Table of Contents
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MAINTENANCE AND OPERATING MANUAL
EDITION
MANUFACTURED
BY
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:
Cod. 100016705
FROM
TO
G D P 2 1 – G D P 3 1
COMPRESSOR DATA PLATE – INFORMATION
03/09
GARDNER DENVER S.r.l.
Via Tevere n°6
21015 Lonate Pozzolo (VA) ITALIA
Tel. 0331.349411 – Fax. 0331.301680
e-mail: bottarini@gardnerdenver.com
www.bottarini.it
RIF. 03
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Table of Contents
Troubleshooting
Summary of Contents for Bottarini GDP21
- Page 1 REFERENCES. FOR ALL THE INQUIRES, PLEASE COMMUNICATE THE TYPE OF THE UNIT AND THE SERIAL NUMBER THAT CAN BE FOUND ON COMPRESSOR INFORMATION PLATE. GARDNER DENVER S.r.l. Via Tevere n°6 FOR INFORMATION AND SPARE-PARTS: 21015 Lonate Pozzolo (VA) ITALIA Tel. 0331.349411 – Fax. 0331.301680 e-mail: bottarini@gardnerdenver.com www.bottarini.it...
- Page 2 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.
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Page 3: Table Of Contents
1. Index Index ............................................1 Foreword ..........................................3 Information on the compressor ..................................3 Normal use ........................................3 Specifications ........................................ 4 Maintenance and care ....................................7 General information ...................................... 7 Security Regulations ......................................8 Identification of safety instructions................................. 8 General safety instructions ..................................8 Modifications and alterations to the machine ............................ - Page 4 1. Index 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) ..........................
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Page 5: Foreword
2. Foreword You do not comply with the safety 2.1 Information on the instructions compressor You do not observe the information in GARDNER DENVER screw compresso- the operating manual rs are the product of many years' research For this reason every person involved in and development. -
Page 6: Specifications
Engine temperature speed min. max. min. max. [m above /min] [barg] [barg] [°C] [°C] [kw] [rpm] [rpm] sea level] GDP21 5.0-8.0 - 10 + 45 1000 D1105 Water 16.3 2000 2700 40.0 5.0-8.0 - 10 + 45 1000 22.7 1800 2700 40.0... - Page 7 2. Foreword Chassis height-adjustable, braked Fig. 2 Chassis height-adjustable, unbraked Fig. 3 Chassis rigid, unbraked Fig. 4...
- Page 8 2. Foreword Chassis rigid, braked Fig. 5...
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Page 9: Maintenance And Care
2. Foreword This fact results in the termination/ 2.4 Maintenance and care 2.5 General information expiration of the guarantee and warranty claims against the manufacturer. Care and maintenance are all-important This operating manual is to help you to if the screw compressor is to meet the get to know the compressor and to use it demands placed upon it. -
Page 10: Security Regulations
3. Security Regulations working. This applies particularly to Define who is responsible for operating 3.1 Identification of safety personnel only using the machine the machine, and authorize him to ignore instructions occasionally, e.g. for setting up and instructions from third parties if these maintaining the machine. -
Page 11: Installation On Site / Starting / Normal Operation
3. Security Regulations For lifting machines or parts of machines Transporting the complete unit 3.5 Installation on site / Starting / with one or more lifting eyes, only hooks Normal operation Make sure that the air vessel is not or shackles complying with local safety under pressure. - Page 12 3. Security Regulations Install the machine so that it is as Take the necessary precautions to make Never use the machine in environments sure that the machine / installation is only horizontal as possible; a slight inclination where the possibility cannot be ruled out operated in a safe, functional condition.
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Page 13: Special Jobs / Maintenance
3. Security Regulations Check the machine / installation for Whenever the machine/system is com- The personnel have to support all measures to improve safety at work. external damage and faults at least once pletely powered down for maintenance per shift. Any changes noticed (including and repair procedures, it has to be Safety devices for preventing or changes in operating performance) must... -
Page 14: Instructions Concerning Particular Hazards
3. Security Regulations Never use solvents with dangerous If work causing heat, flames, or sparks Safety precautions for work with properties for cleaning parts. has to be carried out on a machine, the batteries surrounding components must be Maintenance work, tests, and repairs The fluid contained in batteries is diluted protected with nonflammable material. -
Page 15: Symbols And Definitions
3. Security Regulations Machine and system parts where Follow the local regulations applicable 3.8 Symbols and definitions service, maintenance, and repair work is at the respective site of installation. being carried out must be switched off load, if required by regulations. First check Hydraulic and pneumatic systems the deenergized parts to make sure they are off load, then connect to ground and... - Page 16 3. Security Regulations Options Caution: Caution: Vessel Pressure vessel is pressurised Hoisting point Condensation drain from after-cooler or from after-cooler with subsequent filtering Check filling Observe the level operating instructions Tie down point Bleed water from the pressure vessel after every 24 operating hours or if the water ratio is too high Caution: Protect from wetness.
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Page 17: Construction And Functional Description
4. Construction and functional description Fig. 7 Fuel filter including drain valve Fuel line filter 10 Fuel tank 20 Suction controller 1 Instrument panel 11 Crane ring 21 Pressure tank 2 Taps 13 Air filter 22 Pressure retaining non-return valve Hood 14 Battery 23 Compressor... -
Page 18: Construction
4. Construction and functional description When the preset operating pressure is 4.1 Construction 4.2 Functional description exceeded the P controller (21) of the control (see fig. 8) unit feeds control air to the adjusting Compressor and engine cylinder (4) of the engine speed Oil circuit The core of the sound proofed mobile adjustment system and the intake suction... -
Page 19: System Description
4. Construction and functional description Oil filter – compressor oil Controller unit / relief valve 4.3 System description Temperature switch Solenoid valve 13. Orifice, evacuation line Oiler option Air filter 14. Oil cooler – compressor oil 25. Oiler reservoir Diesel engine 15. -
Page 20: Wiring Diagram
4. Construction and functional description 4.4 Wiring diagram Engine monitoring unit Generator Generator controller Starter Lifting magnet Generator controller Solenoid valve Generator Solenoid valve Pre-heating Motor Compressor Fuel Solenoid Fuel pump pressure temperature temperature shortage valve pressure relief (option) generator idling autom. -
Page 21: Vehicle Socket Connection Plan 13-Pin 12 Volt
4. Construction and functional description 4.5 Vehicle Socket Connection Plan 13-pin 12 Volt Towing vehicle Towed vehicle Indicator left yellow Indicator left Fog tail lamp blue Fog tail lamp Mass for contacts 1-8 white Mass for contacts 1-8 Indicator right green Indicator right Tail light right... -
Page 22: Transport And Installation On Site
5. Transport and installation on site Replacing the trailer coupling ring The contact-breaking cable is 5.1 Transport connected to the towing vehicle. Safety The coupling arrangements which can chains are attached on towing vehicle. Transport safety locking of the towing be used: arrangement The electrical cable (option) is... -
Page 23: Loading/Relocation
5. Transport and installation on site Never relocate the machine if external 5.3 Loading/Relocation 5.4 Installation on site 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... - Page 24 5. Transport and installation on site Attention Attention The screw compressor is to be set up No force may be exerted on the dis- in such a way that no air reflection can charge valves, for example by pulling take place, i.e. neither waste air nor the hoses or fitting additional exhaust emissions may be drawn in;...
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Page 25: Preparing The Compressor For Operation
6. Preparing the compressor for operation 6.1.2 Checking the oil level in the 6.1.3 Checking coolant level Danger engine 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. -
Page 26: Battery
6. Preparing the compressor for operation More information on fuel quality, see 6.3 Filling up the fuel tank 6.2 Battery 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. -
Page 27: Putting The Compressor Into Operation
7. Putting the compressor into operation 7.2 Operating elements 7.3 Start-up 7.1 Initial operation Operating panel: Transport inspection Danger Every GARDNER DENVER screw Before starting up, make sure that no compressor has already run in the factory one is in the danger area of the engine and has already undergone a thorough / screw compressor. -
Page 28: Setting The Operating Pressure
7. Putting the compressor into operation Starting up the compressor: Start-up using jumper cables / auxiliary 7.4 Setting the operating pressure batteries 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. -
Page 29: Monitoring / Fault
7. Putting the compressor into operation * Turn off power to the system using the 7.5 Monitoring / fault 7.6 Operation main switch. Danger Danger After the installation has come to a standstill all the air is automatically blown Interference with the automatic Only operate the compressor at the out of the pressure tank via the blow-off monitoring system is not permitted. -
Page 30: Fuel
GARDNER 21015 Lonate Pozzolo (VA) ITALIA lubricant. DENVER oil AES 82. Tel. 0331.349411 – Fax. 0331.301680 e-mail: bottarini@gardnerdenver.com Attention The special advantages of GARDNER www.bottarini.it DENVER oil are as follows: Do not mix oils of different or your authorized dealer or your local specifications. -
Page 31: Diesel Fuel
8. Fuels 8.6 Recommended lubricants for 8.4 Diesel fuel 8.5 Coolant the bogies Use common diesel fuel with a sulfur Attention content of less than 0.5 %. If the sulfur For relubrication use only lithium content is higher, oil has to be changed at Only operate the engine with coolant saponified grease which fulfils the (water with corrosion protection/... -
Page 32: Maintenance
9. Maintenance 9.2 Engine maintenance 9.3 Maintenance of the fuel 9.1 General maintenance system The maintenance of the engine is to be Danger carried out in accordance with the engine operating manual. Install a "Caution maintenance work" warning sign and cordon off a wide Attention area around the workplace before starting any work. -
Page 33: Maintenance Of Chassis And Brakes
9. Maintenance Emptying the fuel/water separator (4) 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... -
Page 34: Compressor Maintenance / Maintenance Schedule
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) -
Page 35: Oil Filter Replacement (Compressor)
9. Maintenance * For lubricants see “Lubricant Table” 9.5.1 Oil filter replacement 9.5.2 Oil change (compressor) (compressor) * 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 9.5.3 Checking the automatic... -
Page 36: Inspecting / Replacing The Fine Separator
9. Maintenance Fit the lid. Insert the hexagon screws 9.5.4 Inspecting / Replacing the Danger and tighten them across the diagonal fine separator (tightening torque see Chapter 9.5.9 Never clean the air filter cartridge with "Torque specifications"). inflammable liquids. Check for leakage. Reassembling the air filter: Dispose of the old fine separator cartridge in the specified manner. -
Page 37: Control
Identification No. 24 months, whichever occurs first, and fill up with distilled water if necessary. Service Package 1000 h A19052574 GDP21-GDP31 For battery maintenance please also refer to the manufacturer’s instructions Service Package 1000 h A19051574 and the engine operating manual. -
Page 38: Troubleshooting
10. Troubleshooting Problem Possible cause(s) Correction Insufficient or no air supply Clogged air filter Clean air filter Set speed Screw compressor engine speed misadjusted Clogged oil fine separator filter cartridge Replace compressor oil, oil filter and oil fine separator filter cartridge Wrong setting at controller Adjust Clean, replace parts if necessary, readjust... - Page 39 10. Troubleshooting Problem Possible cause(s) Correction Engine starts but switches off again V-belt defective Replace immediately, or the system switches off Oil pressure switch/engine defective Replace while running Oil temperature switch defective Replace Engine temperature switch defective Replace Compressor defective Check Replace or plug onto sensor Cable defective or cable cover not plugged...
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Page 40: Generator Option
11. Generator option generator with high-pressure The stability of the output frequency is 11.1 Introduction equipment. entirely dependent on that of the speed of the combustion engine. You must there- This manual describes the operation * Generators may only accept up to fore ensure that this engine is serviced, and maintenance of synchronous their nominal load if operated... -
Page 41: Operating The Generator (Working Safely With Electrical Equipment)
11. Generator option The generator must not be used to inject The distribution systems (e.g. extension 11.4 Operating the generator power into a construction site distribution cables, device leads) must be carefully (Working safely with electrical system. chosen, laid and maintained. Check the equipment) electrical cables regularly, replacing rather To avoid unwanted interaction, do not... -
Page 42: Testing Insulation Monitoring / Startup / Device Connection
11. Generator option Setting the range switch Note that the starting consumption of Danger devices driven by electric engines is Turn the range switch to the required generally a multiple of the specified Unchecked devices may endanger position: rating. If in doubt, it is advisable to personnel on startup, and may be contact the equipment manufacturer 1st position:... -
Page 43: Technical Characteristics Of 110V 6Kva Gts Generator
11. Generator option Efficiency at nominal output 11.7 Technical characteristics of at 0.8 ind 0.80 400/230V 5/8kVA GTS at 1.0 0.82 generator Distortion factor < 5% Generator model..DWG 8/5-2-ZE Weight 53 kg Generator type... Synchronous, Overall size BG132 internal pole, Overall length 357 mm electronically... -
Page 44: Technical Characteristics Of 110V 7Kva Kwg Generator
11. Generator option Switchbox Switchbox 11.8 Technical characteristics of Degree of protection IP 54 Degree of protection IP 54 110V 7kVA KWG generator Dimensions 250x204x135mm Dimensions 255x205x134mm Design Front panel type Design Front panel type Generator model KWG-110/2-Z11-102 Fusing All poles Fusing All poles Generator type... -
Page 45: Technical Characteristics Of 400/230V 8Kva Kwg Generator
11. Generator option 4 pole black switch contact 11.9 Technical characteristics of black switch contact 400/230V 8kVA KWG not assigned generator not assigned Generator model KWG-110/2-Z11-001 Generator type Synchronous, internal pole, brushless with exciter, electronically controlled Generator frame B3/two bearings Degree of protection IP 54 Generator characteristics: Extremely low dynamic internal resistance,... - Page 46 11. Generator option type Fusing All poles AS16A 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 Activation < 75W Time to speed reduction 100 seconds Outputs Output for speed reduction...
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Page 47: Generator Switchbox Wiring Diagram Gts 110V 6Kva
11. Generator option 11.10 Generator switchbox wiring diagram GTS 110V 6kVA PROTECTIVE ISOLATION WITH INSULATION MONITORING K = OPERATING CURRENT CIRCUIT BREAKER AND FUSING/CIRCUIT BREAKING FOR ALL POLES H =INSULATION FAULT INDIC ATOR LAMP R = GMW/ISO INSULATION MONITOR P = TEST BUTTON 6-PIN CONNECTOR CONTACTS VIEW MODE SELECTOR SWITCH... -
Page 48: Generator Switchbox Wiring Diagram Kwg 110V 7Kva
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... -
Page 49: Troubleshooting
11. Generator option 11.14 Troubleshooting Sockets dead Has insulation Unplug Plug in devices Is insulation Reset the circuit- monitor released? connected one after the monitoring still breaker (indicator lamp lit) devices other enablend? Connected devices are faulty Unplug Does fuse Has fuse blown? connected still blow? - Page 50 11. Generator option Problem Possible cause(s) Correction The generator supplies no or insufficient The generator circuit breaker has tripped due to Check electrical load output. voltage. overload or is defective. Check that all electrical terminals are properly seated. Check generator protective switch and replace if required.
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Page 51: Safety Regulations For The Use Of The Heat Exchanger
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. -
Page 52: Compressed Air Processing Option (After Cooler / Heat Exchanger)
12. Heat exchanger option 13. Compressed air processing option (After cooler / Heat exchanger) In an air cooler (on the cooling air intake 13.1 Safety regulations for side), the compressed air is cooled down to alternate compressed air a temperature close to the prevailing processing ambient air temperature downstream of the pressure vessel. -
Page 54: Oil Temperature Controller Option
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. -
Page 55: Introduction
15. Undercarriage 15.3 KHV7,5 height-adjustable 15.4 Braking system 15.1 Introduction towing system, model B 3.5.13 Introduction Attention The adjustable joint between the * KNOTT over-run brake systems consist The user forfeits all rights to claim if drawbar and intermediate arm, and of over-run hitches and wheel brakes parts other than those of the between the overrun system and... -
Page 56: Adjusting The Braking System
15. Undercarriage Over-run hitches 15.5.2 When the brake is correctly adjusted, Preliminary requirements: the actuating travel of the control cable KNOTT over-run hitches are available When carrying out adjustments, always [11] will be 5-8 mm. for both hydraulic and mechanical brakes. start with the wheel brakes. -
Page 57: Adjusting The Brake Linkage [6]
15. Undercarriage If necessary, adjust the position of the 15.6 Readjusting the braking 15.7 Maintenance and care balance [10] and control cables [11]; in system the case of tandem trailers, also adjust KNOTT – overrun systems the master compensator [9] on the In general, readjusting the wheel brakes The overrun system must be lubricated linkage [6]. -
Page 58: Malfunctions And Remedies
15. Undercarriage Information regarding dual-row angular 15.8 Malfunctions and remedies bail bearings: Danger * These bearings are maintenance-free, have been provided with a lifetime Works on the brake system may only lubrication. and have an extremely high be carried out in specialized running performance. - Page 59 15. Undercarriage Malfunction Cause Remedy Insufficient braking effect Excessive backlash in brake system Re-adjust brake system Brake linings not "run in" Actuate hand-brake lever slightly; drive 2-3 kilometers Brake linings glazed, oily or damaged Replace brake shoes completely; clean braking areas in the brake drums Overrunning hitch hard to operate Grease overrunning hitch...
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Page 60: Tool Oiler Option
16. Tool oiler option Check the oil level in the depressurized tool oiler Fig. 55 Attention Fig. 56 Do not run the machine with an empty * Shut down the screw compressor and oiler tank! The tank must always wait until the compressor is contain a minimum of 0.2 l of tool oil.
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