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Atmos PDK 33 Series, Operation And Maintenance Handbook

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Atmos PDK 33 Series Operation And Maintenance Handbook Download Page 9

SAFETY REGULATIONS

THIS TYPE OF MACHINE IS INTENDED FOR OUTSIDE OF EU EXPORT ONLY.

Do not start!

Read operation and 
maintenance manual before 
start!

Attention!

Hot surface!

Attention!

Read operation and 
maintenance manual before 
starting service work!

Attention!

Do not stand on cocks and 
other parts of the pressure 
system!

Attention!

Do not operate the 
compressor while door or 
covers are open!

Attention!

Do not open the output cock 
before air hoses are 
connected!

Attention!

Hot gases!

Attention!

Pressure!

 

DIESEL

Fuel tanking

Třída / Class

API CH –4   - 

ACEA E5

Motor oil filling

 

VDL 46

Compressor oil filling

Coolant filling

Lifting point

Anchoring point

7

At 2020/N

X.11.2016

Summary of Contents for PDK 33 Series

Page 1: ...nance handbook ATMOS Portable screw compressor ATMOS PDK 33 ATMOS Chrást s r o Plzen ská 149 330 03 Chrást Czech Republic Tel Fax 420 377 860 181 420 377 860 111 420 377 745 247 420 377 945 379 At 2020 N Version X 11 2016 ...

Page 2: ......

Page 3: ...tarting 15 Starting the machine 17 Stopping the machine 18 Emergency shut down 19 Re starting after an emergency shut down 19 Machine monitoring 19 Operation in hard climatic conditions 20 Information about the residual risks 21 Instructions on the protective measures 22 Battery 22 Essential characteristics of tools 23 The conditions in which the machinery meets the requirement of stability 24 Par...

Page 4: ...mpressor drive 32 Alternator belt 32 Air filter 33 Ventilation 33 Cooling fan 33 Fuel system 33 Fuel filter 34 Fuel filter water separator if installed 34 Hoses 34 Electrical system 34 Battery 35 Additional lubricator if installed 35 Pressure system 35 Compressor oil 35 Compressor oil specification 35 Speed and pressure control adjustment 36 Engine 36 Lubrication 36 Engine oil 36 Engine oil specif...

Page 5: ...stment and maintenance 41 Maintenance schedule 41 Notice for maintenance 42 Maintenance 43 Before maintenance 43 Minimal pressure valve 43 Before removing of covers 44 Maintenance on a running machine 44 Maintenance completion 44 Specifications of the spare parts 45 Airborne noise emissions 46 Non ionising radiation 47 3 At 2020 N X 11 2016 ...

Page 6: ...ts Catalogue could lead to the situation for which ATMOS Chrást company cannot bear any responsibility In such a case ATMOS Chrást company does not take any responsibility for potential damage Read the Handbook carefully before operating the machine to fully understand its operation and maintenance requirements Guarantee the Operation and maintenance handbook is always at disposal directly by the ...

Page 7: ...caused by a defect due to workmanship if there has been and intervention carried out on the machine construction if the machine has been repaired by other subjects than the manufacturer or its authorised service centre if the machine has been handed over another owner without a technical inspection carried out by the manufacturer or its authorised service centre if prescribed guarantee inspections...

Page 8: ...MS DESCRIPTIONS AND EXPLANATIONS DIMENSIONS Dimension mm PDK 33 Dimension mm PDK 33 a 750 j 1565 b 2395 k 200 c 2530 m 1485 d 3350 n 1085 e 430 o 1280 f 845 p 1295 g 851 r 2485 h 1265 s 3235 i 92 At 2020 N X 11 2016 6 ...

Page 9: ...ing service work Attention Do not stand on cocks and other parts of the pressure system Attention Do not operate the compressor while door or covers are open Attention Do not open the output cock before air hoses are connected Attention Hot gases Attention Pressure DIESEL Fuel tanking Třída Class API CH 4 ACEA E5 Motor oil filling VDL 46 Compressor oil filling Coolant filling Lifting point Anchori...

Page 10: ...10 0 110 0 110 0 Max oil system overpressure bar 8 6 11 6 13 5 Outlet cocks 2x G 3 4 KAG3 4 2x G 3 4 KAG3 4 2x G 3 4 KAG3 4 Engine PDK 33 Type Model Kubota V1505 T Cylinders 4 Load speed min 1 3000 Idle speed min 1 1500 50 Oil filling vol l 6 7 Fuel tank vol l 70 0 Coolant filling vol l 4 0 Battery V Ah 12 44 Noise emissions PDK 33 Sound power level LWA dB A pW 98 Sound pressure level LpA dB A 20 ...

Page 11: ... Remove the switch from the machine Connect the switch to an independent low pressure supply either air or oil The switch should be switch offat 1 0 bar Reinstall the switch Temperature switch es At three month intervals test the temperature switch circuit s as follows Start the machine Run the machine at idle speed Disconnect the switch connectors one by one Short circuit contacts in the connecto...

Page 12: ...it Test the circuit before each machine start as follows 1 Turn the key to ON position and check that the recharge indicator is on 2 Complete the machine starting sequence 3 The recharge indicator should switch off At 2020 N X 11 2016 10 ...

Page 13: ...CTIONAL DIAGRAM Explanatory notes 1 air outlet 6 air end 2 nozzle min pres valve 7 engine 3 manometer 8 oil cooler 4 separator tank 9 oil filter 5 safety valve 10 thermostat oil air 11 At 2020 N X 11 2016 ...

Page 14: ...DESCRIPTION OF THE WORKSTATION S Does not apply At 2020 N X 11 2016 12 ...

Page 15: ...ressed air All pressure loaded parts including the pressure hoses should be tested regularly No signs of damage should be observed and all parts should be used in conformance with instructions for their use and or for their intended purpose Avoid contact with compressed air The safety valve on the oil separator should be tested regularly according to given instructions When the machine is stopped ...

Page 16: ...s or fuels under high pressure as this can penetrate the skin and result in serious illness Wear eye protection while cleaning the machine with compressed air to prevent eye injury Rotating fan blades can cause serious injury Do not operate the machine without a fan guard installed Avoid contact with hot surfaces an engine exhaust manifold and pipping an air receiver and air discharge pipping etc ...

Page 17: ...TIONS If more than one compressor are connected to the pneumatic equipment at the same time every machine should be equipped with a non return flap valve to avoid back air streaming through the output cocks into the machine 15 At 2020 N X 11 2016 ...

Page 18: ...R VIBRATION The compressor body is equipped with noise absorption panels used for noise control The machine cannot be operated without these noise absorption panels The machine was designed to reduce all risks caused by vibrations to the lowest level At 2020 N X 11 2016 16 ...

Page 19: ...ved by suitable means especially it is necessary to avoid straining of outlet piping system Attach the battery cables to the battery clamps and tighten them securely Attach the positive pole cable before attaching the negative pole cable Warning Nominal pressure of all air pressure equipment installed in or connected to the machine must be equal or greater than nominal pressure of the machine All ...

Page 20: ...especially when the machine is new It is not recommended to operate the machine at maximum load during the first 50 working hours Warning Do not operate the machine with its bonnet covers open This may cause the machine overheating and the operation staff are exposed to high levels of noise Do not move or otherwise manipulate with the machine when it is working Warning Before putting the machine i...

Page 21: ...plained in the table Note Some of the sensors might not be connected on all types in this case these values will not be displayed Note For smooth operation of the machine let the engine warm up Do not operate the engine at full load immediately after it starts up This will shorten the service life of the machine At temperature below 0 C or if there are difficulties during the initial start up 1 Op...

Page 22: ...ven delay the machine stops 4 After the machines stops you can switch off the main key 5 During maintenance etc disconnect the battery and close the compressed air outlet cocks disconnect the hoses if the machine is connected to the compressed air distribution system Warning In emergency situation the machine can be stopped by switching off the main key This is not recommended for regular operatio...

Page 23: ...it staunchness as well as the engine filling circuit 2 Check the air operation overpressure Its value must not exceed the set pressure limit 3 Check the fuel level in the fuel tank 4 No warning lights may flash during the machine operation 5 With outlet cocks closed the engine speed should decrease to no load level once the operation overpressure has been reached The machine should shut down under...

Page 24: ...ermanently increased temperatures 1 Pay attention to regular cleaning of heat exchange surfaces of the coolers 2 Consult the manufacturer due to the suitable compressor oil use Operation in an extremely dusty environment 1 Pay special attention to regular cleaning of heat exchange surfaces of the coolers 2 Check the air intake filter regularly 3 Reduce exchange intervals of the oil filter and the ...

Page 25: ...se materials with skin and do not inhale the vapours After contact with eyes immediately flush them with running water for at least 5 minutes After contact with skin wash it immediately In cases of ingestion seek medical help immediately When inhaled excessive amount of the substance seek medical help immediately Never give fluids to a victim in convulsions try to induce vomiting These safety inst...

Page 26: ...othing wash it immediately with plenty of water If electrolyte is splashed in eyes flush them with large amounts of water and seek medical help immediately Do not use naked light Never attempt to boost a frozen battery as it could explode If boosting a battery mind the correct polarity Make sure the connections are solid First attach the positive clamp of the booster cable Remove the booster cable...

Page 27: ... by the manufacturer approved for the nominal pressure level at least equal to machine maximum operation pressure usable in contact with compressor oil and coolants delivered together with the Handbook for installation and safe operation You will be provided with details regarding suitability of individual parts by ATMOS sell and service centres 25 At 2020 N X 11 2016 ...

Page 28: ...r between the body and the supporting wheel It is also stamped on the undercarriage plate located on the side of the machine body PARKING Before you detach the machine lower the tow bar prop A portable compressor should be braked by moving the hand brake lever into the second utmost position overcoming the force effect of the spring cartridge In this position tighten the safety bolt which prevents...

Page 29: ...cle 5 Check if the safety bolt of the hand brake is not installed during the transport the bolt must be disassembled unconditionally Secure the suspension wheel bar in its upper position or disassemble it UNCOUPLING THE TOW BAR WITH SUSPENSION EYE 1 Lower the suspension wheel and secure the compressor against the movement 2 Uncouple the compressor including the socket COUPLING THE TOW BAR WITH ISO...

Page 30: ...TORAGE PREPARATION If the machine is to be kept unused in a storage for a longer time period follow these instructions and place the machine to a dry dust free place If the machine is to be stored outside put it into a temporary shelter If left uncovered the machine would corrode Start the machine at least once a week to make sure oil gets to all machine parts If it is not possible to start the ma...

Page 31: ...illing battery including electrolyte oil air and fuel filters other oil contaminated parts Parts classified as special waste which should be recycled or given to certified authority for disposal cables wires and other electrical equipment tyres and other rubber and plastic parts heat isolating materials made of mineral fibres 29 At 2020 N X 11 2016 ...

Page 32: ...soiled Clean the oil cooler High ambient temperature Consider changing the machine location Defective temperature switch Contact the manufacturer s service part ner Safety valve leaking Separator insert soiled Change the separator insert Defective safety valve Contact the manufacturer s service part ner An intake valve does not work prop erly Contact the manufacturer s service part ner Oil in comp...

Page 33: ...f the machine has been switched off for safety reasons make sure the machine can be operated safely before an attempted re start Before re starting the machine follow the instructions in Before starting and Starting the machine at page 15 The machine should shut down under these conditions low engine oil pressure high air end discharge temperature high engine coolant temperature 31 At 2020 N X 11 ...

Page 34: ...the substance seek medical help immediately Never give fluids to a victim in convulsions try to induce vomiting These safety instructions are taken from manufacturers of these substance Do not operate the machine inside a building without sufficient ventilation Do not inhale exhaust fumes when working with or near the machine This machine contains substances such as oil diesel oil antifreeze brake...

Page 35: ...ely See paragraph Lubrication on page 36 ASSEMBLY Clean the filter bearing area Spread oil on the new filter gasket and screw the new filter clockwise until the new filter gasket fits in the filter bearing area When the gasket fits in the bearing area tighten the filter cartridge by turning it 3 4 revolution with a filter wrench After the oil filter is completely reassembled check for any oil leak...

Page 36: ...the cooler which would therefore efficiently conduct the heat from oil and water away Warning Hot coolant could cause serious injury When adding coolant or antifreeze stop the engine for at least one minute before opening the cooler cap Use gloves to protect your hands Slowly loosen the tank cap and wipe any released fluid with cloth Do not open the tank cap until the excessive fluid does not flow...

Page 37: ...r body ensuring that the gasket seats properly Reset the soiling indicator Fit the dust collector make sure it is positioned correctly Check that the filter clamps are tight before starting the machine VENTILATION Always check that the air inlets and outlets are clean and the air passage is not blocked Warning Never clean the machine interior with compressed air COOLING FAN Check periodically that...

Page 38: ...engine air intake system should be checked periodically At the recommended intervals see Maintenance schedule on page 41 check all of the intake tubing and all flexible hoses used in the air oil and fuel system Periodically check the piping for cracks leaks etc and replace damaged parts immediately ELECTRICAL SYSTEM Warning Always disconnect the battery cables before any maintenance or repairs Che...

Page 39: ...n operated in severe conditions or has suffered long shut down periods more frequent service intervals are required Warning Never under any circumstances remove any oil drain or filler plugs of the compressor oil system without being sure that the machine is stopped and the system has been completely relieved from overpressure see Stop ping the machine on page 18 paragraph Remove the drain plug s ...

Page 40: ... before 7 bar is reached turn the regulation bolt clockwise to increase the overpressure otherwise turn the regulation bolt counter clockwise to decrease the overpressure Optimal adjustment is achieved when the speed starts falling down at 7 2 bar Close the outlet cocks The engine will slow down to idle speed Warning Never allow the overpressure on the gauge to exceed the maximum overpressure othe...

Page 41: ...cked periodically for tightness see the intervals at Maintenance schedule on page 41 and re tightened if necessary see the Tightening torques table WHEEL BEARINGS Wheel bearings should be packed with grease every 6 months The grease type should conform to specification TYRES PRESSURE The required tyres pressure is specified in Technical parameters on page 6 BRAKES Check and adjust the brake linkag...

Page 42: ...inkage 7 on the brake equalisation assembly 8 Check that brake actuators and cables 11 operate smoothly 2 Brake Shoe Adjustment Tighten adjusting screw 12 clockwise until the wheel locks Loosen adjusting screw 12 anti clockwise approx 1 2 turn until the wheel can be moved freely Slight dragging noises that do not impede the free movement of the wheel are permissible This adjustment procedure must ...

Page 43: ...tem cables brake equalisation system and linkage Check the handbrake cable 5 for a small amount of play and adjust if necessary Variable height only Check the compression spring 9 for pre tensioning Test run If necessary carry out 2 3 test brake actions Test brake action Check the play in brake linkage 7 and if necessary adjust the length of brake linkage 7 until there is no play Apply the handbra...

Page 44: ...les after refitting the wheels see the Tightening torques table TIGHTENING TORQUES Nm Air end transmission engine 39 47 Air filter holder 22 27 Clamp exhaust 12 15 Baffle frame 12 15 Discharge manifold frame 39 47 Drive pins engine flywheel 77 93 Drop leg 72 85 Engine transmission air end frame chassis 73 78 Exhaust flange manifold 23 28 Fan cover 12 15 Fan hub 16 20 Lifting bail bracket frame 29 ...

Page 45: ... I C Separator tank I I P Suction valve service kit I I Lights I Tow hitch I Tyres pressure I I Brakes linkage I I Auto shut down system I Safety valve I TR Undercarriage A Undercarriage bolts I Joints covers I Discs bearings gaskets I Exhaust piping I Pressure system I Pump filter C Separator insert R Emergency thermostat T R Emergency shut down T Manometer I Pressure regulator I Air end belt IA ...

Page 46: ...op the machine secure it against the unintended start and release the pressure Follow all safety instructions including those not mentioned in this Handbook Note Every compressor is supplied with the Service booklet where it is recommended to log all operations performed during maintenance Guarantee inspections regular service operations and repairs carried out by ATMOS service centre should be lo...

Page 47: ...ssed air can be dangerous if handled improperly Before any operation make sure the machine is not under pressure and can not be started accidentally If the automatic depressurization system fails pressure should be relieved manually by the operating personnel Appropriate personal protective equipment should be used Make sure the operating personnel are adequately trained qualified and acquainted w...

Page 48: ...disabled or removed is limited to only those tasks which require the machine to be running with safety protection devices disabled or removed Be aware of all possible risks e g pressurized and live components removed panels covers or guards extreme temperatures air inflow and outflow intermittently moving components safety valve outlet etc Appropriate personal protective equipment is used Secure l...

Page 49: ...pressor oil filter 800601004406 Engine oil filter 272711531280 Air end belt P307316 1 Suction valve service kit KIT 1 P307184 1 Suction valve service kit KIT 2 N307504 1 Suction valve 111128100000 mineral oil 111110000002 Atmosoil 4 111110000004 synthetic oil Spare parts specifications can be found in Spare Parts Catalogue 47 At 2020 N X 11 2016 ...

Page 50: ...AIRBORNE NOISE EMISSIONS Acoustic pressure level A in the operation station is max 98 dB A At 2020 N X 11 2016 48 ...

Page 51: ...NON IONISING RADIATION The machine does not emit non ionizing radiation 49 At 2020 N X 11 2016 ...

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