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OPERATING METHOD TO BE FOLLOWED IN THE EVENT OF ACCIDENT OR

BREAKDOWN

TROUBLESHOOTING

Problem

Cause

Solution

The

compressor

produces

low

amount of air.

Regulation system soiling.

Clean the regulation system, contact the
manufacturer’s service partner.

The compressor cannot reach the ap-
propriate air pressure.

An intake valve does not work prop-
erly.

Check the intake valve.

The engine does not rev up.

Speed control soiling.

Clean the speed control, contact the
manufacturer’s service partner.

The machine runs up heavily.

Compressor under pressure.

Check the intake valve.

Low ambient temperature.

Heat up the machine, consider change
of oil type.

Dense oil.

Change oil, check the oil type.

The machine turns off before the de-
manded pressure is reached.

Temperature protection.

Contact the manufacturer’s service part-
ner.

The machine turns off due to high oil
temperature.

Insufficient oil volume.

Refill the compressor oil.

Oil filter soiled.

Change the oil filter.

Oil cooler 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 compressed air.

Clogged oil drawing off.

Clean the oil drawing off plug.

Defective separator insert.

Change the separator insert.

The intake valve works properly, but
the air delivery is low.

Suction filter soiled.

Change the suction filter insert.

The intake valve does not operate
smoothly.

Clean the intake valve, contact the man-
ufacturer’s service partner.

Leakages in the intake valve or in the

whole system.

Seal the elements, contact the manufac-
turer’s service partner.

This table serves for a customer’s basic orientation when a problem with the machine or its parts appears. Problems

leading to the machine shut down are signalled on a control board display. When a problem appears, please contact the
manufacturer’s service partner immediately.

At 2020/N

X.11.2016

Содержание PDK 33 Series

Страница 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 ...

Страница 2: ......

Страница 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...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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 ...

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

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

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

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

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