CPS 375-12 CPS- CPS

CPS 185 11-12H

5.5
Instruction Manual - Bedienungsanleitung
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 Instruction Manual

CPS 185 - CPS 5.5

Original
instructions

Printed matter N°
2950 5020 03

03/2012
CPS 185 - CPS 5.5 User Manual

Identification (manufacturer plate)

IRMER+ELZE

1092 0499 70
1 kg
1- 2 kg
3 kg

Model 4
p max(e). working Bar 5

Speed Rpm 6

P. engine kW 7

Type 8

S/N 9 Manuf. year 10

IRMER+ELZE
D-32547 BAD OEYNHAUSEN
0038

In any request for further information and/or when ordering spare parts, always mention the following data:
- Compressor type
- Manufacturing number
- Delivery date.
In case of a request for technical information, also mention:
- the present conditions of operation.
- the exact location of the machine.
- the name and telephone number of the person in charge of the machine.
You can get the data regarding the compressor from the manufacturer plate on the machine.

Warranty and Liability Limitation

Use only authorized parts. Maintenance intervals are to be strictly adhered.
Any damage or malfunction caused by the use of unauthorized parts is not covered by Warranty or Product
Liability.
The manufacturer does not accept any liability for any damage arising for modifications, additions or conversions
made without the manufacturer's approval in writing.
While every effort has been made to ensure that the information in this manual is correct, CP does not assume
responsibility for possible errors.

Copyright 2012, Chicago Pneumatic.

Any unauthorized use or copying of the contents or any part thereof is prohibited.
This applies in particular to trademarks, model denominations, part numbers and drawings.
User Manual CPS 185 - CPS 5.5

Contents

1 Important advice ........................................................................................................ 5

1.1 Updating ........................................................................................................................ 5
1.2 Validity of regulations/standards ................................................................................ 5
1.3 Copyright....................................................................................................................... 5
1.4 Scope of this manual.................................................................................................... 5
1.5 Scope of application..................................................................................................... 6
1.6 Warranty (General terms and conditions) .................................................................. 6
1.7 Disclaimer...................................................................................................................... 6

2 Safety and environmental protection standards/regulations................................ 7

2.1 Laws, regulations and directives ................................................................................ 7
2.1.1 Accident prevention standards ...................................................................................... 7
2.1.2 Transportation (Highway code) ..................................................................................... 7
2.1.3 Water Conservation Laws ............................................................................................. 7
2.1.4 Dangerous substances (Liquids)................................................................................... 7
2.1.5 Protection against Immissions....................................................................................... 7
2.2 General safety instructions regarding the compressor............................................ 8
2.2.1 User's obligations .......................................................................................................... 8
2.2.2 Personnel's obligations ................................................................................................. 8
2.3 Potential risks - safety during transportation, operation and maintenance ........... 9
2.3.1 Transportation and unloading ....................................................................................... 9
2.3.2 Machine installation..................................................................................................... 10
2.3.3 Machine start-up ......................................................................................................... 10
2.3.4 Control and operation of the compressor .................................................................... 11
2.3.5 Maintenance................................................................................................................ 12
2.3.6 Repairs ........................................................................................................................ 13
2.3.7 Tool applications safety............................................................................................... 14
2.4 Compressor safety devices ....................................................................................... 15
2.5 Waste handling and disposal .................................................................................... 15

3 Conditions of use and technical specifications ................................................... 16

3.1 Use limitations - Allowed operating conditions....................................................... 16
3.2 Technical Specifications Overview........................................................................... 17
3.2.1 Available options ......................................................................................................... 18
3.3 Torque values ............................................................................................................. 19
3.3.1 For general applications .............................................................................................. 19
3.3.2 For important assemblies ............................................................................................ 19
3.4 Markings and information labels............................................................................... 20

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4 Operation description ..............................................................................................21

4.1 Use of the compressor according to its intended purpose.....................................21
4.2 Design characteristics of the helical compressor....................................................21
4.2.1 Operation..................................................................................................................... 21
4.3 Instruction Manual.......................................................................................................23
4.3.1 Air flow (see Figure 1) ................................................................................................. 23
4.3.2 Oil system (see Figure 1) ............................................................................................ 23
4.3.3 Continuous regulating system ..................................................................................... 24
4.3.4 Automatic operation control......................................................................................... 25
4.3.5 System restoration....................................................................................................... 25
4.3.6 Tool lubricator for pneumatic tools .............................................................................. 26

5 Operating instructions .............................................................................................27

5.1 General instructions before starting .........................................................................27
5.2 Instructions for starting up the compressor.............................................................28
5.3 Instructions for stopping the compressor ................................................................28

6 Maintenance..............................................................................................................29
6.1 Maintenance schedule ................................................................................................30
6.2 Engine and compressor dry air filters.......................................................................31
6.3 Compressor oil change...............................................................................................31
6.4 Compressor oil filter change ......................................................................................31
6.5 Final oil separator........................................................................................................31
6.6 Oil radiator ...................................................................................................................31
6.7 Fuel tank.......................................................................................................................31
6.8 Safety valve..................................................................................................................31

7 Faults .........................................................................................................................32
7.1 Troubleshooting and remedying faults .....................................................................32

8 Electrical system ......................................................................................................35

8.1 Circuit diagram 12V DC (Standard)............................................................................35
8.2 Circuit diagram 12V DC (cold start) ...........................................................................36

9 Recommendations concerning oil..........................................................................37

9.1 Lubrication oils............................................................................................................37

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1 Important advice
1.1 Updating
This user manual is not intended to be updated. We may introduce modifications or improvements at any time,
especially regarding technical specifications, data and figures, as the result of new technical developments. Any
claim to receive modifications or improvements free of charge, for compressors that have already been delivered,
will not be considered.

1.2 Validity of regulations/standards

Laws, regulations, guidelines, standards etc. quoted in this manual, and those on which agreements are to be
based, were valid at the time of editing the manual. The latest valid versions have to be considered, however, and
it is the user's responsibility to keep track of the updates and to apply them always in their more restrictive (i.e.
more demanding) version.

1.3 Copyright
CP retains the copyright for this user manual. All rights are reserved, especially regarding the issue of patents and/
or the registration of designs.
• Before putting the machine into operation, the operator should become familiar with this User Manual
and with all the actions that need to be taken in order to operate the compressor safely. Learn the
maintenance operations that need to be carried out according to safety and competence
requirements.
• Your own safety, the quality of your environment and the safe operation of the machine, without any
risk to other equipment, can be achieved only through a good knowledge of this Manual and full
respect for all recommendations, e. g. accident prevention norms.
• The customer/user must make sure that the machine operators are acquainted with this User Manual
before undertaking any kind of intervention on the compressor, and that the safety and accident
prevention regulations are fully respected, together with all other guidelines and recommendations!

1.4 Scope of this manual

This User Manual is valid only for the compressors listed on the cover. It contains information on the compressor
itself and on all ancillary equipment, insofar as the latter is part of the supplied goods.
Descriptions of any equipment that is not part of the supply are given for information only. They would not give
matter to any claim on such equipment (e. g. options).
Any documentation from other suppliers that may be included (e. g. as an enclosure) is provided on the
understanding that CP are not responsible for its contents, specifications, technical data, etc.

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1.5 Scope of application

All accident prevention, environment protection and safety regulations are in accordance with local regulations.
The customer/user carries full responsibility regarding:
• Compliance to the laws, regulations, guidelines or standards listed or mentioned in the technical
documentation, in order to achieve safe operation and maintenance of the equipment,
• Checking their scope and consistency with local or company rules,
• Installation and use of safety or add-on equipment as recommended by the responsible (local)
Authority

1.6 Warranty (General terms and conditions)

The scope and the warranty period are given by CP in their General terms and conditions, in the paragraph
"General sale and supply conditions". The valid edition is the most recent one at the time of delivery.
Any condition not in accordance with the General terms and conditions should be notified in writing by CP in their
order acceptance.

1.7 Disclaimer
CP does not assume any responsibility in the case of damages occurring for the following reasons:
• Ignorance of or non compliance with this User Manual.
• Use of insufficiently qualified or trained personnel.
• Natural wear.
• Improper or careless use of the compressor. In particular, failure to perform any operation aimed at
insuring installation, start up, operation or servicing according to safety and competence
requirements.
• Effects of chemical, electrochemical and/or electrical agents.
For third-party products, the warranty provided by CP is limited to transferring the warranty granted to CP by the
original equipment manufacturer.

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2 Safety and environmental protection standards/regulations

The person in charge of safety in the user's organisation must become familiar with this chapter before putting the
system into operation for the first time and before undertaking any intervention on the system.

2.1 Laws, regulations and directives

2.1.1 Accident prevention standards
This User Manual does not replace the machine user's instructions. This User Manual has to be completed by the
user with regards to existing national regulations concerning accident prevention and environmental protection.
National regulations concerning accident prevention and environmental protection have to be obeserved and
indicated by the machine user.

2.1.2 Transportation (Highway code)

During transportation or transfer on public roads, the user must comply with the Regulations and rules for road
traffic (including the Highway code).

2.1.3 Water Conservation Laws

As regards handling and use of liquids that can be dangerous and/or harmful to water conservation - e.g. fuel,
lubricants, solvents or detergents or other chemical products - the user must comply strictly with Water
Conservation Laws.
Leakage of the above substances must be corrected immediately and without taking risks (in compliance with
Accident Prevention Standard (1.0), they must be neutralised and disposed of according to the regulations). Never
let these used substances (old oils) penetrate the ground or get into the drains.

2.1.4 Dangerous substances (Liquids)

When handling dangerous substances (cf. Law on Chemical Products, particularly Decree on Harmful
Substances) e. g. battery acid, it is mandatory to use accident prevention measures and wear protective gear.
The user has the obligation to provide information regarding the danger linked to the use of such substances
(Decree on Dangerous Characteristics of Chemical Products)!

2.1.5 Protection against Immissions

During the use of the compressor and all operations described in this User Manual, the user must comply with the
local laws for protection against immissions and associated decrees, as well as with laws on waste disposal.

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2.2 General safety instructions regarding the compressor

This compressor is built according to state-of-the-art techniques in order to ensure safe operation, provided it is
used according to its original purpose. However, if the compressor is operated improperly, used for purposes for
which it was not intended or by insufficiently qualified or trained personnel, it may present a risk for the safety of
personnel or third parties and cause damage to itself or other equipment. Using the compressor properly also
means complying with normal technical rules, adopting safety oriented procedures and following the
recommendations and advice provided by this User Manual, in the course of:
• transportation, installation, preparation before starting operation
• operation start-up and monitoring
• inspection, servicing and maintenance and
• repair.
For maintenance and repairs, use only qualified service personnel, who should have a good knowledge of
accident prevention and safety standards, good knowledge of the machine and this User Manual and who are
suitably aware of the potential hazards of the machine on the installation site.
CP will take no responsibility in the case of damages that are due to unsuitable use of the compressor. In this case
full responsibility rests with the user.

2.2.1 User's obligations

The user must check the compressor before every start-up, assuming all responsibility in ensuring operation
safety and/or traffic safety.
The user must immediately take all measures aimed at preventing risks to personnel and equipment, in
compliance with accident prevention standards.
The user is responsible for a safe execution of all work carried out by his/her own service personnel or by third
party contractors.
All personnel operating on the machine must receive instructions on the machine and/or the installation site
potential risks from the user and operate in a technically safe way and in compliance with the protection measures.
When charging his/her personnel with the execution of repairs and other work, the user must define clear
responsibilities.
No risk should arise because of unclear responsibilities.
When handling a substance that could be dangerous and/or harmful to water conservation (law on Chemical
Products, Law on Water Conservation), all personnel involved must receive the data sheet showing data
concerning the use of the substance according to German Standard DIN 52 9001. The user is responsible for the
disposal of waste and all used substances that may be produced during operation and during maintenance jobs,
in accordance with the regulations in force.

2.2.2 Personnel's obligations

Any person put in charge of any job described in this User Manual on the compressor installation site or at the
workshop, must have read and fully understood the instructions for use, and particularly this chapter "Safety and
environmental protection standards".
Once the compressor is operating, it is too late to do so!
Do not attempt any work method that could put the personnel and the machine at risk.
For transportation on public roads comply with the regulations in force (particularly the Highway Code).
Before starting any work with the machine, obtain all information regarding its devices and control means and pass
this information to the other persons involved.
Handle fuel, minerals and easily inflammable substances with care and beware of the danger of fire and explosion.
Make sure there are sufficient fire-fighting means available and learn the alarm procedures. Make the necessary
regulations for first aid.

1
c.f. EC Conformity Declaration

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Before start-up, make sure that the compressor is ready to operate, that all safety devices are installed according
to safety standards and are in working order, that the machine cover is closed and that nobody is endangered by
operation of the machine.
Never put the machine into operation if the safety devices are only partially effective. Make sure that nobody stops
or works close to the machine or has undue access to the controls.
Check the compressor at least once per shift for external damage or defects.
If there are changes in the behaviour or performance of the compressor, immediately inform the appropriate
person or office appointed by the user. In case of failure, stop the machine immediately, especially if safety could
be put at risk!
Take all measures aimed at preventing any accidental or improper start-up while servicing the machine. Undertake
any maintenance or repair job only when the compressor is clearly switched off and has already cooled down.
Beware of the very hot surfaces of the machine during operation, or immediately after stopping the machine, if the
cover is open.
Always make sure that the safety and accident prevention regulations, the warning signs and the manufacturer's
plate are kept easily readable. Never introduce arbitrary modifications on the compressor, or worse still on its
safety devices. Comply with environmental conservation regulations when disposing of used substances (namely
oil!) and avoid any leakage. Ensure that the compressor installation site is clean and orderly.
Avoid any excess of force during operation, maintenance or repair.
It is forbidden to use excessive force when loosening or tightening screws, etc.; this could damage the equipment
and jeopardise machine safety.

2.3 Potential risks - safety during transportation, operation and maintenance

All the following recommendations should be complied with, otherwise personnel could be put at risk and the
compressor or other equipment could be damaged.

2.3.1 Transportation and unloading

To unload the machine, move it or assemble heavy parts, it is necessary to use a hoist and/or a crane. Only use
suitable, well functioning hoists and lifting tools with the necessary load capacity.
The machine as a whole should only be suspended from its sling hook. Check sling gear for possible damage or
wear before usage.
Suspending the machine may only be carried out by experienced personnel.
Never stop or work under hanging loads! Danger of death!
Before any transfer, check the frame and the lights to comply with road traffic regulations:
• Check the pressure of the tyres and their tread; check that all nuts or bolts are well set and if necessary
tighten them.
• Check the towing gear and the hitch. The trailer hitch must move freely in the suspension pin. The towing
device joints (adjustable in height) must be stretched, fastened and secured using a wrench.
• Check the brakes! Attach the safety chain to the trailer.
• Connect the trailer lighting system; check that all lights are in order.
• Never detach the trailer on the installation site, even if there is little available space. There is a high risk of it
tipping and causing injuries.
• Check that screws frame/towbar are fixed tight with specified torque.
• Glue sealed screws should not be retightened or used again.
• Safety chain must be connected to the towing vehicle.
The compressor must be transported in idle state, with no pressure, the cover being closed and the compressed
air pipes disconnected.
Before starting, check that the bearing wheel is lifted and secured. The compressor must always be connected
horizontally to the draft gear.
With a trailer, never exceed the speed limit. While driving round curves or on a transversal slope, beware of it
turning over.
Always make sure that steering and brakes are in perfect order.

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2.3.2 Machine installation

Before installing the machine, draw out the bearing wheel and lock it in its extended position.
Always install the compressor horizontally on stable ground; engage the handbrake, if available.
Apply wedges under the wheels.
In the case of sloping ground, secure the compressor against rolling or turning over.
Do not obstruct exits! In a dusty environment, make sure that the machine does not suck up dust because of the
wind. Bear in mind that for operation in a dusty environment, maintenance intervals should be made much shorter.
Never install the compressor close to explosive, inflammable or harmful gases or vapours. Engine exhausts
produce carbon monoxide (CO) - a deadly gas. When operating in a closed room, exhausts should be connected
directly to the outside through a duct or flexible pipe of 100 mm minimum diameter.

2.3.3 Machine start-up

Fill up only when the compressor is stopped.
• Do not spill the fuel. Bind up and/or soak up any leakage (Accident prevention standard 1.0). Keep the
machine clean, neutralise the leakage, e.g. with water and vinegar (50/50).
• Fuel must not come into contact with the hot parts of the machine. There is danger of ignition.
• Smoking is forbidden while refuelling. Never refuel close to open flames or sparks.
If an electrical pump is used, a static charge may be produced. Connect a ground cable to the compressor to avoid
sparking. The nominal diameter of the compressed air piping (DN) must be no less than that of the breathing
nozzles and must be chosen according to operating pressure. Never use damaged piping! Use suitable
connections, check seals before connection. When connecting, close air intakes.
Connect the piping carefully before blowing air. There is the risk of a "whip stroke" which could cause injuries to
personnel.
Never move the compressor while the compressed air piping is connected!
Before connecting the compressed air piping, close air intakes.
Regarding safety measures for auxiliary engines, refer to the enclosed User Manual provided by the manufacturer.
Be very careful when handling batteries. Battery acid is very corrosive (it contains sulphuric acid) and during
battery charging, it produces an explosive gas mixture.
For industrial accident prevention, comply with the relevant standards and in any case wear protective glasses
and gloves.
The use of naked flames is forbidden and so is smoking!
To connect the battery, follow this sequence:
• First connect the positive pole.
• Then connect the negative pole (earth).
Always comply with the regulations regarding the disposal of old batteries!

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2.3.4 Control and operation of the compressor

The compressor is controlled exclusively through the control panel located under the door while the machine upper
cover (hood) remains closed. During operation, the door must not be closed, to allow permanent access to the
control panel.
Before putting the compressor into operation - particularly after servicing and repair - remove all tools, cleaning
cloths, ancillary equipment or parts. Any foreign body getting accidentally into the machine can generate damage
or induce malfunctioning! The compressor must be put into operation only once the protective cover (hood) is
closed!
Non compliance with this rule will induce machine overheating and produce an unbearable noise level, besides
putting the safety of personnel at risk!
Operating characteristics - such as pressure, speed and temperature - must always keep close to nominal values
given in the Technical Specifications Table!
Tools (such as compressed air tools) connected to the compressor must have compatible specifications,
particularly regarding operating pressure, which can be adjusted every time and air quality, which must be within
tolerance range. During compressor operation, the operator must wear protective gear (particularly ear protection
gear).
Noise, even at reasonable levels, can cause irritation and disturbance which, over a long period of time, may cause
severe injuries to the nervous system of human beings.
When the sound pressure level, at any point where personnel normally has to attend, is:

below 70 dB(A): no action needs to be taken,

above 70 dB(A): noise-protective devices should be provided for people continuously being present
in the room,
below 85 dB(A): no action needs to be taken for occasional visitors staying a limited time only,
above 85 dB(A): room to be classified as a noise-hazardous area and an obvious warning shall be
placed permanently at each entrance to alert people entering the room, for even
relatively short times, about the need to wear ear protectors,
above 95 dB(A): the warning(s) at the entrance(s) shall be completed with the recommendation that
also occasional visitors shall wear ear protectors,
above 105 dB(A): special ear protectors that are adequate for this noise level and the spectral
composition of the noise shall be provided and a special warning to that effect shall
be placed at each entrance.

Never direct the air flow towards a person and never use it to clean clothes. Be careful when opening the air inlets!
Always wear protective glasses while cleaning equipment! Never breathe compressed air from the
compressor! In the case of compressor malfunction or abnormal noises, irregular motion and/or oscillations or
vibrations, operating characteristics different from nominal specifications, stop the machine immediately and take
all suitable safety measures! Never put the machine back into operation before finding the cause of the malfunction
and correcting it.

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2.3.5 Maintenance
Before starting any maintenance job, the compressor must be stopped, secured against any possibility of rolling
or tilting and emptied completely. Total absence of residual pressure must be checked! Remove the battery
connection to the ground to make it impossible to restart the machine accidentally! Wait until all machine parts,
including the engine, have sufficiently cooled off. Advice: change oil while the machine is still warm after a normal
working cycle, complying with safety standards and using all personal protection gear, as recommended.
To clean the inside of the machine, only blow compressed air; also refer to the Engine User Manual.
Keep all heat-transmitting surfaces (such as cooling fins, etc.) clean to prevent the machine from over-heating.
Keep the machine clean with the utmost care during maintenance and repair operations. Cover or seal the
removed parts as well as the openings left on the machine! Open oil fillers only immediately before filling. Dirt can
induce malfunctions or damage. As used washing water and loose dirt are usually contaminated with service fluids
(fuel, oil), collect washing water and residues and dispose of according to local laws. If required, convey them into
an oil and petrol separator. Never let used washing water penetrate the ground or get into the drains.
While collecting hot lubricants (after operation), beware of scalding! Wear protective gear.
Never heat oil over 160° C and avoid oil leakage onto hot parts of the machine; should this happen, clean
immediately. Oil and its vapours may ignite spontaneously. Collect used lubricants (used oil) only into suitable
containers and dispose of them according to regulations!
Bind up any oil leaks immediately or at least never let it fall onto the ground or into the drains (Accident Prevention
Standard 1.0).
Never mix different kinds of oil, in particular synthetic and mineral oils, oils with a different degree of viscosity or
even oils from different suppliers.
Always discharge oil completely when changing it.
Always store lubricant tins appropriately. Never let synthetic, mineral oils or grease, detergent solutions or other
chemical products drip onto non metallic parts (made of rubber or synthetic substances), e.g. hydraulic pipes,
connection boxes, switches, seals, noise insulating material etc. Never tamper with compressor and engine noise
insulators.
Noise insulators (foam-rubber, insulating felt and cover seals) must always be kept clean and replaced if damaged.
If there is a failure on the electric circuit, stop the compressor immediately. Restart it only after a specialist has
corrected the problem.
If there is a safety device failure, replace the device with an original spare part only, with the proper voltage rating.
You will find safety recommendations regarding the frame, the wheels and the brakes in the manufacturers'
instructions for use. Check tyre pressure and wheel bolts regularly, especially after a long stay at the installation
site. Tyre changing must be carried out only by specialised personnel using suitable tools.
Adjustment, maintenance and repairs to the brakes must be carried out only by specialised personnel or
authorised workshops.

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2.3.6 Repairs
Never tamper with the adjustment and safety devices during maintenance operations or repairs!
Repairs on the compressor must be carried out exclusively by personnel who are specially trained by CP.
Worn or damaged components, following safety intervention during operation, must be replaced immediately.
Spare parts, pieces of equipment and accessories not certified and approved by CP could jeopardise the active
and passive safety of the machine.
Always use original spare parts!
For maintenance, removal and assembly, use only tools in perfect order - never use wrenches with blunt corners,
chipped screwdrivers, hammers and chisels with broken tips. Use the tools according to usual rules, keeping in
mind safety and accident prevention matters! To access high-positioned parts, use lifting means or scaffoldings
that are clean and rust-free. Never climb onto the machine - especially never use the air inlets as climbing aids!
If jobs must be undertaken under the machine to replace tyres etc., the axle should be suitably shored and the
machine should be secured to prevent it from colliding or tilting. Never leave the machine unguarded on the lifter.
Loose screw couplings must be tightened immediately up to the recommended tightening torque using the
standard tool (dynamometric wrench). Damaged screws and nuts, as well as components with worn threads, must
be immediately replaced.
Pay attention to the strength rating of the screws!
Any screw assembly must include a screw retainer which should be reassembled after maintenance intervention.
Should a retainer be missing, this could induce operating problems and jeopardise the safety of machine
operation.
Safety spring or resilient components (locking washers, spring washers, split pins, etc.) must not be reused after
loosening the coupling. Always use new parts.
Never replace hexagonal self-locking nuts (complying with DIN 985) with standard nuts.
Never perform any welding operation on pressurised tanks.
During all welding jobs, keep the fire extinguishers at hand; comply with the fire prevention rules.
When performing a welding job or any other activity which may generate high temperatures or create sparks,
adjacent parts should be protected by heat-shields made of fire-resistant insulating material.
Should you have to undertake a welding operation close to fuel or oil circuits, these must be emptied and freed
from inflammable vapours, e. g. by injecting an inert gas.
For welding jobs in the yard or in closed rooms, abide by the relevant company rules. Obtain authorisation from
the security guards.

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2.3.7 Tool applications safety

Apply the proper tool for each lob. With the knowledge of correct tool use and knowing the limitations of tools,
along with some common sense, many accidents can be prevented.

Special service tools are available for specific jobs and should be used when recommended. The use of these
tools will save time and prevent damage to parts.

1. Use only spanners or sockets whose opening fits the fastener.

2. Apply an open-end spanner only in the plane of the fastener head, square to the thread axis. Never cock an
open-end spanner.
3. Do not use a pipe or other improvised leverage extensions on handles.
4. Do not hammer on spanners or other tools which are not specially designed therefore.
5. Do not use adjustable spanners to tighten or slacken fasteners; they are intended to hold the other end of the
fastener.
6. Always support the ratchet head when using socket extensions.
7. Discard any spanner with broken or battered points or edges.
8. Never use hand type sockets on power or impact tools
9. Select only heavy-duty impact sockets for use with pneumatic or electric impact tools.
10. Replace sockets showing cracks or wear; keep sockets clean.
11. Never use screwdrivers for prying, punching, chiselling, scoring or scraping.
12. Use the correct type and size of screwdriver for the job. The bit must match the fastener.
13. A screwdriver with rounded edges will slip; it needs to be redressed or discarded.
14. Never use a screwdriver or any other tool near a live wire or electrical component. Plastic covering of
handles is for comfort and grip only. They are not intended to act as insulation if such is not clearly marked
by the manufacturer.
15. Never strike a hammer against a hardened object; use a soft drift against the object and strike against the
drift.
16. Strike the object with the full face of the hammer.
17. Never use a hammer with a loose head.
18. Discard a hammer with chipped or mushroomed face.
19. Never use a chisel or punch with a chipped or mushroomed striking face.
20. Always pull on a spanner or socket handle, if possible, and adjust your stance to prevent a fall if something
lets go.
21. Wear approved eye protection when using percussion tools or when scraping, chipping, shaving or grinding
22. Wear protective gloves when holding a chisel or punch.

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2.4 Compressor safety devices

The compressor is shut off by turning the control panel ON/OFF switch (position 51, Figure 2) to the position
0=OFF.
A thermo switch protects the compressor from over-heating.
When the temperature exceeds the limit, the thermo switch stops the fuel supply, thus halting the machine.
The safety valve (position SV, Figure 1) protects the compressor by preventing the pressure from exceeding the
maximum acceptable value.
The motor is protected from insufficient oil pressure, from too high oil temperature and from generator failures. In
case of a fault, a safety switch will immediately stop the machine.
The protection device (upper cover), aimed at protecting against any contact with the machine's rotating parts,
must always be kept closed during operation to avoid excess of noise and to allow a proper cooling of the machine.
The devices aimed at avoiding contact with rotating parts (e. g. the compressor engine, the fans, etc.) must never
be removed and must be fastened accurately before the machine is put into operation for the first time.
The warning signs (placed on the compressor) must never be removed and must always be kept clean and easy
to read. The same applies to the machine manufacturer plate.

2.5 Waste handling and disposal

During maintenance and repair operations, the following waste can be produced and then disposed of under the
personal responsibility of the user:
• Fuel residues.
• Used substances, like lubricating oils and greases.
• Auxiliary substances, e.g. detergents and washing water.
• Expendable material: e.g. filter spares, cleaning cloths, etc.
• Other waste of any kind, including pieces from the machine itself.
When changing the battery, comply with the regulations in force. Dispose of the old battery safely; avoid acid
leakage!
Any leakage or spilling of fuel, oil, solvent, detergent or other chemical substances must be suppressed
immediately without taking risks (Accident prevention standard 1.0).
Dangerous substances must be neutralised as prescribed, i.e. agglomerated and/or sucked up.
Substances which could be harmful or dangerous for water conservation (used oils) as well as contaminating solid
waste (e.g. filter spares) must be collected in closed containers, certified for this purpose. Their disposal should
be organised on a regular base while they should be stored safely in between.
Expendable material should never be disposed of in the ground or in the drains!
Disposal should be carried out according to local or regional laws for protection against immissions, laws for water
conservation as well as laws on waste disposal. Furthermore, comply with company regulations!

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3 Conditions of use and technical specifications

3.1 Use limitations - Allowed operating conditions
The compressor must operate in compliance with the technical specifications included in this User Manual, or with
those stipulated when ordering, always according to its intended purpose.
Operation of the compressor can induce malfunctions or risks to personnel or other equipment in case of:
• Skipping recommended maintenance or repair operations or non compliance with the recommended timing
• Use of unsuitable expendable materials (fuel, oil, lubricant, etc ...) or insufficient supply of the same
• Use of unsuitable or defective spare parts or materials subject to wear. Recommendation: Always use
original spare parts.
During operation, the cover must always be kept closed to ensure a correct cooling of the machine.
Technical specifications must not be exceeded but must be complied with (see 3.2 Technical Specifications
Overview).
The compressor must use only air having a sufficient degree of purity, according to operating conditions.
The air must not contain explosive, flammable, harmful or corrosive gases or vapours.
Avoid absolutely air containing dust or solid particles. Using dirty air always means shorter maintenance intervals;
these are heavily dependent on operating conditions.
Make sure that the floor on the installation site has a sufficient bearing capacity.
Never exceed speed limits during transportation. Always comply with local regulations (highway code, etc...).
The compressor is built with common materials and is protected against corrosion and made insensitive to
environment conditions from the factory.

Technical characteristics, drawings and figures given in this user's manual are not binding and may not give origin
to any claim. We keep the right to introduce modifications without any obligation to update this manual.

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3.2 Technical Specifications Overview

Model CPS 185 - CPS 5.5
Flow rate according to standard ISO 1217
at nominal speed and pressure m3/min 5.3

Adjustable pressure range bar 4.0-7.0

Rated operating pressure bar 7.0
Air intake cocks 3x G3/4
Allowed noise level according to Lwa (EC) db(A) 98

Length with raised towbar mm 3587

Length with extended towbar mm 4339
Width mm 1400
Heigth mm 1280
Fuel tank capacity l 80
Weight including fuel and oil kg 970
Overall operating weight kg 1145
Data with DIN-trailer coupling ring/unbreaked/vertically adjustable
Diesel engine
DEUTZ, oil-cooled Type EPA4: D2011 L03 COM II: F3M2011
Power at nominal speed kW (hp) 36
Nominal speed rpm 2750
Operating speed range rpm with continuous regulation
Air filter dry air filter incl. precleaning
Oil capacity l 8.5
Water capacity l -
other data See engine user's manual
Battery
Voltage V 12
Capacity Ah 63
Compressor
Air filter dry air filter incl. precleaning
Oil capacity l 8.75
Single-axle carriage (compliant with road traffic regulations)
Suspension
Maximum speed km/h 140 (Comply with national regulations)
Brakes
Tyres 165R13 87T
Tyre pressure bar 3.5/3.7
Track mm 1235
Use limitations
Ambient temperatures °C -10/+45
m above sea
Height max. 1000
level
Maximum slope % 15

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3.2.1 Available options

The compressors can be delivered with following options:

Chassis: Vertically adjustable

Section frame (stationary)

Towing eyes: DIN (40 mm) [1.57 in]

Passenger car (Ball 50 mm) [1.95 in]
France (68 mm) [2.65 in]
Italy (45 mm) [1.75 in]
Nato (76 mm) [2.96 in]

Road lights system: Full road signalisation

24 V Adapter

Air quality equipment: Tool lubricator

Aftercooler + water separator

Tool box: Single

Twin
Air take-off: Hose reel

Safety: Safety cartridge

Non return valve
Additional literature set

Cold start: Cold start - 20 °C 1)

Canopy colour: single

1)
Engine preheating system, Thermostatic by-pass valve, 10W40 engine oil, Genoil S and battery with higher
capacity.
Note: Options are available depending on the country. Please contact with the local CP dealer.

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3.3 Torque values

3.3.1 For general applications
The following tables list the recommended torques applied for general applications at assembly of the compressor.

For hexagon screws and nut with strength grade 8.8

Thread size M6 M8 M10 M12 M14 M16

Nm 9 23 46 80 125 205

For hexagon screws and nut with strength grade 12.9

Thread size M6 M8 M10 M12 M14 M16

Nm 15 39 78 135 210 345

3.3.2 For important assemblies

Assemblies Unit Torque value

Wheel nuts Nm 90 +16/-0
Bolts, axle/frame Nm 73 +/-16 glue locked
Bolts, towbar/axle Nm 185 +/-39
Bolts, towbar/A-frame Nm 73 +/-16
Bolts, towing eye/towbar Nm 80 +/-10
Bolts, lifting eye Nm 80 +/-10
Bolts, engine/drive housing (M12) Nm 80 +/-10
Bolts, engine/drive housing (M14) Nm 125 +/-10
Bolts, compressor element/drive housing Nm 80 +/-5
Bolt, fan adapter Nm 205 +/-10 glue locked
Safety switches Nm 35 +/-5

Note:
Secure the tankcap and drain cock of the fuel tank handtight.

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3.4 Markings and information labels

Compressor outlet temperature too

Rotation direction.
high.

Compressor outlet temperature. Inlet.

Compressor outlet pressure. Outlet.

Dangerous outlet. Compressor oil drain.

Read the instruction manual before

Danger, heat flat.
starting.

Electrocution hazard. Service every 24 hours.

Warning!
Engine oil.
Part under pressure.

Engine oil.
Do not stand on outlet valves.
Use at temperatures under -10 °C

Manual. Start-Stop indication of switch.

Read the instruction manual before

Do not run the motor with open doors.
working on the battery.

Reset fuse. Lifting permitted.

On / off button. Use diesel fuel only.

Hours, time. 3.7 bar / 54 psi Tyre pressure.

Prohibition to open air valves without Sound power level in accordance with
connected hoses. Directive 2000/14/EC (expressed in
98 dB (A)).

Compressor loaded.
Horizontal towbar position
required in case of coupling.
Runlamp.

Earthing connections.
Airfilter.

0 = OFF
Generator 1 = ON
Compressor temperature too high.

Insulation fault.

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4 Operation description
4.1 Use of the compressor according to its intended purpose
The compressor, a transportable apparatus, is to be used for producing industrial compressed air.
It compresses air with a normal degree of purity (atmospheric air) up to operating pressure, according to order
stipulations, with the given flow rate.
As regards technical specifications, reference should be made to the data on the order (see also Technical
Specifications Overview).
The statement regarding intended use defines this use in accordance with the intended purpose of the
compressor.
Use of any other kind, the use of fluids other than atmospheric air (excepting inert gasses), use for non industrial
purposes or conditions different from the functional specifications (pressure range, speed, temperature, etc...), as
defined in the order, must be considered as inappropriate.
This vessel shall only be used as a pressure vessel and operated within its specified limits.
National legislation requirements with respect to re-inspection must be complied with.
No alterations shall be made to the vessel without written authority of the manufacturer.
The user shall keep the vessel and its accessories in good condition.
No welding shall be performed on the vessel.
Draining of condensate shall be performed daily.
In the event of fire depressurize the equipment.

4.2 Design characteristics of the helical compressor

The transportable compressor system includes a helical one-stage compressor, cooled through oil spraying.
The heart of the helical compressor includes a pair of rotors, with a special profile ensuring a good yield and
therefore an optimal cost-performance ratio. Its large fueltanks allows continuous availability of compressed air
with limited downtime for refuelling.
The prime mover is a diesel engine whose power is transmitted directly through a coupling to the compressor.

4.2.1 Operation
From the compressor air intakes, air is sucked in through the dry air filter and supplied to the rotor toothed cavities.
Air intake takes place because the toothed cavities, connected to the air inlet, grow progressively during rotor
rotation, until they are completely open. Filled cavities are then closed during rotation by separator walls mounted
on the body towards the air intake. After a short displacement phase, compression starts in the lower side.
Through coupling of the main rotor teeth into the secondary rotor cavities, V shaped chambers are formed, which
shrink continuously during rotation towards the delivery side. In this way, the air trapped in the system is
compressed until the toothed cavities reach the delivery side. Toothed cavities keep shrinking until reaching zero
volume on the front side, so that the compressed air is completely delivered. This cycle is performed four times for
each main rotor turn thus ensuring that compressed air is delivered evenly.

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Figure 1
Compressor Regulating System

without Generator

AF Air Filter DB Drive Belt OCCE Oil Cooler SV Safety Valve

AR Air Receiver (with generator) (compressor element) SVSR Solenoid Valve
AOV Air Outlet Valves DP Drain Plug OF Oil Filter (Speed regulator)
BDV Blow Down Valve E Engine OLG Oil Level Gauge TS Temperature Switch
C Coupling ) F Fan OS Oil Separator UA Unloader Assembly
CE Compressor Element FP Filler Plug PG Pressure Gauge UV Unloader Valve
CV Check Valve FR Flow Restrictor RV Regulating Valve VH Vent Hole
FN Flow nozzle SL Scavenge Line VI Vacuum Indicator
SR Speed Regulator VV Vacuator Valve

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4.3 Instruction Manual

4.3.1 Air flow (see Figure 1)
The system comprises:
AF Air filter
AR/OS Air receiver/oil separator
CE Compressor element
UA/UV Unloader assembly with unloader valve
BDV Blow-down valve
FN Flow nozzle
Air drawn through the airfilter (AF) into the compressor element (CE) is compressed and cooled by oil, injected
during the compressor stage. At the element outlet, compressed air and oil pass into the air receiver/oil separator
(AR/OS).
The check valve (CV) prevents blow-back of compressed air when the compressor is stopped. In the air receiver/
oil separator (AR/OS), most of the oil is removed from the air/oil mixture; the remaining oil is removed by the
separator element.
The oil collects in the receiver and on the bottom of the separator element.
The air leaves the receiver via a flow nozzle (FN) which prevents the receiver pressure from dropping below the
minimum working pressure, even when the air outlet valves are open. This ensures adequate oil injection and
prevents oil consumption.
A temperature switch (TS) and a working pressure gauge (PG) arecomprised in the system.
A blow-down valve (BDV) is fitted in the unloader assembly to automatically depressurise the air receiver (AR)
when the compressor is stopped.

4.3.2 Oil system (see Figure 1)

The system comprises:
AR/OS Air receiver/oil separator
OCCE Oil cooler
OF Oil filter
The lower part of the air receiver (AR) serves as oil tank.
Air pressure forces the oil from the air receiver/oil separator (AR/OS) through the oil cooler (OCCE) and oil filter
(OF) to the compressor element (CE).
The compressor element has an oil gallery in the bottom of its casing. The oil for rotor lubrication, cooling and
sealing is injected through holes in the gallery.
Lubrication of the bearings is ensured by oil injected into the bearing housings.
The injected oil, mixed with the compressed air, leaves the compressor element and re-enters the air receiver,
where it is separated from the air. The oil that collects in the bottom of the oil separator element is returned to the
system through a scavenging line (SL), which is provided with a flow restrictor (FR).
The oil filter by-pass valve opens when the pressure drop over the filter is above normal because of a clogged
filter. The oil then bypasses the filter without being filtered. For this reason, the oil filter must be replaced at regular
intervals.
When cold start equipment is installed; a thermostatic valve will bypass the compressor oil (oil will not pass through
oil cooler OCCE), until the working temperature is reached.

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4.3.3 Continuous regulating system

The system comprises:
RV Regulating valve
UA Unloader assembly
SR Speed regulator
The compressor is provided with a continuous regulating system. This system is provided with a blow-down valve
which is integrated in the unloader assembly (UA). The valve is closed during operation by outlet pressure of the
compressor element and opens by air receiver pressure when the compressor is stopped.
When the air consumption increases, the air receiver pressure will decrease and vice versa. This receiver pressure
variation is sensed by the regulating valve which, by means of control air to the unloader, matches the air output
to the air consumption. The air receiver pressure is maintained between the pre-selected working pressure and
the corresponding unloading pressure.
When starting the compressor, the unloader valve (UV) is kept open by spring force, the engine runs at maximum
speed. The compressor element (CE) takes in air and pressure builds up in the receiver (AR).
The air output is controlled from maximum output (100%) to no output (0%) by:
1. Speed control of the engine between maximum load speed and unloading speed (the output of a screw
compressor is proportional to the rotating speed).
2. Air inlet throttling.

If the air consumption is equal to or exceeds the maximum air output, the engine speed is held at maximum load
speed and the unloading valve is fully open.
If the air consumption is less than the maximum air output, the regulating valve supplies control air to unloader
valve (UV) to reduce the air output and holds air receiver pressure between the normal working pressure and the
corresponding unloading pressure of approx. 1.5 bar above the normal working pressure.
When the air consumption is resumed, the unloader valve (UV) gradually opens the air intake and the speed
regulator (SR) increases the engine speed.
The construction of the regulating valve (RV) is such that any increase (decrease) of the air receiver pressure
above the pre-set valve opening pressure results in a proportional increase (decrease) of the control pressure to
the unloading valve and the speed regulator.
Part of the control air is vented to the atmosphere, and any condensate discharged, through the vent holes (VH).
Interconnected operation with several compressors is only possible when a check-valve is installed
(optional).

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4.3.4 Automatic operation control

In case of operation failure, an electrical safety circuit automatically disconnects the compressor. The motor stops
due to fuel supply interruption and the starter red warning light 61 (Figure 2) lights up.
Both events occur when:
• the generator stops supplying current
• motor oil temperature exceeds the limit
• motor oil pressure is too low. Important: Check oil level every day, top up if necessary,
• fuse 62 (Figure 2) has blown
• a cable got loose or broke.
Safety termo switch is part of the circuit, if temperature gets over the limit, it performs both previous functions and
turns on compressor temperature red warning light 57 (Figure 2).
Before putting the system back into operation, you must:
• find the cause of the failure
• repair the failure
• check that temperature is now below the maximum limit
• check that the electrical circuit is restored.

4.3.5 System restoration

Such failure can be repaired only by qualified personnel, familiar with this User Manual. System restoration can
be achieved as follows:
Disconnect terminal - (minus) from the battery and reconnect it. Compressor temperature warning light 57
(Figure 2) must not light on any more.

Figure 2
57
61 51 ON/OFF Switch
51
52 52 Push-button
53 Compressed air pressure gauge
53 57 Compressor temperature
indicator light
79 61 Starter indicator light
62 Fuse
63 Time meter
COLD START - OPTION
62 79 Push-button (Pre-heat)

63

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4.3.6 Tool lubricator for pneumatic tools

Compressors including a tool lubricator have the advantage to provide a centralised oil supply to all tools
connected to the system. Oil consumption may be adjusted by means of the metering screw 27 (Figure 3). The oil
tank is built in the system. Capacity: approx. 2.4 lt.
To prevent corrosion due to condensate collecting, the oil storage container must always be filled with oil.

Figure 3

27

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5 Operating instructions
5.1 General instructions before starting

Locate the rear-end of the compressor upwind, away from contaminated wind-streams and walls. Avoid
recirculation of exhaust air from the engine. This can cause overheating and engine power decrease. The
compressor oil lifetime will be shortened when the compressor inlet air is contaminated.

• Before putting into operation for the first time, connect the battery supplying the operating power (if you have
not done so already).
• With the compressor standing level, check the level of the engine oil. Add oil, if necessary, to the upper mark
on dipstick. Consult the Engine Operation Manual for the type and viscosity grade of the engine oil.
• Check the level of the compressor oil. The pointer of oil level gauge (Figure 1, OLG) should register in the
green range. Add oil if necessary. See section 9 for the oil to be used.
• Before removing oil filler plug (Figure 1, FP), ensure that the pressure is released by opening an air
outlet valve.
• Check that the fuel tank contains sufficient fuel. Top up, if necessary. Consult the Engine Operation Manual for
the type of fuel.
• In case of start up of the unit, after running out of fuel, pump up the fuel manually with the fuel hand pump
before starting.
• Drain any water and sediment from the fuel filter until clean fuel flows from the drain cock.
• Drain leaking fluid from the frame.
• Press vacuator valves (Figure 1, VV) of the air filter to remove dust.
• Check the air filter vacuum indicators (Figure 1, VI). If the yellow piston reaches the red marked service range,
replace the filter element. Reset the indicator by pushing the reset button.
• Open air outlet valve to allow air flow to the atmosphere.
• For start-up operations, please refer to § 5.2.

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Figure 4
57
61 51 ON/OFF Switch
51
52 52 Push-button
53 Compressed air pressure gauge
53 57 Compressor temperature
indicator light
79 61 Starter indicator light
62 Fuse
63 Time meter
COLD START - OPTION
62 79 Push-button (Pre-heat)

63

5.2 Instructions for starting up the compressor

• Open slightly an air delivery cock.
• Place switch 51 (Figure 4) on "I"; the starter indicator light 61 (Figure 4) must go on.
• When cold-starting (option), press button 79 (Figure 4) and button 52 simultaneously.
• Push button 52 (Figure 4) to start the engine. As soon as the engine starts, release the button; the starter
indicator light should go off.
• When the engine is running, the pressure in the tank increases up to about 4 bar. This pressure will be
reached when the engine warms up.
• If the delivery cocks are closed, the pressure keeps increasing, until reaching the operating pressure, set by
the proportional regulator. It is now possible to connect the compressed air tools and start the operation.

5.3 Instructions for stopping the compressor

• Close the air delivery cocks.
• Place switch 51 (Figure 4) on "0".

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6 Maintenance
Maintenance operations must always be carried out while the system is idle and after pressure is discharged.
Use of SERVICE PAKS:
SERVICE PAKS contain all the original spare parts needed for the regular maintenance on the compressor and
engine.
They are specially matched to the maintenance intervals of your CP compressor plants and contain under one
single part number all the wear parts required for each inspection.
You will find the part numbers in the maintenance schedule applicable to your compressor plant.
Order the SERVICE PAKS from your local CP dealer.
Refer to the maintenance plan in Chapter 6.1 for the parts numbers of the service paks.

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6.1 Maintenance schedule

Daily Initially Yearly Yearly

Maintenance intervals: 50 hours after or every or every

initial start-up 500 hours 1000 hours
Service-Pak 1625 0010 45
Service-Kit Oil separator 1625 0010 57
I) Compressor
Compressor oil level, if nec., replenish oil z
Test safety valve z ()
Air intake vacuum indicator z
Air filter elements (1) „
Empty Air cleaner-Dust valve z
Cooler package (1) S
Compressor oil „
Compressor oil filter „
Change oil separator element (7) „
Leaks in air/oil/fuel/coolant sytem z z
Electrolyte conditions and Battery clamps z z
Torque data wheel nuts z z
Tyre pressure z z

II) Motor
Fuel tank, fill up every day z
Engine oil level, if nec. top up with oil z
Check fuel leakage oil line (2) z
Activate water drain of the fuel filter z
Engine for leaks (Visual control) z z
Engine bearings, if nec. retighten z z
Check engine toothed belts (2) z
Engine oil (2) (3) (4) „
Engine oil filter (2) „
Fuel-filter (6) „
Fuelprefilter „
V-belts (if nec. retighten or change) (2) „ ()
Fuel tank (6) S
Motor min. and max. Numbers of revolutions z z
Valve clearance (3) (5) 

III) Options
Tool lubricator: Clean storage tank z S
Generator plants: Activate safety switch z
Generator plants: Tighten V-belts of the generator drive 
Air preparation: Replace filter inserts „
(1) More frequently when operating in dusty environment. (5) The valves need to be adjusted for the first time before 500
(2) Refer to the motor operation manual. running hours.
(3) Only valid when using SAE 15W40. (6) In case of poor fuel quality, replace more frequently.
(4) Also drain engine oil from engine oil cooler. (7) If pressure drop exceeds 0.8 bar, replace earlier.
(Drain plug engine oil cooler)

Preservation stage: check = z adjust =  clean = S exchange = „

Maintenance operations must always be carried out while the system is idle and after pressure is discharged.
For engine and chassis maintenance, refer to relevant operating manual!

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6.2 Engine and compressor dry air filters

Please refer to the appropriate User's Guide.

6.3 Compressor oil change

The oil must be changed every 500 operating hours (or at least once per year). To drain the oil, open the caps on
the radiator and the pressurised tank. This must be done whilst the machine is still warm. Please only use the
genuine compressor oil GENOIL. After filling with new oil up to the maximum level, perform a brief test run (for
about 1 minute). Then stop the compressor, and after 15 minutes, top up to the maximum level once more. Final
level check should be made once oil has cooled off.

The prescribed interval for compressor oil change shall not be exceeded in any case. When the oil
exchange interval is exceeded, this could lead to serious damage to the compressor.
In case the compressor oil lifetime has been exceeded please consult your local CP dealer for appropriate
cleaning and flushing instructions.

6.4 Compressor oil filter change

Servicing includes oil filter replacement - element OF (Figure 1). The filter must be replaced about every 500
operation hours. No maintenance is required in between.

6.5 Final oil separator

The fine oil separator OS (Figure 1) must be replaced when oil separation is no more satisfactory, i. e. when the
compressed air is saturated with oil. Before replacing the oil separator, check the following:
• the flow indicator must be working properly
• metering on the built-in tool oiler must not be too high
The microfine oil separator must be changed every 1000 operating hours (or at least once per year).

6.6 Oil radiator

The oil radiator OCCE (Figure 1) may get very dirty if operating in a dusty environment. It is therefore necessary
to clean the air intake slots regularly with compressed air. In case of heavy clogging, it is necessary to wash up
the slots and then dry them up with compressed air.

6.7 Fuel tank

Fill the fuel tank only up to 3/4 of its capacity. In this way, there is not risk of fuel spilling from the tank, which is
otherwise possible because of heating and fuel expansion or when the ground is not level.

6.8 Safety valve

Safety valve SV (Figure 1) in the pressure tank avoids exceeding maximum pressure. Normally, no servicing is
needed; however, from time to time, vent it manually during operation.

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7 Faults
7.1 Troubleshooting and remedying faults

Fault Possible cause Remedy

1. Starter indicator light does a. Discharged or defective a. Check electrolyte level and
not come on when main battery. charge battery, if nec.
switch turned to "1", engine replace.
cannot be started. b. Loose battery connection or b. Check and repair.
oxidised terminals.
c. Loose connection or c. Check wiring and
damaged wiring. connections, if nec. repair.
d. Main switch defective. d. Turn main switch to "1".
There must now be voltage
between each of the
terminals and mass. If not,
replace main switch.

2. When the main switch is a. 3-phase AC generator/ a. Replace 3-phase AC

turned to "1", the starter controller defective. generator.
indicator light only glows
weakly or not at all with the
engine stopped, the duty
hour counter moves.

3. Starter does not turn engine a. Low battery power. a. See remedy 1 a.
over when the starting knob b. Starting knob defective. b. Turn main switch to "1", keep
is pressed. starting knob depressed.
There must now be voltage
between each of the
terminals and mass. If not,
replace starting knob.
c. Starter starting relay c. Replace relay board.
defective.
d. Starter solenoid or starter d. Check starter solenoid. Have
defective. starter repaired.

4. Starter turns engine over a. Fuel solenoid valve defective. a. Check mechanical and
when the starting knob is electric components of valve,
pressed but the engine if nec. repair or replace.
does not start. b. Low battery charge. b. see 1 a.

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Fault Possible cause Remedy

5. Engine starts but starter a. Drive belt of 3-phase CA a. Check and if nec. repair.
indicator light remains on, generator is broken or slips.
compressor stops again b. 3-phase AC gen./controller b. Have unit repaired.
when starting knob defective.
released.

6. Engine starts up but cuts a. Starting knob released too a. Only release starting knob
out again immediately after quickly. when the engine is running
the starting knob is properly.
released. b. Engine oil pressure too low. b. Stop immediately, study
engine operating manual.
c. Not enough fuel in the tank. c. Top up fuel.
d. Engine oil pressure switch or d. Remove switches and check,
engine temperature switch if nec. replace.
defective.

7. Duty hour counter does not a. Hour counter defective. a. Replace.

run.

8. Compressor is not a. Proportional controller a. Clean or replace.

regulated, engine runs at defective or clogged.
max. revs, safety valve b. Safety valve opened too b. Replace safety valve.
blows out. quickly.

9. Capacity or pressure of the a. Air consumption exceeds a. Check consumption point

compressor below normal capacity of the compressor. downstream of the
value. compressor.
b. Compressor air filter clogged. b. Replace.
c. Engine does not run at max. c. Check engine speed
speed. controller, service fuel filter.

10. Delivery of the compressor a. Oil separator cartridge a. Replace.

low, pressure is excessively clogged.
high.

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Fault Possible cause Remedy

11. Excessive compressor oil a. Compressor oil level too high. a. Correct oil level.
consumption, oil mist b. Wrong compressor oil grade b. Change oil with correct oil
escapes from withdrawal used. grade.
taps.
c. Drainage line of the oil c. Clean line, if nec. replace
separator clogged, non- non-return valve.
return valve defective.
d. Oil separator defective. d. Replace.
e. Suction control valve leaking e. Replace.
internally.

12. Air and oil flow out of the a. Non-return valve of the a. Replace seal of the non-
compressor air filter after suction control valve leaking. return valve.
engine switched off.

13. Compressor is a. Overheating of the a. See condition 14.

automatically switched off. compressor - is indicated by
pilot light.
b. Engine oil pressure too low. b. Check lubrication system, call
in DEUTZ service.
c. Engine temperature too high. c. Check engine oil system, see
engine operating manual.
d. Cable breakage at one of the d. Replace defective cable.
protective devices.
e. Fuse blown. e. Replace. If it recurs, establish
cause.
f. Not enough fuel. f. Replenish fuel, if nec., vent
fuel line.

14. Overheating of the a. Inadequate compressor a. Adjust plane.

compressor. cooling.
b. Oil cooler clogged externally. b. Thoroughly clean cooler.
c. Oil system clogged internally. c. Consult CP dealer.
d. Compressor oil level too low. d. Correct oil level.
e. Cooling fan defective. e. Replace.
f. Oil fine separator clogged. f. Replace.

15. Toothed belt of the a. Drive belt broken. a. Consult CP dealer.

compressor drive.

If there is any doubt about the cause or remedy of a fault, it is imperative to consult an CP dealer!

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8 Electrical system
8.1 Circuit diagram 12V DC (Standard)

Figure 5 The compressor is equipped with a Gelb

Circuit diagram (No. IEX4002847/5) negative earthed system. Yellow
35 Jaune
Giallo
S1
I O Amarillo
Area: A
Bereich: A h + - S0 Amarelo
Dashboard
Armaturenkasten Geel
H2 P1 H1 F1 Gul
X1 87 86 81 85 84 83 88 82
R1
30
d5

d2
D2 50
d1
D1

K1
d3

d2 d4

d6 D3

X2 65 63 62 64 66 61

S3
1 M M1
T S5 P D+ Y1
B- B+ 2

Area: M + -
Bereich: M S2 T G1
Motor, Compressor
Motor, Kompressor G2

F1 Flat fuse insert (5A) S0 Contact Switch (On - Off)

G1 Alternator S1 Push button (Start)
G2 Battery S2 Thermalcontact (Motor)
H1 Warning light, (red; Compressor temperature) S3 Oil pressure switch (Motor)
H2 Warning light, (red; Generator) S5 Thermalcontact (Compressor)
K1 Relay plate X1 Connector housing (8-pole)
M1 Starter Motor X2 Connector housing (6-pole)
P1 Hourmeter Y1 Fuel solenoid Valve

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CPS 185 - CPS 5.5 User Manual

8.2 Circuit diagram 12V DC (cold start)

Figure 6 The compressor is equipped with a Gelb

Circuit diagram (No. 1605094500/1)
negative earthed system. Yellow
35 Jaune
Giallo
S6
Amarillo
S1
I O Amarelo
Area: A + - Geel
Bereich: A h S0
Dashboard
Armaturenkasten Gul
H2 P1 H1 F1

X1 87 86 81 85 84 83 88 82
R1
30
d5

d2
D2 50
d1
D1

K1
d3

d2 d4

d6 D3

87 86
X2 65 63 62 64 66 61 K5

S3
1 M M1
30 85

T S5 P D+ Y1
B- B+ 2
+ -
Area: MM
Bereich: G1
P2
S2 T
Motor, Kompressor G2
Motor, Compressor

F1 Flat fuse insert (5A) S0 Contact Switch (On - Off)

G1 Alternator S1 Push button (Start)
G2 Battery S2 Thermalcontact (Motor)
H1 Warning light, (red; Compressor temperature) S3 Oil pressure switch (Motor)
H2 Warning light, (red; Generator) S5 Thermalcontact (Compressor)
K1 Relay plate S6 Push button (Glowplug)
M1 Starter Motor X1 Connector housing (8-pole)
P1 Hourmeter X2 Connector housing (6-pole)
P2 Glowplug Y1 Fuel solenoid Valve

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9 Recommendations concerning oil

• May we draw your attention to the importance of a proper lubrication of our high-value machines. A right
choice of the oils to be used will greatly contribute to reach high performance operation and prevent operation
failures.

9.1 Lubrication oils

High-quality, mineral, hydraulic or synthesized hydrocarbon oil with rust and oxidation inhibitors and anti-foam
and anti-wear properties is recommended. The viscosity grade should correspond to the ambient temperature
and ISO 3448, as follows:

Type of lubricant Compressor** Engine*

between -25°C and -10°C GENOIL S

between -10°C and +50°C GENOIL M GENOIL 15W40

GENOIL is the ONLY oil tested and approved for use in all engines built into CP compressors.
Extensive laboratory and field endurance tests on CP equipment have proven GENOIL to match all lubrication
demands in varied conditions. It meets stringent quality control specifications to ensure your equipment will run
smoothly and reliably.
The quality lubricant additives in GENOIL allow for extended oil change intervals without any loss in performance
or longevity.
GENOIL provides wear protection under extreme conditions. Powerful oxidation resistance, high chemical
stability and rust- inhibiting additives help reduce corrosion, even within engines left idle for extended periods.
GENOIL contains high quality anti-oxidants to control deposits, sludge and contaminants that tend to build up
under very high temperatures.
GENOIL's detergent additives keep sludge forming particles in a fine suspension instead of allowing them to clog
your filter and accumulate in the valve/rocker cover area.
GENOIL releases excess heat efficiently, whilst maintaining excellent bore-polish protection to limit oil
consumption.
GENOIL has an excellent Total Base Number (TBN) retention and more alkalinity to control acid formation.
GENOIL prevents Soot build-up
GENOIL is optimized for the latest low emission EURO -3 & -2, EPA TIER II & III engines running on low sulphur
diesel for lower oil and fuel consumption.
GENOIL 5W40 is a Synthetic ultra high performance diesel engine oil with a high viscosity- index. GENOIL 5W40
is designed to provide excellent lubrication from start-up in temperatures as low as -25°C.
GENOIL 15W40 is a mineral based high performance diesel engine oil with a high viscosity- index. GENOIL
15W40 is designed to provide a high level of performance and protection in 'standard' ambient conditions as from
-15°C.

• If you want to use another brand of oil, consult the Engine Operation Manual.

• Never mix oils of different brands or types.

• Use only non-toxic oils where there is a risk of inhaling delivered air.

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Mineral compressor oil GENOIL M:

- 5 liter can: order number 1626 2260 00
- 20 liter can: order number 1626 2261 00

Mineral engine oil GENOIL 15W40:

- 5 liter can: order number 1626 2262 00
- 20 liter can: order number 1626 2263 00

Synthetic engine oil GENOIL 5W40:

- 5 liter can: order number 1626 2258 00
- 20 liter can: order number 1626 2259 00

Synthetic compressor oil GENOIL S:

- 20 liter can: order number 1626 2264 00

• Never mix synthetic with mineral oil.

Remark:
When changing from mineral to synthetic oil (or the other way around), you will need to do an extra rinse:
After doing the complete change procedure to synthetic oil, run the unit for a few minutes to allow good
and complete circulation of the synthetic oil. Then drain the synthetic oil again and fill again with new
synthetic oil. To set correct oil levels, proceed as in normal instruction.

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