Chicago Pneumatic CPS 185 PD7 User manual

“Copyright 2009, Chicago Pneumatic
Any unauthorized use or copying of the contents or any part of this book is
prohibited. This applies in particular to trademarks, model denominations, part
numbers and drawings.”
No. 1310 3012 08
2009-06
Chicago Pneumatic Portable Compressor
CPS185 PD7
Instruction Book 1310 3012 08 Ed. 0 2009-06

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OWNERSHIP DATA
Unit model: Owner's machine no.:
Engine type: Unit service no.:
Delivery date: Engine serial no.:
Service plan: First start-up date:
Selected Lubricants
Compressor: Capacity:
Printed Matter Nos.
Chicago Pneumatic instruction book / rev: Chicago Pneumatic logbook:
Chicago Pneumatic parts list / rev: Engine parts list:
Local Chicago Pneumatic Representative
Name:
Address:
Telephone: Contact persons: Service:
Telefax: Parts:

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Contents
1Safety Precautions for Portable Compressors 4
1.1 Introduction 4
1.2 General Safety Precautions 4
1.3 Safety during use and operation 5
1.4 Safety During Maintenance and Repair 6
1.5 Tool Applications Safety 6
1.6 Batteries 7
1.7 Ether fuel Systems 7
1.8 Pressure vessels 7
1.9 Safety valve 8
1.10 Injury Prevention 8
2Leading Particulars 9
2.1 Description of Safety Pictograms Used in this Manual 9
2.2 General Description 9
2.3 Main Parts 10
2.4 Air Flow (see Fig. 2.4) 12
2.5 Oil system (see Fig. 2.4) 12
2.6 Continuous regulating system 13
2.7 Electrical System 14
3Operating Instructions 16
3.1 Parking, Towing And Lifting Instructions 16
3.2 Before Starting 18
3.3 Starting/Stopping (See Fig. 3.3) 18
4Maintenance 19
4.1 Use of Service Paks 19
4.2 Preventive Maintenance Schedule For The Compressor 19
4.3 Lubrication oils 20
4.4 Cleaning Coolers 21
4.5 Battery Care 21
4.6 Storage 22
4.7 Service Kits 22
5Adjustments and Servicing Procedures 23
5.1 Adjustment of the Continuous Regulating System (See Fig. 5.1) 23
5.2 Air Filter Engine/Compressor 24
5.3 Air Receiver 25
5.4 Safety Valve 25
5.5 Fuel System (see Fig. 5.4) 25
6Problem Solving 25
6.1 Problem Solving Chart 26
6.2 Alternator Precautions 26
7Technical Specifications 29
7.1 Settings of Shutdown Switches and Safety Valve 29
7.2 Compressor/Engine Specifications 29

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IMPORTANT
1 Safety Precautions for Portable Compressors
To be read attentively and acted on accordingly before towing, lifting, operating,
performing maintenance or repairing the compressor
1.1 Introduction
The policy of Chicago Pneumatic is to provide the users of their equipment with safe, reliable and efficient products. Factors taken
into account are among others:
- the intended and predictable future use of the products, and the environments in which they are expected to operate,
- applicable rules, codes and regulations,
- the expected useful product life, assuming proper service and maintenance.
Before handling any product, take time to read the relevant instruction book. Besides giving detailed operating instructions, it also
gives specific information about safety, preventive maintenance, etc.
These precautions are general and some statements will therefore not always apply to a particular unit.
When handling, operating, overhauling and/or performing maintenance or repair on Chicago Pneumatic equipment, the mechanics
are expected to use safe engineering practices and to observe all relevant local safety requirements and ordinances. The following
list is a reminder of special safety directives and precautions mainly applicable to Chicago Pneumatic equipment.
This brochure applies to machinery processing or consuming air or inert gas. Processing of any other gas requires additional
safety precaution typical to the application and are not included herein.
All responsibility for any damages or injury resulting from neglecting these precaution: or by non-observance of ordinary caution
and due care required in handling, operating, maintenance or repair, also if not expressly mentioned in this brochure or the
instruction book(s), is disclaimed by Chicago Pneumatic.
If any statement does not comply with local legislation, the stricter of the two shall be applied. Statements in this manual should
not be interpreted as suggestions:, recommendations or inducements that it should be used in violation of any applicable laws or
regulations.
1.2 General Safety Precautions
1 The owner is responsible for maintaining the unit in a safe operating condition. Unit parts and accessories must be replaced if
missing or unsuitable for safe operation.
2 Use only lubricating oils and greases recommended or approved by Chicago Pneumatic or the machine manufacturer.
Ascertain that the selected lubricants comply with all applicable safety regulations, especially with regard to explosion or fire
risk and the possibility of decomposition or generation of hazardous gases.
3 The supervisor, or the responsible person, shall at all times make sure that all instructions regarding machinery and equipment
operation and maintenance are strictly followed and that the machines with all accessories and safety devices, including the
entire compression or vacuum system with pipes, valves, connectors, hoses, etc., as well as the consuming devices, are in
good repair, free of abnormal wear or abuse, and are not tampered with.
4 Maintenance, overhaul and repair work shall only be carried out by adequately trained personnel; if required, under
supervision of someone qualified for the job.
5 Whenever there is an indication or any suspicion that an internal part of a machine is overheated, the machine shall be
stopped. No inspection covers shall be opened before sufficient cooling time has elapsed; this is to avoid the risk of
spontaneous ignition of the oil vapor when air is admitted.
6 Maintenance work, other than routine attention, shall only be undertaken when the machine is turned off.
7 Before dismantling any pressurized component, the compressor or the equipment shall be effectively isolated from all sources
of pressure and be completely vented to atmosphere. In addition, a warning sign bearing a legend such as "work in progress;
do not open" shall be attached to each of the isolating valves.
8 Before a machine is being repaired, steps shall be taken to prevent inadvertent starting. In addition, a warning sign bearing a
legend such as "work in progress; do not start" shall be attached to the starting equipment. The battery shall be disconnected
and removed or the terminals covered by insulating caps.
9 Normal ratings (pressures, temperatures, speeds, etc.) shall be durably marked.
10 Never operate a machine or equipment beyond its rated limits (pressure, temperature, speed, etc.).
11 Maintenance and repair work should be recorded in an operator's logbook for all machinery. Frequency and nature of repairs
can reveal unsafe conditions.
12 The machinery and pneumatic equipment shall be kept clean, i.e. as free as possible from oil, dust or other deposits.
13 To prevent an increase in working temperature, inspect and clean heat transfer surfaces (cooler fins, intercoolers, water
jackets, etc.) regularly. For every machine establish a suitable time interval for cleaning operations.
14 All regulating and safety devices shall be maintained with due care to ensure that they function properly. They may not be by-
passed.
15 Care shall be taken to avoid damage to safety valves and other pressure relief devices, especially to avoid plugging by paint,
oil coke or dirt accumulation, which could interfere with the functioning of the device.
16 Pressure and temperature gauges shall be checked regularly with regard to their accuracy. They shall be replaced whenever
outside acceptable tolerances.
17 Parts shall only be replaced by genuine Chicago Pneumatic replacement parts.

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18 Safety devices shall be tested as described in the maintenance schedule of the instruction book(s) to determine that they are
in good operating condition.
19 Never use flammable solvents or carbon tetrachloride for cleaning parts. Take safety precautions against toxic vapors when
cleaning parts in or with cleaning products.
20 Observe scrupulous cleanliness during maintenance and repair. Keep away dirt by covering the parts and exposed openings
with clean cloth, paper or tape.
21 Protect the engine, alternator, air intake filter, electrical and regulating components, etc. to prevent moisture ingress, e.g. when
steam-cleaning.
22 When performing any operation involving heat, flames or sparks on a machine, the surrounding components shall first be
screened with non-flammable material.
23 Never use a light source with open flame for inspecting the interior of a machine, pressure vessel, etc.
24 On portable units, support the drawbar and axle(s) securely if working underneath the units or when removing a wheel. Do not
rely on jacks.
25 Prior to stripping a compressor, engine or other machine or undertaking major overhaul on it, prevent all movable parts with a
mass exceeding 15 kg (30 lbs) from rolling over or moving.
26 When repair has been completed, make sure that no tools, loose parts or rags are left in, or on, the machine, the prime mover
or the driving gear. The machine shall be barred several revolutions to ensure that there is no mechanical interference within
the machine or driver.
1.3 Safety during use and operation
To lift a unit, all loose or pivoting parts, e.g. doors shall first be securely fastened. Do not attach cables, chains or ropes directly to
the lifting eye; apply a crane hook or lifting shackle meeting local safety rules.
Helicopter lifting using the lifting eye is forbidden.
It is strictly forbidden to dwell or stay in the risk zone under a lifted load. Never lift the unit over people or residential areas.
Lifting acceleration and retardation shall be kept within safe limits.
1 Before towing the unit:
- ascertain that the pressure vessel is depressurized,
- check the drawbar, the brake system and the towing eye. Also check the coupling of the towing vehicle,
- check that the pivot wheel or stand leg is safely locked in the raised position,
- ascertain that the towing eye can swivel freely on the hook,
- check that the wheels are secure and that the tires are in good condition and inflated correctly,
- connect the signal cable, check all lights and connect the pneumatic brake couplers,
- attach the safety break-away cable to the towing vehicle,
- remove wheel chocks, if applied, and disengage the parking brake.
- Apply safety chains to tow vehicle.
2 If the unit is to be backed up by the towing vehicle, disengage the overrun brake mechanism (if equipped).
3 Never exceed the maximum towing speed of the unit.
4 Place the unit on level ground and chock the wheels before disconnecting the unit from the towing vehicle. Unclip the safety
break-away cable
5 When the unit has to operate in a fire-hazardous environment, each engine exhaust has to be provided with a spark arrestor to
trap incendiary sparks.
6 The exhaust contains carbon monoxide which is a lethal gas. When the unit is used in a confined space, conduct the engine
exhaust to the outside atmosphere by a pipe of sufficient diameter (min. 4 inches); do this in such a way that no extra back
pressure is created for the engine. If necessary, install an extractor.
7 When operating in a dust-laden atmosphere, place the unit so that dust is not carried towards it by the wind. Operation in
clean surroundings considerably extends the intervals for cleaning the air intake filters and the cores of the coolers.
8 Locate the unit away from walls. Take all precautions to ensure that hot air exhausted from the engine and driven machine
cooling systems cannot be recirculated. If such hot air is taken in by the engine or driven machine cooling fan, this may cause
overheating of the unit; if taken in for combustion, the engine power will be reduced.
9 No external force may be exerted on the air outlet valves, e.g. by pulling on hoses or by installing auxiliary equipment directly
to a valve, e.g. a water separator, a lubricator, etc.
10 Distribution pipework and air hoses must be of correct size and suitable for the working pressure.
Never use frayed, damaged or deteriorated hoses. Replace hoses and flexibles of which the lifetime expired. Use only the
correct type and size of hose end fittings and connections. Install safety pins on quick type hose connections.
A hose connected to a 2 inch (50 mm) valve must be provided with a safety wire (8 mm) fixed to the hose for effective
pressures as from 145 psi (10 bar) up, although it is recommended to apply such safeguard already from (60 psi) 4 bar up.
The safety wire ends have to be attached, one to the eye provided next to the compressor air outlet valve, the other one to a
point near to the air inlet of the applied equipment.
Finally a wire mesh hose can be fixed over the hose ends to dampen the blast in case a connection starts leaking or should
become undone.
Close the compressor air outlet valve before connecting or disconnecting a hose. Ascertain that a hose is fully depressurized
before disconnecting it.
When blowing through a hose or air line, ensure that the open end is held securely. A free end will whip and may cause injury.
Never play with compressed air. Never apply it to your skin or direct an air stream at people. Never use it to clean dirt from
your clothes. When using it to clean down equipment, do so with extreme caution and use eye protection.