Rotair MDVN 22K Operating instructions

USER'S AND
MAINTENANCE
MANUAL
Date:
20/02/2017
Code
MAN MDVN 22-26 K
ENG
Motor compressor MDVN 22 K –MDVN 26 K
Revision
02
Copyright © 2014, ROTAIR S.P.A. - All rights reserved This manual is intellectual property of ROTAIR S.P.A. Its
full or partial reproduction is forbidden under any form, on any support and by any means, without the written
authorization by ROTAIR S.P.A.
Page
1/68
USER'S AND MAINTENANCE MANUAL
Motor compressor
MDVN 22K –MDVN 26K

USER'S AND
MAINTENANCE
MANUAL
Date:
20/02/2017
Code
MAN MDVN 22-26 K
ENG
Motor compressor MDVN 22 K –MDVN 26 K
Revision
02
Copyright © 2014, ROTAIR S.P.A. - All rights reserved This manual is intellectual property of ROTAIR S.P.A. Its
full or partial reproduction is forbidden under any form, on any support and by any means, without the written
authorization by ROTAIR S.P.A.
Page
2/68
Dear customer,
Thanks for having purchased this Rotair motor compressor, which is designed and manufactured in
compliance with high standards, in order to ensure high quality performance, as well as easy use and
installation.
For any information, you can contact our customer service at the following address:
ROTAIR Spa
Via Bernezzo, 67
12023 CARAGLIO (CN) - ITALY
Phone: [phone]
Fax [phone]
E-MAIL: [email protected]om

USER'S AND
MAINTENANCE
MANUAL
Date:
22/01/2015
Code
MAN MDVN 22-26 K
ITA
Motor compressor MDVN 22 K –MDVN 26 K
Revision
00
Copyright © 2014, ROTAIR S.P.A. - All rights reserved This manual is intellectual property of ROTAIR S.P.A. Its
full or partial reproduction is forbidden under any form, on any support and by any means, without the written
authorization by ROTAIR S.P.A.
Page
3/68
FOREWORD
These service instructions have been drafted to facilitate the knowledge of the machinery purchased and its
modes of use.
In drafting them, we have intentionally omitted the technical in-depth description of some operations linked to
the motor and the axle, since such information is contained in the user's and maintenance of the respective
manufacturers.
The service instructions contain indications of utter importance concerning the safe appropriate and cost-
effective operation of the machine.
The compliance with said operations helps prevent potentially hazardous situations, additional costs and loss
of time, increasing at the same time its life-span.
The service instructions and safety measures reported in this manual must be complied with by the user of the
machinery.
Besides the service instructions and the accident prevention prescriptions which apply in the countries and
places of installation, all the more general rules of safety at the workplace must be complied with.
It is therefore recommended to carefully read the instructions reported in this manual.
This manual cannot be disclosed, duplicated or copied without the previous authorization by the Manufacturer.
Any lack of compliance with the above shall be pursued under the Law, in particular if the illicit action involves
advantage for competing companies.

USER'S AND
MAINTENANCE
MANUAL
Date:
22/01/2015
Code
MAN MDVN 22-26 K
ITA
Motor compressor MDVN 22 K –MDVN 26 K
Revision
00
Copyright © 2014, ROTAIR S.P.A. - All rights reserved This manual is intellectual property of ROTAIR S.P.A. Its
full or partial reproduction is forbidden under any form, on any support and by any means, without the written
authorization by ROTAIR S.P.A.
Page
4/68
TABLE OF CONTENTS
1General.................................................................................................................................................................7
1.1 Definitions......................................................................................................................................................7
1.1.1 Qualified personnel..................................................................................................................................7
1.1.2 Hazard......................................................................................................................................................7
1.1.3 Hazardous area........................................................................................................................................7
1.1.4 Exposed person .......................................................................................................................................7
1.1.5 Operator...................................................................................................................................................7
1.1.6 Risk ..........................................................................................................................................................7
1.1.7 Guard .......................................................................................................................................................7
1.1.8 Protection Equipment...............................................................................................................................7
1.1.9 Expected use ...........................................................................................................................................7
1.1.10 Reasonably expectable incorrect use......................................................................................................7
1.1.11 Component...............................................................................................................................................7
1.1.12 Control Device..........................................................................................................................................8
1.1.13 Safety interlock.........................................................................................................................................8
1.1.14 Manufacturer............................................................................................................................................8
1.2 Machinery Identification ................................................................................................................................8
1.3 Harmonized technical standards...................................................................................................................9
1.4 General description of the machinery .........................................................................................................10
2Technical characteristics of the machinery...................................................................................................11
2.1 General technical characteristics ................................................................................................................11
2.2 Technical characteristics of the compressor...............................................................................................11
2.3 Technical characteristics of the engine.......................................................................................................12
2.4 Technical characteristics of the electric battery ..........................................................................................12
2.5 Service temperatures..................................................................................................................................12
2.6 Acoustic emissions......................................................................................................................................13
3Symbols and warnings.....................................................................................................................................14
3.1 Hazards.......................................................................................................................................................14
3.2 Forbiddances...............................................................................................................................................15
3.3 Obligations and notices...............................................................................................................................16
3.4 General notices...........................................................................................................................................16
4Use of the machinery .......................................................................................................................................18
4.1 Use allowed.................................................................................................................................................18
4.2 Use not allowed...........................................................................................................................................18
4.3 Residual risk................................................................................................................................................19
5Levels and qualifications of the personnel....................................................................................................20
6Safety provisions..............................................................................................................................................20
6.1 Safety provisions concerning transport.......................................................................................................20
6.2 Safety provisions concerning lifting.............................................................................................................21
6.3 Safety provisions relevant to towing (for road-certified compressors only) ................................................22
6.4 Prescriptions for the installation and parking of the motor compressor......................................................23

USER'S AND
MAINTENANCE
MANUAL
Date:
22/01/2015
Code
MAN MDVN 22-26 K
ITA
Motor compressor MDVN 22 K –MDVN 26 K
Revision
00
Copyright © 2014, ROTAIR S.P.A. - All rights reserved This manual is intellectual property of ROTAIR S.P.A. Its
full or partial reproduction is forbidden under any form, on any support and by any means, without the written
authorization by ROTAIR S.P.A.
Page
5/68
6.5 Safety provisions concerning maintenance ................................................................................................24
7Machinery components....................................................................................................................................25
7.1 Chassis and axle.........................................................................................................................................25
7.2 Body ............................................................................................................................................................25
7.3 Engine.........................................................................................................................................................25
7.4 Compression unit ........................................................................................................................................25
7.5 Separator tank .............................................................................................................................................26
7.6 Belts and pulley...........................................................................................................................................26
7.7 Control panel...............................................................................................................................................26
8Electrical equipment of the machinery...........................................................................................................27
8.1 Operator's panel tools.................................................................................................................................27
8.2 Operator's panel pilot lamps........................................................................................................................28
8.3 Fuses...........................................................................................................................................................32
8.4 Lights (for road-certified version) ................................................................................................................33
9Hydraulic and pneumatic sytems ...................................................................................................................35
9.1 Hydraulic lubrication system .......................................................................................................................35
9.2 Pneumatic system.......................................................................................................................................36
9.2.1 Automatic adjustment of the engine rpm ...............................................................................................37
10 Provisions for the appropriate utilization of the motor compressor ..........................................................38
10.1 Before starting-up........................................................................................................................................38
10.2 Start-up........................................................................................................................................................39
10.3 During the work cycle..................................................................................................................................41
10.4 Stop.............................................................................................................................................................41
10.5 After stopping the machine .........................................................................................................................41
11 Monitoring and testing of the machine ..........................................................................................................42
11.1 Monitoring and testing of engine speed......................................................................................................42
11.1.1 Control system of maximum engine speed............................................................................................42
11.1.2 Control system of minimum engine speed.............................................................................................42
11.2 Monitoring and control of the air pressure of the compressor ....................................................................44
11.3 Monitoring and control of air pressure minimum compressor.....................................................................45
12 Safety device.....................................................................................................................................................46
12.1 Emergency stop buttons .............................................................................................................................46
12.1.1 Operation of the emergency button .......................................................................................................46
12.2 Verification of the safety valve ....................................................................................................................47
13 Maintenance......................................................................................................................................................48
13.1 Routine maintenance ..................................................................................................................................48
13.2 Maintenance program .................................................................................................................................49
13.3 Values of tightening screws and bolts.........................................................................................................51
13.4 Maintenance................................................................................................................................................52

USER'S AND
MAINTENANCE
MANUAL
Date:
22/01/2015
Code
MAN MDVN 22-26 K
ITA
Motor compressor MDVN 22 K –MDVN 26 K
Revision
00
Copyright © 2014, ROTAIR S.P.A. - All rights reserved This manual is intellectual property of ROTAIR S.P.A. Its
full or partial reproduction is forbidden under any form, on any support and by any means, without the written
authorization by ROTAIR S.P.A.
Page
6/68
13.4.1 Checking and cleaning the filter air intake.............................................................................................52
13.4.2 Control the electrical battery ..................................................................................................................53
13.4.3 Fuso replacement ..................................................................................................................................54
13.4.4Replacement lamps light (for version approved) ...................................................................................54
13.4.5 Tyre pressure monitoring.......................................................................................................................55
13.4.6 Clean the radiator cooler........................................................................................................................56
13.4.7 Percentage dosage of cooling liquid......................................................................................................56
13.4.8 Checking and cleaning nozzle oil recovery............................................................................................57
13.4.9 Drainage of the fuel tank........................................................................................................................57
13.4.10 Replacing diesel pre-filter.......................................................................................................................58
13.4.11 Check break device................................................................................................................................58
13.4.12 Control of locking wheel bolts ................................................................................................................59
13.4.13 Oil filter replacement compressor ..........................................................................................................59
13.4.14 Replacement of compressor oil..............................................................................................................60
13.4.15 Checking the oil mist separator..............................................................................................................60
13.4.16 Replacement of the oil separator filter ...................................................................................................61
13.4.17 Engine control and maintenance ...........................................................................................................61
13.4.18 Control, tension and replacement of transmission belts........................................................................62
14 Spare parts........................................................................................................................................................64
15 Faults and troubleshooting .............................................................................................................................65
16 Disposal, elimination, disposal of the machine ............................................................................................67
16.1 Instructions for dismantling .........................................................................................................................67
17 Eliminating the machine ..................................................................................................................................67
18 Waste management..........................................................................................................................................68
18.1 Special waste..............................................................................................................................................68
18.2 Toxic and hazardous waste ........................................................................................................................68
18.3 Temporary storage......................................................................................................................................68
18.4 Features of the containers ..........................................................................................................................68
18.5 Registration requirements...........................................................................................................................68

USER'S AND
MAINTENANCE
MANUAL
Date:
22/01/2015
Code
MAN MDVN 22-26 K
ITA
Motor compressor MDVN 22 K –MDVN 26 K
Revision
00
Copyright © 2014, ROTAIR S.P.A. - All rights reserved This manual is intellectual property of ROTAIR S.P.A. Its
full or partial reproduction is forbidden under any form, on any support and by any means, without the written
authorization by ROTAIR S.P.A.
Page
7/68
1 GENERAL
1.1 Definitions
The most significant definitions contained in this manual are reported hereinafter
1.1.1 QUALIFIED PERSONNEL
"Qualified personnel" are those personnel who are familiar with the rules for installation, assembly, repair and
servicing of the machinery and who are provided with the specified technical qualification, such as e.g.:
Technical training authorizing to operate in compliance with the safety standards as related to the hazards the
presence of electric current, pressure circuits, etc. may involve.
Technical background or - in any case - specific training relevant to the user's and maintenance procedures of
the machinery in safety conditions.
Training in the basic first-aid activities.
1.1.2 HAZARD
A potential source of injury or damage to health
1.1.3 HAZARDOUS AREA
Any area within and/or in proximity of machinery where the presence of a person constitutes a risk for the
health and safety of said person.
1.1.4 EXPOSED PERSON
Any person being fully or partially in a hazardous area
1.1.5 OPERATOR
The person/people charged to install, operate, adjust, clean, repair or move a
Machinery or perform its maintenance.
1.1.6 RISK
Combination of the likelihood and severity of an injury or damage to health which may arise in a hazardous
situation.
1.1.7 GUARD
Part of the machinery utilized to ensure protection by means of a material barrier.
1.1.8 PROTECTION EQUIPMENT
Device (different from a guard) which reduces the risk, by itself or associated to a guard.
1.1.9 EXPECTED USE
The use of the machinery in compliance with the user's information.
1.1.10 REASONABLY EXPECTABLE INCORRECT USE
The use of the machinery in a different way than the one indicated in the user's instructions, but which may
derive from the easily expectable human behaviour.
1.1.11 COMPONENT
A constituent part of the electrical/pneumatic equipment, usually specified by its function, but used in various
applications.

USER'S AND
MAINTENANCE
MANUAL
Date:
22/01/2015
Code
MAN MDVN 22-26 K
ITA
Motor compressor MDVN 22 K –MDVN 26 K
Revision
00
Copyright © 2014, ROTAIR S.P.A. - All rights reserved This manual is intellectual property of ROTAIR S.P.A. Its
full or partial reproduction is forbidden under any form, on any support and by any means, without the written
authorization by ROTAIR S.P.A.
Page
8/68
1.1.12 CONTROL DEVICE
A device introduced in a control circuit and used to control the operation of the system (e.g. position sensors,
manual control switches, relays, electro-magnetic control valves).
1.1.13 SAFETY INTERLOCK
Mechanical, electrical or other device whose purpose is to prevent the parts of the machinery from operating
in specified conditions (generally, until the guard is closed)
1.1.14 MANUFACTURER
Physical or legal person who designed and/or develops machinery or partly-completed machinery which is
subject of this directive and who is liable for the compliance of the machinery or partly-completed machinery
with this directive as related to its marketing with his/her name or brand, or for personal use. In absence of a
Manufacturer as defined above, the Manufacturer shall be considered the physical or juridical person who
markets or puts into service machinery or partly-completed machinery.
1.2 Machinery Identification
The CE identification nameplate is attached on the motor compressor chassis.
Such nameplate reports the Manufacturer's data, the CE brand, the denomination of the machinery, the code
and year of manufacturing.
For any requests for spare parts or actions by our technicians, please refer to the data reported in the
nameplate; in particular the code number of the machinery must always be mentioned.
Figure 1.2-1 CE nameplate of motor compressor MDVN 22K –26K

USER'S AND
MAINTENANCE
MANUAL
Date:
22/01/2015
Code
MAN MDVN 22-26 K
ITA
Motor compressor MDVN 22 K –MDVN 26 K
Revision
00
Copyright © 2014, ROTAIR S.P.A. - All rights reserved This manual is intellectual property of ROTAIR S.P.A. Its
full or partial reproduction is forbidden under any form, on any support and by any means, without the written
authorization by ROTAIR S.P.A.
Page
9/68
1.3 Harmonized technical standards
The machinery has been designed and developed in compliance with the provisions contained in the technical
standards reported herein under:
UNI EN ISO 12100
Safety of machinery -General design principles - Risk assessment and risk
reduction.
UNI EN ISO 13857
Safety of machinery–Safety distances to prevent from reaching the
hazardous areas with the upper or lower limps.
UNI EN ISO 13850
Safety of machinery - Emergency stop system, functional aspects
CEI EN 62061
Safety of machinery - Functional safety of the programmable electrical and
electronic control systems as related to safety
CEI EN 60204-1
Safety of machinery - Electrical equipment of the machineries. Part I:
General rules.
UNI EN 983
Safety of machinery. Safety requirements relevant to systems and related
components for hydraulic and pneumatic transmission. Pneumatics.
UNI EN 349
Safety of machinery - Minimum openings to prevent the crushing of parts of
the human body.
D. LGS. January 27th 2010
no.17
Implementation of Directive 2006/42/CE relevant to machinery, which
modifies directive 95/16/CE relevant to elevators.
UNI EN ISO 14121-1
Safety of machinery - Risk assessment. General principles
UNI EN ISO -TR 14121-2
Safety of machinery - Examples
Machine directive 2006/42/CE.
Article 7. Presumption of conformity and harmonized standards
1. The Member States deem that the machinery provided with the “CE”marking and accompanied by the
CE declaration of conformity, whose elements are provided for in Annex II, Part 1, Section A, comply with the
provisions of this directive.
2. The machinery manufactured in compliance with an authorized standard, whose reference has been
published on the Official Journal of the European Union is assumed to be compliant with the essential health
and safety requirements covered by such harmonized standard.
3. The Commission published the references of the harmonized standards in the Official Journal of the
European Union.
4. The Member States shall take the appropriate measures to allow the social partners influencing - at
national level - the development and control process of the harmonized standards.

USER'S AND
MAINTENANCE
MANUAL
Date:
22/01/2015
Code
MAN MDVN 22-26 K
ITA
Motor compressor MDVN 22 K –MDVN 26 K
Revision
00
Copyright © 2014, ROTAIR S.P.A. - All rights reserved This manual is intellectual property of ROTAIR S.P.A. Its
full or partial reproduction is forbidden under any form, on any support and by any means, without the written
authorization by ROTAIR S.P.A.
Page
10/68
1.4 General description of the machinery
The machinery described in this manual is motor compressor MDVN 22K –MDVN 26K.
The motor compressor is a piece of machinery with the capacity of generating a given quantity of compressed
air in l/m by using a diesel engine as primary energy.
The pneumatic energy finds applications in different fields of use, where "pneumatic" operation tools,
accessories and equipment are utilized. For instance: demolition hammers, drilling hammers, vibrators, drilling
machines, rammers, coating machines, etc.
Each of these tools/-accessories has its own consumption of compressed air, expressed in litters per minute.
The optimum coupling between the compressor and the tool is achieved when the compressed air
consumption does not exceed 85% of the air generated by the compressor (furthermore, it must be taken into
consideration that the quantity of compressed air required by the tool shall increase in time, proportionally to
the wear of the tool itself).
The correct compressor-tool coupling ratio allows the machinery operating in optimum conditions, as
appropriate to ensure long life-span at the highest performance.
An oversized tool - besides creating unfavourable conditions for the appropriate operation of the machinery -
shall not develop full performance, since it cannot resort to the required quantity of compressed air.
This machinery has been designed to work at ambient temperature ranging from -10 and +40°C.