MAHLE EV-1 User manual

OPERATION MANUAL
EV-1
EXHAUST VENTILATION SYSTEM
MAHLE A FTERMARKET I NC ., S ERVICE S OLUTIONS
10 Innovation Drive
York, Pennsylvania 17402 USA
717-840-0678 or 800-468-2321
www servicesolutions mahle com
035-81051-00 (REV A)

Page 1 of 7
T ABLE OF C ONTENTS
A CCEPTANCE OF G OODS 2
D ESCRIPTION OF G OODS 2
S PECIFICATIONS 2
G ENERAL S AFETY R ULES 3
H OW TO P REPARE THE UNIT 4
A DDITIONAL I NSTRUCTIONS 5
F USE R EPLACEMENT 5
C LEANING & M AINTENANCE 5
P ARTS L IST 6
W IRING D IAGRAM 7
ARNING!
R EAD CAREFULLY EACH SECTION SIGNED ITH THE SYMBOL FOR MACHINE
AND UNIT SAFE ORKING CONDITIONS
S UPPLY SYMBOL
D O NOT OPEN , SUPPLY AT 110 VOLTS .

Page 2 of 7
ACCEPTANCE OF THE GOODS
U PON ARRIVAL , IT IS NECESSARY TO CHECK THE QUANTITY COMPLIANCE OF THE EV-1 WITH THE BILL OF LADING
OR INVOICE AND PACKING CONDITIONS TO AVOID THE RELEASE WITH DAMAGE WHICH OCCURRED DURING THE
TRANSPORT I F DAMAGE HAS OCCURRED , HAVE THE FORWARDER APPLY A RESERVE ON YOUR DOCUMENTS FOR
THE DAMAGES AND CONTACT MAHLE O NLY BY OBSERVING THESE FEW RULES , WILL IT BE POSSIBLE TO REPAIR
OR REPLACE DAMAGED PARTS
DESCRIPTION OF THE GOODS
T HIS EQUIPMENT IS FOR THE VENTILATION OF THE EXHAUST GAS OF CARS AND SMALL TRUCKS T HE UNIT IS
EQUIPPED WITH A SLIDING SYSTEM WHICH ALLOWS HEIGHT ADJUSTMENT BETWEEN 8 5 IN (22 CM ) AND 35 5 IN
(90 CM ) T HIS ADJUSTMENT AUTOMATICALLY LOCKS ONCE THE OPERATOR RELEASES THE ADJUSTMENT LOCK
HANDLE A FURTHER MECHANICAL BRAKING DEVICE IS INSTALLED WHICH , IN CASE OF ADJUSTMENT LOCK
FAILURE , DOES NOT PERMIT THE ENTIRE MOTOR UNIT TO DROP COMPLETELY E XHAUST FUMES ARE
DISCHARGED , WITHOUT BEING FILTERED , THROUGH A HEAT RESISTANT HOSE MAX 250
0
F (125° C)
E XHAUST FUMES DO NO COME IN CONTACT WITH THE ELECTRIC MOTOR OR OTHER ELECTRICAL COMPONENTS ,
THUS AVOIDING RISK OF EXPLOSION DUE TO ACCIDENTAL INTAKE OF UNBURNED FUEL OR GAS T HE MACHINE
MUST BE USED ONLY FOR THE AFOREMENTIONED PURPOSE O NLY CORRECT USE OF THE UNIT WILL GRANT A
PROFITABLE RESULT R EAD THIS OPERATION MANUAL CAREFULLY AND READ IT AGAIN EVERY TIME THERE ARE
MACHINE PROBLEMS OR DIFFICULTIES DURING USE
S PECIFICATIONS
W
WW
W IDTH
IDTH IDTH
IDTH 22
2222
22 IN
ININ
IN (55
(55(55
(55 CM
CMCM
CM )
))
)
L
LL
L ENGTH
ENGTHENGTH
ENGTH 22
2222
22 IN
ININ
IN (55
(55(55
(55 CM
CMCM
CM )
))
)
H
HH
H EIGHT
EIGHTEIGHT
EIGHT 40
4040
40 IN
ININ
IN (100
(100(100
(100 CM
CMCM
CM )
))
)
W
WW
W EIGHT
EIGHT EIGHT
EIGHT 73
7373
73 LBS
LBSLBS
LBS (33
(33(33
(33 KG
KGKG
KG )
))
)
E
EE
E LECTRICAL
LECTRICAL LECTRICAL
LECTRICAL S
SS
S UPPLY
UPPLYUPPLY
UPPLY 110
110110
110 VOLTS
VOLTSVOLTS
VOLTS
P
PP
P OWER
OWEROWER
OWER 3
33
3/
//
/4
44
4 HP
HP HP
HP (0 55
(0 55(0 55
(0 55 KW
KWKW
KW )
))
)
A
AA
A-
--
-W
WW
W EIGHTED SURFACE NOIS
EIGHTED SURFACE NOISEIGHTED SURFACE NOIS
EIGHTED SURFACE NOISE RATING
E RATINGE RATING
E RATING C
CC
C ORRECTED
ORRECTED ORRECTED
ORRECTED L
LL
L P
PP
P A
AA
A =
==
= 73
7373
73 D
DD
D B
BB
B (A)
(A)(A)
(A)
W
WW
W ORKING TEMPERATURE
ORKING TEMPERATUREORKING TEMPERATURE
ORKING TEMPERATURE M
MM
M INIMUM
INIMUM INIMUM
INIMUM 23
2323
23
0
00
0
F
FF
F (
((
(-
--
-5°
5°5°
5° C)
C)C)
C) M
MM
M AXIMUM
AXIMUM AXIMUM
AXIMUM 120
120120
120
0
00
0
F
FF
F (49
(49(49
(49
0
00
0
C)
C)C)
C)
F
FF
F USE
USE USE
USE (2)
(2)(2)
(2) 0 39
0 390 39
0 39 X
X X
X 1 49
1 491 49
1 49 IN
ININ
IN (10
(10(10
(10 X
X X
X 38
3838
38 MM
MMMM
MM )
))
) 16
1616
16 A
AA
A MP TIME DELAYED
MP TIME DELAYED MP TIME DELAYED
MP TIME DELAYED 500
500500
500 VAC
VACVAC
VAC

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GENERAL SAFETY RULES
T HE FOLLOWING RULES MUST BE STRICTLY FOLLOWED TO AVOID ANY UNIT DAMAGE OR OPERATOR RISK
:
R EAD THE LABELS ON THE EV-1 N EVER COVER THE LABELS R EPLACE THEM IF DAMAGED
T HE EV-1 MUST BE USED BY AUTHORIZED AND SKILLED PERSONNEL ONLY
L OCK THE WHEELS BEFORE USING THE EV-1
K EEP AWAY FROM CHILDREN AND NON - AUTHORIZED PERSONNEL DURING USE
D O NOT PUT CONTAINERS ON THE EV-1
W ORKING TEMPERATURE SHOULD BE BETWEEN 230 F (-5° C) AND 120
0
F (49° C)
H UMIDITY SHOULD BE LESS THAN 95 PERCENT
D O NOT USE THE UNIT IN AN EXPLOSIVE ENVIRONMENT
D O NOT USE GASOLINE OR SOLVENTS THAT COULD CATCH FIRE
D O NOT USE ACID SOLUTION THAT COULD DAMAGE THE EV-1 OR PERSONNEL
D O NOT CRASH INTO SHELVES OR FRAMEWORKS TO AVOID OBJECTS FALLING
I N CASE OF MALFUNCTIONING OF THE EV-1, CONTACT MAHLE
U SE ONLY MAHLE REPLACEMENT PARTS

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4
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7
HO TO PREPARE THE UNIT
ASSEMBLY OF THE MOUTHPIECE
A TTACH THE MOUTHPIECE AS SHOWN IN THE PICTURE AND
FASTEN IT WITH THE PROVIDED SCREWS
MOUNTING OF THE HOSE
A TTACH THE HOSE AND SECURE IT WITH THE CLAMP
P UT THE END OF THE EXHAUST HOSE OUTSIDE C ONNECT THE
ELECTRICAL PLUG TO THE NEAREST OUTLET T HE EV-1 IS NOW
READY TO OPERATE
ATTENTION!
T O USE THE EV-1 CORRECTLY , YOU MUST HAVE AN UPSTREAM
DIFFERENTIAL PROTECTION SYSTEM OF 30 A MP
A DJUST THE HEIGHT OF THE EV-1 TO PLACE THE SUCTION
MOUTHPIECE AS CLOSE AS POSSIBLE TO THE EXHAUST PIPE L OCK
THE WHEELS OF THE UNIT T URN ON THE EV-1 AND THEN START
THE ENGINE
ATTENTION!
D O NOT SUCK UP PLASTIC BAGS , PAPER , ETC T HEY COULD
CLOSE THE GRILL AND IMPEDE THE EXHAUSTING OF THE EXHAUST
GAS

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ADDITIONAL INSTRUCTIONS
MOUNTING OF THE ADDITIONAL KIT
R EMOVE POWER FROM THE EV-1 BEFORE REMOVING THE
MOUTHPIECE ; SUBSTITUTE THIS PART WITH THE TWO - WAY PIPE
ATTENTION!
R EMOVE POWER FROM THE EV-1 BEFORE REMOVING THE
PROTECTION GRILL T HE MANUFACTURER DISCLAIMS RESPONSIBILITY
FOR DAMAGE TO PEOPLE OR OBJECTS
L IFT THE COVER AND CONNECT THE HOSES
T O USE ONLY ONE HOSE , TAKE AWAY THE SECOND HOSE AND CLOSE
THE COVER
FUSE REPLACEMENT
D ISCONNECT EV-1 FROM POWER U NSCREW THE PROTECTION GRILL
AND REPLACE THE FUSES R EFER TO THE SPECIFICATIONS FOR THE
FUSE SIZE M OUNT THE GRILL AND FIX IT WITH SCREWS
ATTENTION! R EMOVE POWER FROM THE EV-1 BEFORE REMOVING THE PROTECTION
GRILL T HE MANUFACTURER DISCLAIMS RESPONSIBILITY FOR DAMAGE TO
PEOPLE OR OBJECTS
CLEANING AND MAINTENANCE
T HE EV-1 DOES NOT REQUIRE ANY SPECIAL MAINTENANCE , ONLY NORMAL CLEANING , WHICH SHOULD BE DONE
WITH A DAMP CLOTH ( WATER AND ALCOHOL OR NORMAL HOUSEHOLD DETERGENT )
ATTENTION! T HE MACHINE MUST NOT BE CLEANED WITH NITROCELLULOSE BASED
SOLVENTS

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# QTY DESCRIPTION PART NO. QTY DESCRIPTION PART NO.
01 1 PLUG 035-88001-00 22 1 WASHER 035-88022-00
02 4 SCREW 035-88002-00 23 1 FAN 035-88023-00
03 1 COLUMN 035-88003-00 24 1 LEVER 035-88024-00
25 1 SWITCH 035-88025-00
05 4 SCREW 035-88005-00 26 1 LIGHT 035-88026-00
06 4 SCREW 035-88006-00 27 1 GRILL 035-88027-00
07 4 WASHER 035-88007-00 28 1 SPRING 035-88028-00
08 2 WHEEL WITH BRAKE 035-88008-00 29 1 HANDLE 035-88029-00
09 4 NUT 035-88009-00 30 1 LOCKER 035-88030-00
10 5 NUT 035-88010-00 31 2 SLIDE 035-88031-00
11 1 WHEEL 035-88011-00 32 1 FRAME 035-88032-00
12 1 BASE 035-88012-00 33 1 CLAMP 035-88033-00
13 2 HOSE HOOK 035-88013-00 34 14 SCREW 035-88034-00
14 1 SPRING 035-88014-00 35 1 CLAMP 035-88035-00
15 2 FUSE (16 AMP) 035-88015-00 36 1 CABLE 035-88036-00
16 1 FUSE HOLDER 035-88016-00 37 1 MOTOR 035-88037-00
17 1 HOSE 035-88017-00 38 4 SCREW 035-88038-00
18 1 GASKET 035-88018-00 39 1 HANDLE 035-88039-00
19 1 MOUTH 035-88019-00 40 2 POWER CORD HOOK 035-88040-00
20 4 HAND WHEEL 035-88020-00 41 2 SCREW 035-88041-00
21 1 SCREW 035-88021-00

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16 Amp
16 Amp
POWER
SWITCH
POWER
INDICATOR
LIGHT
MOTOR
Fuse
Fuse
QTY DESCRIPTION PART NO.
11GASKET
035-88042-00
21FLANGE 035-88043-00
32CLOSING SYSTEM 035-88044-00
42HOSE WITH SPRINGS 035-88045-00
52GASKET 035-88046-00
62SCREW 035-88047-00
72NUT 035-88048-00
84CLAMP 035-88049-00
94HAND WHEEL 035-88050-00
10 2CONNECTION HOSE 035-88051-00