Chicago Pneumatic equipment.It is the electrical components. expected to operate, responsibility of management to appoint operators Skill level 4: Specialist from the manufacturer - applicable rules, codes and regulations, with the appropriate training and skill for each This is a skilled specialist sent by the manufacturer or - the expected useful product life, assuming proper category of job. its agent to perform complex repairs or modifications service and maintenance, Skill level 1: Operator to the equipment. - providing the manual with up-to-date information. An operator is trained in all aspects of operating the In general it is recommended that not more than two unit with the push-buttons, and is trained to know the people operate the unit, more operators could lead to Before handling any product, take time to read the safety aspects. unsafe operating conditions. relevant instruction manual. Besides giving detailed Skill level 2: Mechanical technician Take necessary steps to keep unauthorized persons operating instructions, it also gives specific A mechanical technician is trained to operate the unit away from the unit and eliminate all possible sources information about safety, preventive maintenance, etc. the same as the operator. In addition, the mechanical of danger at the unit. technician is also trained to perform maintenance and When handling, operating, overhauling and/or Keep the manual always at the unit location, easy repair, as described in the instruction manual, and is performing maintenance or repair on Chicago accessible to the operating personnel. allowed to change settings of the control and safety Pneumatic equipment, the mechanics are expected to See also the safety precautions of the engine and system. A mechanical technician does not work on use safe engineering practices and to observe all possible other equipment, which are separately sent live electrical components. relevant local safety requirements and ordinances. along or are mentioned on the equipment or parts of Skill level 3: Electrical technician The following list is a reminder of special safety the unit. directives and precautions mainly applicable to 7 - Chicago PneumaticChicago Pneumatic equipment. GENERAL SAFETY PRECAUTIONS 9 Care shall be taken to avoid damage to safety These safety precautions apply to machinery valves and other pressure-relief devices, processing or consuming air. Processing of any other 1 The owner is responsible for maintaining the unit especially to avoid plugging by paint, oil coke or gas requires additional safety precautions typical to in a safe operating condition. Unit parts and dirt accumulation, which could interfere with the the application and are not included herein. accessories must be replaced if missing or functioning of the device. unsuitable for safe operation. Neglecting the safety precautions may endanger 10 Pressure and temperature gauges shall be checked people as well as environment and machinery: 2 The supervisor, or the responsible person, shall at regularly with regard to their accuracy. They shall all times make sure that all instructions regarding - endanger people due to electrical, mechanical or be replaced whenever outside acceptable machinery and equipment operation and tolerances. chemical influences, maintenance are strictly followed and that the - endanger the environment due to leakage of oil, 11 Safety devices shall be tested as described in the machines with all accessories and safety devices, solvents or other substances, maintenance schedule of the instruction manual as well as the consuming devices, are in good - endanger the machinery due to function failures. to determine that they are in good operating repair, free of abnormal wear or abuse, and are condition. See the Preventive maintenance All responsibility for any damage or injury resulting not tampered with. schedule for the compressor. from neglecting these precautions or by non- 3 Whenever there is an indication or any suspicion observance of ordinary caution and due care required 12 Mind the markings and information labels on the that an internal part of a machine is overheated, unit. in handling, operating, maintenance or repair, also if the machine shall be stopped but no inspection not expressly mentioned in this instruction manual, is covers shall be opened before sufficient cooling 13 In the event the safety labels are damaged or disclaimed by Chicago Pneumatic. The manufacturer time has elapsed; this to avoid the risk of destroyed, they must be replaced to ensure does not accept any liability for any damage arising spontaneous ignition of oil vapour when air is operator safety. from the use of non-original parts and for admitted. 14 Keep the work area neat. Lack of order will modifications, additions or conversions made without 4 Normal ratings (pressures, temperatures, speeds, increase the risk of accidents. the manufacturer's approval in writing. etc.) shall be durably marked. 15 When working on the unit, wear safety clothing. If any statement in this manual does not comply with 5 Operate the unit only for the intended purpose and Depending on the kind of activities these are: local legislation, the stricter of the two shall be within its rated limits (pressure, temperature, safety glasses, ear protection, safety helmet applied. speeds, etc.). (including visor), safety gloves, protective Statements in these safety precautions should not be clothing, safety shoes. Do not wear the hair long 6 The machinery and equipment shall be kept clean, interpreted as suggestions, recommendations or and loose (protect long hair with a hairnet), or i.e. as free as possible from oil, dust or other inducements that it should be used in violation of any wear loose clothing or jewellery. deposits. applicable laws or regulations. 16 Take precautions against fire. Handle fuel, oil and 7 To prevent an increase in working temperature, anti-freeze with care because they are inspect and clean heat transfer surfaces (cooler inflammable substances. Do not smoke or fins, intercoolers, water jackets, etc.) regularly. See the Preventive maintenance schedule for approach with naked flame when handling such substances. Keep a fire-extinguisher in the the compressor. vicinity. 8 All regulating and safety devices shall be maintained with due care to ensure that they function properly. They may not be put out of action. Chicago Pneumatic 8 -SAFETY DURING TRANSPORT AND - check that the wheels are secure and that the 7 Lifting hooks, eyes, shackles, etc., shall never be INSTALLATION tyres are in good condition and inflated bent and shall only have stress in line with their correctly, design load axis. The capacity of a lifting device Transport of the unit has to be done by authorized/ - connect the signalisation cable, check all lights diminishes when the lifting force is applied at an experienced people. and connect the pneumatic brake couplers, angle to its load axis. When towing, lifting or transporting the compressor ascertain that the signalisation cable can not 8 For maximum safety and efficiency of the lifting in any way, the battery switch must always be drag on the ground when towing the unit, apparatus all lifting members shall be applied as switched off. - attach the safety break-away cable or safety near to perpendicular as possible. If required, a To lift a unit, all loose or pivoting parts, e.g. doors and chain to the towing vehicle, lifting beam shall be applied between hoist and load. towbar, shall first be securely fastened. - remove wheel chocks, if applied, and Do not attach cables, chains or ropes directly to the disengage the parking brake, 9 Never leave a load hanging on a hoist. lifting eye; apply a crane hook or lifting shackle - check whether springs on wheelchocks are 10 A hoist has to be installed in such a way that the meeting local safety regulations. Never allow sharp missing or broken. object will be lifted perpendicular. If that is not bends in lifting cables, chains or ropes. possible, the necessary precautions must be taken 2 To tow a unit use a towing vehicle of ample Helicopter lifting is not allowed. to prevent load-swinging, e.g. by using two capacity. Refer to the documentation of the hoists, each at approximately the same angle not It is strictly forbidden to dwell or stay in the risk zone towing vehicle. exceeding 30° from the vertical. under a lifted load. Never lift the unit over people or 3 If the unit is to be backed up by the towing residential areas. Lifting acceleration and retardation 11 Locate the unit away from walls. Take all vehicle, disengage the overrun brake mechanism shall be kept within safe limits. precautions to ensure that hot air exhausted from (if it is not an automatic mechanism). the engine and driven machine cooling systems 1 Before towing the unit: 4 Never exceed the maximum towing speed of the cannot be recirculated. If such hot air is taken in - ascertain that the pressure vessel(s) is (are) unit (mind the local regulations). by the engine or driven machine cooling fan, this depressurized, 5 Place the unit on level ground and apply the may cause overheating of the unit; if taken in for - check the towbar, the brake system and the parking brake before disconnecting the unit from combustion, the engine power will be reduced. towing eye. Also check the coupling of the the towing vehicle. Unclip the safety break-away towing vehicle, cable or safety chain. If the unit has no parking - check the towing and brake capability of the brake or jockey wheel, immobilize the unit by towing vehicle, placing chocks in front of and/or behind the wheels. When the towbar can be positioned - check that the towbar, jockey wheel or stand vertically, the locking device must be applied and leg is safely locked in the raised position, kept in good order. The unit must always be used/ - keep hands/fingers away from the coupling parked/stored in a non publicly accessible area, device and all other potential pinch points. locked away from access by unauthorized Keep feet away from the towbar to avoid persons. injury if it should slip, 6 To lift heavy parts, a hoist of ample capacity, - ascertain that the towing eye can swivel freely tested and approved according to local safety on the hook, regulations, shall be used. 9 - Chicago PneumaticSAFETY DURING USE AND OPERATION 8 Do not use compressed air from any type of effective. A door should be kept open for a short compressor, without taking extra measures, for period only e.g. for inspection or adjustment. 1 When the unit has to operate in a fire-hazardous breathing purposes as this may result in injury or 15 Periodically carry out maintenance works environment, each engine exhaust has to be death. For breathing air quality, the compressed according to the maintenance schedule. provided with a spark arrestor to trap incendiary air must be adequately purified according to local sparks. legislation and standards. Breathing air must 16 Stationary housing guards are provided on all 2 The exhaust contains carbon monoxide which is a always be supplied at stable, suitable pressure. rotating or reciprocating parts not otherwise protected and which may be hazardous to lethal gas. When the unit is used in a confined 9 Distribution pipework and air hoses must be of personnel. Machinery shall never be put into space, conduct the engine exhaust to the outside correct diameter and suitable for the working operation, when such guards have been removed, atmosphere by a pipe of sufficient diameter; do pressure. Never use frayed, damaged or before the guards are securely reinstalled. this in such a way that no extra back pressure is deteriorated hoses. Replace hoses and flexibles created for the engine. If necessary, install an before the lifetime expires. Use only the correct 17 Noise, even at reasonable levels, can cause extractor. Observe any existing local regulations. type and size of hose end fittings and connections. irritation and disturbance which, over a long Make sure that the unit has sufficient air intake period of time, may cause severe injuries to the 10 If the compressor is to be used for sand-blasting for operation. If necessary, install extra air intake nervous system of human beings. When the sound or will be connected to a common compressed-air ducts. pressure level, at any point where personnel system, fit an appropriate non-return valve (check normally has to attend, is: 3 When operating in a dust-laden atmosphere, place valve) between compressor outlet and the the unit so that dust is not carried towards it by the connected sand-blasting or compressed-air - below 70 dB(A): no action needs to be taken, wind. Operation in clean surroundings system. Observe the right mounting position/ - above 70 dB(A): noise-protective devices considerably extends the intervals for cleaning direction. should be provided for people continuously the air intake filters and the cores of the coolers. being present in the room, 11 Before removing the oil filler plug, ensure that the 4 Close the compressor air outlet valve before pressure is released by opening an air outlet - below 85 dB(A): no action needs to be taken connecting or disconnecting a hose. Ascertain valve. for occasional visitors staying a limited time that a hose is fully depressurized before only, 12 Never remove a filler cap of the cooling water disconnecting it. Before blowing compressed air system of a hot engine. Wait until the engine has - above 85 dB(A): room to be classified as a through a hose or air line, ensure that the open end sufficiently cooled down. noise-hazardous area and an obvious warning is held securely, so that it cannot whip and cause shall be placed permanently at each entrance injury. 13 Never refill fuel while the unit is running, unless to alert people entering the room, for even 5 The air line end connected to the outlet valve otherwise stated in the Chicago Pneumatic relatively short times, about the need to wear must be safeguarded with a safety cable, attached Instruction Book (AIB). Keep fuel away from hot ear protectors, next to the valve. parts such as air outlet pipes or the engine - above 95 dB(A): the warning(s) at the exhaust. Do not smoke when fuelling. When 6 No external force may be exerted on the air outlet entrance(s) shall be completed with the fuelling from an automatic pump, an earthing valves, e.g. by pulling on hoses or by installing recommendation that also occasional visitors cable should be connected to the unit to discharge auxiliary equipment directly to a valve, e.g. a static electricity. Never spill nor leave oil, fuel, shall wear ear protectors, water separator, a lubricator, etc. Do not step on coolant or cleansing agent in or around the unit. - above 105 dB(A): special ear protectors that the air outlet valves. are adequate for this noise level and the 7 Never move a unit when external lines or hoses 14 All doors shall be shut during operation so as not spectral composition of the noise shall be to disturb the cooling air flow inside the are connected to the outlet valves, to avoid provided and a special warning to that effect bodywork and/or render the silencing less damage to valves, manifold and hoses. shall be placed at each entrance. Chicago Pneumatic 1018 The unit has parts, which may be accidentally 25 Remember that where there is visible dust, the SAFETY DURING MAINTENANCE AND touched by personal, of which the temperature finer, invisible particles will almost certainly be REPAIR can be in excess of 80°C (176°F). The insulation present too; but the fact that no dust can be seen or safety guard, protecting these parts shall not be is not a reliable indication that dangerous, Maintenance, overhaul and repair work shall only be removed before the parts have cooled down to invisible dust is not present in the air. carried out by adequately trained personnel; if room temperature. As it is technically not 26 Never operate the unit at pressures or speeds required, under supervision of someone qualified for possible to insulate all hot parts or to install safety below or in excess of its limits as indicated in the the job. guards around hot parts (e.g. exhaust manifold, technical specifications. 1 Use only the correct tools for maintenance and exhaust turbine), the operator / service engineer repair work, and only tools which are in good must always be aware not to touch hot parts when condition. opening a machine door. 2 Parts shall only be replaced by genuine Chicago 19 Never operate the unit in surroundings where Pneumatic replacement parts. there is a possibility of taking in flammable or toxic fumes. 3 All maintenance work, other than routine attention, shall only be undertaken when the unit 20 If the working process produces fumes, dust or is stopped. Steps shall be taken to prevent vibration hazards, etc., take the necessary steps to inadvertent starting. In addition, a warning sign eliminate the risk of personal injury. bearing a legend such as "work in progress; do 21 When using compressed air or inert gas to clean not start" shall be attached to the starting down equipment, do with caution and use the equipment. On engine-driven units the battery appropriate protection, at least safety glasses, for shall be disconnected and removed or the the operator as well as for any bystander. Do not terminals covered by insulating caps. On apply compressed air or inert gas to your skin or electrically driven units the main switch shall be direct an air or gas stream at people. Never use it locked in open position and the fuses shall be to clean dirt from your clothes. taken out. A warning sign bearing a legend such 22 When washing parts in or with a cleaning solvent, as "work in progress; do not supply voltage" shall provide the required ventilation and use be attached to the fuse box or main switch. appropriate protection such as a breathing filter, 4 Before dismantling any pressurized component, safety glasses, rubber apron and gloves, etc. the compressor or equipment shall be effectively 23 Safety shoes should be compulsory in any isolated from all sources of pressure and the entire workshop and if there is a risk, however small, of system shall be relieved of pressure. Do not rely falling objects, wearing of a safety helmet should on non-return valves (check valves) to isolate be included. pressure systems. In addition, a warning sign 24 If there is a risk of inhaling hazardous gases, bearing a legend such as "work in progress; do fumes or dust, the respiratory organs must be not open" shall be attached to each of the outlet valves. protected and depending on the nature of the hazard, so must the eyes and skin. 5 Prior to stripping an engine or other machine or undertaking major overhaul on it, prevent all movable parts from rolling over or moving. 11 Chicago Pneumatic6 Make sure that no tools, loose parts or rags are left 15 Protect the engine, alternator, air intake filter, 22 Make sure that oil, solvents and other substances in or on the machine. Never leave rags or loose electrical and regulating components, etc., to likely to pollute the environment are properly clothing near the engine air intake. prevent moisture ingress, e.g. when steam- disposed of. 7 Never use flammable solvents for cleaning (fire- cleaning. 23 Before clearing the unit for use after maintenance risk). 16 When performing any operation involving heat, or overhaul, check that operating pressures, 8 Take safety precautions against toxic vapours of flames or sparks on a machine, the surrounding temperatures and speeds are correct and that the cleaning liquids. components shall first be screened with non- control and shutdown devices function correctly. flammable material. 9 Never use machine parts as a climbing aid. 17 Never use a light source with open flame for TOOL APPLICATIONS SAFETY 10 Observe scrupulous cleanliness during inspecting the interior of a machine. maintenance and repair. Keep away dirt, cover 18 When repair has been completed, the machine Check the maximum pressure of the tool the parts and exposed openings with a clean cloth, shall be barred over at least one revolution for and hoses against maximum vessel paper or tape. reciprocating machines, several revolutions for pressure. 11 Never weld on or perform any operation rotary ones to ensure that there is no mechanical involving heat near the fuel or oil systems. Fuel interference within the machine or driver. Check Apply the proper tool for each job. With the and oil tanks must be completely purged, e.g. by the direction of rotation of electric motors when knowledge of correct tool use and knowing the steam-cleaning, before carrying out such limitations of tools, along with some common sense, starting up the machine initially and after any operations. Never weld on, or in any way modify, alteration to the electrical connection(s) or switch many accidents can be prevented. pressure vessels. Disconnect the alternator cables gear, to check that the oil pump and the fan Special service tools are available for specific jobs during arc welding on the unit. function properly. and should be used when recommended. The use of 12 Support the towbar and the axle(s) securely if these tools will save time and prevent damage to 19 Maintenance and repair work should be recorded working underneath the unit or when removing a in an operator's logbook for all machinery. parts. wheel. Do not rely on jacks. Frequency and nature of repairs can reveal unsafe 13 Do not remove any of, or tamper with, the sound- conditions. damping material. Keep the material free of dirt 20 When hot parts have to be handled, e.g. shrink and liquids such as fuel, oil and cleansing agents. fitting, special heat-resistant gloves shall be used If any sound-damping material is damaged, and, if required, other body protection shall be replace it to prevent the sound pressure level from applied. increasing. 21 When using cartridge type breathing filter 14 Use only lubricating oils and greases equipment, ascertain that the correct type of recommended or approved by Chicago cartridge is used and that its useful service life is Pneumatic or the machine manufacturer. not surpassed. Ascertain that the selected lubricants comply with all applicable safety regulations, especially with regard to explosion or fire-risk and the possibility of decomposition or generation of hazardous gases. Never mix synthetic with mineral oil. Chicago Pneumatic 12SPECIFIC SAFETY PRECAUTIONS Pressure vessels Safety valves (according to directive 87/404/EEC annex II 2) All adjustments or repairs are to be done by an Batteries Maintenance/installation requirements: authorized representative of the valve supplier (see When servicing batteries, always wear protecting also Preventive maintenance schedule for the clothing and glasses. 1 The vessel can be used as pressure vessel or as compressor). separator and is designed to hold compressed air 1 The electrolyte in batteries is a sulphuric acid for the following application: solution which is fatal if it hits your eyes, and which can cause burns if it contacts your skin. - pressure vessel for compressor, Therefore, be careful when handling batteries, - medium AIR/OIL, e.g. when checking the charge condition. and operates as detailed on the data plate of the 2 Install a sign prohibiting fire, open flame and vessel: smoking at the post where batteries are being - the maximum working pressure ps in bar (psi), charged. - the maximum working temperature Tmax in 3 When batteries are being charged, an explosive °C (°F), gas mixture forms in the cells and might escape - the minimum working temperature Tmin in °C through the vent holes in the plugs. Thus an (°F), explosive atmosphere may form around the battery if ventilation is poor, and can remain in - the capacity of the vessel V in 1 (US gal). and around the battery for several hours after it 2 The pressure vessel is only to be used for the has been charged. Therefore: applications as specified above and in accordance with the technical specifications. Safety reasons - never smoke near batteries being, or having prohibit any other applications. recently been, charged, 3 National legislation requirements with respect to - never break live circuits at battery terminals, re-inspection must be complied with. because a spark usually occurs. 4 No welding or heat treatment of any kind is 4 When connecting an auxiliary battery (AB) in permitted to those vessel walls which are exposed parallel to the unit battery (CB) with booster to pressure. cables: connect the + pole of AB to the + pole of CB, then connect the pole of CB to the mass of 5 The vessel is provided and may only be used with the unit. Disconnect in the reverse order. the required safety equipment such as manometer, overpressure control devices, safety valve, etc. 6 Draining of condensate shall be performed daily when vessel is in use. 7 Installation, design and connections should not be changed. 8 Bolts of cover and flanges may not be used for extra fixation. 13 Chicago PneumaticLeading particulars Description of safety pictograms used in this GENERAL DESCRIPTION Compressor manual The compressor casing houses two screw-type rotors, mounted on ball and roller bearings. The male rotor, This symbol draws your attention to driven by the engine, drives the female rotor. The ! dangerous situations. The operation element delivers pulsation-free air. concerned may endanger persons and cause injuries. Injected oil is used for sealing, cooling and lubricating purposes. This symbol is followed by Compressor oil system supplementary information. The oil is boosted by air pressure. The system has no oil pump. The oil is removed from the air, in the air/oil vessel at first by centrifugal force, secondly by the oil separator element. The vessel is provided with an oil level indicator. The compressors CPS 350-12, CPS 400-7 and CPS Regulation 450-12 are silenced, single-stage, oil-injected screw The compressor is provided with a continuous compressors, built for a nominal effective working regulating system and a blow-down valve which is pressure, ranging from 12 bar (175 psi), 7 bar integrated in the unloader assembly. The valve is (100psi), 14 bar (203 psi) (see chapter Technical closed during operation by air receiver pressure and specifications). opens by air receiver pressure via the compressor element when the compressor is stopped. Engine When the air consumption increases, the air receiver The compressors are driven by a liquid-cooled diesel pressure will decrease and vice versa. engine. This receiver pressure variation is sensed by the The engine's power is transmitted to the compressor regulating valve which, by means of control air to the through a heavy-duty coupling. unloader and engine speed regulator, matches the air output to the air consumption. The air receiver pressure is maintained between the pre-selected working pressure and the corresponding unloading pressure. Chicago Pneumatic 14Cooling system Bodywork The engine is equipped with a liquid cooler and The bodywork has openings at the shaped front and intercooler. All compressors are equipped with an oil rear end for the intake and outlet of cooling air and cooler. hinged door for maintenance and service operations. The cooling air is generated by a fan, driven by the The bodywork is internally lined with sound- engine. absorbing material. Safety devices Lifting eye A thermal shut-down switch protects the compressor A lifting eye is accessible when the small door at the against overheating. The air receiver is provided with top of the unit is unlocked. a safety valve. Control panel The engine is equipped with low oil pressure and high The control panel grouping the air pressure gauge, oil temperature shut-down switches. control switch etc., is placed in the center at the rear end. Frame and axle The compressor/engine unit is supported by rubber Data plate buffers in the frame. The compressor is furnished with a data plate The standard unit has a non-adjustable towbar with a showing the product code, the unit number and the towing eye. working pressure (see chapter Data plate). As an option the unit can be equipped with an Serial number adjustable towbar, an overrun and parking brake and towing eyes type DIN, ball, ITA, GB, NATO, AC The serial number is located on the right-hand side (France), (see chapter Available options). towards the front on the upper edge of the frame and also on the data plate. The braking system consists of an integrated parking brake and overrunbrake. When driving backwards the overrunbrake is not engaged automatically. 15 Chicago PneumaticMain parts IC S OC FF R FPco E FCc OFce AFe AFce OLG EP F FLS A OFe FCft BS FT UV C SV CE RV AR MPV AOV SL TB DP ES CP SN CP Chicago Pneumatic 16Reference Name Reference Name A Alternator FT Fuel Tank AFce Air Filter (compressor element) IC Intercooler AFe Air Filter (engine) MPV Minimum Pressure Valve AOV Air Outlet Valves OC Oil Cooler AR Air Receiver OFce Oil Filter (compressor element) B Battery OFe Oil Filter (engine) BS Battery Switch OLG Oil Level Gauge C Cubicle R Radiator CE Compressor Element RV Regulating Valve CP Control Panel S Silencer DP Data plate SL Support Leg E Engine SN Serial Number EP Exhaust Pipe SV Safety Valve ES Emergency Stop TB Towbar F Fan UV Unloading Valve FCft Filler Cap (fuel tank) FCc Filler Cap (coolant) FF Fuel Filter FLS Fuel Level Sensor FPco Filler Plug (oil compressor element) 17 Chicago PneumaticCOMPRESSOR REGULATING SYSTEM OVERVIEW (LOAD CONDITION) Air Filter Engine Air Filter Safety Cartridge Air Filter Element Air Filter Compressor Vaccum Indicator Engine Air Receiver/Oil Separator Oil Cooler Oil Separator Element Safety Valve Thermostatic Bypass Valve Regulating Valve Fan Engine Scavenge Line Oil Filter Engine Restrictor By-Pass Valve Oil Filter Minimum Pressure Valve Oil Filter Compressor Unloader Assembly Drain Plug Blow Off Valve Coupling Housing Compressor Element Air Outlet Valve Temperature Sensor Manifold Air Atmospheric Pressure Air Regulating Pressure Air Working Pressure Air/Oil Mixture Oil Chicago Pneumatic 18 -Reference Name Reference Name AFE Air Filter Element OSV/CV Oil Stop Valve / Check Valve AFc Air Filter (compressor) RPS Regulating Pressure Sensor AFe Air Filter (engine) RV Regulating Valve AOV Air Outlet Valves AFSC Ait filter Safety Cartridge AR/OS Air Receiver / Oil Separator SL Scavenge Line BOV Blow Off Valve SV Safety Valve BVof Bypass Valve oil filter TBV Thermostatic Bypass Valve CB Cubicle TS Temperature Sensor CE Compressor Element UA Unloader Assembly CH Coupling Housing VI Vacuum Indicator CU Control Unit WPS Working Pressure Sensor CV Check Valve DP Drain Plug E Engine EW Electrical Wiring F Fan LV Loading Valve MPV Minimum Pressure Valve OC Oil Cooler OFc Oil Filter (compressor) OSE Oil Separator Element 19 CP Chicago PneumaticAIR FLOW OIL SYSTEM The system comprises: The system comprises: AF Air filter AR/OS Air receiver/oil separator AR/OS Air receiver/oil separator OC Oil cooler CE Compressor element OF Oil filter UA/UV Unloader assembly with unloader valve The lower part of the air receiver (AR) serves as an oil BDV Blow-down valve tank. LV Loading valve Air pressure forces the oil from the air receiver/oil separator (AR/OS) through the oil cooler (OCce) and Air drawn through the airfilter (AFce) into the oil filter (OF) to the compressor element (CE). compressor element (CE) is compressed. At the element outlet, compressed air and oil pass into the air The compressor element has an oil gallery in the receiver/oil separator (AR/OS). bottom of its casing. The oil for rotor lubrication, cooling and sealing is injected through holes in the The check valve (CV) prevents blow-back of gallery. compressed air when the compressor is stopped. In the air receiver/oil separator (AR/OS), most of the oil Lubrication of the bearings is ensured by oil injected is removed from the air/oil mixture; the remaining oil into the bearing housings. is removed by the separator element. The injected oil, mixed with the compressed air, The oil collects in the receiver and on the bottom of leaves the compressor element and re-enters the air the separator element. receiver, where it is separated from the air as described in section Air flow. The oil that collects on The air leaves the receiver via a minimum pressure the bottom of the oil separator element is returned to valve (MPV) which prevents the receiver pressure the system through a scavenging line (SL), which is from dropping below the minimum working pressure provided with a flow restrictor (FR). (specified in section Limitations), even when the air outlet valves are open. This ensures adequate oil The oil filter by-pass valve opens when the pressure injection and prevents oil consumption. drop over the filter is above normal because of a clogged filter. The oil then by-passes the filter A temperature switch (TS) and a working pressure without being filtered. For this reason, the oil filter gauge (WPG) are comprised in the system. must be replaced at regular intervals (see section Preventive maintenance schedule for the A blow-down valve (BDV) is fitted in the unloader assembly to automatically depressurize the air compressor). receiver (AR) when the compressor is stopped. Chicago Pneumatic 20CONTINUOUS REGULATING SYSTEM Air Receiver/Oil Separator Oil Separator Element Unloader Assembly Blow Off Valve Compressor Element N Air Atmospheric Pressure Air Regulating Pressure Air Working Pressure Mixture Oil CP Chicago PneumaticThe system comprises: The air output is controlled from maximum output The construction of the regulating valve (RV) is such RV Regulating valve (100%) to no output (0%) by: that any increase (decrease) of the air receiver UA Unloader assembly 1. Speed control of the engine between maximum pressure above the pre-set valve opening pressure load speed and unloading speed (the output of a results in a proportional increase (decrease) of the SR Speed regulator screw compressor is proportional to the rotating control pressure to the unloading valve and the speed speed). regulator. The compressor is provided with a continuous regulating system. This system is provided with a 2. Air inlet throttling. Part of the control air is vented into the atmosphere, and any condensate discharged, through the vent blow-down valve, which is integrated in the unloader 3. Blow off valve (BOV). holes (VH). assembly (UA). The valve is closed during operation by air receiver pressure and opens by air receiver If the air consumption is equal to or exceeds the pressure via the compressor element when the maximum air output, the engine speed is held at compressor is stopped. maximum load speed and the unloading valve is fully open. When the air consumption increases, the air receiver pressure will decrease and vice versa. This receiver If the air consumption is less than the maximum air pressure variation is sensed by the regulating valve output, the regulating valve supplies control air to which, by means of control air to the unloader, unloader valve (UV) to reduce the air output and matches the air output to the air consumption. The air holds air receiver pressure between the normal receiver pressure is maintained between the pre- working pressure and the corresponding unloading selected working pressure and the corresponding pressure at approx. 1.5 bar (22 psi) above the normal unloading pressure. working pressure. When starting the compressor, the unloader valve When the air consumption is resumed, the blow off (UV) is kept open by spring force, the engine runs at valve (BOV) closes and the unloader valve (UV) maximum speed. The compressor element (CE) takes gradually opens the air intake and the speed regulator in air and pressure builds up inside the receiver (AR). (SR) increases the engine speed. Chicago Pneumatic 22MARKINGS AND INFORMATION LABELS Compressor outlet temperature too Hours, time. Warning! Part under pressure. high. Prohibition to open air valves without Do not stand on outlet valves. Compressor outlet temperature. connected hoses. Compressor loaded. Start-Stop indication of switch. Compressor outlet pressure. Runlamp. Do not run the compressor with open Dangerous outlet gases. doors. I Airfilter. Lifting permitted. Danger, hot surface. V Compressor temperature too high. diesel Use diesel fuel only. 4 Electrocution hazard. 7 bar Super oil Super oil. Rotation direction. (102 psi) Tyre pressure. GENOIL Genoil M, Genoil S, Genoil S Ultra. Sound power level in accordance Inlet. with Directive 2000/14/EC (expressed in dB (A)). Manual. Sound power level in accordance Outlet. with Directive 2000/14/EC (expressed in dB (A)). Read the instruction manual before working on the battery. Sound power level in accordance Compressor oil drain. with Directive 2000/14/EC (expressed in dB (A)). Reset fuse. Read the instruction manual before Horizontal towbar position required in starting. case of coupling. I On / off button. Service every 24 hours. 24h 23 Chicago PneumaticOperating instructions PARKING INSTRUCTIONS PARKING, TOWING AND LIFTING INSTRUCTIONS Safety precautions (4) (4) Never load the vehicles in excess of the ! permissible total weight. Never overstress the coupling or suspension system due to reckless or aggressive driving or mishandling. (2) (2) Avoid subjecting the axles to any impacts or jolting. Adapt your driving speed at all times to the road conditions. Ensure that wheels and tyres are not 0 misaligned or out-of-balance. (1) Only use the jacking points indicated by Non-adjustable towbar with standard support leg without Parking position of jockey wheel Chicago Pneumatic. brakes The operator is expected to apply all relevant safety precautions, including It must be noted that, with the parking (3) those mentioned on the pages 7 - 13 of ! brake activated, the vehicle can roll back this book. about 30 cm until the braking force takes full effect. Attention: When parking a compressor, secure support leg (1) or Before putting the compressor into use, jockey wheel (2) to support the compressor in a level ! check the brake system as described in position. Be sure that the jockey wheel (2) is blocked section Brake (option) adjustment. by the blocking pin (4). After the first 100 km travel - Yearly or Apply parking brake by pulling parking brake handle every 5000 km: (2) (3) upwards. Place the compressor as level as Check and retighten the wheel nuts and possible; however, it can be operated temporarily in towbar bolts to the specified torque. See an out-of-level position not exceeding 15°. If the section Height adjustment and section (4) compressor is parked on sloping ground, immobilize Torque values. the compressor by placing wheel chocks (available as Check the brake adjustment. See section option) in front of or behind the wheels. Adjustable towbar with jockey wheel and brakes Brake (option) adjustment. Chicago Pneumatic 24TOWING INSTRUCTIONS (1) (3) (2) Locate the rear-end of the compressor upwind, away Label on towbar from contaminated wind-streams and walls. Avoid recirculation of exhaust air from the engine. This Inspections, prior to each run causes overheating and engine power decrease. Check tyre pressure and tyre condition Check wheel fixation Check screwed joints on firm seating. Check functioning of lighting and braking systems (option) O The jockey wheel must be parallel to the direction of travel at all times. Inspect the coupling. The ball joint must fully enclose the ball and be locked. At height adjustable towing facility (option), check the joint connection for a tight fit. 25 - Chicago PneumaticHEIGHT ADJUSTMENT Remove spring pin (1). Before towing the compressor, ensure that the towing equipment of the vehicle (with adjustable towbar) Release locking nut (2) with support tools matches the towing eye or ball connector (Extension tube 3). and ensure that the service doors are Adjust required height of the towbar. closed and locked properly. (B) Tighten locking nut (2) by hand first. For both non-adjustable and adjustable towbar, the (A) Secondly tighten locking nut (2) with a tightening towbar should be as level as possible and the compressor and towing eye end in a level position. (3) torque corresponding to table. With an extension (2) tube (3) ("A" corresponding to table) and Push the hand brake lever (1) completely downwards handforce ("B" corresponding to table) easy and connect breakaway cable (2) to the vehicle. tightening is possible. Secure jockey wheel (3) or support leg in the highest (1) Fix locking nut (2) with spring pin (1). possible position (see figure). The jockey wheel is prevented from turning. Attention: Height adjustment should be undertaken on levelled ground and in coupled condition. Before towing the compressor, make When readjusting, make sure that the front point ! sure that the joints of the towbar are of the towbar is horizontal with the coupling secured with maximum strength without point. damaging the towbar. Be sure that there Before starting a trip, ensure that the adjustment is no clearance between the teeth of the shaft is secure, so that stability and safety is joints. guaranteed while driving. If necessary, tighten the locking nut (2) corresponding with table. For specific instruction see below Type M [Nm/lbf.ft.] "A" [mm/in] "B" [N/lbf] ZV 2000 250 300 / 184.5 221.4 600 / 23.4 420 500 / 94.5 112.5 ZV 2500 350 400 / 258.3 295.2 600 / 23.4 580 660 / 130.5 148.5 Chicago Pneumatic 26INSTRUCTIONS BALL COUPLING (OPTION) COUPLING LIFTING INSTRUCTIONS Open coupling jaw by pulling the lever vigorously upwards in the direction of the arrow. Lower the opened coupling onto the ball of the vehicle coupling and the lever will automatically be lowered. Closing and locking are carried out automatically. Check the "+" (see figure) position. Connect the breakaway cable and electrical plug (option) to the towing vehicle. Raise the jockey wheel up fully and secure by firmly clamping it. Release parking brake before setting off. Visual check: the ball should no longer be visible in coupled condition. UNCOUPLING The handle of the ball coupling and the Lower the jockey wheel. Disconnect breakaway cable When lifting the compressor, the hoist has to be handbrake lever may never be used as a and electrical plug. Pull the lever vigorously upwards placed in such a way that the compressor, which must in the direction of the arrow and hold. Wind down be placed level, is lifted vertically. Keep lifting manoeuvring aid; internal components jockey wheel (option) and lift the compressor off the acceleration and retardation within safe limits. may get damaged. ball of the towing vehicle. The lifting eye (1) should preferably be used after The coupling (ball coupling) on the tow bar is type Secure the compressor by means of a wheel chock opening the small door (2). approved. The maximum load at the coupling may not and/or by applying the parking brake. be exceeded. Lifting acceleration and retardation When coupling lower the jockey wheel to the ground. ! must be kept within safe limits (Maximum 2g). Reverse the car up to the compressor or, in the case of a small compressor, manoeuvre the compressor up to Helicopter lifting is not allowed. the car's trailer coupling. Lifting is not allowed when the unit is running. 27 Chicago PneumaticSTARTING/STOPPING CONTROL PANEL BEFORE STARTING (P1) (H1) (H2) (H3)(H4) (N4) 1. Before initial start-up, prepare battery for operation if not already done. See section Battery care. 2. With the compressor standing level, check the level of the engine oil. Add oil, if necessary, up to the upper mark on the dipstick. Consult the Engine Operation Manual for the type and viscosity grade of the engine oil. 3. Check the level of the compressor oil. See section Compressor regulating system. The pointer of the oil level gauge (OLG) should register in the green range. Add oil if necessary. See section Coolant specifications for the oil to be used. ! Before removing the oil filler plug (FP), ensure that the pressure is released by opening an air outlet valve. 4. Check that the fuel tank contains sufficient fuel. Top up, if necessary. Consult (LV) (PG) (H5) (H6) (H7) (H8) (S) the Engine Operation Manual for the type of fuel. 5. Drain any water and sediment from the fuel filter until clean fuel flows from the P1 Hourmeter drain cock. PG Working pressure gauge 6. Press vacuator valves (VV) of the air filters to remove dust. LV Loading Valve 7. Check the air filter vacuum indicators (VI). If the yellow piston reaches the red N4 Control Module marked service range, replace the filter element. Reset the indicator by pushing the reset button. S Start/Stop Button H1 8. Open air outlet valve to allow air flow to the atmosphere. LED (green) Fuel ON H2 LED (green) Preheat (option) H3 LED (red) Charge Indication H4 LED (red) Compressor Oil Temperature H5 LED (red) Engine Coolant Temperature H6 LED (red) Engine Oil Pressure H7 LED (red) Low Coolant H8 LED (red) Low Fuel Chicago Pneumatic 28Fault situations and protective devices (Also refer DURING OPERATION to chapter Problem solving): Never push the start button when the When the engine is running, the air ! The starter motor is protected against prolonged engine is running. ! outlet valves (ball valves) must always starting. be put in a fully opened or fully closed Make sure the fuel tank is filled up. (max. cranking time: 20 sec. (60 sec. for XAHS position. 186 Dd)). Before starting, first operate the circuit breaker A fault which occurs with the engine, either REGULARLY CARRY OUT FOLLOWING button (F1) at the right side of the control panel alternator voltage (too low), coolant CHECKS: (open right-hand service door first). temperature too high, oil pressure too low or To start, the start/stop button (S) is switched to 1. That regulating valve (see section Main parts, fuel level too low will always and immediately position "I", the green fuel ON lamp (H1), the red RV) is correctly adjusted, i.e. starts decreasing the cause the engine to cut out and one of the engine speed when reaching the preset working charge indication lamp (H3) and preheat lamp (H2) control lamps H3, H5, H6, H7 or H8 to light up pressure in the receiver. go on (preheat lamp only, if "cold start" option is When the outlet temperature of the element 2. Check the air filter vacuum indicators (see section installed). After preheating, the preheat lamp goes becomes too high, a thermocontact will also Main parts, VI). If the yellow piston reaches the out. Push the start/stop button in position. Max. 3 switch off the unit immediately. red marked service range, replace the filter cycles are allowed. The starter motor will set the Control lamp H4 will light up. element. Reset the indicators by pushing the reset The control lamps will remain on until the unit button. engine in motion. Lamps H1 and H3 will go out as soon as the engine has been started. After the start/ has been reset (start button switched to The doors must be closed during position "0") operation and may be opened for short stop button is released, it automatically springs back periods only. to position "I". Run the engine a few minutes at no-load to warm up. When the engine is running smoothly, press loading valve (LV) and release as soon as pressure starts to build up. Shutting down is simply done by pushing the start button in the "0" position. The control panel in addition indicates receiver pressure (PG) and accumulated operating hours (P1). 29 Chicago PneumaticMaintenance LIABILITY SERVICE KITS The manufacturer does not accept any liability for any A service kit is a collection of parts to fit a specific damage arising from the use of non-original parts and repair or rebuilding task. for modifications, additions or conversions made It guarantees that all necessary parts are replaced at without the manufacturer's approval in writing. the same time which improves the uptime of the unit. The order numbers of the Service Kits are listed in the SERVICE PACKS Chicago Pneumatic Parts List. A Service Pak is a collection of parts to be used for a specific maintenance measure. Contact Chicago Pneumatic. It guarantees that all necessary parts are replaced at the same time keeping down time to a minimum. The order number of the Service Paks are listed in the STORAGE Chicago Pneumatic Parts List. Run the compressor regularly, e.g. twice a week, until USE OF SERVICE PACKS warm. Load and unload the compressor a few times to Service Paks include all genuine parts needed for operate the unloading and regulating components. normal maintenance of both compressor and engine. Close the air outlet valves after stopping. Service Paks minimize downtime and keep your If the compressor is going to be stored maintenance budget low. without running from time to time, Order Service Paks at your local Chicago Pneumatic protective measures must be taken. dealer. Chicago Pneumatic 30PREVENTIVE MAINTENANCE SCHEDULE FOR THE COMPRESSOR The maintenance schedule has to be seen as a guideline for units operating in a dusty environment The schedule contains a summary of the maintenance typical for compressor applications. Maintenance instructions. Read the respective section before taking schedule can be adapted depending on application maintenance measures. environment and quality of maintenance. When servicing, replace all disengaged packings, e.g. gaskets, O-rings, washers. For engine maintenance refer to Engine Operation Manual. To determine the maintenance intervals, use service hours, or calendar time, whichever occurs first. Maintenance schedule (running hrs) Daily 50 hrs after initial Every 500 hours Every 1000 hours start-up Or 6 months Or yearly Service Packs CPS 350-12, CPS 400-7 3002 6106 50 3002 6106 60 CPS 450-14 3002 6106 70 3002 6106 80 Oil Separator Kit 3002 6107 70 Engine oil level Check Compressor oil level Check Coolant level (3) Check Coolant (7) Analysis Analysis Air filter vacuator valves Empty Fuel filter water drain Drain Air intake vacuum indicators Check Electrolyte level and terminals of battery Check Check Check 31 - Chicago PneumaticMaintenance schedule (running hrs) Daily 50 hrs after initial Every 500 hours Every 1000 hours start-up Or 6 months Or yearly Leaks in air, oil or fuel system Check Check Check Coolers (Oil, Coolant, Inter) Clean Clean Engine minimum and maximum speeds Check Check Check Torque of wheel nuts Check Check Check Brake system (if installed) Check/Adjust Check/Adjust Check/Adjust Safety valve Test Door hinges Grease Grease Shutdown switches Check Pressure drop over separator element (2) Measure Replace (6) Fan V-belts (3) Adjust Adjust Fuel tank Clean Clean Compressor oil Change Compressor oil filter Replace Replace Air filter elements (1) Replace Safety cartridges (1) (option) Replace Engine oil Change Change Engine oil filter (3) Replace Replace Fuel filter Replace Replace Fuel prefilter (3) Replace Replace Engine inlet and outlet valves (3) Adjust PD/QD filter (option) Replace Chicago Pneumatic 32Notes 1. More frequently when operating in a dusty environment. 2. Replace the element when the pressure drop exceeds 0.8 bar (11.6 psi). 3. Refer to the Cummins operation manual. 4. 500 hours only valid when using GENOIL. 5. In case of poor fuel quality, replace fuel filter more frequently. 6. Clean retainer when replacing element. 7. The following part numbers can be ordered from Chicago Pneumatic to check on inhibitors and freezing point: 2913 0028 00 refractometer 2913 0029 00 pH meter Keep the bolts of the housing, the lifting beam, tow bar and axles securely tightened. For torque values see section Technical specifications. 33 Chicago PneumaticMaintenance schedule Initially Interval Wheels Tyre pressure Before each run Check wheel bolts for firm seating Before first run Check hub caps for firm seating 2,500 km/annually Check tyres for uneven wear 2,500 km/annually Check lateral play of bearings After 500 km 2,500 km/annually Check brake lining wear 5,000 km/annually Towbar Check coupling head for wear, operation and fastening Before first run 5,000 km/annually Check brake play After first run 2,500 km/annually Check height adjustment facility Before each run, during first 500 km 5,000 km/annually Check reversing lever for ease of motion 2,500 km 5,000 km/annually Check safety cable and bowden cable for damage 5,000 km/annually Check/ adjust brake system (if installed) Before first run 2,500 km/annually Lubrication Coupling head and all its moving parts/shaft Before first run 2,500 km/annually Overrun brake Before first run 5,000 km/annually Reversing lever Before first run 5,000 km/annually Overrun coupling Before first run 5,000 km/annually Joints of height adjustable towbar 5,000 km/annually Bearings (conventional bearings only) 5,000 km/annually Chicago Pneumatic 34OIL SPECIFICATIONS COMPRESSOR OIL ENGINE OIL It is strongly recommended to use Chicago Pneumatic branded lubrication Mineral compressor Oil Genoil M Mineral compressor Oil Genoil 15W40 oils for both compressor and engine. If you want to use another brand of oil, Liter Cu.ft Order number Liter Cu.ft Order number consult Chicago Pneumatic. can 5 1.32 1626 2260 00 can 5 1.32 1626 2262 00 High-quality, mineral, hydraulic or synthesized can 20 5.3 1626 2261 00 can 20 5.3 1626 2263 00 hydrocarbon oil with rust and oxidation inhibitors and anti-foam and anti-wear properties is recommended. The viscosity grade should correspond to the ambient temperature and ISO 3448, as follows: Synthetic compressor Oil Genoil S Synthetic compressor Genoil 5W40 Liter Cu.ft Order number Liter Cu.ft Order number can 5 1.32 1630 0175 00 can 5 1.32 1630 0175 00 can 20 5.3 1626 2259 01 Never mix synthetic with mineral oil. Remark: Synthetic compressor Oil Genoil S Ultra When changing from mineral to synthetic oil (or the other way around), Liter Cu.ft Order number Synthetic compressor Genoil Engine Green you will need to do an extra rinse: can 20 5.3 1630 0249 00 Liter Cu.ft Order number After a complete change over to can 5 1.32 1638 0740 00 synthetic oil, run the unit for a few minutes to allow proper and complete can 20 5.3 1638 0750 00 circulation of the synthetic oil. Then drain the synthetic oil again and fill again with new synthetic oil. To set correct oil levels, follow the normal instructions. 35 Chicago PneumaticOIL LEVEL CHECK CHECK COMPRESSOR OIL LEVEL OIL AND OIL FILTER CHANGE Never mix oils of different brands or ! ENGINE OIL AND OIL FILTER CHANGE types. Use only non-toxic oils where there is a See section Preventive maintenance schedule for risk of inhaling delivered air. the compressor. CHECK ENGINE OIL LEVEL Consult also the Engine Operation Manual for the oil specifications, viscosity recommendations and oil (1) change intervals. (2) For intervals, see Preventive maintenance schedule (3) for the compressor. Check engine oil level according to the instructions in the Engine Operation Manual and top up with oil if necessary. With the unit standing level, check the level of the compressor oil. The level of oil must be higher than the middle of sight glass (2). Add oil if necessary. Before removing oil filler plug (1), ! ensure that the pressure is released by opening an air outlet valve (3). Chicago Pneumatic 36COMPRESSOR OIL AND OIL FILTER 2. Drain the compressor oil by removing all relevant CHANGE drain plugs. Drain plugs (3) are fitted at the air receiver (DPar), compressor element (DPcv, DPosv) and compressor oil cooler (DPoc). Catch the oil in a drain pan. Unscrew the filler plug (4) to speed up draining. After draining, reposition and (1) tighten the drain plugs (3). 3. Remove the oil filters (1), e.g. by means of a special tool. Catch the oil in a drain pan. 4. Clean the filter seat on the manifold, taking care (4) that no dirt drops into the system. Oil the gasket of the new filter element. Screw it into place until the (2) gasket contacts its seat, then tighten one half turn (5) only. (3) 5. Fill the air receiver until the oil level reach the bottom of oil filler neck.Be sure that no dirt gets into the system. Reinstall and tighten the filler plug (4). The quality and the temperature of the oil determine the oil change interval. 6. Start the compressor and let it run unloaded for a few minutes. The prescribed interval is based on normal operating conditions and an oil temperature of up to 100 °C 7. Stop the compressor, wait a few minutes and top (212 °F) (see section Preventive maintenance up with oil at bottom of oil filler neck. schedule for the compressor). When operating in high ambient temperatures, in very ! Never add more oil. Overfilling results in oil consumption. dusty or high humidity conditions, it is recommended to change the oil more frequently. In this case, contact Chicago Pneumatic. 1. Run the compressor until warm. Close the outlet valve(s) (5) and stop the compressor. Wait until the pressure is released through the automatic blow-down valve. Unscrew the oil filler plug by a single turn. This uncovers a vent hole, which permits any pressure in the system to escape. 37 Chicago PneumaticCOOLANT SPECIFICATIONS GENCOOL EG Never remove the cooling system filler ! cap while coolant is hot. GENCOOL EG is a ready to use Ethylene Glycol The system may be under pressure. based coolant, premixed in an optimum 50/50 Remove the cap slowly and only when dilution ratio, for antifreeze protection guaranteed to coolant is at ambient temperature. A sudden release of pressure from a heated -40°C (-40°F). cooling system can result in personal For ordering numbers refer to the spare parts list. injury from the splash of hot coolant. Liquid-cooled engines are factory-filled with this type of coolant mixture. It is strongly recommended to use Chicago Pneumatic branded coolant. GENCOOL EG The use of the correct coolant is important for proper Liter Cu.ft Order number heat transfer and protection of liquid-cooled engines. Coolants used in these engines must be mixtures of can 5 1.32 1626 2257 01 good quality water (distilled or de-ionised), special can 5 1.32 1626 2255 01 coolant additives and anti-freeze, if required. Coolant that is not to manufacturer's specification will result can 20 5.3 1626 2256 01 in mechanical damage of the engine. The freezing point of the coolant must be lower than the freezing point that can occur in the area. The GENCOOL Green difference must be at least 5°C (9°F). If the coolant freezes, it may crack the cylinder block, radiator or Liter Cu.ft Order number coolant pump. can 5 1.32 1630 0134 11 Consult the engine's operation manual and follow the manufacturer's directions. can 20 5.3 1630 0134 16 Never mix different coolants and mix the coolant components outside the cooling system. Chicago Pneumatic 38COOLANT CHECK Glycol concentration measurement TOPPING UP/REPLACING COOLANT " To optimise the unique engine protection features " Never remove the cooling system filler Verify whether the engine cooling system is in a ! cap while coolant is hot. of the GENCOOL EG, the concentration of the good condition (no leaks, clean,...). Glycol in the water should always be above " The system may be under pressure. Check the condition of the coolant. " Remove the cap slowly and only when 33 vol.%. " If the condition of the coolant is no longer up to coolant is at ambient temperature. A " Mixtures exceeding a 68 vol.% mix ratio in water standard, the complete coolant should be replaced sudden release of pressure from a heated are not recommended, as this will lead to high (see section Replacing the coolant). cooling system can result in personal engine operating temperatures. " injury from the splash of hot coolant. Always top-up with GENCOOL EG Concentrate / " A refractometer can be ordered from Chicago GENCOOL EG. In order to guarantee the lifetime and quality of the Pneumatic with part number 2913 0028 00. " Topping up the coolant with water only, changes product, thus optimising engine protection, regular the concentration of additives and is therefore not coolant-condition-analysis is recommended. allowed. In case of a mix of different coolant The quality of the product can be determined by three ! products this type of measuring might parameters: provide incorrect values. Visual check " Verify the appearance of the coolant with regard to its colour and make sure that no loose particles are floating around. pH measurement " Check the pH value of the coolant using a pH- measuring device. " The pH-meter can be ordered from Chicago Pneumatic with part number 2913 0029 00. " Typical value for EG = 8.6. " If the pH-level is below 7 or above 9.5, the coolant should be replaced. 39 Chicago PneumaticTOPPING UP WITHOUT DRAINING FROM THE COOLING SYSTEM The quantity of GENCOOL EG Concentrate to be topped up can be estimated with the following formula and/or graph: Corrections concentrate in measured system towards 50% volume by using GENCOOL EG Concentrate PN: 1604 8159 01 Example: Total volume coolant = 14 Liter Measured concentration = 33 Vol 50- 33 = 17 * 14 / 50 = 4,8 Liter GENCOOL EG Concentrate Top-up volume GENCOOL EG Concentrate without drainage 6,0 In case of expansion tank at low level, this quantity is to 5,5 1 be filled without draining from the cooling system. 5,0 2 4,5 4,0 Top-up volume (liter) 3,5 3 3,0 2,5 2,0 4 1. Refractometer indication -20° C (-4° F) (33%) 1,5 4 Refractometer indication -22° C (-7.6° F) 1,0 5 Refractometer indication -25° C (-13° F) 0,5 6 Refractometer indication -30° C (-22° F) 5 0,0 7 Refractometer indication -36° C (-32.8° F) 4 5 6 7 8 9 10 11 12 13 14 15 16 Engine coolant capacity (liter) Chicago Pneumatic 40TOPPING UP AFTER LIMITED QUANTITY DRAINING FROM THE COOLING SYSTEM The quantity of GENCOOL EG Concentrate to be topped up after draining a calculated volume from the cooling system, can be estimated with the following formula and/or graph: Corrections concentrate in measured system towards 50% volume by using GENCOOL EG Concentrate PN: 1604 8159 01 Example: Total volume coolant = 80 Liter Measured concentration = 33 Vol % 50- 33 17 * = 80 / 67 = 20 Liter GENCOOL EG Concentrate 100- 33 = 67 Top-up volume GENCOOL EG Concentrate with drainage 25,0 In case of expansion tank at normal level, this quantity is to be drained from the cooling system. 22,5 1 20,0 2 17,5 Top-up volume (liter) 15,0 3 12,5 10,0 4 7,5 1. Refractometer indication -20° C (-4° F) (33%) 5,0 8 Refractometer indication -22° C (-7.6° F) 9 Refractometer indication -25° C (-13° F) 2,5 5 10 Refractometer indication -30° C (-22° F) 0,0 11 Refractometer indication -36° C (-32.8° F) 4 8 12 16 20 24 28 32 36 40 44 48 52 56 60 64 68 72 76 80 84 Engine coolant capacity (liter) 41 Chicago PneumaticREPLACING THE COOLANT CLEANING COOLERS Drain (3) Protect the electrical and controlling Completely drain the entire cooling system. (2) ! equipment, air filters, etc. against Used coolant must be disposed of or recycled in penetration of moisture. (1) accordance with legislation and local regulations. Close the service door(s). Flush Never leave spilled liquids such as fuel, Flush twice with clean water. Used coolant must ! oil, water and cleansing agents in or be disposed of or recycled in accordance with around the compressor. legislation and local regulations. Using the Chicago Pneumatic Instruction book, ! Caution: Do not top up when the engine determine the amount of GENCOOL EG required is hot. and pour into the radiator top tank. It should be clearly understood that proper cleaning reduces contamination risks. In case of "other" coolant residues inside the Keep the coolers clean to maintain the cooling system, the coolant with the lowest properties efficiency. influences the quality of the 'mixed' coolant. Remove any dirt from the coolers with a Fill ! fibre brush. Never use a wire brush or metal objects. To assure proper operation and the release of trapped air, run the engine until normal engine Then clean by air jet in reverse direction of normal operation temperature is reached. Turn off the flow. engine and allow to cool. Steam cleaning in combination with a cleansing agent Recheck coolant level and add coolant mixture if may be applied. necessary. To avoid damaging the coolers, angle In case of a mix of different coolant ! between jet and coolers should be ! products this type of measuring might approx. 90° (do not use jet at max. provide incorrect values. power). Chicago Pneumatic 42BATTERY CARE ACTIVATING A DRY-CHARGED BATTERY BATTERY MAINTENANCE Take out the battery. Before handling batteries, read the Keep the battery clean and dry. relevant safety precautions and act Battery and electrolyte must be at equal Keep the electrolyte level at 10 to 15 mm above accordingly. temperature above 10°C (50°F). the plates or at the indicated level; top up with Remove cover and/or plug from each cell. distilled water only. Never overfill, as this will If the battery is still dry, it must be activated as cause poor performance and excessive corrosion. described in section Activating a dry-charged Fill each cell with electrolyte until the level battery. reaches 10 mm (0.4 in) to 15 mm (0.6 in) above Keep the terminals and clamps tight, clean, and the plates, or to the level marked on the battery. lightly covered in petroleum jelly. The battery must be in operation within 2 months from being activated; if not, it needs to be recharged Rock the battery a few times so that possible air first. bubbles can escape; wait 10 minutes and check the level in each cell once more; if required, add COMPRESSOR ELEMENT OVERHAUL ELECTROLYTE electrolyte. Refit plugs and/or cover. When a compressor element is due for overhaul, it is recommended to have it done by Chicago Pneumatic. Place the battery in the compressor. This guarantees the use of genuine parts and correct ! Read the safety instructions carefully. tools with care and precision. RECHARGING A BATTERY Electrolyte in batteries is a sulphuric acid solution in distilled water. Before and after charging a battery, always check the electrolyte level in each cell; if required, top up with The solution must be made up before being distilled water only. When charging batteries, each introduced into the battery. cell must be open, i.e. plugs and/or cover removed. Use a commercial automatic battery ! charger according to its manufacturer's instructions. Apply with preference the slow charging method and adjust the charge current according to the following rule of thumb: battery capacity in Ah divided by 20 gives safe charging current in Amp. 43 Chicago PneumaticAdjustments and servicing procedures ADJUSTMENT OF THE CONTINUOUS REGULATING SYSTEM The working pressure is determined by the tension of the spring in the regulating valve (RV). This tension can be increased to raise the pressure and decreased to lower it by turning the adjusting wheel clockwise and anti-clockwise respectively. Air Receiver/Oil Separator Oil Separator Element Unloader Assembly Blow Off Valve Compressor Element Air Atmospheric Pressure Air Regulating Pressure Air Working Pressure Mixture Oil Chicago Pneumatic 44 -To adjust the normal working pressure, proceed as follows: X Y Z2 CPS 350-12 bar 13.5 12 13.2-13.6 1. Start and warm up the engine (see section Starting/Stopping). psi 196 174 191.5-197.5 2. With the outlet valves (AOV) closed, loosen the regulating valve's lock nut and adjust the regulating valve (RV) until a pressure of X bar(e) is reached (see CPS 400-7 bar 8.5 7 8.1-8.5 table). psi 120.5 101.5 117.5- 123.5 3. Check the minimum speed of the engine. Adjust minimum speed stop screw if CPS 450-14 bar 15.5 14 15.2-15.8 necessary. psi 224.5 203 220.5-229 4. Open an outlet valve (AOV) just enough to let the engine (E) run at maximum speed. The working pressure must be Y bar(e); adjust if necessary with regulating valve (RV) (see table). 5. Check the engine maximum speed. Adjust the maximum speed by means of adjusting eccentric nut on top of speed regulator (SR). 6. Close the outlet valves (AOV), check that the pressure is between Z1 and Z2 bar(e) (see table). Lock the regulating valve (RV) by fixing the lock nut. 45 - Chicago PneumaticAIR FILTER ENGINE/COMPRESSOR RECOMMENDATIONS AIR RECEIVER The air receiver (1) is tested according to official The Chicago Pneumatic air filters are (1) standards. Carry out regular inspections in conformity specially designed for the application. with local regulations. The use of non-original air filters may lead to severe damage of engine and/or compressor element. SAFETY VALVE Never run the compressor without air filter element. All adjustments or repairs are to be done ! by an authorized representative of the valve supplier. New elements must also be inspected for tears or punctures before installation. Following checks must be carried out on the safety Discard the element (4) when damaged. valve (2): (6)(2) (3)(4) (5) (8) A dirty safety cartridge (3) is an indication of a mal- a check of the opening of the lifting gear, twice a (7) functioning air filter element. In that case replace the year. This can be done by screwing the cap of the (9) element and safety cartridge. valve anti-clockwise. The safety cartridge cannot be cleaned. an annual check of the set pressure according to 1. Snap clips 6. Vacuator valve local regulations. This check cannot be done on 2. Dust trap cover 7. Vacuum indicator the machine and must be carried out on a proper test bench. 3. Safety cartridge 8. Reset button REPLACING THE AIR FILTER ELEMENT (option) 4. Filter element 9. Yellow indicator 1. Release the snap clips (1) and remove the dust trap 5. Filter housing (2). Clean the trap. 2. Remove the element (4) and the safety cartridge. 3. Reassemble in reverse order of dismantling. Make CLEANING THE DUST TRAP sure the vacuator valve (6) points down. 4. Inspect and tighten all air intake connections. Remove dust daily. 5. Reset the vacuum indicator by pressing the reset To remove dust from the dust trap squeeze the button (5). vacuator valve (6) several times. Chicago Pneumatic 46FUEL SYSTEM BRAKE (OPTION) ADJUSTMENT Before jacking up the compressor, ! connect it to a towing vehicle or attach a (4) (1) minimum weight of 50 kg (110 lb) to the towbar. BRAKE SHOE ADJUSTMENT Check the thickness of the brake lining. Remove both black plastic plugs (5), one on each wheel. When the brake lining has been worn down to a thickness of 1 mm (0.039 in) or less, the brake shoes have to be replaced. After inspection and/or replacement re-insert both plugs. Brake shoe adjustment re-establishes the brake (5) (1) (3) (2) lining-to-drum clearance and compensates for lining wear. Replacing the filter element 1. Adjusting bolt 4. Pin Ø 4 mm Lift and support the compressor. Make sure that all 2. Axle 5. 1. Unscrew the filter element (1) from the adapter brakes are off (overrunbrake and hand brake lever). Plug head. The brake cables must be free from tension. Lock the 3. Brake cable 2. Clean the adapter head sealing surface. Lightly oil swivel cams of the wheel brake from the outside by the gasket of the new element and screw the latter means of a pin Ø 4 mm (4) through the hole as shown Check the position of the equalizer (see section onto the header until the gasket is properly seated, in the Figure. Brake cable adjustment, 6) with the parking brake then tighten with both hands. Turn the adjusting bolt (1) clockwise with a wrench actuated. 3. Check for fuel leaks once the engine has been till the wheel locks up. Center the brake shoes by Perpendicular position of equalizer = identical restarted. actuating the parking brake several times. clearance of wheel brakes. Turn the adjusting bolt anti-clockwise until the wheel Re-adjust the brake shoes, if necessary. is running free in direction of travel (approx. 1 full turn of the adjusting bolt). To test, slightly apply the parking brake and check identical brake torque on left and right side. Remove locking pin (4). Remove clearance from brake cables. Check all lock nuts (Brake cable adjustment, 2). - 47 Chicago PneumaticTEST PROCEDURE OF BRAKE CABLE ADJUSTMENT Correct and wrong position of markings 1. Check if the towing eye rod of the overrun brake mechanism is in the out most position. 2. Check if the adjustable towbar (option) is in the actual towing position. 2 3. Apply the hand brake lever. 4. Push the compressor a few centimeters backwards B. Acceptable so that the brake lever is automatically pulled up further. 5. Check the position of the arrow marking "1" at the catch lock in combination with the arrow marking "2" at the toothed sector, according to A,B,C,D. C. Too loose; adjust brake cables (Section Brake A. Adjusted correctly cable adjustment) D. Too tight; adjust brake cables (Section Brake cable adjustment) Chicago Pneumatic 48 -BRAKE CABLE ADJUSTMENT 1. With the towing eye pulled out in the outmost (1) (6) (4) (2) position and the hand brake lever in the downward position (see Figure), loosen the lock nuts (2). Turn adjusting nuts and brake cable nuts (4) clockwise until there is no slack in the brake mechanism. The equalizer (6) must remain perpendicular to main brake cable (5). 2. Apply the hand brake lever several times and repeat the adjustment. Tighten the nuts with their lock nuts (2). Remove the jack and the blocks. 3. Road test the compressor and brake several times. Check brake shoe and brake cable adjustment and (1) (2) (3) (4) (2) (5) adjust if necessary. Hand brake lever downward brake not operated 1. Brake cable 4. Brake cable nut 2. Lock nut 5. Main brake cable 3. Adjusting nut 6. Equalizer 49 Chicago PneumaticWHEELS LUBRICATION WHEEL CHECK Check wheel bolts for firm seating (initially) Check hub caps for firm seating (every 2,500 km or annually) Check tyres for uneven wear (every 2,500 km or annually) Check lateral play of wheel bearing. If necessary, readjust. Compact bearings (every 2 years) Conventional bearings (after 500 km, every 2,500 km or annually) Tapered type hub cap Greasing bearing race Taper roller bearings and deep groove ball Fill the hub caps to 3/4 full with grease. bearing Fit wheel hubs, adjust the bearing play and fit the hub Axles fitted with taper roller bearings are caps. recognizable by a tapered type hub cap, see Figure. Remove wheels and wheel hubs. Mark dismounted wheel hubs and bearing races so that their identity is not mistaken during reassembly. Clean wheel hubs thoroughly inside and outside. Remove old grease totally. Clean taper roller bearings and seals (using diesel oil) and check for reuseability. Work BPW special longlife grease ECO_Li 91 into the cavities between the taper roller and cage. Smear grease into the hub's outer bearing race. Chicago Pneumatic 50WHEEL BOLTS CHECK Tightening torques of wheel bolts Spanner Thread Tightening width (mm) torque Nm (lbf.ft) 17 (19) M 12x1.5 80 100 Nm 19 M 14x1.5 110 120 Nm 24 M 18x1.5 270 280 Nm Cylindrical hub cap shape Wheel bolts tightening Compact bearings After the first run, likewise after each Compact bearings are recognizable by cylindrical hub wheel change. cap shape, see Figure. Tighten wheel bolts crosswise using a torque wrench Compact bearings are maintenance-free due to and tightening torque in compliance with the table. permanent lubrication and are designed for high mileages. Therefore, there is no grease change or re-greasing necessary. 51 Chicago PneumaticMais conteúdos dessa disciplina
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