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Maintenance

on

BAUERBreathing Air Compressor Units

Service Manual

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Model . . . . . . . . . . . . . . . . . . . . . .

Serial no. . . . . . . . . . . . . . . . . . . . . . . . . .

Year of mfg. . . . . . . . . . . . . . . . . . . . . . . . . .

Date of commissioning . . . . . . . . . . . . . . . . . . . . . . . . .

Warranty period . . . . . . . . . . . . . . . . . . . . . . . . .Phone no. service hotline . . . . . . . . . . . . . . . . . . . . . . . . .

Stamp (Dealer) Date

Sticker dealer data

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Introduction form for the Operator

By adding themselves to this list, the person that signs it confirms having been given a yearly intro-duction//instruction about the function and operation of the compressor unit.

Furthermore, they have be informed about the relevant safety rules and regualtions (TRG, DGRL,

BetrSichV, GSG, GSGV).This form is to be kept safely with the other company documents (acceptance documentation, in-struction manual) and is to be produced if requested by supervisory authorities (TV, GAA) .

Seq-no.

Surname Name Place Date Signature Instructorsname/company

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

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Table of Contents

1. Check oil level, top up 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Cartridge change 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Every 500 Operating hours/ annually / actual operating hours: ____ 13. . . . . . . . . .

4. Every 1000 Operating hours/ every 2 years / actual operating hours: ____ 13. . . . .

5. Every 1500 Operating hours/ every 3 years / actual operating hours: ____ 13. . . . .

6. Every 2000 Operating hours/ every 4 years / actual operating hours: ____ 14. . . . .

7. Every 2500 Operating hours/ every 5 years / actual operating hours: ____ 14. . . . .

8. Every 3000 Operating hours/ every 6 years / actual operating hours: ____ 14. . . . .

9. Every 3500 Operating hours/ every 7 years / actual operating hours: ____ 15. . . . .

10. Every 4000 Operating hours/ every 8 years / actual operating hours: ____ 15. . . . .

11. Every 4500 Operating hours/ every 9 years / actual operating hours: ____ 15. . . . .

12. Every 5000 Operating hours/ every 10 years / actual operating hours: _____ 16. . .

13. Filling hoses 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14. Every 5 years (Pressure vessels) 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15. Every 10 years (Pressure vessels) 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16. Load cycles (Pressure vessels) 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17. Maintenance schedule breathing air compressor units 18. . . . . . . . . . . . . . . . . . . . . . .

18. Modifications 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19. Replaced Parts 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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1. Check oil level, top up

Name of person in charge Compressoroperating

hours *

Refilled oilquantity

Date

* according to B--Timer or other source

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Check oil level, top up (contd)

Name of person in charge Compressoroperating

hours *

Refilled oilquantity

Date

* according to B--Timer or other source

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Check oil level, top up (contd)

Name of person in charge Compressoroperating

hours *

Refilled oilquantity

Date

* according to B--Timer or other source

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Check oil level, top up (contd)

Name of person in charge Compressoroperating

hours *

Refilled oilquantity

Date

* according to B--Timer or other source

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2. Cartridge change

Name of person in charge Compressoroperating

hours *

Difference Date

* according to B--Timer or other source

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Cartridge change (contd)

Name of person in charge Compressoroperating

hours *

Difference Date

* according to B--Timer or other source

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Cartridge change (contd)

Name of person in charge Compressoroperating

hours *

Difference Date

* according to B--Timer or other source

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Cartridge change (contd)

Name of person in charge Compressoroperating

hours *

Difference Date

* according to B--Timer or other source

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3. Every 500 Operating hours/ annually / actual operatinghours: ____

Maintenance work Done Date, signature

Compressor maintenance acc. to schedule chapter 16.

Oil type change: ____________________________

Installation of maintenance kit .....--a

Breathing air test

Miscellaneous

4. Every 1000 Operating hours/ every 2 years / actual operatinghours: ____

Maintenance work Done Date, signature

Compressor maintenance acc. to schedule chapter 17.

Oil type change: ____________________________

Installation of maintenance kit .....--ab

Breathing air test

Miscellaneous

5. Every 1500 Operating hours/ every 3 years / actual operating

hours: ____

Maintenance work Done Date, signature

Compressor maintenance acc. to schedule chapter 17.

Oil type change: ____________________________

Installation of maintenance kit .....--a

Breathing air test

Miscellaneous

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6. Every 2000 Operating hours/ every 4 years / actual operatinghours: ____

Maintenance work Done Date, signature

Compressor maintenance acc. to schedule chapter 17.

Oil type change: ____________________________

Installation of maintenance kit .....--abc

Breathing air test

Miscellaneous

7. Every 2500 Operating hours/ every 5 years / actual operatinghours: ____

Maintenance work Done Date, signature

Compressor maintenance acc. to schedule chapter 17.

Oil type change: ____________________________

Installation of maintenance kit .....--a

Breathing air test

Miscellaneous

8. Every 3000 Operating hours/ every 6 years / actual operating

hours: ____

Maintenance work Done Date, signature

Compressor maintenance acc. to schedule chapter 17.

Oil type change: ____________________________

Installation of maintenance kit .....--ab

Breathing air test

Miscellaneous

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9. Every 3500 Operating hours/ every 7 years / actual operatinghours: ____

Maintenance work Done Date, signature

Compressor maintenance acc. to schedule chapter 17.

Oil type change: ____________________________

Installation of maintenance kit .....--a

Breathing air test

Miscellaneous

10. Every 4000 Operating hours/ every 8 years / actual operatinghours: ____

Maintenance work Done Date, signature

Compressor maintenance acc. to schedule chapter 17.

Oil type change: ____________________________

Installation of maintenance kit .....--abc

Breathing air test

Miscellaneous

11. Every 4500 Operating hours/ every 9 years / actual operating

hours: ____

Maintenance work Done Date, signature

Compressor maintenance acc. to schedule chapter 17.

Oil type change: ____________________________

Installation of maintenance kit .....--a

Breathing air test

Miscellaneous

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12. Every 5000 Operating hours/ every 10 years / actualoperating hours: _____

Maintenance work Done Date, signature

Compressor maintenance acc. to schedule chapter 17.

Oil type change: ____________________________

Installation of maintenance kit .....--ab

Breathing air test

Miscellaneous

13. Filling hoses

Half--year

Maintenance work Date, signature

1 Hose test according to TRG 402/8.2

23

4

5

6

7

8

9

1011

12

13

14

15

16

17

18

1920 Exchange of hoses every 10 years

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14. Every 5 years (Pressure vessels)

Jahr Maintenance work Date, signature

5 Internal inspection of pressure vessels

10

15

20

15. Every 10 years (Pressure vessels)

Jahr Maintenance work Date, signature

10 Water pressure test of pressure vessels

20

16. Load cycles (Pressure vessels)

Date Operating hours Load cycles* Total load cycles

* load cycles are all dynamic pressure load changes in the pressure vessel; refer to operating manual

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17. Maintenance schedule breathing air compressor units

Service and inspection acc. to calender:

Service and inspection acc. to operating hours:

Change filter cartridge

Change gaskets, o--rings included in maintenance kit

additional gaskets, o--rings (not included in maintenance kit)

Change intake and pressure valves at the latest

Change intake filter cartridge

Change piston liner

Change sintered metal filters

Change v--belt(s)

Check automatic condensate drain adjustment, pressure loss

Check cylinders, piston rings, change if required

Check function of automatic condensate drain

Check function of monitoring devices (if fitted)

Check intake and pressure valvesCheck intermediate pressures and oil pressure

Check oil level, oil change, oil filter change

Check pistons

Check piston liner

Check pressure switch, pressure maintaining valve

Check pressure vessels, record no. of load cycles

Check temperature sensors, replace if required (if fitted)

Check tightness of safety valves

Check v--belt(s) and fanwheel

Clean separator, empty condensate collecting tank

Functional test, final inspection, test run

Leak test

Make test report, apply test stickers

Service automatic condensate drain, check function, replace worn of defective parts

Visual check of coolersThe service interval startes from the beginning after the last maintenance work in this list.

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1 year 2 years 3 years 4 years 5 years 6 years 7 years 8 years

500 1.000 1.500 2.000 2.500 3.000 3.500 4.000

as required

X X X X X X X X

as required

X X X X

X X X X X X X X

X X

X X X X X X X X

X

X X X X X X X X

as required

X X X X X X X X

X X X X X X X X

X X X XX X X X X X X X

X X X X X X X X

X

X X

X X X X X X X X

X X X X X X X X

X X

X X X X X X X X

X X X X X X X X

X X X X X X X X

X X X X X X X X

X X X X X X X X

X X X X X X X X

X X X X

X X X X X X X XThe service interval startes from the beginning after the last maintenance work in this list.

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18. Modifications

Designation/description Part numbers Date, signature

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19. Replaced Parts

Designation Part no. Manufacturer s part no.

Old New

Date, signature

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Date, signatureManufacturers part no.

Old New

Part no.Designation

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. Customer servicePhone no: (089) 78049--129 or --149Fax no: (089) 78049--101

. Technical customer servicePhone no: (089) 78049--246 or --176Fax no: (089) 78049--101

. Training managerPhone no: (089) 78049--175Fax no: (089) 78049--101

Notes:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Breathing Air Compressors

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Dear customer

We are happy to give you advice on any questions regarding your BAUER compressor and helpas soon as possible with any arising problems.

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What to do in an emergency

Keep calm!What has happened?

H Leak H Fire H Explosion H other incident

What to reportH WHERE did it happen? Place!H WHEN did it happen? Time!H HOW MANY injured? Number!H WHO reported the trouble? Name!

FIRE BRIGADE 112POLICE 110SPECIALIST FOR ACCIDENT INJURIESACCIDENT HOSPITAL

CLINIC FOR BURNS

In the case of irregularities, immediately inform!1. Tel.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. Tel.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. Tel.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4. Tel.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tel.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5. Tel.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. Security forces Tel.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .In case you cannot get hold of the management Tel.. .

Assembly point in an emergency:

Neighbour Tel.Neighbour Tel.Neighbour Tel.Neighbour Tel.

Tel.Tel.Responsible supervisory authority Tel.

Authorization office Tel.TV/GAA Tel.

In an emergency, if necessary additionally inform: