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Safety Section  

 

 

 

Compressor Welder Generator 

 

 

2

 

Safety 

2.1

 

Important Safety Information 

Safety  precautions  and  warnings  may  be  listed  in  this 

manual  and  applied  to  the  product  (supplied  by 

Australian Diversified Engineering) in the form of safety 

signs and labels. 

 

Safety  signs  and  labels  may  be  positioned  on  specific 

parts  of  the  product  to  draw  attention  to  objects  and 

situations  affecting  health  and  safety.  If  these  hazard 

warnings  are  not  heeded,  bodily  injury  or  death  may 

occur to you or other persons. 

 

The  severity  of  the  consequences  of  the  hazard  may 

be easily identified by the alert symbol at the top of the 

label. 

 

The 

DANGER 

alert  symbol  is  used  to  warn  of  a 

hazardous  situation  that  is  likely  to  be  life  threatening. 

Ensure  you  are  aware  of  situations  and  locations  on 

the product displaying this alert symbol. 

 

 

 

The 

WARNING 

alert  symbol  is  used  to  warn  of  a 

hazardous  situation  that  is  not  likely  to  be  life 

threatening.  Ensure  you  are  aware  of  situations  and 

locations on the product displaying this alert symbol. 

 

 

 

The  wording  given  underneath  the 

DANGER

  or 

WARNING

  alert  symbol  will  warn  of  the  hazard,  the 

consequences of the hazard followed by information on 

how to prevent the hazardous situation from occurring.  

 

Some  signs  placed  on  the  product  or  machine  (which 

do not contain a safety alert or symbol such as 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  form  of  specific  information  applicable  to 

the task to be performed. 

 

Australian Diversified  Engineering cannot anticipate all 

possible hazards. For  instance, some hazards may be 

specific to your workplace or the equipment or tool you 

employ to complete the task. 

 

Plan  the  job  before  proceeding.  Planning  before 

commencement  of  the  job  will  help  identify  possible 

hazards  in  the  job  procedure  which  can  be  eliminated 

or controlled. 

 

Be  aware  of  unintended  movement  when  assembling 

and  disassembling  components  and  ensure  machines 

are isolated in accordance with workplace and supplier 

instructions when performing maintenance. 

 

Ensure  items  are  installed  properly  and  are  not 

damaged  during  the  installation  procedure  or  during 

operation  of  the  machine.  If  damaged  or  installed 

incorrectly the product may not operate and perform as 

intended and may be made unsafe as a result. Ensure 

all  items  are  repaired  or  replaced  and  care  is  taken 

when installing items on the machine. 

 
Operate  and  maintain  the  machine  in  accordance  with 

procedures  specified  by  the  original  equipment 

manufacturer  and  information  contained  within  this 

manual. 

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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