ADE ADE015759 Instruction manual

ADE018327
REV00
Operation &
Maintenance
Manual
Compressor Welder
Generator Unit
ADE015759
Truck-based CWG
Ph: +61 7 3863 5800
www.ade.net.au
Table of Contents
TABLE OF CONTENTS ....................................................1
1
GENERAL INFORMATION.................................1
2
SAFETY ...................................................................2
2.1
IMPORTANT SAFETY INFORMATION .......................2
2.2
SAFETY SIGNS & LABELS .......................................3
3
PRODUCT ID INFORMATION ...........................4
3.1
4
UNIT ID PLATE.......................................................4
CWG EQUIPMENT ...............................................5
4.1
CATERPILLAR/PERKINS ENGINE .............................5
4.2
ALTERNATOR .........................................................5
4.3
AIR COMPRESSOR SYSTEM .....................................5
4.4
KEMPI WELDER......................................................5
4.5
CONTROL CABINET ................................................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 ............13
6.6
CONSUMABLES FOR MAINTENANCE .....................17
7
LITERATURE REFERENCE MATERIALS ....18
7.1
OLYMPIAN GENERATOR DOCUMENTATION ..........18
7.2
AIR COMPRESSOR SYSTEM DOCUMENTATION .....18
Overview
Compressor Welder Generator
1
1 General Information
This guideline provides all the necessary information to
operate
and
maintain
Generator
(CWG)
Diversified
Engineering.
the
unit
Compressor
supplied
Use
this
by
Welder
Australian
information
in
conjunction with the Olympian OEM information and
mine site instructions where applicable.
Refer 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 Engineering Pty Ltd for the latest available
information. Selected manuals may be found at
www.ade.net.au containing the most up to date
information for the product.
General Information
Compressor Welder Generator
1
2 Safety
2.1
Important Safety Information
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
Safety precautions and warnings may be listed in this
background. Read and obey the information contained
manual and applied to the product (supplied by
on these labels.
Australian Diversified Engineering) in the form of safety
signs and labels.
The NOTICE heading may be contained within this
manual and is used to highlight or alert to certain
Safety signs and labels may be positioned on specific
aspects of the product. Commonly the NOTICE
parts of the product to draw attention to objects and
heading is used to highlight the weight of an object or
situations affecting health and safety. If these hazard
some other form of specific information applicable to
warnings are not heeded, bodily injury or death may
the task to be performed.
occur to you or other persons.
Australian Diversified Engineering cannot anticipate all
The severity of the consequences of the hazard may
possible hazards. For instance, some hazards may be
be easily identified by the alert symbol at the top of the
specific to your workplace or the equipment or tool you
label.
employ to complete the task.
The DANGER alert symbol is used to warn of a
Plan the job before proceeding. Planning before
hazardous situation that is likely to be life threatening.
commencement of the job will help identify possible
Ensure you are aware of situations and locations on
hazards in the job procedure which can be eliminated
the product displaying this alert symbol.
or controlled.
Be aware of unintended movement when assembling
and disassembling components and ensure machines
are isolated in accordance with workplace and supplier
The WARNING alert symbol is used to warn of a
instructions when performing maintenance.
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.
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
The wording given underneath the DANGER or
all items are repaired or replaced and care is taken
WARNING alert symbol will warn of the hazard, the
when installing items on the machine.
consequences of the hazard followed by information on
how to prevent the hazardous situation from occurring.
Operate and maintain the machine in accordance with
procedures
Some signs placed on the product or machine (which
specified
by
the
original
equipment
manufacturer and information contained within this
manual.
Safety Section
Compressor Welder Generator
2
2.2
Safety Signs & Labels
There are several specific safety signs specific to the
service vehicle. Their exact location and description 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
Safety Section
Compressor Welder Generator
3
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
Product Identification Section
Compressor Welder Generator
4
4 CWG Equipment
4.3
Air Compressor System
The CWG is equiped with a 40 CFM air compressor
4.1
Caterpillar/Perkins Engine
system, which is controlled and monitored at the
control cabinet. The system consists of the following
The CWG is driven by a Perkins 403D-11G engine.
components:
The engine is a inline 3 piston diesel engine, governed
1. Air end
at 1500 RPM. The engine is fueled the truck’s diesel
2. Oil separator tank, with:
tanks, and is operated from the control cabinet.
o
Oil filter (small can)
o
Separator/De-oiler filter (large can)
3. Oil cooler
4. Air cooler
5. Air filter/water sepator regulator
4
2
3
1
4.2
Alternator
The alternator used in the CWG provides 7.5 kVA of
5
single phase 240 V AC electricity. Alternator status
information and output power points are provided by
4.4
Kempi Welder
the control cabinet.
The CWG unit will also be provided with Kemppi
Miniarc EVO 150 portable MMA welder. The Kemppi
provides up to 140A of welding current.
Operation Section
Compressor Welder Generator
5
4.5
Control Cabinet
All CWG functions are controlled and monitored from
the control cabinet, 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.
Operation Section
Compressor Welder Generator
6
5 Operation of CWG
1
2
Ensure you are familiar with the functionality, operation
and all warnings associated with this equipment before
attempting any form of operation.
5.1
Basic CWG Operation and Monitoring
To start the CWG:
1. Check all personnel are clear of the CWG unit.
5
4
3
2. Press the Engine Start button (1).
3. The
unit
will
move
through
a
pre-start
5.2
Utilising the 240V AC
sequence, then crank the engine.
The 240V AC power can be utilised at any time that
the CWG is running. However, to prevent stalling the
To stop the CWG:
1. Push the Compressor Stop switch, if running
engine, the air compressor will be shut down at high
current draw (approximately 6A). At extremely high
(see over page)
current draw (20A), the clutch will also be disengaged.
2. Press the Engine Stop button (2).
3. The unit will run a cool down sequence, then
cut the engine.
4. To cancel the cooldown sequence, press and
hold the Engine Stop button, then press the
return button (3).
5.2.1 Operating the Kemppi Welder
Due to the high yet intermittant current draw of arc
welding, it is recommended that the the air compressor
be switched off and clutch disengaged before welding
5. In case of emergency, press the CWG
commences. Operating the air compressor while
Emergency Stop button (see over page). This
welding may adversely affect the longevity of the
should only be done in an emergency situation
clutch.
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.
Operation Section
Compressor Welder Generator
7
5.3
Air Compressor Operation and
Monitoring
To start the air compressor:
5.4
Compressor Overtemperature
The
air
compressor
is
protected
by
an
over
temperature switch. If the compressor outlet reaches
1. Check all personnel are clear of the CWG unit.
105 °C the switch will shut down the compressor and
2. Press the Compressor On button.
prevent it from restarting until it cools to 90 °C.
3. The clutch will engage immediately, and the
compressor
load
valve
will
operate
Possible causes:
approximately 30 seconds afterward.
1. Cooler filter element may be blocked.
4. The compressor load valve will be modulated
2. Low compressor oil level.
to keep air pressure within an acceptable
range.
To stop the air compressor:
5.5
Generator Has Priority
If the generator and compressor are running at the
1. Push the Compressor Off switch.
same
2. The compressor will unload immediately, but
undergoing a large current draw:
the clutch will remain engaged for several

minutes in order to cool the compressor oil.
The CWG must left running during this time
(cooldown cycle is acceptable).
Monitoring the air compressor:


time,
the
generator
takes
priority
Above 6A – The compressor is unloaded,
clutch remains engaged.

Above 20A – The compressor is unloaded,
clutch is disengaged.
When underaking tasks with intermittant but high
The Compressor Air Pressure gauge displays
current draw, such as welding, it is recommended that
the air pressure available in the reservoir.
the compressor is switched off to prevent excessive
The Compressor Hours gauge tracks the air
cycling of the clutch.
compressor’s hours of operation.

when
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.
Operation Section
Compressor Welder Generator
8
6 Maintenance Section
6.1.2 Crushing & Cutting Prevention
Disconnection of hoses and removal of
supporting pins and bolts of the service
vehicle may result in unintended machine
movement and/or release of stored energy.
Personal injury or death may result. Before
disassembly of any components of the
service vehicle ensure that stored energy has
been
relieved
and
components
are
chocked/blocked to prevent unintended
movement.
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 machine.
NOTICE

You must read and understand the warnings
and instructions contained in the Safety
Section of this manual, before performing any
maintenance procedures.
6.1
General Hazard Information
Support equipment and attachments properly when
working beneath them. Never attempt adjustments
while the machine is moving or the engine is
running unless otherwise specified.

Stay clear of all rotating and moving parts.
Perform all maintenance unless otherwise specified as
follows:

The vehicle parked on level ground.

The engine and CWG stopped.

The start switch key off and the key removed.

All disconnect switches locked out and a Do Not
Start Tag applied.

Pressure relieved in the system which is to be
serviced.

All other external energy sources disconnected
from the machine.
6.1.1 Oils & Coolant
Oils and coolant may be hot and under
pressure. Before serving components on this
vehicle ensure all pressure is relieved in the
system and fluids have been allowed
sufficient time to cool.
Maintenance Section
Compressor Welder Generator
9
6.2
CWG Maintenance Schedule
6.2.5 Every 500 Hours (or 1 year)
This schedule is based on the CWG operation

Fuel system filter – Replace
hours,

Engine air cleaner Element – Clean/Replace

Engine oil and filter – Change

Hose and clamps – Inspect/Replace

Radiator - Clean
which
are
displayed
on
the
Engine
Monitoring screen of the CWG control panel.
Note – This maintenance schedule is indicative only.
Please refer to Section 9 of the Olympian Operator and
Maintenance Instruction Manual, and page 60 of the
Perkins
Operation and
6.2.6 Every 1000 Hours
Maintenance Manual for
detailed requirements and instructions.
6.2.1 When Required

Belts – Replace

Engine valve lash – Inspect/Adjust

Gearbox oil - Change

Engine – Clean

Engine air cleaner element – Clean/Replace

Fuel system – Prime

Alternator – Inspect

Severe service application – Check

Engine crankcase breather – Replace

Engine mounts – Inspect

Starting motor – Inspect
6.2.2 Daily
6.2.7 Every 2000 Hours

Engine oil level – Check

Engine coolant level – Check

Driven equipment – Check

Engine air cleaner service indicator – Inspect

Engine air precleaner – Check/Clean

Fuel injector – Test/Change

Fuel system primary filter/water separator –

Water pump – Inspect
6.2.8 Every 3000 Hours

Cooling system water temperature regulator –
Replace
Drain

Walk-around inspection
6.2.3 First 100 Hours ONLY
6.2.9 Every 6000 Hours (or 3 years)

Cooling
system
coolant
– Change (if
Commercial Heavy-Duty)

Gearbox oil – Change/Flush
6.2.10 Every 12000 Hours (or 6 years)
6.2.4 Every 250 Hours (or weekly)


CWG control system handling of electrical
Cooling
system
coolant
– Change (if
Extended Life Coolant)
faults by simulating faults – Test

Exhaust connections – Check/Tighten

Electrical connections – Check/Tighten

Belts – Inspect/Adjust

Gearbox oil level - Check
Maintenance Section
Compressor Welder Generator
10
6.3
CWG Maintenance Tasks
Maintenance tasks not described here are detailed in
Section 9 of the Olympian Operator and Maintenance
Instruction Manual, and page 60 of the Perkins
Operation and Maintenance Manual.
1
6.3.1 Checking the Gearbox Oil Level
1. Remove oil level inspection plug (1).
2. Check oil level via the oil level inspection hole.
Oil level should meet the inspection hole, or be
just under.
3. Replace the oil level inspection plug..
2
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
3
gearbox oil into the tank.
8. Allow oil to drain into the gearbox.
9. Check oil level via the oil level inspection hole.
Oil level should be filled to the level of the
inspection hole. Fill more if required.
10. Replace the oil level inspection plug and the
breather.
Maintenance Section
Compressor Welder Generator
11
6.4
Air Compressor Maintenance Schedule
This schedule is based on the air compressor
operation hours, which are displayed on the
Compressor Hours gauge on the CWG control
cabinet.
Note – This maintenance schedule has been adapted
from Section 15 of the Compressor 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 Every 2000 Hours

Clean the finned surface of the oil and air
coolers

Change the oil separator/de-oiler filter
Maintenance Section
Compressor Welder Generator
12
6.5
Air Compressor Maintenance Tasks
6.5.2 Draining
Maintenance tasks not described here are detailed in
Section
15
of
the
Compressor
Unit
OEM
documentation.
Condensate
from
Separator Tank
1. Ensure CWG and truck are shut down and
isolated.
6.5.1 Checking Compressor Oil Level
1. Switch off the air compressor.
2. Wait for the machine to cool down.
3. Slowly turn on the tap (2) and let the
condensate flow out.
2. Wait a few minutes for the foam in the
separator tank to subside.
4. When the first traces of oil appear, turn off the
tap.
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.
2
1
Maintenance Section
Compressor Welder Generator
Oil
13
6.5.3 Cleaning the Air Suction Filter
1. Ensure CWG and truck are shut down and
6.5.4 Belt Tension
1. Ensure CWG and truck are shut down and
isolated.
isolated.
2. Remove filter cover (2).
2. Remove the belt guard.
3. Remove the filter.
3. Slacken the air end screws by half a turn (3).
4. Clean the filter with a jet of air, working from
4. Loosen the locknut (4).
inside to outside. DO NOT USE WATER OR
5. Adjust the tension by turning screw (5).
SOLVENTS. Alternatively, fit a new filter.
a. New belt - deflection should be 6mm
5. Clean the disk on which the filter rests with a
for
clean cloth.
a
4kg
force
applied
at
the
centreline, at right angles to the belt.
6. Fit the filter and the cover.
b. 100 hrs Operation - deflection should
be 2mm for a 2.5kg force applied at
the centreline, at right angles to the
belt.
2
6. Tighten the locknut.
7. Tighten air end screws.
8. Replace belt guard.
5
4
3
Maintenance Section
Compressor Welder Generator
14
6.5.5 Changing the Oil
1. Ensure CWG and truck are shut down and
6
isolated.
2. Oil should be changed while machine is warm
(i.e. right after operation)
3. Drain oil from oil separator tank via the tap
(see Section 1.1.1). Close tap.
4. Remove air suction filter housing and pour 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
7
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 plug.
8
8. Start the compressor and run for approximately
1 minute. Re-check oil level and add/remove
more if necessary.
Maintenance Section
Compressor Welder Generator
15
6.5.6 Replacing the Oil Filter and Separator
Filter
6.5.7 Cleaning the Filtering Panel
1. Ensure CWG and truck are shut down and
1. Ensure CWG and truck are shut down and
isolated.
2. Before
isolated.
2. Remove filtering panel (11) from cowling via
removing
the
oil
filter
(9),
or
separator/de-oiler filter (10), ensure that there
slot.
3. Clean filtering panel with a jet of air and wash
with water. DO NOT USE SOLVENTS.
is no stored pressure in the reservoir.
3. Remove desired filter.
4. Reinstall the filtering panel via slot, and adjust
4. Lubricate new filter seals with a little oil before
from the front to ensure it sits correctly.
fitting.
5. Tighten new filter by hand.
10
9
Maintenance Section
Compressor Welder Generator
11
16
6.6
Consumables for Maintenance
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
ADE018549
separator filter
Pre-cooler filtering panel
ADE018207
Belt
ADE017854
Maintenance Section
Compressor Welder Generator
17
7 Literature
Materials
7.1
Reference
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.
Reference Information
Compressor Welder Generator
18