ROTAIR S.p.A.

MANUALE DI USO E MANUTENZIONE - RICAMBI

MANUEL D’ENTRETIEN - PIECES DE RECHANGE
OPERATING MAINTENANCE - PARTS MANUAL
BEDIENUNG UND WARTUNGSANLEITUNGEN
MANUAL DE USO Y MANTENIMIENTO - RECAMBIOS

MOTOR COMPRESSOR
ROTAIR S.p.A.

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-- 1) IDENTIFICATION DATA --

Here follows details of the information printed on the machine identification plate situated
at the front of the machine.

MODEL: MDVS 170 P

REGISTRATION NO.:

MASS (Kg): 2700

AIR DELIVERY (litres per minute) * : 17.000

WORKING PRESSURE (bar): 8

YEAR OF CONSTRUCTION:

ACOUSTIC POWER dB(A) ** : < 100

(*)Measured in accordance with ISO 1217 standards (±5%).

(**)Measured in accordance with directive CEE 84/533, technical adaptation 85/406/CEE.

CAUTION:

The use of non-original ROTAIR spares will result in the immediate cancellation of
the guarantee.
On requesting assistance or ordering of parts always cite the model number and
registration number above.

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-- 2) TECHNICAL DATA --

COMPRESSOR:

-- WORKING PRESSURE: 8 bar

-- MAXIMUM FINAL PRESSURE: 9 bar
-- MINIMUM WORKING PRESSURE: 5 bar
-- MAX. ROTATION SPEED.: 2550 r.p.m.
-- AIR YIELD AT WORKING PRESSURE: 17000 litres/1’
-- COOLING: hydraulic oil (*)
-- OIL SYSTEM CAPACITY: 17 litres

(*) SHELL CORENA D 46 is recommended.

Corresponding types allowed: VERETRUM 46 IP.

DICREA 46 AGIP.
SCHUMANN 46 Q8.
RASUS 424 MOBIL.
RASUS 425 MOBIL.
AIRCOL PD 32 CASTROL.

MOTOR:

-- MODEL: PERKINS 1006-6T

-- NUMBER OF CYLINDERS: 6
-- DISPLACEMENT: 6000 cm³
-- AVAILABLE POWER: 112 KW (154 HP)
-- COOLING: liquid type
-- MAX. ROTATION SPEED: 2550 r.p.m.
-- MIN. ROTATION SPEED: 1500 r.p.m.
-- BATTERY: 12 Volt – 200Ah – 1250A EN

For all other information, regarding the motor, consult the use and maintenance booklet of
the manufacturer itself, enclosed with this documentation.

COMPLETE MACHINE:

-- MAX. ENVIRONMENTAL TEMPERATURE: 40 °C Max

-- LENGTH 3870 mm
-- WIDTH: 1940 mm
-- HEIGHT: 2221 mm
-- WEIGHT IN WORKING
CONDITION (approximate): 2700 Kg
-- TYRES TYPE: P225 / 75 R16

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-- 3) THE PURPOSE OF THE MANUAL AND WHO IT IS TO BE CONSULTED BY -

The owner, user and maintenance technician must carefully study the manual
to ensure that it is used for the purposes for which it has been designed and constructed.
It is essential that all the information contained in this manual are applied, in
order to ensure optimum use of the machine under the safest conditions.
This manual fully describes:
- the information concerning the drawing, lifting and parking of the
machine;
- the general standards and useful advice for both ordinary and
special maintenance;
- the means for the identification and ordering of spares.
NB: The instructions for correct motor use are provided by the
motor manufacturer itself.
The correct and careful use of the machine in accordance with the instructions
contained in this manual, will ensure the long life of the machine, and will also enable the
personnel to prevent the risk of any accidents or injury during work.
This manual must be careful conserved, in its special case, away from any
humidity, heat and sun's rays, to ensure that it is ready for consultation at any time, both
by the operational personnel and the maintenance staff.
It is important to ensure that the special maintenance operations in particular
are undertaken by specialized personnel.
In the event of loss or damage of this manual, ROTAIR must be asked for a
copy, citing the relative machine identification details as shown on the plate on the
machine.
Should the plate become illegible, use the details quoted on the invoice on
requesting a new manual.
Further information or instructions for use or relating to any further interventions
necessary on the machine can be request ROTAIR SPA directly, always citing the
machine identification details.
This machine has been exclusively designed and built to supply compressed
air in the conditions as envisaged by the manufacturer. Any other use not envisaged in
this description will be considered as being "non conforming" and will release the
manufacturer from any further responsibility which will fully that of the user itself.

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“Conforming use" presupposes the observance of the following regulations

concerning the use, maintenance and transport of the unit itself.
It is also necessary to ensure that all the accident prevention regulations hereby
described are followed, also in accordance with general safety regulations as indicated in
the current legislation.
The constructor declines any responsibility in the event of any modifications
made to the machine without its authorization.
The machine is supplied complete with the following documents:
1) - General use and maintenance booklet;
2) - Motor use and maintenance booklet;
3) - Declaration of machine conformity to the R.E.S. of EEC directive 89/392;
4) - Conformity certificate of the oil separator tank;
5) - Certificate of conformity of the safety valves of the oil separator tank;
6) - Motor guarantee certificate;
7) - Compressor guarantee certificate.

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-- 4) ENVISAGED MACHINE USE --

The MDVS motor-driven compressor is a machine which generated a well-

defined quantity of compressed air measures in litres per minute.
There are many field of application for the use of all those tools, accessories
and implements which have a "pneumatic" function such as demolition hammers,
perforation hammers, vibrators, drills, starters, compactors, plasterers, etc...
Each instrument has a compressed air consumption measured in litres per
minute.
The best ratio between compressor and tool is when the compressed air
consumption of this last does not exceed 85% of the air generated by the compressor
(also bear in mind that the quantity of compressed air requested by the tool, will increase
in proportion to the wear of the tool itself).
A correct compressor-tool ratio will ensure that the machine operates efficiently
and will guarantee maximum performance.
If the tool is too big it will jeopardize the correct function of the machine, and its
performance will be impaired, not having the necessary amount of compressed air.
This machine has been designed to work at an environmental temperature of
between -10 and +40°°C.

COUNTER-INDICATIONS

The compressed air generated by this unit contains minute traces of oil and it is
therefore not suited to use in those systems that require totally oil-free air (i.e. food
industry, pharmaceutical industry, flour and powder transport, etc...).

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PRECAUTIONS

The operator must avoid compressed air outlets as the force and the speed of the
air may cause injury to those in direct contact with the air jet.

Should the machine have to work in closed environments it is necessary to

convey the discharge gas externally by means of a conduit (a spiral pipe of
stainless steel with a diameter of at least 60 mm is advisable), the length of which
must be as short as possible. It is also necessary to create a ventilation system which
conveys the dirty, warm and dust saturated air externally, to ensure that the machine
takes in fresh and clean air.
It is however totally prohibited to operate the machine in closed environments in which
vapours or corrosive or explosive gas mixtures exist.
However when operating in outside environments it is necessary to make sure that the
exhaust gas always comes about on the lee side and never in the direction of walls or
other obstacles, which may affect the discharge and the dispersion of these exhaust
gases.

When undertaking demolition, drilling or sandblasting operations or any other

operations which generate dust, the tool must be connected to the compressor by
means of a flexible pipe, which is resistant to pressure and of sufficient length to
ensure the distancing of the machine from the work site, thereby avoiding the blockage of
both the suction filters mounted on the unit and of the radiator for the cooling of the
lubricant and refrigerating liquids. In this case also the operator must undertake to position
the machine in the lee side of the working area.

The machine has been designed and constructed to work with lowered bonnet
and therefore it must not be raised when the motor is on as it will cause
excessive noise and impede the necessary internal ventilation necessary for the
correct compressor function.
On selecting the flexible piping for connection of the machine to the utensil they must be
of the correct dimensions, taking into account their length and the volume of air to be
applied; if the pipe diameter is too small or too long, the air flow is impeded, causing a loss
in the charge and poor tool performance.

The flexible piping which delivers the compressed air from the machine to the
tool or any attached device, must be fitted with a tap positioned at the end
connected to the tool; this tap must be kept closed during the connection of the
piping to the machine and the tool in order to prevent the incorrect opening of the tap on
the machine which may cause extreme wobbling of the piping with a risk of physical injury.

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-- 5) TECHNICAL DESCRIPTION --

This unit, like the entire MDVS range is an oil injection screw mobile motorized
compressor, single-stage and silenced.
The motor is of internal combustion type, and runs on gas oil, and transmits
power to the compressor by means of an elastic joint positioned co-axially between the
two.

-- 5.1) CHASSIS AND AXLE --

The chassis (part 1) is made from contoured and electrowelded metal sheet
and is of load-bearing type. This chassis undergoes two painting treatments which
guarantee corrosion resistance and rust-proofing.

-- 5.2) BODYWORK --

The bodywork is entirely made of galvanized sheet steel consisting of two

elements: the first called "fixed part", is solidly fixed to the chassis, while the second called
"bonnet" is hinged to the chassis. It can be easily tilted thanks to two gas lifting elements
which permits easy access to the main machine parts. Part of the bodywork is covered by
sound deadening and fireproof material.
Special openings have been created in the bodywork, which on the one side
permit the intake of fresh air necessary for motor and compressor cooling, and the
expulsion of heated air on the other side. These openings have been carefully sized and
shaped to permit the most efficient internal machine ventilation: therefore please take the
greatest care in maintaining these channels unobstructed and in good condition.
The control panel is situated on the left side of the bodywork, which is protected
by a transparent polycarbonate flap, which permits the reading of the compressed air
pressure, the temperature of the compressor air and visual checking of the indicators,
each of which indicates the presence of any anomalies of the machine parts to which they
are linked. The starting device is ensured against use by non-authorized persons thanks
to a transparent polycarbonate flap which also has a lock.
The bodywork in galvanized steel is treated with special paint which ensures
excellent quality finish as well as maximum knock-resistance and rust-proofing.

-- 5.3) MOTOR --

The unit is equipped with a Diesel motor, the features of which are described in
paragraph 2 (Technical data).
Consult the use and maintenance instructions and the manual supplied by the
manufacturing company and enclosed with this documentation.

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-- 5.4) COMPRESSION UNIT --

It is completely manufactured in the ROTAIR factory and consists of a central

body (cylinder) inside which are fitted two screw rotors with asymmetric section, a male
one with 5 lobes and female one with 6 lobes.
The cylinder is closed at the ends by two head sections which contain the
bearings which bear the radial and axial loads created by the air compression.
A series of channels, inside the cylinder and heads, undertake to deliver the oil
to the various components. The distribution of the lubricant , serves to lubricate the
bearings and to maintain a coating of oil between the rotors and the bearings themselves
as well as the internal cylinder walls, thereby promoting compression resistance. Another
important function of the oil injected between the rotors is that of absorbing the heat
generated by the air compression.
The compressed air supplied by this compressor is free of any pulsations and
compression comes about axially.
A "regulator" unit is mounted on the compression unit, the purpose of which is
to regulate the quantity of air taken in according to the amount of air consumed. A double-
stage filter mounted on the top of this unit guarantees maximum purity of the suctioned
air.

-- 5.5) OIL SEPARATOR TANK --

Consists of a pressurized container, and due to its construction features it is

exempt from the annual I.S.P.E.L. inspection and is supplied with a conformity certificate
issued by the manufacturer. The identification and inspection details are impressed on a
plate which is welded to the machine.
The lid features the following elements: safety valve for overpressure, a thermal
switch which intervenes if the temperature inside the tank exceeds 100°C and valves
which regulate the maximum and minimum pressure of the machine.

-- 5.6) BELL AND FLEXIBLE COUPLING --

The engine and the compressor are interconnected by a bell which

guarantees concentricity between the engine flywheel and the compressor shaft.
A large-size block joint with rubber pieces interspaced transmits power in a
smooth and silent way without splitting.
The engine-compressor thus assembled is clamped to the frame with four
flexible supports (silent-blocks) which completely absorb the vibrations it generates. A fan
is splined to the engine shaft on the opposite side to the flywheel which generates large
air displacement which cools the machine fluids and elements.

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-- 5.7) CONTROL INSTRUMENTS AND DEVICES --

The machine control devices are all positioned on the control panel.
Figure 2 illustrates the various control and command devices.

CAUTION: Beware of hanging any other keys together with the starter key (part
2, fig. 1) to ensure that it is always free to return to its original position on release
after ignition.

INSTRUMENT DESCRIPTION.

1) "START WORK" device

2) Ignition key
3) Obstruction air filter indicator
4) Motor oil pressure indicator
5) Alternator - battery charger indicator

6) High temperature indicator

7) Air pressure manometer
8) Hour-meter
9) Gas-oil indicator

11) Plug pre-heating push-button

Fig. 1

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-- 5.8) SAFETY DEVICES --

These devices protect the machine from all malfunctions which could cause serious
damage to the machine, if they are not promptly eliminated.

• Minimum oil pressure gauge: This device prevents the starting up if the machine until
the pressure inside the oil separator tank has not fallen to under 1.5 Bar. This device
consists of a pressure gauge which de-energizes relay B, which as a result open its
contact, cutting off power to the starter motor.

• Motor oil pressure gauge: N.C Contact device, which intervenes in the event of
insufficient pressure in the motor oil circuit. By means of the relay K, it de-energizes the
H gas oil solenoid valve and I discharge solenoid valve causing the motor to come to an
immediate stop. The Z light comes on, indicating the anomaly.

• Oil separator tank thermal contact: N.O. contact device which protects the oil separator
tank from temperatures of over 100°C. This, by means of relay K, de-energizes the H
and I solenoid valves immediately stopping the motor. Light V comes on indicating the
anomaly.

• Thermocontact on compressor: N.O. contact device, which intervenes in the event of

the overheating of the interior of the compressor which by means of relay K, de-
energizes solenoid valves H and I immediately stopping the motor. Light V comes on
indicating the anomaly.

• Thermocontact on motor head: N.O. contact device which intervenes in the event of
motor over-heating. The relay K intervenes to de-energize solenoid valves H and I
which immediately stops the motor. Light V comes on indicating the anomaly.

• Spark plug fuse: Protective device against anomaly currents which could
damage the Motor N glow plugs or station M during glow plug pre-heating. The capacity
of this fuse is of 40A.

• Secondary fuse: Protective device against anomaly current which may

damage components such as the solenoid valves, relays, hourmeters, etc. This fuse
has a capacity of 16A..

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- 5.9) OLEOPNEUMATIC PLANT (Fig 2) --

-- 5-9-1) COMPRESSOR LUBRICATION SYSTEM --

The system includes the oil separator tank (Z), the thermostatic valve (U) on
which, at the entrance, the oil filter (V) and the oil cooling radiator (M) are mounted.
As shown in fig. 4 the lower part of the oil separator tank (Z) acts as an oil tank,
will the filtering part is situated at the top which separates the air from the oil.
On starting up the machine, the pressure generated by the compressor, makes
the oil inside the tank flow through the conduit in the direction indicated by the arrow. A
thermostatic valve (U) is positioned along the route, which according to the actual oil
temperature, conveys it all or partially to the cooling radiator (M), more specifically:
- at temperatures of below 65°c, the thermostatic valve remains open and the
oil in circulation is directly injected into the compressor, without going through the radiator
(M).

FIG. 3

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During the working cycle the oil is heated and when it reaches a temperature of
65°C, the thermostatic valve (U) begins to close, thereby making it necessary for part of
the oil to go through the cooling radiator (M).
When the oil temperature reaches 75°C, the thermostatic valve (U9 closed
completely and from then on all the oil in circulation goes through the radiator and is
thereby cooled (M).
From the radiator (M) the oil is injected into the compressor (O).
The filter (V) has an internal "by-pass" valve which permits oil circulation even if
it gets blocked. In which case the oil will circulate regularly without being filtered. It is
therefore necessary to replace the filter at regular intervals, as indicated in the
maintenance programme.
The cooled and filtered oil thereby reaches the compressor (O) and by means
of the various internal channels it is distributed to the various parts (rotors, bearings etc)
which are thereby cooled and lubricated. From the compressor (o), the oil mixed with
compressed air is sent to the tank (Z), inside which the separator (Y) undertakes to
separate it from the air.
We have mentioned that the separator filter (Y) provides to separate the air
from the oil; however a very small quantity is still able to penetrate the inside of the filter,
and deposits itself on the low and concave part of the same. It is sucked through the
piping on which the calibrated nozzle and the single-direction valve are positioned. The
latter impedes the return of oil into the oil separator filter when the machine is stopped.

-- 5-9-2) PNEUMATIC SYSTEM (Fig. 2) --

The system includes: the suction filter (A), the suction regulator (B), compressor
(o), tank (Z) and the oil separator element (Y), the minimum pressure and non-return valve
(L), the cock (R) and the maximum pressure valve (G), and the discharge solenoid valve
(P).
The suctioned air, after having passed through the double stage filter (A)
reaches the suction regulator, followed by the compressor which conveys it, together with
the injected oil, into the oil separator tank. Where the air is separated from the oil. This
separation process firstly comes about by means of centrifugal spinning and in the second
stage with the use of the oil separator filter (Y).
The air which is cleansed of the oil, is conveyed by the minimum pressure valve
(l), and only opens when the pressure in the tank reaches the pre-set value. This minimum
pressure formed in the tank guarantees oil circulation even when the air discharge taps
(R) are in fully open position.
It is however a good idea not to use tools and equipment, which excessively
consume compressed air, and which may cause the tank pressure to fall to below 5-5.1
bar.
In fact prolonged working conditions at below 5 bar, may cause compressor
overheating, due to insufficient lubrication, and inadequate air and oil separation, resulting
in excessive lubricant consumption.
The solenoid valve (P), on stopping the machine, opens automatically, gently
discharging all the compressed air still inside the system into the atmosphere.

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The minimum pressure valve (L) also acts as a single-direction valve, impeding
return into the compressed air unit of air coming from channels or tools connected to the
machine.

-- 5-9-3) AUTOMATIC MOTOR SPEED REGULATION (Fig. 2) --

The system controls the speed of the diesel motor according to the compressed air taken
in and consists of: maximum pressure valve (G), suction regulator (B), accelerator control
piston (E), contrast spring (H).

• With motor on and the cock (R) fully open, the motor speed is at the maximum and the
suction regulator is fully open.
• By slightly closing the cock (R) reduced air consumption is simulated with consequent
increase in pressure in the tank (Z).
• On closing the cock (R), the pressure reaches the pre-set value and the maximum
pressure valve (G) opens, allowing compressed air to flow out, which acts on the
accelerator control piston (E) and beneath the suction regulator valve (B).
• Being stimulated by this pressure the piston (E) is able to exceed the contrast force of
the spring (H), and by means of a lever system, the motor is proportionally decelerated.
• At the same time the suction regulation valve (B) also closed proportionally, thereby
reducing the suction air passage. Therefore with cock (R) closed and with no air
suction, the motor stabilizes at the minimum set speed while the suction valve (B) of the
regulator reaches almost total closure position.
• In this stage of the cycle the suctioned air is minimal and it serves to compensate for
any leakage within the circuit itself.
• At this stage the maximum final pressure will be indicated on the pressure gauge of the
control panel.
• On resumption of air intake stage the maximum pressure valve (G) will start to close up
and it will be totally closed when the pressure value falls to below approx. 1 bar in
relation to the maximum final pressure value.
• During this stage the compressor delivers the maximum capacity to the working
pressure as the spring (H), without the contrasting effect of the accelerator piston (E),
accelerates the motor to maximum speed and the suction regulator valve reaches fully
open position.
• In the event of use of tools with a consumption exceeding the nominal capacity of the
compressor, a reduction in the pressure will be noted on the gauge, which must
however never be less than 5 bar.
• Avoid any sudden opening of the cocks: they cause excessive stress on the oil
separator filter and serious damage to the same.

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-- 6) MACHINE HANDLING AND PARKING --

-- 6.1) LIFTING INSTRUCTIONS (Fig. 3) --

The bodywork has a special opening protected by a rubber covering, making it

possible to easily reach the lifting hook, without lifting the bonnet.
A lifting clevis is supplied for this purpose together with the compressor.

a) Check that the lifting parts (crane, hoist etc) have the capacity to move the
weight of the unit (see par. 2). If the crane is positioned on the vehicle, position the
lateral anti-tilting stabilizers.
b) Hitch the clevis and the rope (fig. 3) to the hook of the lifting means.
c) Gently and smoothly lift the unit.
d) Avoid making the machine sway during lateral movement.

The machine user must periodically check the state of efficiency of the lifting
equipment described above, and must immediately replace it when it is no longer
safe. No other hitching and lifting systems are permitted except those fitted on the
machine.

FIG.3

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-- 7) INSTRUCTIONS FOR MACHINE USE --

Specialized personnel are not required for the operation of this compressor,
however it is essential that the operation personnel have read the manual and that they
can put into practice all the instructions and advice provided.
It is only necessary to use specialized personnel for special maintenance
operations, and those with the necessary technical know-how as provided by the "Rotair"
assistance service.

-- 7.1) BEFORE STARTING UP THE MACHINE --

Before starting up the machine carefully proceed according to the following instructions:

-7.1.1) Make sure that the machine is level; using the support foot or wheel; an
inclination of over 15° is not permitted;

-7.1.2) Check that the electric wires are connected to the battery terminals; when
making connections always take the greatest care to ensure that the cable which
comes from the starter motor is connected with the positive pole (+) of the battery
and that the wire connected to earth is connected to the negative pole (-) of the battery;

-7.1.3) Check the motor oil level; refer to the instructions contained in the use
and maintenance manual as concerns the type and quantity of lubricant to be used
enclosed with this machine documentation;

-7.1.4) Check the compressor oil level: this operation must be undertaken no sooner than
5 (five) minutes after the machine has been stopped, this is in order to permit the lubricant
in circulation to completely flow into the oil separator tank.

- Before unscrewing the cap of the filler to which the graduated level rod
is fixed make sure that the system is no longer under pressure (the manometer should
indicate 0 bar)

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- Remove the cap and clean the

level indicator rod
- Tightly screw back the filler cap
and then re-extract it to ensure that
the lubricant level is between the
two notches (minimum level and
maximum level) on the rod.
- if necessary add the required
amount of oil: the level must never
exceed the maximum level notch.
- Use only the oil types indicated in
paragraph 2 (Technical data).
-7.1.5 Check the level of
the cooler liquid in the radiator
(Fig.9).

FIG. 8

ATTENTION: The radiator cap must never be removed while the engine is hot, as
this would cause a sudden escape of liquid that could cause serious burns.
Any top-ups must be made using a mixture of water and anti-freeze liquid, in the
percentages as indicated on the container of the same.

-7.1.6) Fuel check: turning the key of the starter block in clockwise direction
(part. 2- Fig. 1 check the fuel indicator (part. 9- Fig.1). If it lights up top up with fuel. Use
fuels with similar characteristics to those indicated in the motor manufacturer's manual.

-7.1.7) Carefully check to make sure that there are no traces of oil or fuel inside
the machine as the result of top ups.

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- 7.2) STARTING UP --

1) Completely close the air delivery taps

2) Position the switch (part. 1 fig.1) to START
3) Turn the key (part. 2 fig. 1) of the starter switch
in a clockwise direction until the first click which
causes lights 5 and 4 to come on (alternator and
oil pressure).

Should any of these lights fail to come on, make

sure that they are not burnt out, if they replace
using bulbs of the same type.

FIG. 1

4) Keep the plug preheating button (11) pressed for a max. time of 20 seconds.
5) Turn the key another notch in a clockwise direction and keep in this position until the
motor starts. If the motor fails to start at once, do not insist in order to prevent any damage
to the starter motor; repeat the operations starting from points 2,3,4.

WARNING: - Release the key as soon as the diesel motor gives signs of
starting up.
- Do not extend the starting times to over 10 seconds.
- In the event of any difficulty in starting, repeat the operation
with short and spaced starting operations.

6) With motor on and the switch (1) positioned to START, the motor is rpm is at a
minimum and the pressure gauge indicates a pressure of between 2-3 bars, while the
lights on the control panel must be all off.
Should one or more lights still be on after 5-6 seconds, immediately stop the machine and
find out the cause.
7) After allowing the motor to warm up for a few minutes, position the switch to "WORK".
The machine is now ready to work
8) Therefore connect the compressed air delivery piping to the relative utensils.
9) Gradually open the cocks.

-- 7.3) DURING THE WORKING STAGE --

1) The machine must always operate with bonnet lowered and closed.

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2) The suction inlets must be constantly checked to prevent any obstruction by foreign
particles such as paper, plastic, etc.
3) Check the fuel level.

-- 7.4) STOPPING --

1) Fully close the delivery cocks.

2) Position the switch (1) to "START" and wait for the pressure to fall to 2-3 Bar.

3) Turn the starter block key in anti-clockwise sense by one notch. It should be in start
position and the lights must all be off

VERY IMPORTANT: if these instructions are not respected carefully, it could

happen oil escapes from cocks during the compressor starting.

-- 7.5) AFTER MACHINE STOP --

1) After machine operation in very dusty conditions, it will be necessary to clean and
replace the air filter and check that the cooling radiator is clean

2) Check that there has been no oil or fuel leakage during operations. If there has, find the
cause.

3) Store the machine in a covered area if possible.

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-- 8) MACHINE SETTING AND TUNING --

-- 8.2) CHECKING AND SETTING OF THE MAXIMUM FINAL VALUE (Fig. 5) --

The maximum final pressure is set during the machine testing stage. With
motor running at minimum and cocks closed, the pressure value indicated on the gauge
on the control panel must correspond to that indicated in paragraph 2. In the event of a
variation of over ± 5% proceed with calibration of the maximum pressure valve as
follows:

1) Keep the machine running with cocks

closed.
2) Loosen the lock-nut (2) fig. (5)
3) Tighten the regulation screw (1) to
increase the pressure.
Loosen regulation screw (1) to reduce the
pressure.
4) Re-secure the counter-nut (2).
5) Slightly open the air delivery cock for 3-4
seconds in order to accelerate the motor,
then close again. Repeat this operation 2 -
3 times for valve positioning.

FIG. 5

6) Read the pressure on the gauge and if necessary repeat calibration as indicated in
points 2 - 3 - 4, until a value as indicated in paragraph 1 is obtained 1.

WARNING: Should the gauge have a jerky discontinuous function, it must be

replaced. Therefore before undertaking any calibration of the maximum and
minimum pressure valves, make sure that the gauge itself is efficient and reliable.

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-- 8.3) MINIMUM PRESSURE CHECKING AND SETTING (Fig. 6) --

The purpose of this valve is to ensure that during operation the pressure in the
oil separator tank does not drop under the minimum value, in order to ensure the
necessary oil circulation.

CHECKING AND SETTING:

1) Start up the machine as described in paragraph (7.2).

2) With motor warm, at right temperature, gradually proceed to fully open the air cock; the
motor will reach maximum rpm and a pressure of between 4.5 - 5 bar must appear on the
gauge.

Should a different pressure appear

2 than that indicated above, proceed
with setting as follows (fig. 6):
3 Release the lock-nut (1) .
4 Tighten the regulation screw (2)
1 to increase the pressure to the
desired value.
5 Loosen the regulation screw (2)
to reduce the pressure to the
desired value
6 Tighten the lock nut (1) and
close the cocks.
7 Slowly re-open the air cock and
then close it again repeating the
operations several times in order to
permit the valve to settle into
place.

Fig. 6

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-- 8.4) SAFETY VALVE CHECK (Fig. 7) --

This valve is positioned on the oil separator tank and operates to discharge any
accidental overpressure.
This valve is calibrated and checked at the factory, and cannot therefore be
altered or tampered with for any reason.
Its efficiency can be checked periodically as follows:

1. Start up the machine as described in paragraph (7.2).

2. With cocks closed and motor running at a minimum, lift the pin upwards using pliers, as
indicated in fig. 18, and release as soon as the valve can be seen to discharge air.

FIG. 7

WARNING: The air which escapes from the valve during this checking operation
is mixed with oil particles and therefore to avoid soiling the operator and the
inside of the machine it is advisable to bind the valve with a cloth.

If the pin fail to rise after being guided with the pliers, thereby preventing valve breathing, it
must be replaced at once.
New replacement safety valves must be of the same type as the original and must be
complete with conformity certificate issued by the manufacturer.
As this valve plays a vital role in preventing any dangerous overpressure which could
cause the piping, or the oil separator tank to burst, it is important to request the original
spare part from ROTAIR SPA citing the machine serial number.

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ROTAIR will not accept any responsibility in the event of the use of non-original and non-
conforming valves.

-- 9) MAINTENANCE PROGRAMME --

This programme indicates all the necessary periodic operations to be

undertaken in the machine and which are essential to ensure its efficient function and long
life.

ORDINARY MAINTENANCE

Can be undertaken by the personnel who operate on the machine and includes
all those periodic programmed maintenance operations such as checks on the oil level, air
filters, refuelling, cleaning operations and checks to isolate any eventual leakage of
lubricant or fuel inside the machine.

Here follows a list of all the operations relating to the compressor part, in order
of frequency, while for those relating to the "motor" please refer to the USER AND
MAINTENANCE MANUAL, supplied by the motor construction company with the machine.

-- 9.1) DAILY CHECKS --

-- 9.1.1) DAILY AND BEFORE STARTING UP THE MACHINE --

- Check on the compressor oil level

- Motor oil level check (consult manufacturer's manual).
- Check for any lubricant or fuel leakage.
- Refuelling
- Check on the cooling liquid level (in the case of liquid cooled machine)

-- 9.1.2) DAILY AND WITH MOTOR RUNNING --

- Check on all the indicator lights positioned on the control panel

- Check on the maximum pressure level
- Check on the minimum pressure level

-- 9.2) WEEKLY --

- Check on air compressor filter

- Check on motor air filter (see manufacturer's manual).
- Check on the electrolyte level in the battery
- Check on the tyre pressure

WARNING: Should the compressor operate in a very dusty environment the air
filter must be checked, cleaned or replaced more often than indicated above.

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-- 9.3) EVERY THREE MONTHS --

- Check on motor minimum and maximum rpm

- Safety valve efficiency check
- Oil cooling radiator cleaning
- Check on the oil recovery nozzle
- Tank fuel drainage
- Braking system efficiency check
- Wheel checking and blocking

-- 9.4) ANNUALLY OR ACCORDING TO THE PLANNED FREQUENCY ACCORDING

TO HOURS OF OPERATION -

As concerns the motor refer to the manufacturer's user and maintenance manual.

After the first 50 HOURS: Compressor oil filter replacement.

Compressor oil replacement.

Every 500 HOURS: Compressor air filter replacement

Compressor oil filter replacement

WARNING: The replacement of the compressor air filter can also be undertaken
more often, according to the amount of dust in the working environment.

Every 1500 HOURS: Compressor oil replacement

Every 2000 HOURS: Oil separator element replacement

Every 3000 HOURS: General check on the various components by the "Authorized
Rotair" assistance service.

WARNING: during the various maintenance operations it is necessary to carefully

examine the rubber piping and should it be found to be excessively hardened and
rigid, they must be replaced with materials having equivalent technical features.
The piping must be in accordance with SAE 100 R1 standards.

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*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-

-- 10) PERIODIC MAINTENANCE --

-- 10.1) BATTERY CHECK --

- Unscrew the caps of the elements and check the electrolyte liquid level. Top up with
distilled water if necessary.

-- 10.2) COOLING RADIATOR CLEANING --

The cooling liquids of the compressor and motor are cooled by a radiator which
must therefore be kept clean to ensure that the ventilation air can easily pass through its
honeycomb flaps.
Should the flaps become clogged with dust of other particles, there is a risk of
harmful overheating of the mechanical parts of the screw compressor, seriously
jeopardizing its function and duration. It is therefore advisable to check it regularly and
clean it using compressed air or wash it using a pressurized water jet.

-- 10.3) OIL RECOVERY NOZZLE CHECKING AND CLEANING --

This must be undertaken in the event of any leakage of nebulized oil mixed with
compressed air, as follows :

• Unscrew the connection (Z)

positioned at the centre of the
tank.

• Inside the connection (Z) is a

nozzle (U); ensure that its
gauged hole is not clogged
(blow with a jet of compressed
air).

• Re-assemble.

FIG. 8

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WARNING: During the regular function of the compressor it is normal to note a

certain amount of oil flow out of the transparent piping which starts from the
connection (Z), towards the compressor head.

-- 10.4) FUEL TANK DRAINAGE --

The purpose of this operation is to drain away any water which may be left at
the bottom of the tank as the result of formation of condensation or due to the inlet of
polluted fuel.
Usually on site, cans are used for refuelling, which may contain traces of water which,
being heavier than the gas oil deposit on the base and may accumulate until it reaches the
level of the fuel fishing pipe.
It is therefore very important that drainage operations are regularly carried out,
to ensure against the risk of the water being suctioned and injected into the motor itself;
which would cause seizure of the pump and the injection device, as well as the rapid wear
of the cylinders with a consequent reduction in motor power.
It is also advisable to undertake refuelling at the end of the work shift in order to
prevent the risk of sudden temperature variation of the walls of the tank causing the
formation of condensation within the same.
Together with tank drainage undertake to replace the fuel filter, in order to
eliminate all traces of water from the supply system.
The tank must be drained at least 30 minutes after having stopped the
machine, in order to give the water time to separate from the gas oil and deposit on the
bottom of the tank.

Proceed as follows:

• Position the machine horizontally.

• Position a can under the tank of sufficient capacity to collect the discharge fuel.
• Unscrew the cap of the filler (part B )
• Partially unscrew the discharge cap (part C) until the liquid begins to flow and allow it to
flow out until no more traces of water can be seen. It is easy to recognize as the
presence of water tends to make the gas oil a whitish, opaque colour.
• Re-cap making sure that there are no leaks or drips.

WARNING: Should the leakage of impure or solid residues be noted during the
drainage operation, it will be necessary to completely empty the tank and clean
it.

The polluted fuel which has been drained must be collected and delivered to
specialized pollutant substance collection centres. It must under no circumstances be
disposed of in lakes or rivers, or be sent to public dumps.

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-- 10.5) COMPRESSOR OIL FILTER REPLACEMENT (Fig. 9) --

• Use a chain pipe wrench to unscrew the filter to

be replaced (part A ).
• Oil the seal of the new filter which must be
tightened and secured by hand only.
• Start up the machine and ensure that there is
no leakage near the seal; if there is; switch off
the machine and check the condition of the
machine and that it is correctly positioned in its
slot.

FIG. 9

WARNING: The old filter is impregnated with polluted and harmful mineral oil. It
must therefore be sent to the special collection centres.

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-- 10.6) COMPRESSOR OIL REPLACEMENT --

Compressor oil replacement must also be undertaken taking into account the
working conditions under which the machine operates (dusty conditions, very high
temperatures etc) and in any event at intervals which must never exceed 1500 working
hours, or at least once a year.
The relative filter must also be changed when oil is changed

Carry out this operation with the machine still warm, as follows:

1) Make sure that there is no pressure in the tank;

2) Unscrew the filler cap of the tank itself
3) Unscrew the emptying cap after having placed a container of adequate capacity
beneath it;
4) Unscrew and replace the oil filter cartridge ;
5) When the oil has completely come out, screw back the cap making sure to replace the
copper seal. Pour the lubricant oil through the fuller mouth to the right level (quantities and
characteristics as indicated in paragraph 2 )
6) Close the filler the machine checking to make sure there is no oil leakage. Allow the
machine to heat up and then stop it. Check the oil level again after 15 minutes and top up
as necessary.

WARNING: The replacement oil must be collected in a can and consigned to

the specialized centres authorized in the collection of pollutant products. It must
not be disposed of in the ground or lakes or rivers.

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-- 10.7) OIL SEPARATOR ELEMENT --

-- 10.7.1) CHECKING OF OIL SEPARATOR ELEMENT --

This operation is reserved for specialized and qualified personnel.

The frequency is usually estimated as being of about every 2000 working
hours, but it strictly depends on the observance of all the maintenance regulations
indicated in this manual.
Insufficient oil in the tank, failure to comply with the lubricant replacement
frequency indications or use of the machine with clogged cooling radiator, may all result in
serious damage to the separator filter.
Therefore after having checked the condition of the recovery nozzle and having
made sure of the correct oil level in thank, should there be any further traces of oil in the
compressed air, it is necessary to replace the oil separator filter (fig. 10).
To find out the degree of blockage of the oil separator filter proceed as follows:
- install a gauge at the top of the oil separator and check that the one on the machine is
efficient.
- Start up the machine and position the switch to ”WORK” (see paragraph 7.2)
- Partially open the delivery piping until the control panel gauge indicates the working
pressure.
- Read the pressure on the gauge positioned at the top of the oil separator and compare
the two values: should a difference of over 1 bar be found, it is a clear indication that the
filter is blocked and it must be neither cleaned or washed, but replaced.

-- 10.7.2) INSTRUCTIONS FOR THE REPLACEMENT OF THE OIL SEPARATOR

ELEMENT --

1. The operation must be undertaken with machine off and no pressure in the oil
separator tank.
2. Disconnect all the pipes from the connections positioned on the closure flange of the
separator tank, marking them so there is no problem on re-assembly.
3. Loosen the screws (fig. 10, part A) and remove the flange (B).
4. Extract the filtering element (D) together with the seals (C) and (E).
5. Assemble the new seal (E) in the relative slot which has been previously cleaned.
Endure that a metallic insert has been clipped to the seal in order to avoid the isolation
of the filter and the accumulation of static electricity. Otherwise there is a risk of the
separator filter catching fire.
6. Insert the new separator element correctly positioning it into the relative slot.
7. Assemble the second seal (C) with the same precautions as above.

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8. Reassemble the flange (B) in the pre-assembly position.

9. Tighten the bolts,(A), with a tightening torque of 80 Nm.
10.Re-connect all the pipes to the respective fittings.
11.Start up the machine ensuring there is no leakage between the cap and the tank.
12.Allow the machine to operate for 10-15 minutes with closed cocks and switch
positioned on “WORK”.
13.Stop the machine with tank depressurized to 0 bar, re-check the screw tightening (A).

FIG. 10

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