Koci Elektromaschinen KC 100 User manual

Kontakt:
Zittauer Straße 12 Tel. + 49 35844/ 70234 www.elektromaschinen-koci.de
O R I G I N A L
Operating Instruction
Compressor unit with direct current motor
KC 100 and KC 200
Manufacturer:
Koci Elektromaschinen GbR
Zittauer Straße 12
02796 Kurort Jonsdorf
Germany
Edition: 07.2016

Kontakt:
Zittauer Straße 12 Tel. + 49 35844/ 70234 www.elektromaschinen-koci.de
List of content
1. Introduction .................................................................................................................................. 1
1.1 Owner’s responsibility .............................................................................................................. 1
1.2 Copyright .................................................................................................................................. 1
1.3 General advices ....................................................................................................................... 1
EC – Declaration of Conformity ..................................................................................................... 1
2. Warranty and complaints ............................................................................................................ 2
3. Reference of utilization ................................................................................................................ 2
3.1 conventional utilization ............................................................................................................. 2
3.2 unconventional utilization ......................................................................................................... 2
4. Technical information about the compressor unit ................................................................... 3
4.1 Components account ............................................................................................................... 3
4.2 Technical description ............................................................................................................... 3
4.3 Technical Data ......................................................................................................................... 4
5. Commissioning ............................................................................................................................ 5
5.1 Location and assembly references .......................................................................................... 5
5.2 Installation – electrical ............................................................................................................. 6
6. Maintenance.................................................................................................................................. 8
General reference notes ................................................................................................................ 9
Compressor block .......................................................................................................................... 9
Cylinder head and valves .............................................................................................................. 9
Clean and replace air filter ............................................................................................................. 9
Maintenance of the bearings and carbon brushes of the DC motor .............................................. 9
Checking the safety valve ............................................................................................................ 10
Pressure container (accessory if requested) ............................................................................... 10
Performance check ...................................................................................................................... 10
Torque specification ..................................................................................................................... 10
Reference notes to anti-freeze pump .......................................................................................... 11
7. Safety regulations – environment protection .......................................................................... 11
7.1 Safety regulations .................................................................................................................. 11
7.2 Environment protection .......................................................................................................... 11
8. Troubleshooting ......................................................................................................................... 12
9. Storing & Transport ................................................................................................................... 13
10. Replacement parts ................................................................................................................... 13

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1
1. Introduction
These operating instructions are applicable for the compressor units KC 100 and KC 200.
Description: compressor unit with direct current motor
Type: ___________________________________
Machine no.: ___________________________________
Please read these operating instructions carefully to enable a safe operation.
1.1 Owner’s responsibility
These operating instructions are part of the product. The owner/ operator has to consider on own authority:
Operating and maintenance staff has access to these operating instructions always.
All advices and safety regulations have to be fulfilled during shutdown and operating.
These operating instructions have to be retained for further utilization.
1.2 Copyright
The duplication of text, technical data, drawings or similar is prohibited and demands the agreement of the
manufacturer.
Technical changes at the compressor unit stay reserved for the manufacturer.
1.3 General advices
The company Koci Elektromaschinen GbR determined that requirements regarding to spare parts and their
delivery, information for reparation or questions about technical issues of the compressor can be handled
only with the correct type or machine number.
If you did not purchase the compressor directly from the manufacturer please first contact your provider.
Additionally it is prohibited to remove the appliance rating plate.
EC – Declaration of Conformity

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2. Warranty and complaints
The legal foundation of our guarantee management is the German Civil Code. But please consider the
following regulations:
Work carried out on our compressors under guarantee is only done in our workshop as a matter of
principle because the machines are classified as easy to transport. In case of contact by others any
guarantee claim cannot be asserted.
Equally guarantee does not apply, if the compressor has been modified or altered without
consultation and approval by our company.
The guarantee is limited to the compressor only and includes material and manufacturing faults.
Faults resulting from natural wear and tear, improper use, installation or insufficient maintenance are
disregarded. Wear and tear elements are:
Solenoid discharge valve
Non-return valve
Pressure switch
Air filter
Fuse
Furthermore the tube cooler is excluded from guarantee in case of traceable use as carry handle,
what is not allowed and results destruction of itself.
We reserve the right to determine how and by whom the repairs are to be made.
Costs that may arise as an after-effect of the compressor’s breakdown will not be accepted by our
company.
3. Reference of utilization
3.1 conventional utilization
The compressor units with DC motor are designed for versatile applications in which a compressed air
supply is needed to permanent disposition.
The compressor is provided solely for production of compressed air. Any other use is considered improper.
The manufacturer is not responsible for any damages resulting from improper utilization – the risk carries
the operator by himself.
Correct use includes also the compliance with the manufacturer’s regulations of installation, operating and
maintenance.
3.2 unconventional utilization
The compressor unit must not be used in hazardous areas - it is not protected against explosions.
Without additional air treatment compressed air from oil lubricated compressors is not suitable for the filling
of breathing air equipment and use in dentistry or for operations where compressed air comes directly into
contact with food.
Compressed air must never be directed at people. The concentrated energy causes a life-threatening
situation.

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4. Technical information about the compressor unit
4.1 Components account
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
4.2 Technical description
The compressor unit with DC motor and control unit is a compact, powerful unit in block manner, which is
composed of two main parts, the single cylinder – compressor and the DC motor as a drive source.
Furthermore, we would like to mention following principal technical details that are integrated into the
compressor and contribute to increased safety and functionality.
General area: Area control block: Field electric machine:
intake silencer with air filter
4 rubber mounts for vibration
damping
tube cooler
compressed air tank/ pressure
container (delivery on request)
solenoid discharge valve1
pressure switch
non-return valve
safety valve
silencer for the discharge air
antifreeze pump with
antifreeze reservoir(installation
on request)
power relay
suppression equipment
thermostats
low voltage protection
operating voltage independent
of the control voltage
ensure a low control current
security protection by circuit
board against false engaging
from the outside of the
compressor
To ensure the electrical connection security and the corresponding control over the compressor, a control
light outside the device signals the respective operating.
An integrated momentum balance in the engine reduces vibration and provides a quiet and low-wear run.
For further noise reduction the compressor units are fixed on four rubber mounts and completed with an
intake silencer and an exhaust box on the discharge valve.
1 only compressors with antifreeze pump
1 oil filler neck
2 oil drain plug
3 oil level eye
4 air filter and intake manifold
5 pressure – adjustment screw
6 pressure switch
7 solenoid discharge valve1
8 antifreeze reservoir1
9 switch summer/ winter operation of
the antifreeze pump1
10 safety valve
11 adjustment screw for antifreeze1
12 non-return valve
13 cable entry for battery 31 -
14 main terminal negative 30 +
15 cable entry
16 fine-wire fuse 12 V or 24 V

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4.3 Technical Data
Compressor Unit KC 100/1.2.1
12 V 24 V 48 V 80 V 110 V
Max. working pressure: bar 10 10 10 10 10
Inlet volume: l/min 75 75 75 75 75
Effect. capacity 6 bar: l/min 52 52 52 52 52
Compressor speed: rpm 1500 1500 1500 1600 1600
Motor rating: kW 0,5 0,5 0,53 0,53 0,55
Power consumption: A 48 24 13 8 5,5
System of protection: IP 66 66 66 66 66
Shielded: yes yes yes yes yes
Oil filling: l 0,13 0,13 0,13 0,13 0,13
Weight: kg 20 20 20 20 20
Noise level: dB(A) 84 84 84 84 84
Dimension (LxWxH): mm 390x255x320 390x265x320
Compressor Unit KC 200/1.2.1
12 V 24 V 48 V 80 V 110 V
Max. working pressure: bar 10 10 10 10 10
Inlet volume: l/min 150 150 150 150 150
Effect. capacity 6 bar: l/min 104 105 105 106 106
Compressor speed: rpm 2400 2500 2500 2600 2600
Motor rating: kW 1 1 1 1,2 1,2
Power consumption: A 96 48 24 16 5,5
System of protection: IP 66 66 66 66 66
Shielded: yes yes yes yes yes
Oil filling: l 0,13 0,13 0,13 0,13 0,13
Weight: kg 25 25 25 25 25
Noise level: dB(A) 84 84 84 84 84
Dimension (LxWxH): mm 440x255x320 440x285x320

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5. Commissioning
5.1 Location and assembly references
Before the initial start-up the compressor unit must be screwed tightly on its location
The compressor unit must be protected from dust and dirt to ensure the conventional functionality.
The connection of the compressor should be chosen in accordance to the guidelines for the
installation of compressed-air lines with a slight incline towards the boiler.
Enough cooling should be provided.
In case of installation in a vehicle, the cooling direction must no work against the airflow.
The connection of the compressor unit should be done with a flexible hose connection.
Please use the rubber mounts for placement and storing.
The device has IP66 (splash-proof). So please protect the air supply (flexible hose connection
towards air filter) and all the other parts from intensive water contact.
The environment is not allowed to be humid or wet and no gases or liquids should be places nearby
the compressor.
under voltage protection and control light
1. Under voltage protection
The operator should provide an operating voltage between -10 % and +20 % of the rated voltage.
The following faults occur, when the operating voltage does not lie correctly:
a) The compressor cannot be switched on – Fault: operating voltage under -10% of rated voltage.
b) The compressor turns off automatically – Fault: operating voltage under -25% of rated voltage.
c) The compressor turns off automatically and can be switched on again only after the control
switched was turned off and a waiting time of about 10 seconds. – Fault: short interruption of
operating voltage or control line (loose connection).
A correct and safe operation is only guaranteed, when the connection follows the description of the
manufacturer or a confirmed (by the manufacturer) compliant circuit.
You have to be able to switch off the compressor at any time.
Any self-made changes in the original circuit during the legal warranty period cause an immediate
loss of any claims.
2. Control light
The control switch and light have to be installed within the operator’s viewing area.
An illumination of the control light indicates:
Loose connection – Motor turns off automatically
excess temperature – Motor turns off automatically and can be switched on after its cooling (ca. 45
min).
Please always investigate the reason of an occurring fault or glowing control light and arrange quick
remedy to avoid consequential damages.

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5.2 Installation – electrical
It is the responsibility of the operator/ owner to ensure that the compressor is wired professionally. Any
electrical work should be carried out by a competent electrician and installed to meet all applicable local
and national codes and regulations.
Therefore please read the following regulations carefully:
Current, voltage and polarity of the power system must match the information on the appliance rating
plate of the motor.
The fuse regarding to the control lead should have (61) 2A.
safety fuse in the lead-in:
12 V 24 V 48 V 80 V 110 V
KC100/1.21 80 A 40 A 16 A 10 A 10
KC200/1.21 150 A 80 A 40 A 20 A 16
The cross-sectional area of the lead-in must be chosen in such a way that, when the compressor is
operating, the voltage on the terminal board or power relay does not fall below the necessary
operating voltage. (12, 24, 48 or 80 V)
Cu wire in mm²:
Cu wire Cu wire > 1m length
KC100/1.21 12V 10,0 16,0
KC100/1.21 24V 6,0 10,0
KC200/1.21 12V 25,0 35,0
KC200/1.21 24V 10,0 16,0
KC100/1.21 48V 2,5 4,0
KC100/1.21 80V 1,5 2,5
KC200/1.21 48V 2,5 4,0
KC200/1.21 80V 2,5 4,0
KC100/1.21 110V 1,5 2,5
KC200/1.21 110V 2,5 2,5
The control 61 and KK can have at maximum a 0,75mm² Cu wire.
The oil level on the compressor block must be checked. The oil level must be within/ at the red circle
of the oil level eye.
Regulation:
The compressor is regulated automatically by means of a pressure switch depending on the compressed
air requirements. After the system has been switched on for the first time, the pressure switch controls the
compressor’s operating corresponding to the set pressure.
Pressure switch settings made at the factory
max. operational
excess pressure
pressure switch - off
excess pressure
pressure switch – on
excess pressure
10 bar 8 – 9 bar ca. 7 bar

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Connection plug – cable installation – control line
view of cable or solder side
BLUE
YELLOW
GREEN
RED
control switch with control lamp
anti-rotation
element
31a ground for control
lamp, etc.
KK
compressor control
normal operation – dimly illuminated
case of fault – brightly illuminated (low voltage)
61
feed of the control voltage from the
alternator control lamp cable.
Or, if no alternator control lamp cable is used,
from ignition lock switch via control switch.
D
feed to the control switch if the
alternator control lamp cable is not used
D
(RED)
or optional if D is
not used, the cable must
be insulated as it carries
voltage from the
compressor
D+ (RED)
control lamp
cable from
vehicle
alternator
61 (GREEN)
feed of the control voltage to the
compressor
31a (BLUE) ground for compressor control
KK
(YELLOW)
compressor control carries
voltage during operation in case of fault

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KC 100 and KC 200 48 V and more
jack in compressor for main cable entry
jack in compressor for control lead
anti
-
rotation
negative max. 4mm² (blue, black or brown)
positive max. 4mm² (red)
anti
-
rotation element
D carries voltage during operation (red)
31a ground for control lamp, etc. (blue)
KK
control lamp (yellow)
carries voltage during normal operation
and in case of fault
61 feed of the voltage to the switch (green)

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6. Maintenance
We advise the owner/ operator of the following maintenance guideline that have to be kept necessarily.
General reference notes
Please be sure that the compressor unit is switched off completely. Pressure leading lines have to be
exhausted – drain the pressure in the container. Work on power-operated equipment must be carried out
only by trained personnel or by specialists.
Compressor block
Check the oil level every six months – the oil level is not allowed to fall below the red circle in the oil level
eye.
Attention:
If the oil level has dropped below the lower mark, oil must be refilled necessarily as it is
determined by the oil regulations. Under no circumstances should more oil be filled than
displayed in the max. oil level of the oil level eye.
Switch off the compressor.
Do an oil change every 500 operational hours or at least once per year.
Unscrew the oil drainage screw and drain off all the oil in warm condition.
Collect the oil in a receptacle and dispose of it correctly.
The casing should be rinsed out with a small amount of new oil and then fill up with new oil.
If due to unfavourable operating conditions water is discovered in the oil – this can be identified by a
milky coloration in the oil level eye – the oil must be changed immediately.
Please consider using a sieve or the original can when refilling the oil.
Oil regulation: motor – Oil SAE 5 W30
Cylinder head and valves
The cylinder head is to be unscrewed after 3.000 operating hours, the function of the valves is to be
checked and please clean the plate of the valve.
Complete valve plates and/ or cylinder heads can be delivered from store.
The compressor should be rebuilt after about 10.000 operating hours.
Clean and replace air filter
The changeable insert in the air filter cap and the filter itself are made of foam or felt material.
The filter should be replaced if a notable layer of dust is discovered on the filter or after 500 operating
hours at least.
Maintenance of the bearings and carbon brushes of the DC motor
The motor bearings are permanently lubricated and do not require re-lubrication.
Under normal operating conditions, with system and surrounding temperatures of about 25 °C, the
bearings should be replaced by new ones after about 10.000 hours of operation (rebuild).
Increased wear of the bearings is to be expected if the surrounding temperature is much higher,
approx. 40 °C, whereby changing the bearings is recommended after about 5.000 operating hours.
The bearings should be replaces after three years regardless of the number of operating hours.
After 1.500 operating hours the dc motor should be cleaned inside. Please make a visual inspection
of the carbon brushes in that case.
The carbon brushes are to be replaced as needed by the manufacturer or a specialist.
If the commutator has shrunk considerably or if it is no longer round, it is necessary to rework this
by the manufacturer or a specialist.

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Checking the safety valve
If the maximum permissible operating pressure (10 bar) is exceeded in the pressure container, the
safety valve opens and ejects the excess air (at 11 bar) in order to protect the compressor and the
compressed air user attached to it.
The safety valve must be bled occasionally in order to prevent the valve seat sticking.
A defect safety valve has to be replaced completely.
The compressor must be switched of thereby and the compressed air reservoir emptied.
Attention: Interventions in the controls are prohibited as such action cancels any liability.
Pressure container (accessory if requested)
The condensed water that gathers in the pressure container must be drained off every day using
the condensed water drainage tap.
Leaky pipe connections can lead to extensive loss of pressure.
Occasional tightening of the pipe connections in necessary to prevent loss due to leakage.
Performance check
The effective performance of the compressor can be checked by measuring the compressed air reservoir
filling time:
Switch off the compressor.
Close the compressed air reservoir.
Release container pressure using condensation drainage tag and then close it again.
Switch on the compressor and simultaneously check the refill time until excess pressure and
compare it with the table.
Filling time in seconds (ca.) for 10-litre pressure container with the conditions of a constant
voltage. (1 V deviations are about 100 rpm)
Typ 3 bar 6 bar 8 bar 10 bar
KC100/1.21 12V 24V 30 60 90 120
KC100/1.21 48V 80V 28 55 80 115
KC100/1.21 110V 28 55 80 115
KC200/1.21 12V 24V 20 35 50 65
KC200/1.21 48V 80V 20 35 50 65
KC200/1.21 110V 20 35 50 65
Torque specification
Please consider the following torque specifications during maintenance or assembly of replacement parts:
E-connections KC 100 M5 3Nm
E-connections KC 200 M8 10Nm
oil drain plug 15 Nm
oil level eye 2 Nm
cylinder head and
cylinder M6 15 Nm
bearing shield and
crankcase M5 5 Nm
blower wheel M6 3 Nm
rubber mount 20 Nm
cam plate M8 30 Nm
lid beneath M5 2 Nm

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Reference notes to anti-freeze pump
Your new compressor is equipped optionally with an anti-freeze pump that includes an anti-freeze
reservoir.
Please use the following notes to ensure the correct functionality of this equipment:
Anti-freeze: You can use a standard commercial anti-freeze.
Switching over the pump: (from winter to summer operation)
The pump can be switched from winter to summer operation of the compressor.
Blue – winter operation: slide to the right
Red – summer operation: slide to the left
Attention: Do not switch over when the compressor is working!
Setting the anti-freeze pumping capacity
The pump is set to the min. anti-freeze pumping capacity. Depending on the weather conditions the pump
can be set to a higher capacity by turning the adjusting screw (M6 hex socket screw) more toward the
outside.
Attention: First loosen the securing nut – then adjust the adjusting screw – then tighten the
securing nut again.
7. Safety regulations – environment protection
Explanation of the compressor’s danger sign:
Caution: Hot surface – Please touch only with safety gloves!
7.1 Safety regulations
The European standards provide the most important regulation that the owner/ operator has to care
about.
Furthermore we recommend considering the following:
Be sure that no flames or sparks appear in the surroundings of the compressor.
It is not allowed to switch on the compressor without the fan cover as protection from rotating parts.
The fan cover hast to be screwed tightly after any maintenance or reparation.
Ensure that the compressor only intakes clean air without any detrimental mixture.
Never use the tube cooler as carry handle because of possible damage (breakage) increasing the
loss of performance and possibility of injuries.
During operation of the compressor, the tube cooler’s surface is very hot – only touch with safety
gloves.
7.2 Environment protection
Replacement parts, operating and auxiliary materials are to be disposed of according to the
corresponding environmental regulations.

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8. Troubleshooting
Before you start working on the compressor and its electrical system, be sure that it is turned off
completely and can not be switched on again/ by accident. Check professionally that the compressor
carries no voltage.
Work on the compressor must be carried out only by trained personnel or by specialists.
Where is the fault? Fault and remedy
Operating voltage to contact terminal Pre-fuse is defective, change fuse,
30 relay (+), D+ (61) no control voltage – (31), no voltage from the alternator,
control light is not on Check alternator, not properly connected,
Check electrical system on the vehicle!
Operating voltage to contact terminal 30 relay (+), Check Fuse F1, change fuse,
No operating voltage to Plug D (Fuse F1) Bend contacts in fuse holder,
– (31), control light is not on no voltage from alternator,
not properly connected,
Check electrical system on the vehicle!
Operating voltage to contact terminal 30 relay (+), Defective control switch,
operating voltage to plug D ( Fuse F1), not properly connected,
No voltage at Plug 61 left plug under check circuit against circuit diagram.
Fuse F1 in connection box, Check electrical system on the vehicle!
control light is on - dim
Operating voltage to contact terminal 30 relay (+), Power contact on power relay (K1)
operating voltage at Plug D (Fuse F1), no flow-through,
no voltage at Plug 61 left plug Exchange power relay (K1).
under Fuse F1 in connection box, operating voltage
at power relay (K1) on,
control light is on – dim
Operating voltage to contact terminal 30 relay (+), Control voltage too low < 75%
operating voltage at Plug D (Fuse F1), of operating voltage
voltage at Plug 61 – left Plug under Check electrical system on the vehicle,
Fuse F1 in connection box, increase control voltage!
control light is on – bright
if control voltage < 90% of operating
voltage the controls function again,
motor can be switched on again.
Switch off control switch and switch
on again after c. 15 seconds.
If motor doesn't run:
please send in for repair!
Motor sometimes switches off but can be Loose contact – check fault on controls
switched back on after a short while. Automatic reconnection lock has been
triggered.
Check electrical system on the vehicle!
Switch off control switch and switch
on again after c. 15 seconds.
Compressor running too slowly, not enough power, Operating voltage at terminal 30 relay (+)
check operating voltage at contact terminal 30 contacts terminal 31 (-) at motor
relay (+) on. if voltage drop at the cable, use cable
of greater sectional diameter.
Check electrical system on the vehicle!

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Compressor running, not enough power, Safety valve won't close,
operating pressure not achieved, Screw Pos. 11 (undo brass screw on the
when the compressor has switched off, air escapes front of the control block SW 24),
at noise absorber clean relief valve and seat and
check for damage –
put back together again,
If there is damage: renew valve cone or
send control block in for repair.
Compressor running, not enough power, Relief valve won't close,
operating pressure not achieved, Remove aluminium cap on the left side of the
during operation air escapes control block (unscrew), check voltage at the
at noise absorber (underside of control block – coil, if there is voltage,
left next to the safety valve) exchange defective coil,
If no or too little voltage:
Send compressor in for repair.
Compressor running, not enough power, clean relief valve
operating pressure not achieved, dismantle relief valve with coil,
during operation air escapes clean valve cone and seat, check for
at noise absorber damage and put back together again.
If there is damage:
exchange relief valve or send control block
in for repair.
control light on – bright Triggered by temperature sensors.
After longer operation motor becomes very hot and Send compressor in for repair.
switches off, motor can only be switched on Not enough cooling
again after a longer period (c. 1 hour).
Safety valve discharges at a pressure under Safety valve is defective
11 bar. Change safety valve.
Compressor does not work at all – main fuse Motor or compressor may had to work under
is faulty. Pressure. Solenoid discharge valve,
Please first investigate the reason before non-return valve are damaged.
replacing the fuse.
If there are any faults not appearing in this table or that you cannot repair, please do not hesitate to
contact our company.
9. Storing & Transport
The storage should be dry to avoid corrosion.
Temperatures under 0 °C could damage the compressor, if water would remain in the inside.
During the transport the compressor must be standing.
It must be screwed tightly on the four rubber mounts.
Use a wood pallet to give more stability.
Never let oil drain out of the compressor during the transport.
10. Replacement parts
With spare parts requirements please contact our company to enable the fastest possible processing.
This manual suits for next models
1
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