ADE ADE015759 Operation & Maintenance Manual Download Page 1

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ADE018327

REV00

Ph: +61 7 3863 5800

www.ade.net.au

Operation &

Maintenance

Manual

Compressor Welder

Generator Unit

ADE015759

Truck-based CWG

Summary of Contents for ADE015759

Page 1: ...ADE018327 REV00 Ph 61 7 3863 5800 www ade net au Operation Maintenance Manual Compressor Welder Generator Unit ADE015759 Truck based CWG ...

Page 2: ... 6 5 OPERATION OF CWG 7 5 1 BASIC CWG OPERATION AND MONITORING 7 5 2 UTILISING THE 240V AC 7 5 3 AIR COMPRESSOR OPERATION AND MONITORING 8 5 4 COMPRESSOR OVERTEMPERATURE 8 5 5 GENERATOR HAS PRIORITY 8 6 MAINTENANCE SECTION 9 6 1 GENERAL HAZARD INFORMATION 9 6 2 CWG MAINTENANCE SCHEDULE 10 6 3 CWG MAINTENANCE TASKS 11 6 4 AIR COMPRESSOR MAINTENANCE SCHEDULE 12 6 5 AIR COMPRESSOR MAINTENANCE TASKS 1...

Page 3: ...fer to the Parts Manual for part information when sourcing replacement parts The serial number of the CWG unit found on the ID plate may be required to determine appropriate parts Refer to Section 3 1 in this manual for further information on the location of the ID plate Whenever a question arises regarding the information contained within this manual please consult Australian Diversified Engineer...

Page 4: ... Danger or Warning are to indicate that an instruction must be carried out The label will contain black text on a white background Read and obey the information contained on these labels The NOTICE heading may be contained within this manual and is used to highlight or alert to certain aspects of the product Commonly the NOTICE heading is used to highlight the weight of an object or some other for...

Page 5: ...n of the hazard are reviewed in this section Make sure that you can read all safety signs You must replace a label if it is damaged missing or cannot be read If a label is on a part that is replaced make sure a new label is installed on the replaced part Contact Australian Diversified Engineering for replacement labels This sign is located on the top of the electrical cabinet ...

Page 6: ...4 3 Product ID Information 3 1 Unit ID Plate An ID plate has been fitted to each machine to indicate information such as the date of manufacture and serial number Refer to the fitted ID plate for further information ID plate affixed near the oil separator tank ...

Page 7: ... Alternator status information and output power points are provided by the control cabinet 4 3 Air Compressor System The CWG is equiped with a 40 CFM air compressor system which is controlled and monitored at the control cabinet The system consists of the following components 1 Air end 2 Oil separator tank with o Oil filter small can o Separator De oiler filter large can 3 Oil cooler 4 Air cooler ...

Page 8: ...et fitted in the rear driver s side cabinet Functionality available includes Start and stop the engine Monitor the engine s oil pressure RPM and operating hours Monitor the alternator s voltage frequency and output current Start and stop the air compressor system Monitor the air compressor systems status air pressure and operating hours ...

Page 9: ...ergency Stop button see over page This should only be done in an emergency situation as it bypasses the engine s cooldown sequence Monitoring the CWG Pressing the Engine Monitoring button 4 displays the engine oil pressure RPM and operating hours Pressing the Alternator Monitoring button 5 displays the alternator voltage frequency and current draw 5 2 Utilising the 240V AC The 240V AC power can be...

Page 10: ...cks the air compressor s hours of operation The compressor s filter regulator must be set at 110 PSI or higher otherwise compressor activation will cause the engine to stall If lower pressure regulation is required a separate regulator must be used at the air outlets 5 4 Compressor Overtemperature The air compressor is protected by an over temperature switch If the compressor outlet reaches 105 C ...

Page 11: ...tand the warnings and instructions contained in the Safety Section of this manual before performing any maintenance procedures Unintended machine movement may result in personal injury or death Before performing maintenance on this machine ensure it has been isolated in accordance with mine site and manufacturer procedures and a Do Not Start Tag has been applied in the appropriate location on the ...

Page 12: ...n Walk around inspection 6 2 3 First 100 Hours ONLY Gearbox oil Change Flush 6 2 4 Every 250 Hours or weekly CWG control system handling of electrical faults by simulating faults Test Exhaust connections Check Tighten Electrical connections Check Tighten Belts Inspect Adjust Gearbox oil level Check 6 2 5 Every 500 Hours or 1 year Fuel system filter Replace Engine air cleaner Element Clean Replace ...

Page 13: ...place the oil level inspection plug 6 3 2 Changing the Gearbox Oil 1 Run the CWG up to operating temperature 2 Shut down then isolate CWG and truck 3 Undo oil drain cap 2 4 Allow gearbox oil to drain into a container a funnel may be required 5 Replace oil drain cap 6 Remove oil level inspection plug 1 7 Remove breather 3 from the oil expansion tank and pour approximately 350mL of new gearbox oil i...

Page 14: ...pressor Unit OEM documentation which should be referred to for further instructions 6 4 1 Daily Walk around inspection Check compressor oil level 6 4 2 Every 25 Hours Drain condensate from oil separator tank Clean cooler filter panel 6 4 3 Every 250 Hours Clean air suction filter Check belt tension 6 4 4 Every 1000 Hours Change the oil Change the oil filter Change the air suction filter 6 4 5 Ever...

Page 15: ...in the separator tank to subside 3 Check fluid level is visible on the sight glass 1 The minimum fluid level is at the bottom of the sight glass while the maximum is at the top of the sight glass 4 If the oil level is below the minimum top up 6 5 2 Draining Condensate from Oil Separator Tank 1 Ensure CWG and truck are shut down and isolated 2 Wait for the machine to cool down 3 Slowly turn on the ...

Page 16: ...ts with a clean cloth 6 Fit the filter and the cover 6 5 4 Belt Tension 1 Ensure CWG and truck are shut down and isolated 2 Remove the belt guard 3 Slacken the air end screws by half a turn 3 4 Loosen the locknut 4 5 Adjust the tension by turning screw 5 a New belt deflection should be 6mm for a 4kg force applied at the centreline at right angles to the belt b 100 hrs Operation deflection should b...

Page 17: ... 1L of oil slowly down the neck 6 while cycling the compressor by using a ratchet on the compressor pulley note pulley bolt is reverse thread Ensure that the oil is being pumped out of the air end or else the air end may be damaged 5 Open oil fill plug 7 6 Add approximately 2 5L of oil to the tank The tanks should be full according to tank sight glass 8 Fill more if required 7 Replace oil fill plu...

Page 18: ...sure in the reservoir 3 Remove desired filter 4 Lubricate new filter seals with a little oil before fitting 5 Tighten new filter by hand 6 5 7 Cleaning the Filtering Panel 1 Ensure CWG and truck are shut down and isolated 2 Remove filtering panel 11 from cowling via slot 3 Clean filtering panel with a jet of air and wash with water DO NOT USE SOLVENTS 4 Reinstall the filtering panel via slot and a...

Page 19: ...e The following consumables required by the CWG are available for order from ADE Part Part Number Gearbox oil ADE018575 Air compressor oil ADE018547 Air compressor oil filter ADE018548 Air compressor oil separator filter ADE018549 Pre cooler filtering panel ADE018207 Belt ADE017854 ...

Page 20: ...18 7 Literature Reference Materials 7 1 Olympian Generator Documentation The Olympian generator documentation has been provided with the CWG 7 2 Air Compressor System Documentation The CSA 10 air compressor documentation has been provided with the CWG ...

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