Bottarini GDP21, GDP31 Maintenance And Operating Manual

Bottarini GDP21 is a powerful and versatile air compressor designed for a wide range of applications. It features a durable construction, reliable performance, and easy maintenance. With its compact size and portability, the GDP21 is ideal for use in confined spaces or on the go.

PDF

Document

GB

EDITION

MAINTENANCE AND OPERATING MANUAL

Cod. 100016705

FROM

TO

03/09

G D P 2 1 – G D P 3 1

COMPRESSOR DATA PLATE – INFORMATION

RIF. 03

MANUFACTURED

COMPRESSOR TYPE

SERIAL N.

MAX PRESS.-bar

(Maximum pressure)

YEAR

NOTE: PLEASE REFER TO THE MANUAL FOR ALL THE TECHNICAL INFORMATION AND SPARE PARTS

REFERENCES. FOR ALL THE INQUIRES, PLEASE COMMUNICATE THE TYPE OF THE UNIT AND THE

SERIAL NUMBER THAT CAN BE FOUND ON COMPRESSOR INFORMATION PLATE.

FOR INFORMATION AND SPARE-PARTS:

GARDNER DENVER S.r.l.

Via Tevere n°6

21015 Lonate Pozzolo (VA) ITALIA

Tel. 0331.349411 – Fax. 0331.301680

e-mail: [email protected]

www.bottarini.it

CALIFORNIA

Proposition 65 Warning

Diesel engine exhaust and some of its constituents are known to the State of

California to cause cancer, birth defects, and other reproductive harm.

1. Index

1 Index ........................................................................................................................................................................................................................ 1

2 Foreword ................................................................................................................................................................................................................. 3

2.1

Information on the compressor ...................................................................................................................................................................... 3

2.2

Normal use ..................................................................................................................................................................................................... 3

2.3 Specifications ................................................................................................................................................................................................ 4

2.4 Maintenance and care .................................................................................................................................................................................. 7

2.5 General information ...................................................................................................................................................................................... 7

3 Security Regulations ............................................................................................................................................................................................. 8

3.1

Identification of safety instructions................................................................................................................................................................. 8

3.2 General safety instructions .......................................................................................................................................................................... 8

3.3 Modifications and alterations to the machine ........................................................................................................................................... 8

3.4

Loading/Relocation/Transport ........................................................................................................................................................................ 8

3.5

Installation on site / Starting / Normal operation ........................................................................................................................................... 9

3.6

Special jobs / Maintenance .......................................................................................................................................................................... 11

3.7 Instructions concerning particular hazards .............................................................................................................................................. 12

3.8 Symbols and definitions ............................................................................................................................................................................. 13

4 Construction and functional description .......................................................................................................................................................... 15

4.1

Construction .................................................................................................................................................................................................. 16

4.2

Functional description (see fig. 8) ................................................................................................................................................................ 16

4.3

System description ....................................................................................................................................................................................... 17

4.4 Wiring diagram ............................................................................................................................................................................................ 18

4.5 Vehicle Socket Connection Plan 13-pin 12 Volt ...................................................................................................................................... 19

5 Transport and installation on site...................................................................................................................................................................... 20

5.1 Transport ...................................................................................................................................................................................................... 20

5.2

Attachment of the contact-breaker cable on braked chassis ..................................................................................................................... 20

5.3

Loading/Relocation ....................................................................................................................................................................................... 21

5.4 Installation on site ....................................................................................................................................................................................... 21

6 Preparing the compressor for operation .......................................................................................................................................................... 23

6.1 Checking levels ........................................................................................................................................................................................... 23

6.1.1

Checking the oil level in the pressure tank ................................................................................................................................. 23

6.1.2

Checking the oil level in the engine ............................................................................................................................................. 23

6.1.3

Checking coolant level .................................................................................................................................................................. 23

6.2

Battery ........................................................................................................................................................................................................... 24

6.3 Filling up the fuel tank................................................................................................................................................................................. 24

6.4

Fuel water separator .................................................................................................................................................................................... 24

6.5

Checking the air filter maintenance display ................................................................................................................................................ 24

7 Putting the compressor into operation ............................................................................................................................................................. 25

7.1

Initial operation ............................................................................................................................................................................................. 25

7.2

Operating elements ...................................................................................................................................................................................... 25

7.3 Start-up ......................................................................................................................................................................................................... 25

7.4

Setting the operating pressure ..................................................................................................................................................................... 26

7.5 Monitoring / fault .......................................................................................................................................................................................... 27

7.6 Operation ..................................................................................................................................................................................................... 27

7.7 Shutdown ..................................................................................................................................................................................................... 27

7.8 Decommissioning ........................................................................................................................................................................................ 27

8 Fuels ...................................................................................................................................................................................................................... 28

8.1

Recommended lubricant for compressor .................................................................................................................................................... 28

8.2

Recommended engine oil ............................................................................................................................................................................ 28

8.3 Tool lubricants ............................................................................................................................................................................................. 28

8.4 29

8.4

Diesel fuel ..................................................................................................................................................................................................... 29

8.5 Coolant ......................................................................................................................................................................................................... 29

8.6 Recommended lubricants for the bogies .................................................................................................................................................. 29

9 Maintenance .......................................................................................................................................................................................................... 30

9.1

General maintenance ................................................................................................................................................................................... 30

9.2 Engine maintenance ................................................................................................................................................................................... 30

9.3 Maintenance of the fuel system ................................................................................................................................................................. 30

9.4 Maintenance of chassis and brakes ......................................................................................................................................................... 31

1. Index

9.5

Compressor maintenance / Maintenance schedule .................................................................................................................................... 32

9.5.1

Oil filter replacement (compressor) ................................................................................................................................................ 33

9.5.2

Oil change (compressor) ............................................................................................................................................................... 33

9.5.3

Checking the automatic monitoring system ............................................................................................................................... 33

9.5.4

Inspecting / Replacing the fine separator .................................................................................................................................... 34

9.5.5

Air filter replacement (compressor / engine) .................................................................................................................................. 34

9.5.6

Checking the safety valve ............................................................................................................................................................... 34

9.5.7

Control ............................................................................................................................................................................................. 35

9.5.8

Battery maintenance ...................................................................................................................................................................... 35

9.5.9

Torque specifications ..................................................................................................................................................................... 35

9.6

Spare parts for maintenance purposes ....................................................................................................................................................... 35

10 Troubleshooting ................................................................................................................................................................................................... 36

11 Generator option ................................................................................................................................................................................................. 38

11.1 Introduction .................................................................................................................................................................................................. 38

11.2 Generator safety precautions .................................................................................................................................................................... 38

11.3

Operating principle ....................................................................................................................................................................................... 38

11.4

Operating the generator (Working safely with electrical equipment) ......................................................................................................... 39

11.5 Testing insulation monitoring / startup / device connection ................................................................................................................... 40

11.6 Technical characteristics of 110V 6kVA GTS generator ........................................................................................................................ 41

11.7 Technical characteristics of 400/230V 5/8kVA GTS generator ............................................................................................................. 41

11.8

Technical characteristics of 110V 7kVA KWG generator ........................................................................................................................... 42

11.9 Technical characteristics of 400/230V 8kVA KWG generator ............................................................................................................... 43

11.10 Generator switchbox wiring diagram GTS 110V 6kVA ......................................................................................................................... 44

11.11

Generator switchbox wiring diagram GTS 400/230V 8kVA ...................................................................................................................... 44

11.12 Generator switchbox wiring diagram KWG 110V 7kVA ........................................................................................................................ 45

11.13 Generator switchbox wiring diagram KWG 230/400V 8kVA ................................................................................................................ 45

11.14

Troubleshooting ........................................................................................................................................................................................... 46

12 Heat exchanger option ...................................................................................................................................................................................... 48

12.1

Safety regulations for the use of the heat exchanger................................................................................................................................. 48

12.2 Design and operation ................................................................................................................................................................................. 48

12.3

Maintenance/Care ........................................................................................................................................................................................ 48

13 Compressed air processing option (After cooler / Heat exchanger) ........................................................................................................... 49

13.1 Safety regulations for alternate compressed air processing .................................................................................................................. 49

13.2

Design and operation ................................................................................................................................................................................... 49

13.3 Maintenance instructions ........................................................................................................................................................................... 49

13.4 Troubleshooting........................................................................................................................................................................................... 49

14 Oil temperature controller option ................................................................................................................................................................... 50

14.1 Safety regulations for the use of an oil temperature controller .............................................................................................................. 50

14.2

Design and function...................................................................................................................................................................................... 50

14.3 Maintenance / care ..................................................................................................................................................................................... 50

14.4

15 Undercarriage ....................................................................................................................................................................................................... 51

15.1 Introduction .................................................................................................................................................................................................. 51

15.2

Safety ............................................................................................................................................................................................................ 51

15.3

KHV7,5 height-adjustable towing system, model B 3.5.13......................................................................................................................... 51

15.4 Braking system ............................................................................................................................................................................................ 51

15.5

Adjusting the braking system ....................................................................................................................................................................... 52

15.5.1

Preparations .................................................................................................................................................................................... 52

15.5.2

Preliminary requirements .............................................................................................................................................................. 52

15.5.3

Adjusting the brake.......................................................................................................................................................................... 52

15.5.4

Adjusting the brake compensating system ................................................................................................................................ 52

15.5.5

Adjusting the brake linkage [6] ..................................................................................................................................................... 53

15.6

Readjusting the braking system ................................................................................................................................................................... 53

15.7

Maintenance and care .................................................................................................................................................................................. 53

15.8

Malfunctions and remedies .......................................................................................................................................................................... 54

16 Tool oiler option ................................................................................................................................................................................................... 56

2. Foreword

2.1 Information on the compressor

GARDNER DENVER screw compressors are the product of many years' research and development. These preconditions, together with high quality standards, guarantee the manufacture of screw compressors with a long service life, a high degree of reliability and cost-effective operation. The strict environmental protection standards have of course been complied with.

Confirmation of Conformity

The compressor and its accessories as supplied by GARDNER DENVER conform to the basic health and safety requirements included in the EC

Machinery Directive 98/37/EC. The compliance with the directive is confirmed by the "CE mark" (Fig. 1).

Fig. 1

2.2 Normal use

The compressors have been built using the latest techniques in design and in accordance with recognized safety regulations.

Nevertheless, the operator or third parties may be exposed to risk to life and limb in the course of the use of the compressor (e.g. through flying pieces of building material, swirling particles of dirt or dust, electrical current, thermal vibrations, noise or mechanical hazards), and the machine or other tangible assets may be impaired, for reasons that could not have been avoided through preventive constructional safety measures.

Hazards occur particularly when:

* The compressor is not used for its intended purpose

* The compressor is not operated by trained personnel

* Unauthorized changes or modifications are carried out on the compressor

* You are not wearing the prescribed protective clothing

* You do not comply with the safety instructions

* You do not observe the information in the operating manual

For this reason every person involved in the operation, maintenance and repair of the compressor must read and observe the operation manual and the safety regulations. This is to be confirmed by signature as required.

Furthermore, the following naturally apply:

* The relevant accident prevention regulations

* Generally recognized safety and traffic regulations

* Particular national regulations

The compressor is designed for providing compressed air:

* For operating compressed-air appliances

* For conveying bulk material

* For sandblasting and paint-spraying operations

* For cleaning machines and shuttering material - do not direct towards persons!

* For blow-cleaning drilled holes. Any other use, or any additional use, for example as respiratory air, is regarded as not being for the originally intended purpose. The manufacturer / supplier accepts no liability for any resulting damage. The risk is assumed by the user alone.

The compressor may only be used in a technically perfect condition, for its intended purpose, with appropriate awareness of safety regulations and hazards, subject to compliance with the operating manual. In particular, faults representing safety hazards are to be corrected at once.

2. Foreword

2.3 Specifications

Ambient temperature

Engine speed

GDP21

GDP31 min. max.

[°C] [°C] [m 3 /min] [barg]

2.0

3.0

7.0

[barg]

5.0-8.0

- 10

+ 45

[m above sea level]

1000

[l]

6.3

6.6

[kw] min. max.

[rpm] [rpm]

D1105

V1505

Water

[l]

16.3

22.7

2000

1800

2700

5.4

6.0

[l]

5.1

6.0

[l]

40.0

Operational weight

GDP21

GDP31

[kg]

750

500

750

[kg]

580

611

[kg]

558

588

[kg]

539

570

[kg]

500

[kg] [mm]

3227

2925

3005

2937

3227

2925

3005

[mm]

1200

[mm]

1194 4 1/2Jx13H2 145/80 R13

1196

1194

1160

1194

4 1/2Jx13H2

3.50B x 10H

4 1/2Jx13H2

145/80 R13

5.00 - 10C

145/80 R13

1196

1194

4 1/2Jx13H2 145/80 R13

[barg]

2.2

1 x 3/4"

2.75

2.2

2 x 3/4"

2.2

[dB/1pW]

[dB(A)] [dB(A)]

81 68

82 69

2. Foreword

Chassis height-adjustable, braked

Fig. 2

Chassis height-adjustable, unbraked

Fig. 3

Chassis rigid, unbraked

Fig. 4

2. Foreword

Chassis rigid, braked

Fig. 5

2. Foreword

2.4 Maintenance and care

Care and maintenance are all-important if the screw compressor is to meet the demands placed upon it. Compliance with the prescribed maintenance intervals and careful execution of care and maintenance work are therefore essential, especially under difficult working conditions.

Service

In case of faults, or should you require spare parts for the screw compressor, please contact your local GARDNER

DENVER agent.

In case of damage, the trained technical staff will guarantee a fast, expert repair using GARDNER DENVER spare parts.

Original GARDNER DENVER spare parts are manufactured according to the state of the art and guarantee continued reliable operation.

If you have important questions,

2.5 General information

This operating manual is to help you to get to know the compressor and to use it for its intended applications. It contains important information about how to operate the compressor safely, costeffectively and with due care. Compliance with the instructions in this manual will help to avoid danger, reduce repair costs and downtime, and increase the reliability and service life of the compressor.

This operating manual is to be supplemented by instructions concerning current national regulations for accident prevention and environmental protection.

It must always be available at the site of the compressor. The operating manual is to be read and used by all persons in charge of work with the compressor, for example operation, including setting up, correcting faults during operation, disposal of waste products from production, care, disposal of process materials, upkeep

(maintenance, inspection, repair) and transport.

Besides the operating instructions and the current regulations applicable in the user's country and at the sites of operation concerning accident prevention, the recognized technical rules for safe and proper working are also to be complied with.

This fact results in the termination/ expiration of the guarantee and warranty claims against the manufacturer.

Safety regulations

Danger

It is important that you follow the safety regulations in Chapter 3 of the operating manual.

Technical modifications

We reserve the right to undertake modifications without notice in the interests of technical progress.

Fig. 6

Please enter the data from the identification plate for your compressor, in the spaces above. In case of questions or orders for spare parts, please give us the compressor type, compressor number and the year of construction as given on the identification plate.

If you give us this data you can be sure that you will be given the correct information or sent the spare parts you require.

Warranty

Only use this compressor with accurate knowledge of and in compliance with this manual.

GARDNER DENVER S.r.l. do not accept responsibility for safe functioning of the compressor for actions that do not correspond to normal use or for purposes not mentioned in the manual.

Warranty claims cannot be entertained for:

* Operating errors

* Inadequate maintenance

* Incorrect fuels

* Damage caused by non-use of original

GARDNER DENVER parts

* Modification of the system.

The Guarantee and Liability terms of

GARDNER DENVER's General Terms and Conditions are not extended through the above instructions.

Any unauthorized modification of the compressor system/station or the installation of components (e.g. fine separators) not released by the manufacturer result in the loss of the

CE symbol.

3. Security Regulations

3.1 Identification of safety instructions

GARDNER DENVER accepts no responsibility for any damage or injury caused by non-compliance with these safety measures or non-observance of normal care and caution during the handling, operation, maintenance or repair of this compressor, even if not expressly stated in this operating manual.

If any of the regulations contained in this manual do not correspond to local statutory provisions, particularly with reference to safety, then the stricter of the two applies.

These safety instructions are of a general nature and are applicable to various types of machine and equipment.

For this reason it is possible that some information may not apply to the aggregate(s) described in this manual.

Danger

Places thus marked refer to possible dangers for persons.

Attention

Places thus marked refer to possible dangers for machines or parts of machines.

Note

Places thus marked give general and technical information for optimum, costeffective machine use.

3.2 General safety instructions

Organizational measures

Please keep this operating manual handy at all times on the site of the machine / installation, in the bag provided.

Please note and pass on general statutory and other binding regulations that may supplement the operating manual for the prevention of accidents and the protection of the environment.

Such obligations may be for example the handling of hazardous materials, or the provision and/or wearing of personal protective equipment, or traffic regulations.

Instructions, including supervisory responsibility and duty of notification for taking account of special in-plant factors, for example regarding work organization, sequences of operations, personnel assigned to certain tasks, are to be added to the operating manual.

Personnel delegated to work with the machine must have read the operating manual before beginning this work, particularly the chapter on safety instructions. It is too late to do this while working. This applies particularly to personnel only using the machine occasionally, e.g. for setting up and maintaining the machine.

Safety and danger-conscious working by the personnel in compliance with the operating manual should be checked at least occasionally.

The personnel must not have long, loose hair, or wear loose clothing or jewellery, including rings, due to risk of injury through catching. Personal protective equipment should be worn if necessary or as required by regulations.

Pay attention to all safety and danger warnings on the machine/ installation!

Make sure that all safety and danger warnings on the machine / installation can be read.

For all safety-relevant modifications to the machine / installation or its operating behavior, stop the machine / installation immediately and report the fault to the competent authority / person.

Spare parts must meet the technical requirements laid down by the manufacturer. This is always guaranteed when original spare parts are used.

Replace hydraulic hoses at the given intervals, or at suitable intervals, even if no safety-relevant defects are visible

(DIN 20066, Part 5).

Observe the intervals stipulated or those given in the operating manual for routine checks and inspections.

Workshop equipment suitable for carrying out maintenance work is essential.

The location and operation of fire extinguishers must be made known.

Observe the instructions concerning fire alarm and fire fighting.

Limiting values (pressure, temperature, time settings etc.) must be permanently marked.

Define who is responsible for operating the machine, and authorize him to ignore instructions from third parties if these instructions could compromise safety.

Only allow personnel that are training, that are under instruction or are attending a course of general training to use the machine / installation under the constant supervision of an experienced person.

Work on the electrical systems of the machine / installation may only be carried out by a trained electrician in accordance with electrical regulations.

Only persons with special knowledge and experience of hydraulics may work on system elements, for example components under pressure.

3.3 Modifications and alterations to the machine

No alterations, additions, or modifications to the machine may be carried out without the approval of the manufacturer. This is also true for the installation and the adjustment of safety devices and valves as well as for welding at supporting and pressurized parts.

Unauthorized modifications to the machine are prohibited for reasons of safety.

Original parts are specially designed for our machines. We must explicitly point out that parts and special accessories not supplied by us are not approved by us.

Installing or using such products may thus adversely aff ect active and/or passive safety.

The manufacturer accepts no liability whatsoever for damage resulting from the use of non-original parts or special accessories. This also applies to the installation and adjustment of safety devices and valves as well as to welding on bearing and pressurized parts.

Note

The General Type Approval becomes invalid in case of modifications or alterations which change or infringe upon the external geometry as well as the gross axle weight rating.

Personnel selection and qualification; basic tasks

Work on or with the machine / installation may only be carried out by reliable personnel. Observe the minimum statutory age.

Only trained or specially instructed personnel may be assigned to this work.

The responsibility of the personnel for operating, setting up, maintaining and repairing the machine / installation must be clearly defined.

Make sure that only authorized personnel use the machine.

3.4 Loading/Relocation/Transport

Loading / Relocation

All loose parts that could fall down when the machine is lifted must first be removed or secured; pivoting parts like doors, etc.

must be immobilized.

For lifting heavy parts, hoisting gear and heavy-lift facilities with the appropriate capacities, which have been checked and approved in accordance with local safety regulations, must be used.

3. Security Regulations

For lifting machines or parts of machines with one or more lifting eyes, only hooks or shackles complying with local safety regulations may be used. Never fasten cables, chains or ropes to or through lifting eyes.

Lifting hooks, lifting eyes, shackles etc.

must never be bent and must always be stressed in alignment with the loadcarrying axis. The load capacity of the hoisting gear is reduced if the lifting force is applied at an angle to the axis.

All bearing parts must be stressed vertically, as far as possible, for maximum safety and optimum performance of the hoisting gear. If required, a support is to be installed between the hoisting gear and the load. Secure the load properly.

When heavy loads are being conveyed by means of hoisting gear, it is imperative to keep well clear of the load in order to avoid accidents.

Never leave the load suspended on the hoisting gear.

Acceleration or braking of the means of transport must remain within the approved limits.

The hoisting gear is to be set up in such a way that the object is lifted vertically.

Should this not be possible, precautions must be taken to prevent the load from swinging. Thus it is possible to use two sets of hoisting gear, both with an angle of inclination of not more than 30° to the vertical.

Nominate experienced supervisors for the lifting process.

Machines may only be hoisted correctly using hoisting gear in accordance with the information in the operating manual (limit stop points for heavy-lift facilities etc.)

Only use a suitable transport vehicle with sufficient carrying capacity.

Before or immediately after completion of loading, secure the machine / installation to prevent accidental shifting.

Display an appropriate warning. Before putting the machine / installation back into operation, the securing devices must be duly removed.

Parts to be removed for transport purposes must be carefully refitted and fixed again before putting the machine / installation back into operation.

When putting the machine / installation back into operation again, only proceed in accordance with the operating manual.

Transporting the complete unit

Make sure that the air vessel is not under pressure.

Lift and secure supporting gear.

Make sure that the drawbar eye can move freely in the tow bar.

Check to make sure that the drawbar is adjusted to the bar height of the towing vehicle.

Check to make sure that the body is closed and locked, and that the cable for the rapid-emergency brake is connected to the towing vehicle.

Join up the connections of the air brake, if present.

Check to make sure that the wheels are properly tightened, that the tyres are in a roadworthy condition, that the tyre pressure is correct and that the brakes function properly.

Connect the cable for the signalling and lighting fittings. Check the proper functioning of the lighting.

Release the handbrake.

Before transporting the unit, always check to make sure that the accessories are firmly attached so that they can cause no accidents!

When using public roads, tracks and spaces, observe the current traffic regulations, and if necessary make the unit roadworthy first!

Never exceed the maximum towing speed. Observe national regulations!

Always switch on lights if visibility is poor and during lighting-up time!

When going through underpasses, bridges, tunnels, overhead power lines, etc., always make sure that you have enough clearance!

Always keep a safe distance from the edges of foundation ditches and embankments!

Do not travel across slopes transversely: always keep equipment and loads near ground level (for example, do not place them on the bodywork).

On descents, always adapt speed to the circumstances! Never change into low gear during the descent, but always beforehand. When leaving the driver's seat, always secure the unit to make sure that it cannot roll away or be used without authorization!

Avoid all operations that adversely affect the stability of the unit.

3.5 Installation on site / Starting /

Normal operation

Installation on site

Besides the general technical operation in accordance with the regulations of the local authorities, it is essential that the following guidelines be observed.

Before switching on the machine / installation, or starting it up, make sure that nobody can be injured by the machine / installation as it starts up.

The installation is to be set up in such a way that it is adequately accessible and that the necessary cooling is ensured.

Never block the admission of air.

The air intake is to be designed in such a way that no dangerous admixtures

(inflammable solvent vapors etc., but also dust and other dangerous or toxic substances) can be taken in. This also applies to flying sparks.

The air intake is to be designed in such a way that no loose personal clothing can be drawn in.

Make sure that the compressed air line from the compressor to the air network can expand as a result of heat and cannot come into contact with inflammable materials.

The compressed air line connected at the air exit of the unit must not be under strain.

Compressed-air lines have to be marked distinctly according to local regulations.

If several compressors are arranged in a system, manually operated valves have to be installed so that each machine may be shut off individually. For the purpose of shutting off pressurized systems, you should never rely on the effectiveness of return valves alone.

Safety devices, protective covers, or insulations mounted on the system must not be removed or modified in any way.

All pressure tanks located outside the unit with an approved operating pressure higher than atmospheric pressure and fitted with two or more pressure feed lines must be equipped with an additional safety device to automatically prevent the approved operating pressure from being exceeded by more than 10%.

Pipes and other parts with a surface temperature of more than 80 °C must be suitably secured against contact and suitably marked.

Electrical connections must comply with local regulations.

With compressors fitted with generators, use equipotential bonding systems for the protection of persons.

3. Security Regulations

Install the machine so that it is as horizontal as possible; a slight inclination is permissible (see information in Chapter

"Installation").

Set up the machine in such a way that no inlets, outlets or gates are blocked, even when the doors are open.

Before disconnecting the machine from the towing vehicle, apply the handbrake.

Disconnect the rapid-emergency brake cable and lighting cable, disconnect the lines of the air brakes, use chocks to ensure that the machine does not roll away.

If a machine with a combustion engine has to work in a fire-risk environment, the unit must be fitted with a spark catcher.

In dusty environments, set up the machine in such a way that the wind does not blow dust in its direction. During operation in clean environments, the intervals for cleaning the air intake filter and the cooler elements are much longer.

Do not install the machine directly in front of walls. Make sure that the warm air coming from the engine and cooling systems is not drawn into the air intake under any circumstances. Drawing this warm air in through the engine or cooler fan could lead to overheating; if it is drawn into the combustion chamber, this will result in a loss of power.

Never relocate the machine if external lines or hoses are connected to the discharge valves, in order to avoid damage to the valves and/or collecting pipe and hoses.

No force may be exerted on the discharge valves, for example by pulling the hoses or fitting additional equipment

(e.g. a water separator, compressed air oiler, etc.) directly to the discharge valve.

Make sure that:

* All bolted connections have been tightened

* All electrical wiring has been connected correctly and is in good condition

* The engine exhaust system is operationally safe and that no inflammable material is in the vicinity

* The wheel nuts are properly tightened; never exceed the specified torque.

Normal operation

Before starting work, make yourself familiar with the working environment at the installation site. The working environment includes, for example, obstacles in the working and transport areas, the carrying capacity of the ground, and any necessary cordoning off of the building site from public traffic areas.

Take the necessary precautions to make sure that the machine / installation is only operated in a safe, functional condition.

Only operate the machine when all protective devices, shutdown devices, sound-insulating equipment and extraction equipment is in place and working.

Be careful: loose articles of clothing, hair or limbs can still be drawn in by revolving parts.

Verify regularly that:

* All protective equipment is properly positioned and fixed in place

* All hoses and/or pipes within the system are in good condition, are properly fixed in place and do not chafe

* There are no leaks (fuel, oil or coolant leaks)

* All bolted connections have been tightened

* All electrical wiring is properly connected and is in perfect condition

* Safety valves and other pressure-relief devices are in perfect condition and are not blocked, for example by dirt or paint

* The safety devices all work properly

All connected components must be of the correct size and be suitable for the specified operating pressure and temperature.

Only use the correct type and size of hose coupling and connection.

Before blowing through a hose or air line, it is essential to hold the open end firmly. If the open end is not held firmly, it can whiplash and cause damage or injury.

Avoid any working methods that could be considered risky!

Never play about with compressed air.

Never direct compressed air onto the skin or towards another person.

Never use compressed air for cleaning clothing. When using compressed air to clean equipment, work with extreme caution and always wear suitable eye protection.

The compressed air produced by these compressors must not be used as breathable air, unless it has been processed specially for such an application in accordance with the “Safety requirements for breathable air.”

When breathing apparatus with cartridges is used, make sure that the correct cartridge has been inserted and that its service life has not expired.

Never use the machine in environments where the possibility cannot be ruled out that inflammable or toxic vapors may be taken in.

Never operate the system at temperatures and/or pressures below or above the values indicated in the technical data sheet.

Persons working in environments or rooms in which the acoustic pressure is

85 dB(A) or higher must wear ear muffs.

Caution: this may impair communication between persons. Warnings may not be heard. Inform supervisor.

Shieldings and doors must be closed during operation so that the flow of cool air within the housing is not deflected and the efficiency of the sound-insulating is not reduced. Doors and hoods may only be opened briefly.

With water-cooled combustion engines with a closed cooling circuit, the cap of the coolant recovery bottle must not be removed before the system has cooled down to ambient temperature.

Never fill up with fuel while the engine is running. Make sure that fuel does not come into contact with hot machine parts.

Do not smoke while filling up with fuel.

Filling up at a pump can cause static electricity and possibly sparks. In order to avoid this, a ground cable must be connected to the system while it is being filled up.

The exhaust from the system contains carbon monoxide, a lethal gas.

The exhaust must be routed to the outside via a pipe or a hose with an internal diameter of not less than 100 mm if the compressor is used indoors.

Adequate ventilation must be assured.

The use of an exhauster system is urgently recommended.

Before connecting or disconnecting hoses, always close the compressor air outlet valves. Before disconnecting a hose, always make sure that it is not under pressure.

A hose connected to an air valve must be fitted with a safety wire for operating pressures above 7 bars; it is in fact recommended that this safety device should be used for pressures above

4 bars. The steel wire has a diameter of

8 mm and is firmly clamped to the hose at least every 500 mm. Both ends are fitted with cable lugs.

3. Security Regulations

Check the machine / installation for external damage and faults at least once per shift. Any changes noticed (including changes in operating performance) must be reported immediately to the authority or person in charge. If necessary, shut down and secure the machine immediately.

In case of malfunction, shut down and secure the machine / installation immediately. Have malfunctions corrected immediately.

Observe the operating manual for startup and shutdown procedures as well as inspection displays.

3.6 Special jobs / Maintenance

Care

Observe the setting, maintenance, and inspection work and intervals stipulated in the operating manual, including information about the replacement of parts / partial sections. This work may only be carried out by specialists.

Maintenance work, tests and repairs should be carried out in a well ventilated room, away from heat, open flames, or sparks. Appropriate prohibition signs (fire, open flames, no smoking) must be put up.

Loss of oil leads to a very slippery floor.

Statistics have shown that many accidents can be attributed to the installation or maintenance of machines on oily floors or machine components. For this reason, always start maintenance work by cleaning the floor and the machine exterior.

Inform operating personnel before beginning to carry out special work or maintenance. Nominate a supervisor.

After completing repair work, always check to see whether any tools, loose parts or cloths have been left in or on the machine, driving engine or driving equipment.

Maintenance and repair work is only to be carried out under the supervision of or by a person qualified for this work.

For all work concerning the operation, production adjustment, conversion, or settings of the machine / installation and its safety-relevant equipment, as well as servicing, maintenance, and repair, observe the operating manual for startup and shutdown procedures and the instructions for maintenance work.

All maintenance and repair work may only be carried out when the system is shut down, or, with electrical systems, when the mains power supply is switched off. Make sure that the equipment cannot be switched on by accident.

Whenever the machine/system is completely powered down for maintenance and repair procedures, it has to be secured against unintentional power-on or the mains supply has to be cut off with electrical systems.

* Switch off battery master switch and/or detach connector.

* Put up a warning sign on the main switch “Attention! Maintenance work.”

Close off the complete maintenance area, if required.

* Disconnect the starter battery.

Individual parts and larger subassemblies must be carefully attached to the hoisting gear and secured in case of replacement.

Only use suitable, technically perfect hoisting gear and load suspension devices with adequate carrying capacity. Keep clear of suspended loads.

Before removing any part under pressure, separate the aggregate effectively from all sources of pressure and release the pressure from the complete system.

Never use inflammable solvents or carbon tetrachloride to clean parts.

Take precautions to avoid toxic vapors from cleaning fluids.

Absolute cleanliness is essential during maintenance and when carrying out repairs.

Only carry out maintenance and repair work when the machine is located on an even, stable base and is secured against running away and against buckling.

Only carry out inspection, maintenance, and repair work when the screw compressor system is at a standstill and is not under pressure.

Protective devices, i. e. protective grids, may not be removed during operation.

Caution while the screw compressor is in operation.

After the work has been completed, replace any protective devices that have been removed. Operation without protective devices is not permissible.

Working clothing should be close-fitting during work on running screw compressor systems.

Maintenance

During maintenance and repair work, the contractor has to inform the personnel about the dangers that can occur during their work and about measures to avert such dangers.

The personnel have to support all measures to improve safety at work.

Safety devices for preventing or eliminating dangers must be serviced regularly and their functioning tested at least once per year. Faults discovered must be corrected at once or reported to the supervisor.

Only use the correct tools for maintenance and repair work.

Only use original spare parts.

All maintenance and repair work may only be carried out when the system is shut down, or, with electrical systems, when the mains power supply is switched off. Make sure that the aggregate cannot be switched on by accident.

* Switch off battery master switch and/or detach connector.

* Put up a warning sign on the main switch “Attention! Maintenance work.”

Close off the complete maintenance area, if required.

* Disconnect the starter battery.

Before removing or opening any part under pressure, separate the equipment effectively from all sources of pressure and release the pressure from the complete system.

For moveable machines support the towing mechanism and axle with appropriate means if work is to be carried out underneath the units (a jack is not sufficient).

Observe the safety precautions for work on batteries.

Pay attention to cleanliness. Prevent dirt from entering by sealing the parts and exposed openings with a clean cloth, paper, or tape.

Before the aggregate is approved for operation after maintenance or an overhaul, make sure that operating pressures, temperatures, and time settings are correct and that the control and shutdown devices are working properly.

The electric motor, generator, air filter, electrical components and control equipment are to be protected against the penetration of dampness - for example when cleaning with a steam jet - by covering or sealing them.

Under no circumstances should the sound-insulating material be removed or modified.

3. Security Regulations

Never use solvents with dangerous properties for cleaning parts.

Maintenance work, tests, and repairs should be carried out in a well ventilated room, away from heat, open flames, or sparks. Appropriate prohibition signs (fire, open flames, no smoking) must be put up.

Wear suitable eye protection when inspecting the system. Make sure that the openings of spray containers, valves, pipes, or atomizers are never directed at yourself or at any other person during the inspection.

The fuel used in these systems is highly inflammable, toxic and poisonous. Avoid contact with eyes and skin, and never inhale vapors. Should you accidentally swallow fuel, do not induce vomiting, but seek medical attention.

Should fuel come into contact with the eyes, or in case of eye irritation by vapors, flush eyes with plenty of clean water and seek medical attention.

Every time a message is displayed or there is a suspicion that an internal part of the machine has overheated, the machine must be shut down. Never open the inspection cover, however, before the machine has cooled down sufficiently to rule out the possibility of the oil vapors igniting spontaneously when mixed with air.

In order to avoid an increase in operating temperature, inspect and clean the heat transfer surfaces (cooling ribs etc.) regularly. Draw up a schedule for the most suitable cleaning intervals for each machine.

Avoid damaging the safety valves and other pressure-reducing devices. In particular, make sure that they are not blocked through paint, oil carbon, or dust accumulation, which could impair the effect of these devices.

The insulation or protective shielding of parts whose temperature may exceed

80 °C and which may accidentally be touched by personnel may not be removed before these parts have cooled down to room temperature.

Check the accuracy of the pressure and temperature displays regularly. If the permissible tolerance limits have been exceeded, then they must be replaced.

Never carry out welding work or any other work that produces heat in the vicinity of fuel or oil systems. Systems, which could contain fuel or oil, have to be completely drained and cleaned, e.g. by means of a steam jet, before proceeding with the work to be carried out.

Never carry out any welding work on any pressure tank or components under pressure, or modify them in any way.

If work causing heat, flames, or sparks has to be carried out on a machine, the surrounding components must be protected with nonflammable material.

Before dismantling or overhauling a compressor, engine, or any other machine, make sure that no movable part with a weight of more than 15 kg can move or roll away.

Machines whose main movement is back and forth must be moved at least once, rotating machines several times, in order to make sure that there is no mechanical malfunction in the machine or in the driving part.

Only experienced persons may be charged with slinging loads and instructing crane drivers. These instructors must remain within sight of the operator or be in touch with him via walkie-talkie or similar device.

During assembly work above body height, use appropriate or otherwise safetyrelevant climbing aids and working platforms. Do not use machine parts as climbing aids! W ear safety belts when carrying out maintenance work at greater heights.

Keep all steps, handles, railings, platforms, scaffolds, and ladders free of dirt, snow, and ice.

Before beginning maintenance and repair, clean the machine, particularly couplings and bolted connections, of oil, fuel, and special care products. Do not use aggressive detergents. Use lint free cloths for cleaning.

After cleaning, remove all covers and seals.

After cleaning, check all fuel, engine oil, and hydraulic fluid lines for leaks, loose connections, chafing and damage. Correct any faults immediately.

Always tighten bolted connections loosened during maintenance and repair work.

If it is necessary to dismantle safety devices during machine set-up, maintenance, and repair work, the safety devices must be reassembled and checked immediately after completing the maintenance and repair work.

Ensure safe, environment-friendly disposal of process materials as well as replaced parts. Oil containing components, such as fine separators and oils, must be disposed of in accordance with the relevant legal provisions. Oil must not enter the soil!

Safety precautions for work with batteries

The fluid contained in batteries is diluted sulfuric acid which can cause blindness if brought into contact with the eyes, or serious burns if brought into contact with the skin. For this reason it is essential to work with the greatest of care when servicing batteries, e.g. when checking battery charge, and to take all necessary safety precautions.

Always wear long-sleeved overalls, acidresistant gloves and safety goggles.

On charging a battery, an explosive gas mixture is formed in the cells, which can escape through the vent holes in the sealing caps. If ventilation is poor, a highly explosive atmosphere can form around the battery, and can persist for several hours after charging.

Thus:

* Never smoke in the vicinity of batteries that are being charged or have just been charged.

* Put up prohibition signs for fire, open flames and smoking in workshops where batteries are charged.

* Never interrupt a current-carrying circuit at battery terminals because of the danger of spark formation.

* Proceed particularly cautiously when connecting or disconnecting reinforcement cables or quick-charge cable clamps.

When starting up using jumper cables or auxiliary batteries, first connect the positive terminals and then the negative terminals. After starting the engine, first disconnect the negative terminal (ground cable) and only then the positive terminal.

Disconnect the auxiliary battery after the starting procedure in order to avoid the risk of the release of gas (explosion hazard).

3.7 Instructions concerning particular hazards

Electrical Energy

Only use original fuses with the specified amperage.

In case of faults in the electrical power supply, shut down the machine / installation immediately!

Work on electrical systems or equipment may only be carried out by a trained electrician or by trained persons under the leadership and supervision of a trained electrician in accordance with the standards of electrical engineering.

3. Security Regulations

Machine and system parts where service, maintenance, and repair work is being carried out must be switched off load, if required by regulations. First check the deenergized parts to make sure they are off load, then connect to ground and short-circuit, and insulate neighbouring parts that are under tension.

The electrical equipment of a machine / installation must be inspected / tested regularly. Faults, such as loose connections or overheated cables, must be corrected immediately.

If work has to be carried out on live parts, then call in a second person to operate the emergency stop switch or master switch with over voltage release.

Cordon off the working area with a redand-white safety chain and a warning sign.

Only use insulated tools.

Keep an adequate distance between the machine/unit and overhead power lines! When working near overhead power lines, equipment must not come near the power lines! Danger! Find out about the safe distance to be observed!

After touching high-voltage lines:

* Do not leave the machine.

* Move the machine away from the danger area.

* Warn outsiders not to come closer or touch the machine.

* Make sure that the voltage is switched off.

* Do not leave the machine until the line which has been touched or damaged, has been switched off load!

When working with high-voltage assemblies, ground the supply cable after voltage has been isolated, and short-circuit the components, e.g.

capacitors, with a ground rod!

Gas, dust, steam, smoke

Only carry out welding, burning, and grinding work on the machine / installation when this has been explicitly permitted, as there may be for example risk of fire and/or explosion.

Prior to welding, burning and grinding remove any dirt and inflammable substances from the machine/system and its environment and ensure proper ventilation

(danger of explosion)!

Only operate combustion engines in properly ventilated rooms. Ensure ventilation is adequate before starting up in closed rooms.

Always adhere to the legal provisions applicable to the particular location!

Follow the local regulations applicable at the respective site of installation.

Hydraulic and pneumatic systems

Work on hydraulic equipment may only be carried out by persons with special knowledge of and experience in hydraulics.

Check all lines, hoses, and bolted connections regularly for leaks and visible damage. Repair any damage immediately.

It is essential that damaged parts should be replaced! Spurting fluid can lead to injuries and fires.

Before beginning repair work, relieve the pressure in system sections to be opened and in pressure lines (hydraulic and compressed-air lines) in accordance with the descriptions of the subassemblies.

Hydraulic and compressed-air lines must be routed and fitted in accordance with the regulations. Do not confuse the connections!

The fittings, length, and quality of hoses must be in accordance with the requirements.

Noise

Protect personnel at risk from noise, in accordance with EU Directive 2003/10/EU.

Oils, Greases and Other Chemical

Substances

When handling oils, greases and other chemical substances, observe the safety regulations applicable for the product.

Caution when handling process materials (risk of burning / scalding).

Potentially-explosive environments

The operation of the compressor in areas where there is a risk of explosion is strictly forbidden! (Exception: speciallymade compressors with the necessary technical modifications for use in such areas)

Note

GARDNER DENVER accepts no responsibility for any damage or injury caused by noncompliance with these safety measures or noncompliance with normal care and caution during the handling, operation, maintenance or repair of this compressor, even if not expressly stated in this operating manual.

3.8 Symbols and definitions

100009377

Shut down

Emergency stop

Master switch

Do not operate with the hood open

Do not step on pressureconducting parts

Do not remove the compressor documentation

Do not inhale compressed air

Caution: Hot surfaces

Caution: Hot and dangerous exhaust fumes

Caution: Under pressure

Only operate with protective grating

3. Security Regulations

Caution:

Pressure vessel

Caution: Vessel is pressurised

Options

Hoisting point

Condensation drain from after-cooler or from after-cooler with subsequent filtering

Check filling level

Observe the operating instructions

Tie down point

Bleed water from the pressure vessel after every 24 operating hours or if the water ratio is too high

A93630300

Caution: Hot surfaces

Caution: Do not move with the transport safety locking

A13222974

Caution: Hot and dangerous exhaust fumes

100003144

Caution: Do not use ether spray

97 98

A93634770 A93634780

Sound level data

Caution: Remember the handbrake

2,2

BAR

100009583

2,8

BAR

A13145874

Note tyre pressure

Caution: Protect from wetness.

Do not direct a water jet at the generator.

Danger of electric shock

4. Construction and functional description

Fig. 7

1 Instrument panel

2 Taps

3 Hood

4 Chassis

5 Identification plate

6 Radiator

7 Expansion tank

8 Engine actuating cylinder

9 Fuel filter including drain valve

10 Fuel tank

11 Crane ring

13 Air filter

14 Battery

15 Oil filter (compressor)

16 Proportional controller

17 Main switch

18 Fuel pump

19 Fuel line filter

20 Suction controller

21 Pressure tank

22 Pressure retaining non-return valve

23 Compressor

24 Engine

4. Construction and functional description

4.1 Construction

Compressor and engine

The core of the sound proofed mobile compressor system is a single-stage, oilflooded screw compressor. The

GARDNER DENVER screw profile represents the state-of-the-art.

The air is delivered pulsation-free.

The drive assembly is a medium-cooled diesel engine, which drives the screw rotors of the compressor by a flexible coupling.

Fairing (Body)

The fairing consists of a monocoque subframe box to which a canopy which can be opened for servicing and maintenance purposes is attached. The opening of the cover is effectively supported by pneumatic springs. The hook inside is for hanging up a load suspension device. The machine rests on rubber elements to prevent vibrations and noise.

For convenient assembly, all individual parts of the cover are screwed together with machine screws. For the prevention of corrosion, the compressor body is fully galvanised, electrostatically powder coated and burnt at °C 220. The sound absorbing mats are inserted and easy to be cleaned.

Frame and chassis

The complete compressor unit is mounted on an easy-to-transport singleaxle chassis. The chassis is equipped with automatic overrun brakes and parking brakes, as well as a jockey wheel adjustable in height.

4.2 Functional description

(see fig. 8)

Oil circuit

The oil required for sealing and cooling the rotors as well as for lubricating the roller bearings is injected into the compressor (8) from the pressure tank

(15), which is under system pressure.

The difference in pressure between the pressure tank and the oil injection position is approx. 1 bar. The oil hereby passes the oil cooler (14) and the oil filter (11).

The suction controller (9) is fitted with a non-return function, so that when the system is switched off, flooding of the air filter (1) is prevented.

Air circuit

The intake air flows through the air filter

(1) and the suction controller (9) into the compressor (8). During compression, oil is injected in order to lubricate, cool and seal the screw rotors. The compressed air-oil mixture flows into the pressure tank (15).

Centrifugal preseparation of the oil is ensured through tangential entry into the tank.

Any remaining oil is separated from the air in the fine separator.

The compressed air is fed via the pressure retention valve (18) to the compressed air discharge (19). The pressure retention valve (18) effectively prevents the system pressure from falling below the minimum operating pressure required for the system to work properly. A temperature monitoring device (12) as well as an operational pressure manometer

(20) are integral parts of the air circuit.

When the preset operating pressure is exceeded the P controller (21) of the control unit feeds control air to the adjusting cylinder (4) of the engine speed adjustment system and the intake suction controller (9) in order to modify the comnpressor's intake volume.

This causes a change in engine speed and in compressor intake volume until the preset operating pressure is maintained constant.

The system is kept in equilibrium and any condensate occurring in the control line is blown off by means of the nozzle

(5) of the engine management system (4) and the nozzle (10) of the suction controller (9).

The speed/intake regulation system steplessly matches the volumetric flow to air take-off between 0 and 100 %.

If air tale-off drops to zero, the intake controller (9) is closed and the diesel engine (2) is run down to idling speed by the engine control cylinder (4).

If operating pressure drops below the preset value, the control air pressure of the P controller (21) of the control unit; the intake controller (9) opens and engine speed in increased by the engine control cylinder (4).

When turning off the engine the backlash flap inside the controller will be closed through the system pressure. The release valve (23), which closes parallel to the engine lifting magnet, looses power and opens. The container pressure drops down to zero.

Airflow

Fresh air is sucked in through the admission opening at the back of the compressor. The air intake volume is air for the engine and for the compressor too, as well as cooling air for the engine and for the oil cooler of the compressor.

Regulation

Starting procedure: At start-up, the connection between the P controller (21) of the control unit and the adjusting cylinder (4) for engine speed control is interrupted by the automatic idling control solenoid valve 24) for 10 seconds, with the result that the engine runs up to maximum speed at minimum system pressure. The increasing system pressure immediately closes the intake suction controller (9). The engine is automatically adjusted to idling speed after expiry of the preset time.

Switching from idling to operating speed takes place by means of actuation of the load knob load switching valve (22).

The compressor then starts to deliver (8) and system pressure in the vessel (15) increases.

4. Construction and functional description

4.3 System description

Air filter

Diesel engine

3. Water cooler - diesel engine

4. Engine actuating cylinder

5, Nozzle - engine actuating cylinder

Engine temperature transmitter

Engine oil pressure

8. Compressor

9. Suction controller

10. Nozzle – suction controller

11.

Oil filter – compressor oil

12.

Temperature switch

13. Orifice, evacuation line

14. Oil cooler – compressor oil

15. Pressure tank

16.

Fine separator

17.

Safety valve

18. Pressure retention valve

19. Air bleeding cock 1 x 3/4" (2 x 3/4")

20. Pressure gauge

21.

Controller unit / proportional controller

22.

Controller unit / load switching valve

23.

Controller unit / relief valve

24.

Solenoid valve

Oiler option

25. Oiler reservoir

26. Oiler valve

Compressed air processing option

27.

After cooler

28. Condensation run-off

29. Heat exchanger

Oil temperature controller

30.

Compressor oil temperature controller

Fig. 8 A13522874

4. Construction and functional description

4.4 Wiring diagram

Engine monitoring unit

Generator controller

Generator

Fig. 9

Starter Lifting magnet Generator controller Solenoid valve Generator Solenoid valve pressure relief (option) generator idling autom.

Pre-heating Oil Motor Compressor pressure temperature temperature

Fuel shortage

Solenoid valve load run

Fuel pump

A13519674

4. Construction and functional description

4.5 Vehicle Socket Connection Plan 13-pin 12 Volt

Towing vehicle

Indicator left

Fog tail lamp

Mass for contacts 1-8

Indicator right

Towed vehicle yellow Indicator left blue white green

Fog tail lamp

Mass for contacts 1-8

Indicator right

Tail light right brown

Brake lights red

Tail light right

Number plate light

Brake light right

Brake light left

Number plate light

Tail light left

Reversing light

Tail light left black

Reversing light

Permanent positive 12 volt

Charging + for battery

Not assigned

Mass for contacts 9-13

Socket plug grey

13-pin DIN 72570

Fig. 10

View of socket from front View of plug from front

135 338 74

5. Transport and installation on site

5.1 Transport

Transport safety locking of the towing arrangement

Transport safety locking

Fig. 11

Before moving the compressor for the first time slacken the ratchet on heightadjustable towing gear and remove the transport securement. Then adjust the towing gear from the vertical transport position to the required attachment height for the towing vehicle and lock it in place in the toothing using the ratchet (see

Section 15. Undercarriage, heightadjustable towing gear).

Fig. 12

Danger

Make sure to check the torque after

50 kilometers following wheel mounting and at regular intervals.

Tighten wheel nuts or screws evenly in a diagonal sequence to the specified torque using a torque wrench.

Replacing the trailer coupling ring

The coupling arrangements which can be used:

* Trailer coupling ring RD 40

* Coupling 50 dia.

* Coupling ring 2" dia. (only for UK)

* Coupling ring 68 x 25 dia. (only for

France)

A different coupling unit in the form of a complete kit may be ordered, if necessary.

Replacing the trailer coupling ring is permitted only if proper fitting is carried out by an inspectorate for the sector covered by the Regulations Authorizing the Use of

Vehicles for Road Traffic (e.G. the TÜV -

Technical Inspectorate, DEKRA - German

Motor Vehicle Monitoring Association, etc.). The inspection station provides a fitting certificate to be kept with the vehicle documents.

Danger

The screw compressor may only be transported on public roads if

* The machine group (engine) is not running,

* The pressure tank is not under pressure,

* The shielding is closed,

* The blocks are firmly hooked in place,

* Hoisted and secured tail wheel,

* The tyres and brakes are operationally safe and roadworthy,

* The lighting is fully functional.

Never exceed the maximum towing speed! Danger! Observe national regulations!

Please also observe the safety instructions in Chapter 3 on the subject of transporting.

Before transporting the compressor, check to make sure that the draw gear of the towing vehicle and the drawbar eye or trailer hitch ball connection are aligned exactly to each other.

When transporting the screw compressor with a vehicle, the following points must be observed:

* The shielding is closed.

* The blocks are firmly hooked in place.

* The support(s) is(are) retracted and locked in position (jockey wheel).

* Drawbar is connected to the towing vehicle.

* The drawbar is adjusted to the height of the towing vehicle (option).

* The contact-breaking cable is connected to the towing vehicle. Safety chains are attached on towing vehicle.

* The electrical cable (option) is connected to the vehicle and to the screw compressor .

* Check the lights (tail lights, brake lights, indicator lights, and rear fog lamp) (option).

* Check to make sure that the wheels are properly tightened, the tyres are in a roadworthy condition.

Attention

Check tyre pressure, and adjust if necessary (risk of accident). A too high tyre pressure can lead to overstraining of safety parts.

* When parking the compressor prior to uncoupling from the towing vehicle actuate the handbrake, detach the contact-breaker cable and the lighting cable, and secure the compressor against rolling using chocks. Then adjust to the horizontal position by means of a support or support wheel.

Attention

Always keep a safe distance from the edges of foundation ditches and embankments! Do not travel across slopes transversely.

5.2 Attachment of the contactbreaker cable on braked chassis

If the towing connection becomes uncoupled, the trailer is braked by the breakaway cable. Put the breakaway cable in the eye provided or wind it around the towing collar and hitch it up to the cable with the snap link.

The breakaway cable must be attached in a way that ensures that even on extremely sharp bends there is no danger of activating the locking brake.

Fig. 13

5. Transport and installation on site

5.3 Loading/Relocation

Fig. 14

Danger

Only use hoisting gear (e.g. crane) with appropriate lifting capacity for the loads occurring!

Only use the correct suspension gear!

Keep clear of the swiveling range of the hoisting gear!

Keep clear of suspended loads!

All loose parts that could fall down during hoisting must first be removed or secured; pivoting parts, like doors, towbars, etc. must be secured in such a way that they cannot move.

Never leave the load suspended on the hoisting gear. Acceleration or braking of the means of transport must remain within the approved limits.

Please also observe the safety instructions in Chapter 3 on the subject of loading.

Attention

Do not attempt to use a crane hook or similar load suspension devices direct on the lifting device to avoid damages to the lifting device!

Use proper hoisting gears only such as hoisting straps in compliance with DIN standard 61360 with proper lifting capacity for connecting the load suspension device (e.g. crane) and the lifting device.

Only deploy load bearing equipment which corresponds to the safety instructions for lifting gear.

Use a transport harness compliant with local regulations for transporting by helicopter. The eyes provided may not be used for this purpose (max.

acceleration if the eyes are used =

2 x g)

Never lift up or lash down the unit using the shieldings!

Never relocate the machine if external lines or hoses are connected to the discharge valves, in order to avoid damage to the valves and/or collecting pipe and hoses.

When loading, the following points must be observed:

* Secure the load suspension device or the hoisting gear in the lifting device of the screw compressor.

* When hoisting the compressor, set up the hoisting gear in such a way that the compressor, which must be set up horizontally, is lifted vertically.

* Only relocate the compressor by itself.

* Raise and lower the compressor carefully.

* After relocating, remove the load suspension device or the hoisting gear from the lifting device.

* Tie down the compressor on the cargo area of the means of transport.

* Lash only on the tow pipe of the chassis and on the rear fixing point.

* When dismantling the chassis, the fairing and the machine set may be supported only under the longitudinal stringers of the subframe box. New self-locking nuts must be used for installation. See section 9.5.9 for tightening torques.

5.4 Installation on site

Fig. 15

Danger

The air intake must be positioned in such a way that loose personal clothing cannot be drawn in.

Make sure that the pressure pipe from the compressor to the aftercooler or the air system can expand as a result of heat, and that it does not come into contact with inflammable materials.

The air intake is to be designed in such a way that no dangerous admixtures

(inflammable solvent vapors etc., but also other dangerous or toxic substances) can be taken in. This also applies to flying sparks.

Pipes and other parts with a surface temperature of more than 80 °C must be suitably secured against contact and suitably marked.

The operation of the compressor in areas where there is a risk of explosion is strictly forbidden! (Exception: specially-made compressors with the necessary technical modifications for use in such areas)

Please also note the safety instructions in Chapter 3 on the subject of installation on site.

Location

The complete system is to be set up in such a way that it is easily accessible and that the required cooling is guaranteed.

Never block the air intake. Ensure that the entering of moisture and dirt together with the intake air is kept to a minimum.

The compressor is to be set up away from walls.

5. Transport and installation on site

Attention

The screw compressor is to be set up in such a way that no air reflection can take place, i.e. neither waste air nor exhaust emissions may be drawn in; the same applies to dangerous admixtures to the air. Drawing this waste air in could lead to overheating and a loss of power.

The compressor must be set up in as horizontal a position as possible.

Maximum permissible inclination during operation:

* In direction of pull: 15 degrees

* Backwards: 15 degrees

* To the right and to the left: 15 degrees

Attention

No force may be exerted on the discharge valves, for example by pulling the hoses or fitting additional equipment (e.g. a water separator, compressed air oiler, etc.) directly at the discharge valve.

Temperatures/air humidity

Install the compressor in a location with maximum possible frost protection. The suction air temperature must be within the range specified on the data

Attention

An oil-temperature regulator (option) is necessary for operation of the system at high temperatures (+40° C and above) and/or high rel. air humidity

(greater than 90 %) or at temperatures below 0°C. For operation involving long periods of idling and/or low partial loads an oil temperature regulator is also required.

Fig. 16

Attention

Greater inclinations endanger the operating reliability of the screw compressor.

When setting up the unit on ground that is not horizontal, or with a variable angle

(see operating instructions) please consult

GARDNER DENVER.

Set up the machine in such a way that no inlets, outlets or gates are blocked, even when the doors are open. Prior to uncoupling from the tow vehicle actuate the handbrake, detach the contact-breaker cable and the lighting cable, and secure the compressor against rolling using chocks. Then adjust to the horizontal position by means of a support or support wheel.

Note

In dusty environments, set up the machine in such a way that the wind does not blow the dust in the direction of the machine.

During operation in clean environments, the intervals for cleaning the air intake filter and the cooler elements are much longer.

Altitude

For operation at an altitude above

1,000 m, the compressor and engine must be adapted (modified design).

Note

Particularly in case of installation out of doors and at night, observe fuel temperature. At temperatures below 0 °C, summer diesel fuel tends to precipitate and block the fuel filter. In this case use winter diesel fuel.

6. Preparing the compressor for operation

Danger

Check the machine / installation for external damage and faults at least once per shift. Any changes noticed

(including changes in operating performance) must be reported immediately to the authority or person in charge. If necessary, shut down and secure the machine immediately.

6.1.2 Checking the oil level in the engine

6.1.3 Checking coolant level

6.1 Checking levels

6.1.1 Checking the oil level in the pressure tank

Fig. 17

Danger

Only check the oil level when the engine is at a standstill and the compressor is not under pressure.

The pressure tank may be under pressure and the oil may be hot.

Risk of scalding! Spill no oil!

Check for leaks.

Proceed as follows:

* Shut the compressor down and wait until the system is depressurized, in no case less than 5 minutes.

* Before checking the oil level ensure that the vehicle is standing horizontally.

* Unscrew dipstick.

* The oil level should be within the marks on the dipstick.

* Correct as required.

* Check the seal on the dipstick and replace if required.

* Screw in dipstick and tighten firmly.

Attention

After a short test run, the oil level should be between the markings on the dip stick.

For oil specifications, see recommended lubricants, Chapter 8.1.

Fig. 18

Danger

Only check the oil level when the compressor engine is at a standstill.

Spill no oil! The oil may be hot. Risk of scalding!

Check for leaks.

Proceed as follows:

* Shut the compressor down and wait for

5 minutes.

* Before checking the oil level ensure that the vehicle is standing horizontally.

* Unscrew dipstick.

* The oil level should be within the marks on the dipstick.

* Correct as required.

* Screw in dipstick.

* Close oil filler.

* For oil specifications, see “Engine

Operating Manual”.

Attention

After a short test run, the oil level should be between the markings on the dip stick.

For oil specifications, see engine instruction manual.

Fig. 19

Danger

The coolant header tank may be under pressure and its contents may be hot!

Caution when opening the cap, danger of scalding!

Avoid contact with the eyes and/or skin, danger of corrosive burns!

In case of contact with the skin and/or eyes, wash out/off under flowing water and obtain medical assistance immediately.

Proceed as follows:

* Shut down the compressor,

* Position the compressor horizontally before checking the coolant level,

* The coolant level must be between the two marks (MIN) and (MAX) (see Fig.

19)

* Correct as required.

Attention

The coolant must be changed not less frequently than every two years.

Only use corrosion inhibitors and antifreezes recommended and approved by the engine manufacturer!

Dispose of used coolant in accordance with the relevant regulations.

6. Preparing the compressor for operation

6.2 Battery 6.3 Filling up the fuel tank

More information on fuel quality, see engine operating manual.

For outside temperatures below 0 °C, observe the operating manual of the engine manufacturer for winter operation.

You can reduce the occurrence of condensation in the fuel tank considerably by filling it up in good time. This also prevents downtimes and starting problems that can occur when the fuel tank is run dry.

Fig. 20

Danger

When working with battery acid

(electrolyte), wear acid-resistant goggles, gloves and apron.

The gases released by the battery are explosive. Avoid sparks and open fires in the vicinity of the battery.

Do not allow acids to come into contact with skin or clothing. Wear safety goggles.

Place no tools on the battery.

The battery is filled and charged in accordance with DIN 43539. The battery is fastened with clamping strips.

The batteries used are ready to be installed and ready for service.

Replacement batteries should be of the same type as the batteries installed

(low gassing). The replacement battery should be unfilled and only be preloaded so that it has to be filled with battery acid.

The battery and the acid should have a temperature of at least +10 °C.

Proceed as follows:

* Fill up with battery acid as far as the base of the control insert

* Leave the battery to stand for some time

* Then shake it gently

* If required, top up with acid

* Tighten sealing caps

* Leave for 1 hour

* The battery is ready for use

Fig. 21

1 Tank lid

Danger

Only fill up with fuel when the screw compressor is at a standstill.

Cleanliness is essential! Spill no fuel!

Filling up at a pump can cause static electricity and possibly sparks.

Proceed as follows:

* Open tank lid (1)

* Fill up tank with commercially available branded diesel fuel, using a sieve (use summer or winter diesel fuel depending on outside temperatures)

* Close tank tight with tank lid

* With the Deutz engines M2011, the injection pump is self-ventilating. When the tank is empty, immediately fill in fuel to ensure that the fuel pump is always filled with fuel. This condition may result in starting problems.

* Close hood.

Bleeding

Danger

To avoid accidents, never bleed the fuel system with the engine in hot condition. Danger of fire!

Bleeding of the fuel system is described in the operating manual for the engine. It is necessary in the following cases:

* maintenance work on the fuel system

(priming pump, filter with water separator, piping)

* failure of the engine due to lack of fuel

* before restarting after prolonged periods of non-use.

Note

The fuel tank should always be filled up in good time. For outside temperatures below 0 °C, use only winter diesel fuel.

6.4 Fuel water separator

Fig. 22

The condensate must be drained out of the tank every day or at every filling operation!

6.5 Checking the air filter maintenance display

Fig. 23

The air filter element must be replaced when the red section of the servicing indicator (2) is fully visible (see

Section 9.5.5, "Air filter replacement")

Empty the dust emission valve by pressing together the emission slot (1) in the direction of the arrow.

Note

Clean the emission slot from time to time.

7. Putting the compressor into operation

7.1 Initial operation

Transport inspection

Every GARDNER DENVER screw compressor has already run in the factory and has already undergone a thorough test before shipment. This test ensures that the compressor complies with the given data and works perfectly.

Independent of the care taken in the factory, it is still possible for the compressor to be damaged during transport. For this reason it is recommended that the unit should be examined for possible damage during transport.

Remove any transport seals (dummy flange, plugs, etc.) and dehydrating agents before start-up. Distribution tubes and connection lines must have the specified dimensions and must be suitable for use with the max. operating pressure and the media to be taken up.

During the first hours of operation, the compressor should be observed in order to be able to ascertain any possible malfunctions.

7.2 Operating elements

Operating panel:

Fig. 24

1 Ignition switch

2 Load button

3 Hours of operation counter

4 Operating pressure gauge

5 LED 1 Pre-heating

6 LED 2 Battery charge

7 LED 3 steady => Oil pressure flashing=> Fuel shortage

8 LED 4 Motor and compressor temperature

9 LED 5 Load run

Fig. 25

F1 Main fuse

F2 Fuel pump

F3 Lifting magnet

Fig. 26 Main switch

7.3 Start-up

Danger

Before starting up, make sure that no one is in the danger area of the engine

/ screw compressor.

Compressors may not be operated in hazardous environments unless they have been specially designed for this purpose (e.g. exhaust protected against emission of flying sparks etc.).

Never, under any circumstances, use

"Startpilot" (Spray-can starting aid), ether or other starting aids - Danger of explosion!

After service work has been completed:

Make sure that all protective devices have been refitted and that all tools have been removed.

The exhaust from the system contains carbon monoxide, a lethal gas.

The exhaust must be routed to the outside via a pipe or a hose with an internal diameter of not less than

100 mm if the compressor is used indoors.

Adequate ventilation must be assured.

The use of an exhauster system is urgently recommended.

Only operate the compressor with the hood closed. The hood may only be opened briefly for minor adjustments while the compressor is running.

Skilled personnel only are authorized to work with the hood open.

When working with the screw compressor in operation and with the shielding/hood open, wear ear protection.

Caution: this may impair communication between persons.

Warnings may not be heard. Inform supervisor.

Attention

Opening the covering interferes with the flow of cool air in the compressor section.

Full sound-insulating is only achieved when the covering is closed.

Check the oil levels in the pressure tank and in the engine of the compressor each time before start-up.

Do not start the compressor unless the air tapping cocks are closed.

7. Putting the compressor into operation

Starting up the compressor:

* Close air tapping cocks.

* Switch on main switch.

* Turn ignition switch to position "On" I .

* All pilot lamps flash three times, automatic self-test, then the Preheat, battery charge and engine-oil pressure lamps illuminate.

* Engine can be started immediately if ambient temperature is ≥ 10° C: Turn ignition switch further to ,

At ambient temperatures < 10° C wait until the Preheat indicator lamp goes out and then turn the ignition switch further to .

* Hold the ignition switch in position until the engine starts running and the

“Battery charge” and “motor oil pressure” indicator lamps go off.

* Release the ignition switch.

* If the engine has not started after

15 seconds at the latest, turn the ignition key back to position (Off-

Aus). As soon as the starter has reached a standstill and the pressure tank is no longer under pressure, the engine can be started again.

* After the start, the engine runs at the idling speed and the compressor at reduced pressure.

* If the engine was started cold, let it warm up for approximately 2 minutes and then press the load button (S2).

If the engine is warm, the load button can be pressed immediately.

* The installation is now ready to operate. Check that all the hoses and tools have been connected correctly and open the desired air outlet valves.

Start-up using jumper cables / auxiliary batteries

7.4 Setting the operating pressure

Fig. 27

Danger

Longer operation with an auxiliary battery or jumper cables connected can lead to sudden emissions of gas.

An inflammable air / gas mixture is formed. Explosion hazard!

Attention

Serious damage can be caused to the electrical system if wrongly connected.

Ignition switch in position (Off-Aus)

First connect positive terminal then negative terminal (ground).

* Start as described in section “Starting up the compressor.”

Note

After the engine has started, first disconnect the negative cable (ground) and then the positive cable.

Fig. 28

Danger

The setting of the operating pressure may only be carried out by a specialist.

The operating overpressure of the screw compressor is set by the manufacturer

(see the identification plate on each compressor).

Pressure values can be set between

5 bar and the operating overpressure stated on the rating plate. Pressure values higher than this are not permitted.

Operating pressure is set by a specialist at the controller.

* Remove counternut below the control knob of the regulator.

* Raise pressure by turning the adjusting knob of the regulator clockwise

(towards +).

* Lower the pressure by turning the adjusting knob of the regulator anticlockwise (towards –).

* In order to lower the pressure, open an air discharge valve.

* After altering the pressure, lock the adjusting knob using the locknut.

This readjusted operating pressure is to be checked using the pressure gauge on the instrument panel at 100% air discharge and maximum engine speed.

7. Putting the compressor into operation

7.5 Monitoring / fault

Danger

Interference with the automatic monitoring system is not permitted.

Attention

Disconnect the battery or generator only when the engine is not running.

In case of a problem

* Compressor temperature too high

* Engine oil pressure too low

* Engine temperature too high

* Battery voltage too low

* Fuel shortage (indicated by flashing

LED for insufficient oil pressure) the system switches off automatically and indicates the problem that caused the trip.

The fault indication goes off when ignition switch S1 is turned to the (Off) position. If the system is started without elimination of the problem, it will stop again after a function test and indicate the problem.

Switch the system off if an oil mist is entrained in the compressed air or if excessive oil consumption is apparent

(see "Trouble-shooting")

Check whether operating pressure is within the permissible limits.

Pressure gauge for display:

“Operating pressure”

Fig. 29

Danger

Do not operate the compressor at pressures above the permissible operating pressure.

The pressure gauge shows the operating pressure of the compressor.

The permissible operating pressure is indicated on the nameplate!

7.6 Operation

Danger

Only operate the compressor at the permissible operating pressure and at the permissible temperature.

Only use the compressor for its intended purpose (see Chapter 2.2 of this operating manual) in order to avoid residual risk for persons and assets.

Only operate the compressor in a safe, functioning condition.

All components, hoses etc. fitted must be of the correct size and designed for the specified operating pressure and temperature.

When working with compressed air, wear suitable protective clothing (e.g.

protective suit, safety goggles, etc.).

Wearing ear muffs may impair communication between persons.

Warnings may not be heard. Inform supervisor.

Check the compressor regularly.

Check the machine / installation for external damage and faults at least once per shift. Any changes noticed

(including changes in operating performance) must be reported immediately to the authority or person in charge. If necessary, shut down and secure the machine immediately.

Leaking condensation contains a proportion of oil and must be collected and disposed of under safe conditions.

Condensation must not enter the soil or the rivers. Major quantities of condensation accumulate particularly in versions with aftercoolers for processing compressed air. Provide a collecting basin.

7.7 Shutdown

In order to shut down the compressor:

* Close air discharge valves. The screw compressor reduces the speed of the engine back to idling speed after the preset final pressure has been reached.

* Allow the screw compressor to idle for a few minutes.

* Return the ignition switch (1) to the position (Off-Aus).

Note

This switch can also be used as an emergency stop switch. No other switching off method is provided.

* Turn off power to the system using the main switch.

After the installation has come to a standstill all the air is automatically blown out of the pressure tank via the blow-off valve.

Danger

It is important that you ensure that the pressure is completely blown off via the blow-off valve.

Should this not be the case, open the air outlet valves, identify the fault and correct it.

7.8 Decommissioning

Fig. 30

If the system is to be closed down for a longer period of time (approx. 3 months or longer) the following preservation measures must be taken:

* Engine preservation (see separate engine operating manual).

* Disconnect battery cables.

* No special measures are required at the compressor.

* Relieve the strain on tyres by jacking up the vehicle.

* Check tyre pressure every 2 months.

* Release the handbrake.

Attention

When putting back into operation, carry out the maintenance work in accordance with Chapter 9

“Maintenance.”

8. Fuels

8.1 Recommended lubricant for compressor

Note

In these screw compressors, circulating oil has not only a lubricating function, but in particular it also has cooling and sealing functions. It is therefore exposed to more difficult conditions. In particular the temperature conditions at the installation site and the consistency of the air (dust, dirt, and humidity content, as well as chemical influences) must be taken into account when selecting a suitable lubricant.

Attention

Do not mix oils of different specifications.

The maintenance intervals and the maximum and minimum operating temperatures given in this operating manual only apply when high-quality multi-grade oils are used.

Use of the wrong oil leads to impairment of function.

Change the compressor oil more frequently than specified if the equipment is operated under abnormal conditions, i.e. at a high ambient temperature, high air humidity or in a dusty environment. If necessary, analyse the oil.

Out of consideration for the high loads imposed on the lubricant in screw compressors with oil injection cooling, we recommend the use of suitable, non ageing, non foaming, corrosion-protective oils. They must meet the following requirements for hydraulic fluids:

H-LP 32 and H-LP 46 in accordance with

DIN 51524, Part 2, June 1985.

At normal operating temperatures, the viscosity of the lubricating oils used should conform with Viscosity Class ISO VG 32 DIN

51519, July 1976, viz. 28-35 mm 2 /s (cSt)/40°

C (obtainable in 20 l canisters under

GARDNER DENVER ID No.: SACO32-

20).

At ambient temperatures continuously above +25° C, the viscosity of the lubricating oils sued should conform with

Viscosity Class ISO VG 46 DIN 51519,

July 1976, viz. 41-50 mm 2 /s(cSt)/40° C

(obtainable in 25 l canisters under

GARDNER DENVER ID No.: SACO46-

25).

Attention

Conventional engine oils marked HD must not be used.

When using oils with the “Brief Description HYD 10/HYD 20" in accordance with the ‘Standard Lubricants for Building

Machinery and Vehicles’ published by the

‘Hauptverband der Deutschen Bauindustrie e.V.’ (Principal Association of the

German Building Industry), only the given hydraulic fluids may be used in accordance with ISO VG 32 and

ISO VG 46.

If other lubricants are to be used, please contact:

GARDNER DENVER S.r.l.

Via Tevere n°6

21015 Lonate Pozzolo (VA) ITALIA

Tel. 0331.349411 – Fax. 0331.301680

e-mail: [email protected]

www.bottarini.it

or your authorized dealer or your local branch.

8.2 Recommended engine oil

Lubricant specifications for the driving engine can be found in the enclosed engine operating manual.

For normal service conditions:

15W40 API CH-415J (ACEA E-3,

ACEA E 5)

8.3 Tool lubricants

Attention

Do not run the machine with an empty oiler tank! The tank must always contain a minimum of 0.2 l of tool oil.

The wrong tool lubricants lead to deposits that cause malfunctions in the appliances connected!

For the perfect lubrication of concrete breakers and pneumatic spades, we recommend the use of GARDNER

DENVER oilers or automatic pipe oilers, using the special synthetic GARDNER

DENVER oil AES 82.

The special advantages of GARDNER

DENVER oil are as follows:

* Biodegradable,

* Ice guard down to -50 °C, for use with sound absorbers,

* Very good lubricity, thus wear-reducing,

* No irritating exhaust gases, work in enclosed rooms possible,

* Good cleaning effect, no residue formation

* Excellent preservation properties, protects from corrosion.

When using compressed air consumers made by other manufacturers, then their regulations must be observed.

8. Fuels

8.4 Diesel fuel

Use common diesel fuel with a sulfur content of less than 0.5 %. If the sulfur content is higher, oil has to be changed at shorter intervals.

The following fuel specifications are applicable:

* DIN 51 601

* Nato Codes F 54, F 75, and F 76

* BS 2869: A1 and A2 (observe sulfur content with A2)

* ASTM D 975-81 : 1-D and 2-D

* VV-F-800a : DF-A, DF-1, and DF-2.

Note

See engine instruction manual.

At low temperatures,paraffin precipitation can cause blocks in the fuel system and disruptions in operation.

Below outside temperatures of 0 °C use winter diesel fuel (to -15 °C). (This is usually available at gas stations in good time before the winter season begins.)

Diesel fuel with additives is frequently offered for use at temperatures as low as

-20 °C („Superdiesel“).

Note

Only mix in the tank. First put in the required quantity of petroleum, then fill up.

See engine instruction manual.

Below -15 °C or -20 °C, petroleum must be added.

If it is necessary to use summer diesel fuel below 0 °C, petroleum can also be added up to 60 %.

In most cases, adequate resistance to low temperatures can be achieved by adding a product to improve flow properties (fuel additive). Consult your engine service station.

Attention

The compressor must not be fuelled with bio-diesel (DIN 51606) or vegetable oil.

8.5 Coolant

Attention

Only operate the engine with coolant

(water with corrosion protection/ antifreeze fluid)!

Pure water may cause damage to the cooler and the engine.

Only use corrosion inhibitors and antifreezes recommended and approved by the engine manufacturer!

Recommendation:

GARDNER DENVER ID-Nr. A92131840

Texaco: Havoline AFC

The coolant consists of 50% water and

50% corrosion protection/antifreeze fluid.

Use drinking water only.

Do not use sea, brackish, industrial, rain or distilled water.

The coolant should be changed not less frequently than every two years.

Products of differing product groups must not be mixed!

8.6 Recommended lubricants for the bogies

For relubrication use only lithium saponified grease which fulfils the following specifications:

* consistency groups (NLGI) 2

DIN 51818

* worked penetration 265-295

DIN ISO 2137

* dripping point > 180 °C

DIN ISO 2176

* operational temperature

– 40 °C … +140 °C

This corresponds to a DIN 51502 lubrication grease, designation KP2N-4U.

Greases with different thickeners

(soap base) must not be mixed.

Recommended grease: Fuchs Renolit

LZR 2.

9. Maintenance

9.1 General maintenance

Danger

Install a "Caution maintenance work" warning sign and cordon off a wide area around the workplace before starting any work.

During inspection, adjustment, or maintenance work, remember that the surfaces of machine parts can be hot, particularly the exhaust system (risk of burning) and that the control device may move during operation (risk of crushing).

Clean the screw compressor at regular, not too long intervals:

* Blow-clean all valves, controllers, fittings, pressure tank, oil cooler, radiator, screw compressor, and engine with compressed air or a steam jet appliance.

* Inspect the cooling ribs of the radiator to make sure that air can pass through.

* Clean the body at regular intervals.

Then grease or oil the hinges of the body hood with multi-purpose grease.

If sound-absorbing matting has to be replaced, remove the retaining brackets, replace the old sound-absorbing matting with new matting, replace the retaining brackets.

9.2 Engine maintenance

The maintenance of the engine is to be carried out in accordance with the engine operating manual.

Attention

In addition to the maintenance intervals given in the engine operating instruction the following items apply after 50 operating hours after the startup of new or overhauled engines:

* Check engine for leaks, repair if necessary

* Change engine oil

* Replace oil filter cartridge

* Changing the fuel filter cartridge and advance fuel filter

* Check tappet clearance, adjust if necessary

* Check engine mounts, tighten if necessary

* Check V-belt, tension if necessary

Full load speed is factory-set by the manufacturer and must not be modified.

The idling speed must not be changed either, as this might cause serious damage to the screw compressor, e.g. damage to the coupling!

9.3 Maintenance of the fuel system

Fig. 31

1 Fuel tank - Filler socket

2 Fuel prefilter

3 Electrical fuel pump

4 Fuel filter with fuel/water separator

Advance fuel filter (2)

The filter changing intervals are specified in the engine manual. Change the advance filter more often if there is considerable dirt.

Danger

Change filters only with the engine off and in cool condition.

Do not spill fuel.

Note

Ensure the system is free from leakage.

Check the hoses for cracks and replace if necessary.

Changing the advance fuel filter:

* Release the clamps.

* Draw the ends of the hoses off.

* Insert a new filter.

* Fit the hose ends.

* Fasten the clamps.

* Dispose of contaminated filters in accordance with the regulations.

Attention

The fuel system must be bled in accordance with the engine operating manual!

9. Maintenance

Emptying the fuel/water separator (4)

Fig. 32

The reservoir must be emptied if the red indicator is in the range shown (4.1) (see engine operating manual)!

Danger

Change the fuel/water separator only with the engine off and in cool condition!

Empty the fuel/water separator:

* Dispose of the contents (fuel/water) in accordance with the applicable regulations,

* Bleed the fuel system (see engine operating manual)

Attention

The fuel system must be bled in accordance with the engine operating manual!

9.4 Maintenance of chassis and brakes

The maintenance of the chassis and the brakes must be carried out in accordance with the chassis instruction manual.

Work on the brakes may only be carried out by trained technical staff or by specialist brake services!

Danger

Changing the fuel filter (4)

Intervals for filter changing in accordance with the engine operating manual.

Danger

Change the fuel filter only with the engine off and in cool condition!

Attention

The fuel system must be bled in accordance with the engine operating manual!

9. Maintenance

9.5 Compressor maintenance / Maintenance schedule

Danger

Install a "Caution maintenance work" warning sign and cordon off a wide area around the workplace before starting any work.

Daily:

Visual checking for external damage, defects and leaks

Check the oil level in the diesel engine

Check the coolant level

Check the oil level in the compressor

Empty fuel water separator (option)

Clean air filter (screw compressor/engine) between times or renew if the red field appears

Engine maintenance

Every 500 h, although at least every 6 months:

Note the maintenance indicator

See the engine operating instructions for maintaining the engine

Check tyre pressure and wheeluts, retighten ifecessary

Adjust brake system (option) or have checked

Lubricate chassis / draw gear

Inspect safety valve

Lubricate hood hinges

Every 1000 h, although at least each year:

Change air filter (screw compressor/motor)

Change oil filter of the screw compressor

■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■

■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■

■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■

Oil change (screw compressor)

Inspect automatic operational monitoring

Change fine separator every year or if differential pressure > 1bar

Check hose lines for damage (leaks, formation of cracks) and replace, if damaged

Clean screen of the suction-off line

Inspect control (adjustment/function)

Inspect solenoid valves

■

■ ■ ■ ■

■

Check the battery acid level

Check clamping bolts anduts and retighten, if necessary (chassis, frame and bodywork)

■ ■ ■ ■ ■

Check suspension components

Unscrew optional vessel for tool oil and check inside for any corrosion. If rust is found, replace the vessel with aew, original spare part.

■

Every 2000 h, although at least every 2nd year:

Clean cooler (more frequently if used in a dusty environment)

■ ■

Change coolant ■ ■

■

For your own benefit, put a cross on the servicing schedule against maintenance work when performed.

■

■ ■

■

9. Maintenance

9.5.1 Oil filter replacement

(compressor)

9.5.2 Oil change (compressor)

* For lubricants see “Lubricant Table”

* Check sealing ring on dipstick, replace if necessary

* Screw in and tighten dipstick

* Start screw compressor, run for approx.

two minutes, check for leaks

* Switch off screw compressor

* Check oil level, add oil if necessary

Fig. 33

Danger

Only replace the oil filter cartridge when the engine is at a standstill and the screw compressor is not under pressure.

Caution with hot oil: risk of scalding!

Spill no oil!

Attention

Change the oil filter every 1,000 operating hours, but at least once per year.

Note

Dispose of oil filter cartridge in accordance with the relevant regulations - hazardous waste!

Check for leaks.

Changing the oil filter:

* Unscrew the oil filter cartridge using appropriate tools

* Dispose of oil filter cartridge

* Apply a thin coat of oil to the seal of the new oil filter cartridge

* Screw on and tighten the new oil filter cartridge (follow the instructions on the oil filter cartridge)

* Check for leaks

* Check oil level, add oil if necessary

Fig. 34

Danger

Only change the oil when the engine is at a standstill and the system is not under pressure.

Caution when draining off hot oil: risk of scalding! Spill no oil!

Attention

Change the oil filter every 1,000 operating hours, but at least once per year.

The screw compressor must not be under pressure during oil change.

Drain the oil at operating temperature.

Do not mix oils of different specifications.

Note

Collect used oil, do not allow it to enter the soil. Dispose of oil in accordance with the relevant regulations - hazardous waste!

Spill no oil! Check for leaks.

Changing the oil:

* Unscrew dipstick

* Place oil drain pan under oil drain valve

* Unscrew the sealing cap of the pressure vessel

* Collect used oil in the oil drain pan

* When the used oil has been drained completely, use a new sealing ring on the sealing screw of the pressure vessel, position and tighten screw or close the oil drain valve

* Fill up with new oil (see section

"Specifications" in chapter 1 for initial oil capacity; use a little less oil when performing an oil change).

9.5.3 Checking the automatic monitoring system

Danger

Interference with the automatic monitoring system is not permissible!

Check individually every 1000 operating hours:

Temperature sensor - screw compressor (pressure connection)

2. Oil pressure switch - engine

Oil temperature gauge - engine

Fuel shortage

Checking the automatic monitoring system:

1. Compressor temperature controller

Bridge connections

1.1

Start the compressor, the system must shut down after completion of the automatic function test of the engine monitoring system.

The fault is indicated by illumination of the LED

Engine oil pressure transducer

Connect to earth (ground)

2.1 Proceed as for 1.1

Engine temperature transducer

Connect to earth (ground)

3.1 Proceed as for 1.1

4. Engine temperature transducer

Bridge connections

4.1 Proceed as for 1.1

Attention

Correct functioning of the engine monitoring system must be restored after completion of the check!

9. Maintenance

9.5.4 Inspecting / Replacing the fine separator

Fig. 35

1 Connection for P controller

2 Connection for compressor suction line

3 Oiler connection

Danger

Pressure tank is under pressure. Only work when the motor is at a standstill and the screw compressor is not under pressure.

Caution with hot oil: risk of scalding!

Spill no oil!

Note

Dispose of fine separator in accordance with the relevant regulations - hazardous waste!

Check for leaks.

Replace the fine separator at least once per year or measure the differential pressure as follows:

* When the engine is at a standstill and the screw compressor is not under pressure, unscrew the dipstick from the pressure tank.

* Screw in the reducing adapter.

* Screw the pressure gauge into the reducing adapter.

* Start the screw compressor.

* The difference in pressure between the pressure gauge on the pressure tank and the pressure gauge on the instrument panel must not exceed 1 bar.

If the differential pressure is > 1 bar, the fine separator cartridge must be replaced.

* Remove all hexagon screws around the circumference of the lid.

* Remove the lid and the old fine separator.

* Remove the old seals from the pressure vessel, clean the sealing surface and fit a new seal.

* Insert a new fine separator into the pressure vessel and fit a new seal.

* Fit the lid. Insert the hexagon screws and tighten them across the diagonal

(tightening torque see Chapter 9.5.9

"Torque specifications").

* Check for leakage.

* Dispose of the old fine separator cartridge in the specified manner.

9.5.5 Air filter replacement

(compressor / engine)

Danger

All inspections and servicing work must be carried out when the engine is at a standstill and the screw compressor is not under pressure.

Danger

Never clean the air filter cartridge with inflammable liquids.

Reassembling the air filter:

* Clean the sealing surface in the filter housing.

* Insert safety cartridge and ensure correct seating.

* Insert the filter cartridge and make sure that the seal is properly seated.

* Replace filter hood and fasten using the tensioning brackets (the tensioning brackets can only be closed if the filter cartridge with seal is seated properly on the sealing surface of the filter housing).

* Reset the maintenance indicator by pressing the reset lever.

9.5.6 Checking the safety valve

Fig. 36

Note

Check the air filter every week for dust.

The air filter is supplied with a maintenance indicator, which indicates the adding of the filter cartridge. The maintenance intervals of the air filter depend on the environmental conditions.

If the red field of the maintenance indicator is visible and stays engaged when the screw compressor is turned off, you must exchange the air filter cartridge (at least every 12 months).

Replace the air filters of the screw compressor and of the engine once yearly.

Do not clean or reuse the air filter.

Attention

Replace the safety cartridge at the latest every third time the air filter element is replaced.

Replace air filter

* Loosen the tensioning brackets at the air filter and fold away.

* Remove filter hood.

* Remove filter cartridge from the filter hood.

* Remove safety cartridge from the housing.

* Replace filter cartridge.

Fig. 37

Check the operation of the safety valve at least twice a year. The check is carried out with the system pressurised. Carefully turn the knob anti-clockwise, until the internal pressure lifts the valve cone, releasing a mixture of oil and air. Then turn the knob fully clockwise again.

In accordance with national standards, but at least once a year, carry out a suitable test to check whether the valve blows down at the correct pressure.

If the valve is not working properly, replace it immediately with a new one designed for the system. This type of operation may only be carried out by trained personnel.

Danger

The screw compressor must not be operated with a faulty safety valve!

A mixture of oil and air will escape when the valve is checked/tested.

9. Maintenance

9.5.7 Control

Fig. 38

The control system takes the form of a stepless speed/volumetric flow regulation system. It consists of:

* The intake control valve,

* The engine control cylinder,

* The regulator.

The intake control valve comprises:

* the control piston / check valve piston for the volume flow-rate throttle control and for preventing flooding of the suction control valve and the air filter with oil when the screw compressor is switched off.

9.5.8 Battery maintenance

Attention

Check the acid level after a maximum of 1,000 operating hours, or after

24 months, whichever occurs first, and fill up with distilled water if necessary.

For battery maintenance please also refer to the manufacturer’s instructions and the engine operating manual.

9.6 Spare parts for maintenance purposes

Designation

Service Package 1000 h

GDP21-GDP31

Identification No.

A19052574

Service Package 1000 h

GDP21-GDP31

(air-oil separator)

Spare parts list

A19051574

100009334

9.5.9 Torque specifications

The following tightening torques apply to screwed connections:

Wheel screws

Pressure vessel cover

90 Nm

13 Nm

50 Nm Safety valve

Engine bearing/ rubber metal element

Compressor bearing/ rubber metal element

90 Nm

Rubber metal element / frame

Chassis mounting screw suspension / frame property class 12.9

(Durlok screw) property class 8.8

suspension cross girder hose clips

(engine, compressor/cooler) hose clips

(compressor/pressure container)

50 Nm

Air-oil separator el

90 Nm Seal ement

169 Nm

90 Nm

3 Nm

30 Nm

Service parts

Filter element

Spare filter

Spare cartridge for fuel filter 100012359

Fuel line filter

Spare cartridge for motor oil filter

A13306974

A04819974

100008391

100008389

100007223

A93185860

Fig. 39

Danger

The gases released by the battery are explosive.

Avoid sparks and open fires in the vicinity of the battery.

Do not allow acids to come into contact with skin or clothing. Wear safety goggles.

Place no tools on the battery.

The battery is maintenance-free in accordance with DIN.

10. Troubleshooting

Problem

Insufficient or no air supply

Insufficient pressure

Compressor becomes excessively hot

(automatic shutdown)

Screw compressor will not start

(starter motor not turning)

Screw compressor will not start

(starter motor turning)

Compressor shuts down.

Engine oil pressure LED flashes

Engine starts, but runs at reduced speed and very high engine vibrations which lead to the destruction of the coupling.

Possible cause(s)

Clogged air filter

Screw compressor engine speed misadjusted

Clogged oil fine separator filter cartridge

Wrong setting at controller

Spring and plunger inside the intake control valve are not fully opened

Pressure control valve defective

Outflow valve dirty

Control line defective

Intake control valve defective

Wrong oil

Compressor oil level too low

Fan broken

Oil cooler dirty (outside)

Oil filter clogged

Leak in oil line

Air short circuit

No power on instrument panel

Operating voltage low

Electrical connection loose, corroded, or broken

Starter defective

Switch defective

No control system test (LEDs flashing) after activation of S1

No fuel

Fuel pump not delivering

Fuel filter clogged

Fuel line loose, broken, or jammed

Air in system

Lifter magnet not working

11.1 Introduction

This manual describes the operation and maintenance of synchronous generators with switchboxes.

All information relates to data available at the time of going to press.

The manufacturer reserves the right to make changes at any time, without prior notice or obligation. It is therefore always advisable to check for updates.

No part of this publication may be reproduced or transmitted in any form or by any means, without the prior written consent of the manufacturer.

Synchronous generators may only be used as such. No other form of use is permitted.

11.2 Generator safety precautions

Do not top up current-generating units

(generators) with fuel during operation!

Follow the additional fire and explosion protection regulations in the case of installation in enclosed spaces.

Attention! Exhaust gases are toxic!

Do not operate generators in nonventilated, enclosed spaces!

Check that electrical loads and their connections are in perfect condition.

Synchronous generators operate safely and reliably. Before commissioning, read through the safety precautions in this manual carefully.

* Ensure that children under the age

Danger of fourteen and animals do not have access to the generator while it is running.

To avoid endangering people or animals, or causing accidents or damage to the machine, always carry out the usual checks before switching the generator on.

* There is always a risk of electric shock if a generator is used improperly. Never touch the generator, or equipment connected to it, with wet hands.

* When using several generators, or if the public mains is available, do not interconnect these systems.

* Caution! Connecting the generator to the public mains can damage it and severely endanger personnel.

* The IP 54 protection means the generator is protected against splashes, spray and other foreign bodies. Do not, however, clean the generator with high-pressure equipment.

* Generators may only accept up to their nominal load if operated according to the standard temperature range and cooling conditions specified. If installed under different conditions, or if cooling of the engine or generator is impaired, for example in confined spaces or under unfavourable circumstances, their output must be reduced.

* Do not modify the generator/ switchbox. Such changes, or the use of unsuitable parts, will invalidate approval under machinery safety legislation and certification to

EU/EEC Directives.

Opening of the terminal box / fuse box only by trained, qualified staff. Opening of the terminal box not earlier than

5 seconds after motor shutdown.

Observe the following safety rules:

* Disconnect the system from the power supply.

* Secure the system against being switched on again.

Ensure that the system is deenergised.

Earth the system and short-circuit it.

Cover or cordon off neighbouring energised parts.

11.3 Operating principle

The generator is a self-excited brushless synchronous internal pole generator which is controlled electronically. It consists of the main machine, exciter, rotary rectifiers and generator regulator assemblies, housed in a common enclosure. The main machine of the synchronous 3-phase generators has various design features, including a damping cage and balancing system, which allow it to handle an extremely asymmetrical load. All of the other equipment required for safe electrical operation is accommodated in the unit (generator - switchbox).

The splashproof and dustproof generator is driven by the engine using Vbelts. Over the range from no-load to nominal output, the voltage it supplies is controlled by a highly integrated electronic regulator, which is fully encapsulated in the cover of the switchbox, so that the output voltage over this range complies with IEC 38 requirements. This standard is comparable with the public mains.

The stability of the output frequency is entirely dependent on that of the speed of the combustion engine. You must therefore ensure that this engine is serviced, maintained and operated properly.

If the generator is overloaded briefly (for less than the thermal response time of the circuit breaker), or devices with excessive startup consumption levels are connected, the regulator automatically limits the output/startup consumption (through the excitation current). This leads to a

(desired) withdrawal of the output voltage.

Please take account of this when operating several devices simultaneously on your generator.

Note

Switch devices (loads) on one after the other, starting with that with the least favourable startup characteristics.

If the generator is extremely dirty, insufficiently ventilated, or operating under otherwise unacceptable conditions, to prevent it or the regulator being damaged by overheating, the output voltage is reduced to about half its nominal value if the temperature inside the switchbox exceeds

80 °C. This compromises the connected devices, which must be switched off or unplugged immediately.

Always avoid operating the generator under such conditions, and keep it clean

(particularly fan cowl air inlets, cooling fins).

The generator is fitted with a thermalmagnetic circuit breaker, which not only protects against overloads, but also switches off in the event of an insulation fault on a connected device. Interruption of power distribution during operation may be caused by an insulation fault on a device

(in which case an indicator lamp comes on), or an overload (when it does not). If an overload has occurred, eliminate its cause, wait for a short time, then reset the circuit breaker. On generators with a hinged glass cover over the circuit breaker, open the cover, grasp the breaker’s operating handle and push upwards (always in the centre = yellow mark, not on one side!). Then carefully close the cover again, and tighten its knurled screws, without exerting force.

After the circuit breaker has released due to an overload (indicator lamp off), wait for a short time until it can be reset. The thermal-magnetic or thermal circuit breaker is designed in accordance with the machine specifications, particularly in relation to shock and vibration resistance, and ambient temperature. Only use an original part if replacements are needed.

11. Generator option

11.4 Operating the generator

(Working safely with electrical equipment)

This state-of-the-art synchronous generator has been designed and built with maximum safety in mind. It will help you get the most out of your work or leisure activities. However, like all electrical equipment, it can represent a source of danger (e.g. risk of electric shock) if the operating instructions in this section are not followed exactly. Please observe the instructions and the notes on dangers affixed to your generator.

Before starting the generator, all devices must be unplugged and switched off. Only plug the devices in (one after the other) and switch them on after the engine driving the generator has reached its nominal operating speed.

Keep the glass cover over the circuit breaker on the front panel closed at all times. Tighten the knurled screws by hand to maintain IP protection.

Do not open the generator or the switchbox. The brushless synchronous design does not require maintenance.

Do not modify the internal wiring.

Repairs to electrical components and to electrical operating equipment (supply cables, loads) may only be carried out by suitably trained electricians.

The circuit breakers, control, alarm and release devices and the insulation monitors are specially designed for the generator and its sockets. Only use original spare parts if replacements are needed.

The generator meets the requirements of the Protective isolation with equipotential bonding conductor and insulation monitoring with circuit breakers regulation in IEC 60364-5-551 and the German Gas

Installation and Plumbing Association

(DVGW) regulation GW 308. The system is an IT type, with neutral and PE

(equipotential bonding conductor).

The generator does not have to be earthed (with a ground rod for example) to ensure adequate safety protection.

However, if desired or required, defined earthing of the generator can also be provided.

Earthing of the neutral (N), or connecting of the neutral to the equipotential bonding conductor (PE), is prohibited on the generator, the distribution system and all other devices. The use of so-called neutralised devices is not permitted, and would lead to insulation monitoring being enabled automatically.

The generator must not be used to inject power into a construction site distribution system.

To avoid unwanted interaction, do not connect distribution systems with additional insulation monitors to the generator with its built-in equivalent.

During insulation and voltage tests carried out on the generator by trained electricians, disconnect the insulation monitor.

Because the generator is not earthed, fault current circuit breakers used in distribution systems and equipment cannot be relied upon to operate correctly when such units are connected to the generator, and, due to the Electrical isolation with insulation monitoring and circuit breaking protective measure, are not actually required.

The insulation monitor and circuit breaker should be checked daily when the generator is in use, following the quick reference instructions for Testing/ insulation monitoring/starting/connecting equipment which are affixed to the generator.

Attention

Devices connected the generator which cause the circuit breaker to release, and the red indicator lamp for

Insulation fault to light up, must not be connected to other generators (without insulation monitoring), or to the public mains. Have equipment with insulation faults immediately replaced or repaired by the manufacturer or a suitable electrical specialist.

When working in restricted conductive areas, i.e. as defined in DIN/VDE 0100

706 (e.g. in boilers), only one power tool or mobile measuring instrument may be connected to the generator, or for each such load an additional isolating transformer, or one isolating transformer with several secondary windings, should be used. Handheld lights may only ever be used in restricted conductive areas when operated off a SELV (safe extra low voltage) isolating transformer.

Many portable power tools conform to

German protection class II (i.e. they are double insulated, symbol ■ ). These devices should be used if possible. Use a cable and plug to connect any protection class I device (i.e. with metal housing parts that are not double insulated) to be used to the PE (equipotential bonding) conductor.

Only connect devices and distribution systems which are in good condition to the generator. The insulation, and plug and socket combinations, must be in good condition to ensure user safety. Do not use any damp or dirty connectors.

The distribution systems (e.g. extension cables, device leads) must be carefully chosen, laid and maintained. Check the electrical cables regularly, replacing rather than repairing any that are faulty.

To cope with the greater mechanical strains and stresses on the generator’s distribution system, use rubber-sheathed cables to the minimum standard of H07RN-

F or A07RN-F in accordance with DIN/VDE

0282 Part 810, or equivalent designs, as moveable (extension) cables. W here the cables may be under severe stress, lay them in mechanical protection systems, or with strong covers, or use NSSHöü cables in accordance with

VDE 0250.

The lengths and conductor cross sections of the extension cables must match the type of equipment and the duty.

It is essential to ensure supply cables do not exceed the maximum lengths specified! When using extension cables or moveable distribution systems, the sum of the lengths of all extension cables connected to a generator must not exceed

250 metres (for a copper conductor cross section of 2.5 mm 2 - for all sockets). The total length of the extension cable, or the moveable distribution system, connected to any particular socket must not exceed

60 m for a copper conductor cross section of 1.5 mm 2 , or 100 metres for one of

2.5 mm 2 .

Note

For defined releasing of the circuit breaker, a loop resistance of 1.5 Ω per socket must not be exceeded.

The circuit breaker must not be used for routine switching on of the 3-phase generator. If several devices, particularly those with different power consumption levels, are connected to the AC sockets, different voltage drops can arise, depending on the turn-on time of the neutral.

Avoid overloading the generator. In particular, to ensure user safety and optimum performance, it is essential to observe the following rules:

Only devices whose voltage and frequency data on the load identification plate conform to those on the generator identification plate may be connected.

2. Only devices whose power consumption does not exceed the output specified on the generator identification plate may be used. The total power consumption of all of the loads connected to the generator must not exceed its output.

11. Generator option

Note that the starting consumption of devices driven by electric engines is generally a multiple of the specified rating. If in doubt, it is advisable to contact the equipment manufacturer directly.

The maximum current specified for each socket must not be exceeded.

If normal cooling cannot be maintained, or the operating conditions are unacceptable in other respects, reduce the consumption, rather than operating the generator right up to its rating.

Ideal operating conditions are:

1. Ambient temperature:

2. Air pressure:

3. Relative humidity:

25 °C

100 kPa (1 bar)

30%

Do not operate the generator at ambient temperatures above 40 °C, below –10 °C, or in direct sunlight.

More detailed instructions for operation under unfavourable conditions can be found in the combustion engine manual.

11.5 Testing insulation monitoring / startup / device connection

Testing insulation monitoring

Attention

Do not start the generator until you have fully read and thoroughly understood the safety precautions and operating instructions in this manual.

During operation, check at least once a day that the protective measure for the risk of electric shock through indirect contact (in accordance with DIN and

GW 308 requirement for Protective isolation with insulation monitoring and circuit breaking) is working properly

With the engine running, carry out the following test:

Unplug all devices connected to the generator; open the glass cover and switch the circuit breaker to ON/I.

Press the test button (red or blue).

3. Check whether the circuit breaker releases and red the INSULATION

FAULT indicator lamp lights up.

Switch the circuit breaker to ON/I; close the glass cover (tighten the knurled screws by hand); the generator is now ready for use.

Attention

The generator may only be used if the circuit breaker released during the test and the red indicator lamp came on.

Setting the range switch

Turn the range switch to the required position:

1st position:

Compressed air and electrical power, variable engine speed.

* Compressed air and electrical power can be consumed up to maximum engine speed.

Note that engine speed is reduced in the event of an overload.

* Compressed air mode without consumption of electric power:

–> engine speed matched to demand

* Additional consumption of electric power: –> variable engine speed is matched to consumption automatically, up to maximum speed

* Automatic no-load operation, i.e. the engine continues to run at maximum speed for 100 seconds, if the electrical power consumption is less than 75 VA for a brief period.

2nd position:

As 1st position, but with the engine running at constant speed

* Same functions as for 1st position, but with the engine running at constant, maximum speed

Switching on

Fig. 40

Danger

Follow safety precautions!

* Carry out the usual checks (safety precautions, installation location, oil level, fuel, etc) before using the machine.

* Ensure that all the devices on the generator output sockets have been disconnected.

Note

All device switches must be in the

AUS / 0 / OFF position.

Danger

Unchecked devices may endanger personnel on startup, and may be damaged or cause damage.

* Start the generator.

Note

Do not load the generator until the engine has warmed up.

* Check that the circuit breaker is engaged in the ON / I position

(close the glass cover).

Fig. 41

Connect the devices to the output sockets one after the other, ensuring that the current specified for each socket is not exceeded, and the generator is not overloaded.

Note

Turn the devices on, one after the other, using the device switches.

If possible, plug in/switch on devices with high startup currents first. Only connect suitable equipment in perfect condition to the generator.

Switching off

* Turn the devices off, one after the other, using the device switches.

Note

If possible, switch devices with the highest current consumption off last.

* Switch the devices off one after the other.

Note

Ensure the covers of unused sockets are closed again properly.

11. Generator option

Efficiency at nominal output at 0.8 ind 0.80

at 1.0 0.82

Distortion factor

Weight

Overall size

Overall length

< 5%

53 kg

BG132

357 mm

Fig. 42

* Allow the engine to continue running for about 2 minutes, so that the generator cools down.

* Stop the generator.

11.6 Technical characteristics of

110V 6kVA GTS generator

Generator regulator

Model

Connector assignment

8 pole Pin

LCAR3

Colour red

Function

F1 grey F2 not assigned 3

5 yellow yellow

4-pole

4 yellow brown

L1 blue N black switch contact black switch contact not assigned not assigned

Generator model

Generator type

WG 6,0-2ZE

Synchronous, internal pole, electronically

Generator frame controlled

B3/two bearings

Degree of protection IP 54

Switchbox

Degree of protection IP 54

Dimensions

Design

Fusing

250x204x135

Front panel type

All poles

U1 C32A

U2 2 x 16A

Generator characteristics:

Extremely low dynamic internal resistance, same output voltage whether hot or cold, no dangerous overvoltage during dynamic overspeed, small reactive effect from nonlinear or very inductive equipment, troublefree operation of equipment with phase control, no dangerous overvoltage of the unloaded phases, load current may have significant DC components

Insulation monitoring

Model

Controls

GMW-RISO1.0

Red test button

Areas of application engines difficult to get running, welding devices (incl. inverters), pumps, compressors, tools, construction machinery, illumination

Power system

(IEC 38/50Hz) 1-phase AC

2 x 115V

Generator data

Winding Colour Ins. class Resistance

(at 20°C)/ Ω

Amplified phases 3

U1-N

U2-N

W-N brown-blue black-blue black-blue

ZU-ZN

ZV-ZN yellow-yellow yellow-yellow

ZW-ZN yellow-yellow F

1F1-1F2 red-grey H

0.165

0.28

2.5

22.1

Nominal output

(0.8 cap/ind)

Nominal current

Startup current

Operating mode

Nominal speed for nominal frequency

Min. speed for nominal output

7000VA

32A + 2 x 16A

4.1 times I rated

S1, continuous

Protective measure Electrical isolation, with equipotential bonding conductor in accordance with

Coolant

VDE 0100.728

Air/externally ventilated with own fan, independent of direction of rotation

3000 rpm

(All resistances measured using the 4-wire

R method)

11.7 Technical characteristics of

400/230V 5/8kVA GTS generator

Generator model........ DWG 8/5-2-ZE

Generator type........... Synchronous, internal pole, electronically controlled

Generator frame ........ B3/two bearings

Degree of protection .. IP 54

Generator characteristics:

Power system

(IEC 38/50Hz) 3-phase AC

400V/230V

Nominal output (0.8 cap/ind) single-phase 5000VA

3-phase (sym)

Nominal current

8000VA single-phase

3-phase (sym)

Startup current

21.6A

11.5A

4.1 times I rated

Operating mode S1, continuous

Protective measure Electrical isolation,

Coolant with equipotential bonding conductor in accordance with

VDE 0100.728

Air/externally ventilated with own fan, independent of direction of rotation

Nominal speed for nominal frequency

Min. speed for nominal output

3000 rpm

Efficiency at nominal output at 0.8 ind at 1.0

0.80

0.82

Distortion factor

Weight

Overall size

Overall length

< 5%

53 kg

BG132

357 mm

Generator regulator

Model LCAR 3

Connector assignment

8 pole Pin Colour Function

1 red F1

2 grey F2

3 violet 1/2U

4 violet 1/2V

5 violet 1/2W

11. Generator option

Switchbox

Degree of protection IP 54

Dimensions

Design

Fusing

250x204x135mm

Front panel type

All poles

L1 B16A

L2 B16A

L3 B16A

N leading N

Insulation monitoring

Model

Controls

GMW-RISO1.0

Red test button

Areas of application engines difficult to get running, welding devices (incl. inverters), pumps, compressors, tools, construction machinery, illumination

Generator data

Winding Colour Ins. class Resistance

(at 20°C)/ Ω )

U-N

V-N brown-blue white-blue

0.59

W-N black-blue

1/2 U-N yellow-blue

1/2 V-N yellow-blue

1/2 W-N yellow-blue

1F1-1F2 red-grey

0.59

0.65

(All resistances measured using the 4-wire

R method)

11.8 Technical characteristics of

110V 7kVA KWG generator

Generator model

Generator type

Generator frame

KWG-110/2-Z11-102

Synchronous, internal pole, brushless with exciter, electronically controlled

B3/two bearings

Degree of protection IP 54

Generator characteristics:

Power system

(IEC 38/50Hz)

Nominal output

(0.8 cap/ind)

Nominal current

2 x 115V

6000VA

54.5A

Startup current 4.1 times I rated

Operating mode S1, continuous

Protective measure Electrical isolation, with equipotential bonding conductor in accordance with

VDE 0100.728

Coolant Air/externally ventilated with own fan, independent of direction of rotation

Permissible speed range 0 to 4000 rpm

Speed for nominal output 3000 to 4000 rpm

Efficiency at nominal output at 0.8 ind at 1.0

0.81

0.84

Distortion factor

Weight

Overall size

Overall length

Generator regulator

Model

Connector assignment

8 pole

3 pole

4 pole

< 5%

53 kg

BG132

420 mm

DCB

Colour red grey yellow yellow yellow brown blue not assigned

Function

L1 black switch contact black switch contact not assigned not assigned

Switchbox

Degree of protection IP 54

Dimensions

Design

255x205x134mm

Front panel type

Fusing

All poles

AS32A

2 x AS16A

Insulation monitoring

Model KWG-ISO-001

Controls Red test button

Green reset button

Areas of application engines difficult to get running, welding devices (incl. inverters), pumps, compressors, tools, construction machinery, illumination

Electronic evaluation system

Integrated on the generator controller

Speed reduction

Time to speed reduction

Activation < 75W

100 seconds

Outputs

Output for speed reduction

Switch voltage:

Current:

Make-break capacity max. 1500V AC

Admissible load current

Mode switch

Type

Display

Generator data

Winding Colour Ins. class Resistance

(at 20°C)/ Ω )

U1-N brown-blue F 0.195

U2-N black-blue

ZU-ZN yellow-yellow

ZV-ZN yellow-yellow

ZW-ZN yellow-yellow

0.195

1.25

1F1-1F2 red-grey H 25.4

(All resistances measured using the 4wire R method)

Potential-free make contact max. 250V AC max. 40V DC/1A max. 6A

5A/AC1 at 1x10

Areas of application engines difficult to get running, welding devices (incl. inverters), pumps, compressors, tools, construction machinery, illumination

5 switching cycles

1A/24V DC L-R load at 2x10 5 switching cycles

1 key switch yellow LED ”1“ yellow LED ”2“

11. Generator option

11.9 Technical characteristics of

400/230V 8kVA KWG generator

Generator model

Generator type

KWG-110/2-Z11-001

Synchronous, internal pole, brushless with exciter, electronically controlled

Generator frame B3/two bearings

Degree of protection IP 54

4 pole

Generator characteristics:

Power system

(IEC 38/50Hz) 3-phase AC

400V/230V

Amplified phases 3

Nominal output (0.8 cap/ind) single-phase 5000VA

8000VA 3-phase (sym)

Output current single-phase

3-phase

Startup current

21.6A

11.6A

4.1 times I rated

Operating mode S1, continuous

Protective measure Electrical isolation, with equipotential

Coolant bonding conductor in accordance with

VDE 0100.728

Air/externally ventilated with own fan, independent of direction of rotation

Permissible speed range 0 to 4000 rpm

Speed for nominal output 3000 to 4000 rpm

Efficiency at nominal output at 0.8 ind 0.85

at 1.0 0.88

Distortion factor

Weight

Overall size

< 5%

53 kg

BG132

Overall length

Generator regulator

420 mm

Model

Connector assignment

DCB

Pin Colour

3 pole

3 red grey yellow yellow

Function

1/2 U

1/2 V yellow blue

1/2 W

N not assigned

4 black switch contact black switch contact not assigned not assigned

Generator data

Winding Colour

U-N

Ins. class Resistance

(at 20°C)/

Ω

) brown-blue F 0.29

V-N

W-N white-blue black-blue

1/2 U-N yellow-blue

1/2 V-N yellow-blue

1/2 W-N yellow-blue

1F1-1F2 red-grey H

0.29

0.15

25.4

(All resistances measured using the 4-wire

R method)

m m

D e s i g n

5 x

4 x

F t n r o p a n e l

4 i o n s n s

D i m e t e c p r o o n i t f o

P r e e g e b o c h i t

S w x

11. Generator option

type

Fusing

All poles

AS16A

AS16A leading N

Insulation monitoring

Model KWG-ISO_001

Controls Blue test button

Green reset button

Electronic evaluation system

Integrated on the generator controller

Speed reduction

Time to speed

Activation < 75W reduction 100 seconds

Outputs

Output for speed reduction

Potential-free make

Switch voltage: contact max. 250V AC

Current: max. 40V DC/1A max. 6A

Make-break capacity max. 1500V AC

Admissible load current

5A/AC1 at 1x10 5 switching cycles

1A/24V DC L-R load at 2x10 5 switching cycles

Mode switch

Type

Display

1 key switch yellow LED ”1“ yellow LED ”2“

11. Generator option

11.10 Generator switchbox wiring diagram GTS 110V 6kVA

PROTECTIVE ISOLATION WITH INS ULATION MONITORING

AND FUSING/CIRCUIT BREAKING FOR ALL POLES

K = OPERATING CURRENT CIRCUIT BREAKER

H =INS ULATION FAULT INDIC ATOR LAMP

R = GMW/ISO INS ULAT ION MONITOR

P = TEST BUTTON

6-PIN CONNECTOR

CONTACTS VIEW

MODE SELECTOR SWITCH

POSITION 1: OPEN

POSITION 2: CLOSED

OPTIONAL, EXTERNAL PE CONNECTION

MECHANICAL

COUPLING TO F1

TO 4 POLE AMP

PLUG ON WLAX-

CONTROLLER

BROWN <

BLACK

BLUE

CURRENT CONVERTER

ON WLAX CONTROLLER

IF THERE IS NO INFOR MATION

ON THE LINE LEAD CROSS-

SECTION, THEY ARE 2.5 mm 2

POWER SUPPLY

AUTO MATIC NO-LOAD OPERATION

ATTENTION:

TRIP-FREE RELEASING OF ALL

CIRCUIT BREAKERS COUPLED

CONNECTION WITH COMPR.

WIRING HAR NESS

INSERTION SIDE VIEW

SW ITCHBOX

TOTAL LENGTH OF EQUIP MENT

SUPPLY CABLES

∑ < 250M

EXAMPLE:

LOAD PROTECTION CLASS I

(ALSO CLASS II/SEE OPERATING

MANUAL)

AC-L-Load AC-L-Load AC-L-Load

Fig. 43

11.11 Generator switchbox wiring diagram GTS 400/230V 8kVA

PROTECTIVE ISOLATION WITH INSULATIO N MONITORING

AND FUSING/CIRCUIT BREAKING FOR ALL POLES

K = OPERATING CURRENT CIRCUIT BREAKER

H =INS ULATION FAULT INDIC ATOR LAMP

R = GMW/ISO INS ULAT ION MONITOR

P = TEST BUTTON

6-PIN CONNECTOR

CONTACTS VIEW

YELLOW/GREEN

OPTIONAL, EXTERNAL PE CONNECTION

OPTIONAL

BROWN

WHITE

BLACK

BLUE

YELLOW/

GREEN

MECHANICAL

COUPLING TO F1

TO 4 POLE AMP

PLUG ON LCAR3-

CONTROLLER

CURRENT CONVERTER ON

LCAR3 CONTROLLER

ATTENTION:

TRIP-FREE RELEASING OF ALL

CIRCUIT BREAKERS COUPLED

BROWN

WHITE

BLACK

POWER SUPPLY

AUTO MATIC NO-LOAD OPERATION

PRESSURE REDUCTION

BLUE

VERSION 1.10

CONNECTION WITH COMPR.

WIRING HAR NESS

INSERTION SIDE VIEW

SW ITCHBOX

TOTAL LENGTH OF EQUIP MENT

SUPPLY CABLES

∑ < 250M

EXAMPLE:

LOAD PROTECTION CLASS I

(ALSO CLASS II/SEE OPERATING

MANUAL)

3PH-Y-L-Load AC-L-Load AC-L-Load

Fig. 44

11. Generator option

11.12 Generator switchbox wiring diagram KWG 110V 7kVA

RED 1

GREY 2

BLUE 6

YELLOW 3

YELLOW 4

YELLOW 5

BROWN 1

BROWN 2

BLACK 5

BLACK 6

BLUE 3

BLUE 4

GREEN/YELLOW 7

FUSE 5A

Fig. 45

11.13 Generator switchbox wiring diagram KWG 230/400V 8kVA

RED 1

GREY 2

ORANGE 8

YELLOW 3

YELLOW 4

YELLOW 5

BROWN 1

BLUE 4

BLUE 5

WHITE 2

BLACK 3

GREEN/ YELLOW 6

FUSE 5A

Fig. 46

11. Generator option

11.14 Troubleshooting

Sockets dead

Has insulation monitor released?

(indicator lamp lit) no yes

Unplug connected devices

Has fuse blown?

yes

Unplug connected devices no

Contact customer service or take device in for checking.

Reset the circuitbreaker

Plug in devices one after the other

Is insulation monitoring still enablend?

Connected devices are faulty yes

Does fuse still blow?

Connected devices are faulty yes

11. Generator option

Problem

The generator supplies no or insufficient voltage.

Possible cause(s)

The generator circuit breaker has tripped due to overload or is defective.

Complete or significant voltage drop during operation under load.

Excessive generator voltage.

Voltage fluctuates in short intervals.

Generator heats up to unacceptable levels.

Drive motor speed too low.

Generator circuit breaker not depressed.

Compressor operating pressure set too high, engine overloaded, speed decreases.

Coil of the "Speed increase" solenoid valve defective.

Insufficient engine speed or speed control inoperative.

The engine output has been reduced due to climatic or other conditions.

Compressor operating pressure set too high.

Excessive engine speed.

Diesel engine operates irregularly.

The engine speed control operates irregularly or is defective.

Clogged cooling air supply.

Machine is dusted.

Output reduction due to set-up at too high an altitude.

Ambient temperature too high.

Correction

Check electrical load output.

Check that all electrical terminals are properly seated.

Check generator protective switch and replace if required.

Check connected electrical loads for short or earth contact.

Set to nominal speed, max. 3,100 rpm.

Press the protective switch.

Re-adjust the operating pressure at the adjuster.

Check and replace solenoid valve if required.

Have the nominal speed adjusted by the engine after-sales service to max.

3,100 rpm.

Check that all electrical terminals are properly seated.

Check connected electrical loads for short or earth contact.

Do not operate the generator at nominal output, see the operating instructions for the engine.

Re-adjust.

Have adjusted to nominal speed.

Have checked by the engine after-sales service.

Check according to the operating instructions supplied by the engine manufacturer.

Ensure that the cooling air supply is not restricted.

Clean the machine and position in a way that dust-free cooling air only will be taken in. It is strictly recommended that the cooling air is cleaned at regular intervals.

Partial load operation possible only.

The generators are designed to ensure that no danger exists at ambient temperatures of up to 35 °C. In higher ambient temperature environments, the generator may be operated at partial load only.

When additional problems occur, call for compressor service!

Attention

Use genuine spare parts only!

11. Generator option

12.1 Safety regulations for the use of the heat exchanger

Danger

When operating the compressor, please observe the general safety regulations laid forth in the compressor operating manual.

The heat exchanger operates fully automatically. Operating errors at the heat exchanger are excluded.

12.2 Design and operation

With the aid of the compressor oil the compressed air whose thermal energy and moisture are extracted in the after cooler is heated again in the heat exchanger (re-heater).

See function diagram P. 17, Fig. 8

12.3 Maintenance/Care

This system is maintenance-free.

13.1 Safety regulations for alternate compressed air processing

Danger

When operating the compressor, please observe the general safety regulations laid forth in the compressor operating manual.

13.2 Design and operation

System function diagram: see page 17, Fig. 8

After cooler option

In an air cooler (on the cooling air intake side), the compressed air is cooled down to a temperature close to the prevailing ambient air temperature downstream of the pressure vessel. A condensate separator with continuous condensate discharge is installed downstream the aircooler.

Attention

When there is a danger of freezing or when the machine is switched off for a prolonged period, any remaining condensation must be drained from the secondary cooler. For doing this the bottom cover of the secondary cooler must be opened and it must be emptied utilising the pressure remaining in the machine.

The oil-containing condensate has to be collected. Do not allow to enter into the soil or into the drains!

13.3 Maintenance instructions

Danger

Prior to and when carrying out maintenance and repair procedures, please do observe the general safety regulations in chapter 3 of the compressor operating manual.

Fig. 47

1 After cooler

2 Condensate separator

3 Heat exchanger

13.4 Troubleshooting

Problem Possible cause(s)

Increased air humidity of the compressed air Contaminated air cooler.

Oil in discharge air line

Aperture or silencer in condensate separator collecting tank clogged.

See chapter 10 "Troubleshooting" in this manual.

Aperture or silencer in filter collecting tanks clogged.

Correction

Clean

Replace or clean

14. Oil temperature controller option

14.1 Safety regulations for the use of an oil temperature controller

Danger

Please observe the general safety regulations in the compressor manual when operating the compressor.

Operation of the oil temperature controller is fully automatic.

Maloperation of the oil temperature controller itself is impossible.

14.2 Design and function

See page 17, Fig. 8, for system function diagram.

With the aid of the oil temperature controller, the compressor oil circuit is kept at an optimum service temperature.

The oil temperature controller regulations the temperature of the oil within the set temperature limits, and only feeds as much oil to the cooler as is necessary to achieve the desired oil temperature.

Oil inlet

Oil outlet

Fig. 48

14.3 Maintenance / care

This system is maintenance-free.

14.4 Troubleshooting

Compressed air temperature too low

Oil temperature controller in the oil line is defective -> replace it.

15. Undercarriage

15.1 Introduction

Attention

The user forfeits all rights to claim if parts other than those of the manufacturer are used.

We reserve the right to modify design and performance without prior notice.

Please quote axle number, model and article number when contacting us with queries or ordering spare parts.

15.2 Safety

* It is most important that the wheel and the hub are compatible dimensionally.

This means that the P.C.D., wheel bolts and inset must all be compatible both with the hub and the rim.

Particular attention must be paid to the recommended torque figures for the wheel bolts.

* No welding is permitted on the axle.

* Please note the swing arm movement.

(See assembly instructions).

* The wheel brakes are matched to the overrun devices.

Before using an overrun from another manufacturer, please check the compatibility with our Technical -

Department.

Attention

Model details must not be obscured by paint now concealed by components.

15.3 KHV7,5 height-adjustable towing system, model B 3.5.13

The adjustable joint between the drawbar and intermediate arm, and between the overrun system and intermediate arm, consists of toothed heads or retainers with Hirth-type or radial serrations.

The radial serrations are secured with fastening screws. The fastening nut must be tightened to the specified torque in order to establish a no-play, torque transmitting connection. The tightening torque depends on the permitted gross weight of the trailer and the length of intermediate (swivelling) arm

Adjusting procedure

After the spring-loaded plugs have been released from the fastening nuts, the nuts can be loosened until the teeth are exposed. The angle of the intermediate arm can then be adjusted.

Danger

Care must be taken without fail to ensure that the overrun or towing system is always aligned parallel with the drawbar.

The vehicle must not be driven unless the overrun system is parallel with the drawbar!

After the coupling has been adjusted for height, the serrations should be locked together with the clamping nuts and secured against working loose by means of the spring-loaded plugs.

15.4 Braking system

Introduction

* KNOTT over-run brake systems consist of over-run hitches and wheel brakes used in combination with KNOTT torsional thrust spring axles. They are approved in all countries of the EC and in Switzerland.

* With the KNOTT autoreverse system

‘Backmat’ there is no problem changing the direction of travel from forward to reverse. The braking system is ready for immediate operation again when changing from reverse to forward travel.

* KNOTT torsional thrust spring axles as well as rubber spring axles have superb springing and excellent dampening characteristics. With the torsional thrust spring axles the spring elements with their vulcanized rubber are pretensioned before being pressed into the axle tubes. There is no squashing of the rubber during spring action. Instead the rubber is stretched in accordance with its characteristics.

With the rubber spring axles theaxle tube bears the axle by pretensioned rubber strings. The results of the stretching are exceptionally long life and zero maintenance.

Attention

* Use the jack only under the fixing brackets or at the chassis, never in the centre.

* Towing eye and ball coupling may only be changed by specialists.

* Use a new safety nut every time one of these items is changed.

* Use specified torque setting:

Ball coupling

M12 8.8: T = 77 Nm

Towing eyes

M12 10.9: T = 115 Nm

* When using the ball coupling, please follow the instructions given.

Fig. 49

15. Undercarriage

Over-run hitches

KNOTT over-run hitches are available for both hydraulic and mechanical brakes.

Handbrake lever with power reservoir, code „KH“

With the type “KH” the spring reservoir is under torsion at the centre point. If the handbrake is applied, then it works automatically and requires almost no force. The system is designed so that when the handbrake is applied, sufficient energy is stored within the spring. When transmitted through the brake rods this prevents the brake shoes from slipping away from the brake drum.

15.5 Adjusting the braking system

15.5.1 Preparations

* Jack up the trailer

* Release the handbrake

* Pull out the drawbar [5] of the overrunsystem as far as it will go

15.5.2

Preliminary requirements:

* When carrying out adjustments, always start with the wheel brakes.

* When carrying out adjustments, turn the wheel only in the direction of forward travel.

* Insert the security bolt [15] (see warning plate)!

* Do not pre-tension the expanding locking mechanism in the brake. If necessary, loosen the brake linkage [6] at the brake compensator [8].

* Check the expanding locking mechanism and control cable [11] for ease of movement.

Attention

* The compression spring [7] may only be lightly pre-tensioned and must not become fully compressed when activated!

* Bowden cable [14] must not activate brake.

* Never readjust the braking system or brakes by the brake linkage [6] or turnbuckles (if fitted) in the linkage!

When the brake is correctly adjusted, the actuating travel of the control cable

[11] will be 5-8 mm.

Carry out the adjustment procedure, as described, on all the wheel brakes in succession.

15.5.4

Adjusting the brake compensating system

15.5.3

Adjusting the brake

Fig. 53 KNOTT transmission system for tandem and single-axle chassis.

6 Brake linkage

7 Compression spring

8 Compensating balance assembly

9 Compensating balance (tandem) or master compensator

10 Compensating balance (single axle)

11 Control cable

Fig. 50 KNOTT overrun brake

1 Contact-breaking cable

2 Trailer coupling ring (varies by type)

3 Handbrake lever

4 Transmission lever

5 Drawbar and bellows

Danger

When any disconnection of the braking system takes place, secure handbrake lever by reinserting the security bolt

[15] (see warning plate [16]).

Fig. 51

15 security bolt

16 Warning plate

Fig. 52 KNOTT wheel brake

12 Adjusting screw

13 Cable entry

Tighten the adjusting screw [12] (on the outside of the brake plate, opposite the cable entry [13]), turning clockwise until the wheel can only be turned with difficulty or not at all.

Wrench sizes for adjusting screws [12]

Brake size

160x35 / 200x50

250x40

300x60

Wrench size

SW 17

SW 19

SW 22

Ease off the adjusting screw [12] in the anticlockwise direction (approx. 1/2 turn) until the wheel turns freely. Slight rubbing noises, which do not effect the free turning of the wheel, are permitted.

Fig. 54 KNOTT transmission system for tandem and single-axle chassis.

14 Bowden cable for handbrake

* Insert the security bolt [15] (see warning plate)!

* Remove the bowden cable [14].

* Preadjust the length of the brake linkage [6] (slight play permitted).

* Insert the bowden cable [14].

* Remove the security bolt [15].

* Operate the handbrake lever [3] and check the position of the compensating balances [9 and 10]. They should be at right angles to the direction of towing.

15. Undercarriage

* If necessary, adjust the position of the balance [10] and control cables [11]; in the case of tandem trailers, also adjust the master compensator [9] on the linkage [6].

* The compression spring [7] may only be lightly pre-tensioned and must not become fully compressed when activated!

15.5.5 Adjusting the brake linkage [6]

Adjust the brake linkage [6] so that it is free of play longitudinally, without initial tension (reversing lever [4] free of play).

15.6 Readjusting the braking system

In general, readjusting the wheel brakes adequately serves to readjust the braking system, i.e. to compensate for brake lining wear. To readjust the wheel brakes, proceed as described under 'Adjusting the braking system'. Check the play in the linkage [6] and readjust if necessary.

Attention

* Check the expanding locking mechanism and control cable [11]

* The expanding lock compensator must not be pre-tensioned in the brake.

* Do not attempt to compensate for ease of movement caused by brake lining wear by readjusting (shortening) the brake linkage [6], e.g. by way of the linkage screw fastenings

Readjustment

* Operate the handbrake lever [3] powerfully several times in order to settle the braking system.

* Check the position of the brake compensating balances [9 and 10] which should be at right angles to the direction of towing

* Check the play in the linkage [6]; if necessary, adjust the linkage [6] again so that it is free of play, but without initial tension

Slight play in the bowden cable [14] must persist.

* Check the position of the handbrake lever [3]; when checking the dead centre of the lever, resistance starts 10-15 mm above dead centre

* Check that the wheels rotate freely with the brake released.

Readjustment

* Operate the handbrake lever [3] powerfully several times in order to settle the braking system

* Check the position of the brake compensating balances [9 and 10]

(which should be at right angles to the direction of towing).

* Recheck the play in the linkage [6]; if necessary, adjust the linkage [6] again so that it is free of play, but without initial tension.

* Check the positions of the handbrake lever [3], the play in the bowden cable and compression spring [7] (only light initial tension);

* when checking the dead centre of the lever, resistance starts 10-15 mm above dead centre

Final check

* Check fastenings for security (secure the hexagon locking nuts of the screw fastenings for the transmission system, control cables, brake compensators, turnbuckle, linkage, etc.).

* Check the bowden cable for slight play

[14]; if neccessary, adjust the cable.

* Check the compression spring [7] for initial tension.

Test run

* If necessary, carry out 2-3 brake tests

Final check

* Check the screw fastenings for the transmission system (control cables, brake compensators, linkage, etc.).

* during operating braking with empty trailer should be used maximally 1/2 of the overrun travel

* Check tthe bowden cable for slight play

[14]; if neccessary, adjust the cable.

* Check the tension of the compression spring [7]

Brake test

* Recheck the play in the brake linkage

[6] and, if necessary, readjust the linkage [6] for length free of play ( during operating braking with empty trailer should be used maximally 1/2 of the overrun travel )

15.7 Maintenance and care

KNOTT – overrun systems

* The overrun system must be lubricated with lithium-soap grease by way of the grease nipples and at all the moving parts.

a) every 5000 km (3000 miles) b) or every 6 months c) or if they become stiff

* Inspect the bellows for damage, replace if necessary

* Replace the overrun shock absorber every 20,000 km (12,500 miles) or every 3 years at the latest.

* Check the play at the coupling point every 20,000 km (12,500 miles). If the play exceeds 3 mm, replace the guide bearing or drawbar.

* Check the tightening torques of the fastening screws at the guide bearing every 5000 km (3000 miles);

Screws with grease nipple

50 +5 Nm

Screws without grease nipple

80 +5 Nm

* Check the tightening torques at the clamping block of the drawbar and clamping socket (drawbar tube - axle joint) every 5000 km (3000 miles);

M12 screws

M14 screws

80 +5 Nm

90 +10 Nm

* Check that the braking system is correctly adjusted every 5000 km

(3000 miles).

Vertically adjustable drawbars

Clean the faces of the tooth systems free of fretting rust or other contamination at least once a year in order to maintain a good fit.

Lubricate the threaded bolts and joints once a year or at any time if they become stiff.

Attention

Do not grease the tooth system!

If desired, a lifting and adjusting system can be installed between the drawbar and the overrun system. The control arms of the adjusting system permit swivelling about an angle of -10° to +49° in six positions. In every case, the overrun system or drawgear always remains horizontal.

An integral gas-filled strut automatically generates lifting force which reduces the force required by the user. If the strut becomes damaged or develops a leak, it must be replaced.

15. Undercarriage

Information regarding dual-row angular bail bearings:

* These bearings are maintenance-free, have been provided with a lifetime lubrication. and have an extremely high running performance.

* The bearings have been fixed in their correct position using a safety flanged nut. This flanged nut must be tightened with a torque of 280 +/- 10 Nm.

* It is recommended to check this tightening torque in the course of service works.

* The flanged nut can only be unscrewed and re-used once. Afterwards. a new nut must be used. When releasing or tightening the flanged nut, grease the threads slightly, so as to avoid damage to the fine thread.

* Due to the high durability and the maintenance-free design of these dualrow angular ball bearings, there will be no damage at the bearings under normal conditions.

* If. due to exceptional circumstances.

problems were to occur with these bearings, completely new brake drums with pressed-in bearings, circlips and new locking nuts should be installed in principle.

* Due to the design characteristics of the bearings, the brake drums and the wheels may have a slight axial and tilting play; however, this is insignificant.

15.8 Malfunctions and remedies

Danger

Works on the brake system may only be carried out in specialized workshops.

When replacing braking shoes, make sure that all brake shoes of the axle are replaced.

When working at the wheel brakes, make sure that the springs, the brake shoes and the spreading lever are correctly installed; observe the correct sense of rotation.

When adjusting the wheel brakes, turn wheels in forward direction!

Basically, a readjustment according to chapter 15.6 "Fitting of the braking system" must be effected whenever works are carried out at the brake system.

If the wheel brakes or the brake drum have got very hot, continue to drive carefully on, if possible, until they have somewhat cooled down.

15. Undercarriage

Malfunction

Insufficient braking effect

Cause

Excessive backlash in brake system

Brake linings not "run in"

Brake linings glazed, oily or damaged

Brake reacts by jerks

Overrunning hitch hard to operate

Brake linkage is jammed or deformed

Brake Bowden cables rusty or kinked

Excessive backlash in brake system

Shock absorber of overrunning hitch defective

Backmat brake shoe is jammed in the brake shoe holder

Trailer is braked unilaterally Wheel brakes are actuated unilaterally

Causes: possibly specified under

"Insufficient braking effect"

Trailer is already braked when the accelerator pedal is released

Shock absorber of overrunning hitch defective

Reverse driving had to accomplish, or Brake system adjusted too tightly even impossible

Bowden cables pre-loaded

Braking action of hand-brake insufficient

Backmat brake shoe is jammed in the brake shoe holder

Incorrect setting

Wheel brakes get hot

Ball coupling does not rest on ball

Causes: possibly specified under

"Insufficient braking effect"

Backmat brake shoe is jammed in the brake shoe holder

Brake system incorrectly set

Causes: possibly specified under

"Insufficient braking effect"

Backmat brake shoe is jammed in the brake shoe holder

Wheel brakes dirty

Reversing lever of overrunning hitch is jammed

Handbrake lever not or only partially released

Coupling dirty on the inside

Ball of towing vehicle too big

Remedy

Re-adjust brake system

Actuate hand-brake lever slightly; drive 2-3 kilometers

Replace brake shoes completely; clean braking areas in the brake drums

Grease overrunning hitch

Eliminate cause

Replace Bowden cables

Re-adjust brake system

Replace shock absorber

Replace compl. brake shoes with brake shoe holders

Re-adjust brake system see above

Replace shock absorber

Re-adjust brake system

Replace compl. brake shoes with brake shoe holders

Re-adjust brake system

Actuate hand-brake lever as far as possible idem

Replace compl. brake shoes with brake shoe holders

Re-adjust brake system idem

Replace compl. brake shoes with brake shoe holders

Clean

Remove reversing lever, clean it and grease it with Molykote

Set handbrake lever into zero- position

Clean and grease thoroughly

Check ball diameter: According to DIN 74058, the ball on the car must not exceed 50 mm in diameter when new. If the ball diameter decreases to less than 49.5 mm, the ball has to be replaced.

The ball must be perfectly spherical

16. Tool oiler option

Check the oil level in the depressurized tool oiler

Fig. 55

Attention

Do not run the machine with an empty oiler tank! The tank must always contain a minimum of 0.2 l of tool oil.

Danger

Only refill the tool oiler, when the screw compressor is out of operation and depressurized!

Only screw off the oiler reservoir, when the screw compressor is out of operation and depressurized!

Do not spill any oil!

Watch out for leakage!

The oil dosage is continuously variable at the adjusting knob.

* Turning the adjusting knob clockwise

(symbol »–«) will reduce the oil flow up to 0-quantity (i.e. no oil for tool lubrication in the compressed air).

* Turning the adjusting knob counterclockwise (symbol »+«) will increase the oil flow.

Fig. 56

* Shut down the screw compressor and wait until the compressor is depressurized.

* Unscrew the screw plug.

* The oil must be visible in the oiler reservoir; refill, if necessary (oil to be used: GARDNER DENVER AES 82).

* Check the seal of the screw plug, replace if required.

* Screw in the screw plug with the seal and tighten.

* Check for leaks after start-up of the screw compressor.

Key features

Compact size and portability
Durable construction and reliable performance
Easy maintenance and operation
California Proposition 65 Warning compliant

Frequently asked questions

It is not specified in the provided text.

Contact GARDNER DENVER S.r.l. at Via Tevere n°6, 21015 Lonate Pozzolo (VA) ITALIA, Tel. 0331.349411, Fax. 0331.301680, or via email at [email protected].

It is not specified in the provided text.