Appendix to:

Bulkline 650 & 1000

Installation,
Operating &
Maintenance
Instructions

BULKLINE
650 & 1000 LNC

Low Noise
Cooler Package

4990877002
September 2013
 Form 1085

Gardner Denver Drum Ltd PO Box 178 Tel: +44 (0) 1274 718100
Springmill Street Fax: +44(0) 1274 718101
Bradford
West Yorkshire, UK
BD5 7YH

EC Machinery Directive

2006/42/EC

DECLARATION OF INCORPORATION

Vehicle Discharge Equipment Comprising:

Machine Name:
Bulkline LNC (Low Noise Cooler) Package

Machine Assembly Number:

TW910188, TW910189

Machine Installation /Operating Instructions:

T-BA-4000/4050-3-GB-xx-xx & 4990877xxx

Is in conformity with the provisions of the following other EEC Directives:

N/A

Harmonised standards applied (including parts/clauses of):

N/A

The equipment above must not be put into service until the machinery into which it has been
incorporated has been declared in conformity with the provisions of the directive.

Signed: …………….…………………….

Date: ….…………………..

Name: Barry Thomas

Position: Director Engineering (Gardner Denver Drum Ltd)

Being the responsible person appointed by the manufacturer.

See KP01 – 08 for information on completion

Document Ref: QUA-Doc-1025 Issue 1 Page 1 o f 1 26/02/2010.

 Contents

Chapter Page

1 General
1.1 Health & Safety ...............................................3
1.2 Product General Description ..........................4
1.3 Package Components................................. 5-6
1.4 Package Dimensions .................................. 6-8

2 Installation
2.1 General ............................................................9
2.2 Lifting .............................................................9
2.3 Mounting & Drive ...................................... 9-13
2.4 Air Inlet Connection ......................................13
2.5 Instrumentation ............................................14
2.6 Air Inlet Filter Restriction Indicator ..............14
2.7 Discharge Air Pressure Gauge .....................14
2.8 Compressor Oil Pressure Gauge .................14
2.9 Air cooler ......................................................15
2.10 Electrical Connection ....................................15

3 Maintenance
3.1 Package Maintenance Schedule ..................17
3.2 Replacing the Drive Belt ...............................17
3.3 Replacing/Cleaning the Integral Filter ..........18
3.4 Cleaning the Cooling Radiator .....................19

To be used in conjunction
with the Bulkline 650 & 1000
machine instructions

Do not use in isolation

4990877002 - 02/10 Bulkline 650/1000 LNC Package - Installation, Operating & Maintenance Instructions Page 3
 General
1.1 Health & Safety

Static electricity
Ensure, that where required, the compressor and ancillaries are earthed
in accordance with BS5958 Part 1 1983; ‘Control of Undesirable Static
Electricity’. Powder-air combinations are potentially explosive.

Drive line
It is the responsibility of the installer of the equipment to ensure all rotating
and moving parts of the installation are adequately guarded to a standard
which complies with the prevailing safety legislation.

Compressor
The compressor has internal moving parts some of which may be accessed
through the inlet and outlet apertures. Do not place any objects especially
fingers into these apertures since personal injury could result.

Fire
The compressor includes seals made of fluoroelastomer polymers which
degrade if exposed to temperatures above 300°C. If the material has been
so exposed then it must not be handled with bare hands.

Relief Valve
A relief valve must be fitted in the outlet pipe work as close to the compres-
sor as possible. The valve must be positioned so as not to vent air onto any
personnel since the air discharged will be hot and can cause severe burns.
The operation of the valve should be checked every month to clear the valve
seat and check the valve is functional. (Ear protection is recommended)

Hot Surfaces
To avoid the risk of burns, do not touch pipework, compressor body or
stand next to venting valves. If there is a risk for any reason we recommend
the use of heat resistant gloves/clothing.

Noise
Prolonged exposure to noise should be avoided, it is recommended
earplugs should be provided.

Lifting
The machine should be handled using correctly rated lifting equipment,
and the method shown in this manual.

Page 4 Bulkline 650/1000 LNC Package - Installation, Operating & Maintenance Instructions 4990877002 - 02/10
 1
General
1.2 Product general description

The package is a fully assembled compressor and ancillary unit mounted on

a common bracket. The unit produces air at low noise levels for discharging
temperature sensitive dry bulk materials from road tankers. The configuration
is designed for out-of-the box direct mounting to vehicle chassis. Depending
on the specification, the unit may include a cooler and/or a full enclosure.

Hot and cold connections are provided at the front of the package and a rear
‘cool-air’ discharge kit is available as an option.

The assembly is designed to be driven directly from the PTO inside the
chassis to make best use of the space available and facilitate prop shaft
driving. Versions are available in clockwise (right hand) and anti clockwise
(left hand) rotation.

The Bulkline 650/1000 LNC Package includes a cooler and an enclosure.

Figure 1a - Bulkline 650/1000 LNC Package Clockwise (Right Hand) Rotation

Figure 1b - Bulkline 650/1000 LNC Package Anti-Clockwise (Left Hand) Rotation

4990877002 - 02/10 Bulkline 650/1000 LNC Package - Installation, Operating & Maintenance Instructions Page 5
 General
1.3 Package Components
COOLED AIR COMPRESSOR OIL COMPRESSOR DELIVERY
DELIVERY PRESSURE GAUGE AIR PRESSURE GAUGE
3" BSP

HOT AIR
DELIVERY
3" BSP

ONE-PIECE GRP
ENCLOSURE

COOLING AIR
OUTLET

ACCESS COVER FOR

AIR FILTER ELEMENT

Figure 2a - Components Front View Clockwise (Right Hand) Rotation

CHECK VALVE

FILTER RESTRICTION
MOUNTING BRACKET ASSEMBLY
INDICATOR
DISCHARGE AIR
TRANSFER ELBOW

GAUGE CONSOLE

DISCHARGE
SILENCER
HOT AIR DELIVERY
CONNECTION

BULKLINE 1000
COMPRESSOR
COOLED AIR DELIVERY
CONNECTION

AIR COOLER
ASSEMBLY
COMPRESSOR
AIR INLET

OPTIONAL REAR DISCHARGE PIPE

Figure 2b - Components Front Isometric View with Enclosure Removed Clockwise (Right Hand) Rotation

Page 6 Bulkline 650/1000 LNC Package - Installation, Operating & Maintenance Instructions 4990877002 - 02/10
 General
1.3 Package Components (Cont..)

AIR INLET
CONNECTION
COOLER ASSEMBLY

COMPRESSOR OIL
FILLER/BREATHER

RELIEF VALVE

BELT TENSIONER
ELECTRIC FAN

Figure 2c - Components Rear Isometric View with Enclosure Removed Clockwise (Right Hand) Rotation

1.4 Package Dimensions

60°
n18

R5
R5
M12 X 1.75 P
10

30
50
35
8

0,000
(+- 0,025)

0,200
54 +- 0,000

Figure 3a - Dimensions - Drive Shaft Key 50

n40 h7
0,000
10 +- 0,036

1X45~
A-A A
(34,6)
Tape

A
2,862 0

0,000
13,65 +- 0,200
r 1:1
°

Figure 3b - Dimensions - Bulkline 650/1000 LNC Package Drive Shaft and Keyway

4990877002 - 02/10 Bulkline 650/1000 LNC Package - Installation, Operating & Maintenance Instructions Page 7
 Page 8
COOLED AIR DISCHARGE 3" BSP MALE FRONT VIEW COMPRESSOR OIL PRESSURE
852 & DISCHARGE AIR PRESSURE
DIMENSION "X" SEE TABLE FOR VALUES OF
SIDE VIEW GAUGES BEHIND WINDOW
"X" & "Y" IN "HIGH" & "LOW"
POSITIONS WITH OPTIONAL
BELT LENGTHS HOT AIR DISCHARGE 3" BSP MALE

DIMENSION "Y"
730
ALTERNATIVE LOW
PULLEY POSITION
REMOVABLE BOTTOM PANEL
FOR ACCESS TO COMPRESSOR
OIL FILTER ELEMENT
COOLING AIR DISCHARGE ACCESS COVER RETAINING NUTS INLET AIR FILTER ELEMENT
FROM RADIATOR BEHIND ACCESS COVER
BELT TENSIONER
360 68
COMPRESSOR AIR INLET

PROVISION FOR LIFTING EYE: INLET AIR FILTER

TAPPED HOLE M16 x 25 DEEP RESTRICTION INDICATOR

199 100

154
ACCESS TO COMPRESSOR OIL FILLER
60 COVER RETAINING SCREWS

320
n102
1.4 Package Dimensions

10
17
2:1

654
2:1
2:1
2:1
2:1

2:1
General

1.79:1
1.79:1
1.79:1

1.79:1
RATIO

280
280
DIA

250

280
280
250
250

250
280
280
(Cont..)

211

Figure 3c - General Arrangement Drawing - BL1000 Clockwise (Right Hand) Rotation Package (Pulley Shown in High Position)
427

4°
LOW
LOW

LOW
LOW
LOW
HIGH
HIGH
HIGH

HIGH
HIGH

763
POS'N

n77

Bulkline 650/1000 LNC Package - Installation, Operating & Maintenance Instructions

1500
1500
1550

1590
1550
1550
1500

1550
1590
1500
PULLEY PULLEY BELT

2
n1

30
LENGTH

n1
326 360
168
181

142

187
168
206
181

192
201
156

COUNTERSHAFT MAY BE MOUNTED

IN A "HIGH" OR "LOW" POSITION. OPTIONAL: FLANGE CONNECTION
SHOWN IN "HIGH" POSITION FOR REAR COOLED AIR DISCHARGE
507
428

507

513
507
437
429

513
437
426

REAR VIEW
DIM "X" DIM "Y"
INPUT FLANGE CENTRE POSITIONS

TOP VIEW

4990877002 - 02/10
 FRONT VIEW
COMPRESSOR OIL PRESSURE
HOT AIR DISCHARGE & DISCHARGE AIR PRESSURE
SIDE VIEW SEE TABLE FOR VALUES OF
3" BSP MALE GAUGES BEHIND WINDOW
DIMENSION "X" "X" & "Y" IN "HIGH" & "LOW" 852
POSITIONS WITH OPTIONAL
BELT LENGTHS

4990877002 - 02/10
COOLED AIR DISCHARGE 3" BSP MALE

ACCESS COVER RETAINING NUTS

INLET FILTER ELEMENT BEHIND ACCESS COVER

DIMENSION "Y"
730
ALTERNATIVE HIGH
PULLEY POSITION REMOVABLE BOTTOM PANEL
COOLING AIR DISCHARGE FOR ACCESS TO COMPRESSOR
FROM RADAIATOR OIL FILTER ELEMENT
FACE OF OPTIONAL REAR
5
DISCHARGE FLANGE

283

68 PROVISION FOR LIFTING EYE:

TAPPED HOLE M16 x 25 DEEP

100 165
2:1

2:1
2:1
2:1

2:1
2:1

BELT TENSIONER 60

211
1.79:1
1.79:1

10
1.79:1

1.79:1

17

154
RATIO

INLET AIR FILTER

RESTRICTION

320
250
250

280
280
DIA

250

280
250
280
280

280

INDICATOR
98
General

n COVER
RETAINING
SCREWS

654
LOW
LOW
LOW

LOW
LOW
HIGH

HIGH
HIGH

HIGH
HIGH
1.4 Package Dimensions (cont..)

POS'N

ACCESS TO
COMPRESSOR
476

Figure 3d - General Arrangement Drawing - BL1000 Anti-Clockwise (Left Hand) Rotation Package (Pulley Shown in Low Position)
OIL FILLER
763
1500

1550
1550
1590
1550

1500
1550
1500

1590
1500
PULLEY PULLEY BELT

Bulkline 650/1000 LNC Package - Installation, Operating & Maintenance Instructions

LENGTH

n77
181

195
202
207

171
171

4°
182
157

190
142

0
12
n

n13
453

538
461
461

530
531
453
448

538
530

311
INPUT FLANGE CENTRE POSITIONS

DIM "X" DIM "Y"

OPTIONAL: FLANGE CONNECTION REAR VIEW

FOR REAR COOLED AIR DISCHARGE

TOP VIEW

Page 9
 2
Installation
2.1 General

When selecting the machine mounting position, the following points should
be considered:
• Ensure visibility of gauges.
• Ensure easy access to the air filter (via access cover).
• Ensure visibility of the filter restriction indicator.
• Ensure easy access to the oil filler (via access cover where fitted).
• Ensure easy access to the relief valve.
• Ensure that, where necessary, covers can be removed for maintenance
access to oil filters, oil drain plugs, belts, etc.
• Ensure that adequate access is available to the air inlet pipe connection
and consider the likely pipe route (minimise length where possible)
• To achieve maximum cooling performance, air entering the cooler should
be as clean and cool as possible. ie install away from vehicle exhaust and
other sources of heat and dirt.

2.2 Lifting

The Bulkline 650/1000 LNC Package should be lifted for installation using the
pallet provided.
See Section 1.1 Health & Safety OR
Any equipment used for lifting should be rated accordingly. The machine, on
the delivery pallet, weighs approximately 350kg, including pulleys and belts.
There is provision for attaching a lifting eye to the mounting bracket (Figures
3c and 3d).

2.3 Mounting and drive

Fixing to the Chassis
The Bulkline 650/1000 LNC Package vehicle mounting brackets should be
attached to the vehicle chassis using 6 mounting bolts, washers & nuts
(Fig. 4a – items 3, 4 & 5). All mounting fasteners should be M16 grade 8.8
(or higher).

All M16 grade 8.8 fasteners should be tightened to a torque setting of 210Nm.

The mounting brackets should be positioned against the chassis so that the
maximum amount of surface to surface contact is made to eliminate any
potential flexing of the brackets.

On some vehicles it may be necessary to offset the mounting brackets from the
vehicle chassis to achieve clearance for other chassis mounted equipment. In
this event it may also be necessary to fit a spreader plate between the brackets
and the chassis to distribute the clamping loads. See vehicle manufacturer’s
instructions for further guidance.

The mounting hole centres should be positioned as shown. Figure 4f shows

the preferred location of the mounting holes. However, if required, the hole
centres can be positioned elsewhere within the shaded area shown in Figure
4g to suit existing holes in the chassis. The holes should be vertically spaced
as far apart as the vehicle chassis will practically allow, and no less than 75mm,
If required, further fixing holes (in addition to the six recommended) may be
drilled in any other location on either of the two brackets, provided that they
are a minimum of 50mm from any existing holes.
Page 10 Bulkline 650/1000 LNC Package - Installation, Operating & Maintenance Instructions 4990877002 - 02/10
 Installation
2.3 Mounting and drive (Cont..)
Fixing to the Chassis

Figure 4a - Installation of Vehicle Mounting Brackets to Vehicle Chassis

5
1 4

Figure 4c - Alternative Bracket Position (1)

2

4
3

Figure 4d - Alternative Bracket Position (2)

No. Description
1 Vehicle Chassis
2 Vehicle Mounting Brackets
3 M16 Bolt
4 M16 Washer
5 M16 Nut Figure 4b - Brackets Fixed to Chassis

Figure 4e - Alternative Bracket Position (3)

100 100
40 50 30 30 30
40
60

Package Package
Mounting Mounting
100

Holes Holes
(Pre-Drilled) (Pre-Drilled)
320
320

240

Chassis Chassis
100

Mounting Mounting
Holes Hole Centres
(Drilled By To Be Within
Customer) The Shaded
Area

Figure 4f - Recommended Vehicle Chassis Mounting Bracket Hole Positions. Figure 4g - Permissable Vehicle Chassis Mounting Bracket Hole Positions.

4990877002 - 02/10 Bulkline 650/1000 LNC Package - Installation, Operating & Maintenance Instructions Page 11
 Installation
2.3 Mounting and drive (Cont..)

Fixing the Package to the Brackets

Initially, the vehicle mounting brackets should be loosely attached to the
vehicle chassis (tightened later), the Bulkline package is then fastened to
the brackets.

The Bulkline 650/1000 LNC Package should be attached to the mounting

bracket using a total of 6 (3 on either side) flanged mounting screws M16
grade 8.8 or higher (Figure 5b).

The package mounting bracket has two sets of 6 x M16 tapped holes on
each side to permit alternative mounting heights. The side mounting screws
should be tightened to a torque of 210Nm before then tightening the screws
holding the brackets to the vehicle chassis to 210Nm.

Figure 5a
Figure 5b

11

3
3

2
2

No. Description
1 Package Mounting Bracket
2 Vehicle Mounting Brackets
3 M16 Flanged Screws

Figure 5 - Installation of Bulkline 650/1000 LNC Package to the Vehicle Mounting Bracket/Chassis

Ensure that adequate clearance exists between the vehicle chassis and the
Bulkline acoustic package. Figures 5c and 5d show that particular care needs
to be taken to avoid interference between the vehicle chassis and the drive
belts. There are two sets of mounting holes for the drive shaft housing so
that it may be installed in a high or low position.

Figure 5c - Chassis/Package Clearance Figure 5d - Chassis/Package Clearance

Page 12 Bulkline 650/1000 LNC Package - Installation, Operating & Maintenance Instructions 4990877002 - 02/10
 Installation
2.3 Mounting and drive (Cont..)

Oil
Drain
Oil Drain Plug

Oil
Oil Drain Plug Plug
Drain
Plug
Oil
Oil Filter

Filter

Figure 5e - Underside Cover Removal Figure 5f - Access From Underside of Package

The package is supplied without the bottom cover installed. It must be fitted
before the machine is put into service. (Figure 5e).
If the optional rear connection for cooled air is included, care should
be taken to ensure that piping may be connected to the flange without
contacting chassis components.
The Bulkline machine and the drive shaft/pulley assembly are mounted
within the package at an angle of 4 degrees to the horizontal to allow easy
parallel alignment/adjustment with the vehicle PTO shaft.
See Section 1.1 Health & Safety

NOTE
The package should be
mounted at the appropriate
angle to ensure that the pulley
4°

4°

drive shaft axis is parallel to

the PTO axis.

Figure 5g - Bulkline & Pulley Package Mounting Arrangement

4990877002 - 02/10 Bulkline 650/1000 LNC Package - Installation, Operating & Maintenance Instructions Page 13
 Installation
2.3 Mounting and drive (Cont..)

≤12º 9
>12º
8
NOTE
The compound prop. shaft
angle must also be less than 12°

≤1º 9
>1º
8
9
Figure 5h - Package Alignment
8
2.4 Air Inlet Connection
The Bulkline 650/1000 LNC Package is supplied with a 4” OD air inlet
connection (Figures 6a, 6b). The air inlet piping kit comprises of a 4” nominal
bore flexible pipe connected to the inlet stub pipe with a cuff and hose clip.
The other end should be connected to the raincap mounted in a position that
will result in only cool, clean and dry air entering the assembly.
Figure 6a - Air Inlet Connection Location Figure 6b - Bulkline Package
Air Inlet Duct Installation
Air Inlet Connection

Hose Clip
Air Inlet
Connection
Air Duct 4” Nominal Bore with Cuff

Page 14 Bulkline 650/1000 LNC Package - Installation, Operating & Maintenance Instructions 4990877002 - 02/10
 Installation
2.5 Instrumentation

The Bulkline Package has a gauge panel (figures 7a and 7b) mounted behind
a window carrying the following:
• Oil pressure gauge
• Delivery air pressure gauge
In addition, there is a filter restriction indicator mounted at the rear of the
package (figure 2b).

Oil Pressure
Oil Pressure Gauge
Gauge

Gauge
Panel
Delivery Air
Location DischargePressure
air Pressure
Gauge
Gauge
Figure 7a - Gauge Panel Location Figure 7b - Gauge Panel Layout

2.6 Air Filter Restriction Indicator

The air filter restriction indicator shows when the air filter element is
excessively dirty. See Section 3.3 for actions to clean or change the filter
See Section 1.1 Health & Safety element.

2.7 Discharge Air Pressure Gauge

The discharge air pressure gauge shows the pressure at which the
machine is currently operating.
See the compressor operating instructions for more information on the
recommended operating pressure range of the compressor.

Figure 8 - Discharge Air Pressure Gauge Display

2.8 Oil Pressure Gauge

The oil pressure gauge shows the current oil pressure of the compressor and
has a range of 0 – 7bar. When the system is at operating temperature the
pressure, with a new oil filter, should be > 1.0 bar and < 6.0 Bar.

During operation, the oil pressure should not fall below 0.5 bar. If it does, then
the oil filter should be changed and the oil level checked.

See the compressor operating instructions for more information on the

maximum oil pressure for the machine.

Figure 9 - Oil Pressure Gauge Display

4990877002 - 02/10 Bulkline 650/1000 LNC Package - Installation, Operating & Maintenance Instructions Page 15
 Installation
2.9 Air cooler
• The cooling air enters the package from the rear of the unit as shown in
Figure 10a.
CAUTION • The air is blown across the integral radiator by the electric cooler fan and
The temperature of the the exhaust air is discharged from the front of the package as shown in
discharge couplings will Figure 10b
exceed 80 deg C.
Use protective gloves when
handling couplings.

Figure 10a - Cool Air In Figure 10b - Hot Air Out

Optional

As an option, a flanged connection may be provided to discharge cooled air

at the rear of the package (Figures 3c and 3d).

Cooling performance

To obtain the maximum cooling effect:

• Do not obstruct the inlet air path into the package.

• Locate the assembly so that only cool air will be drawn into the package,
ie away from engine exhausts or other heat sources, eg hot piping, relief
valves etc.

2.10 Electrical connection

The cooler should be connected to a 24 volt DC supply as shown in Figures 11a,
11b and 11c. This must be a permanent connection and must not be switched.
All connections to the chassis electrical system, and all details of the electrical
See Section 1.1 Health & Safety wiring, must be strictly in accordance with the vehicle manufacturer’s
instructions, and also in accordance with local legislation.
Fuses, if not part of the chassis system, should be located as close as possible to
the connection to the vehicle system and before any switches, relays, etc.
All electrical installation work must be carried out by suitably qualified personnel.
On installation check that the direction of air flow from the fan is correct, see
Figure 11d
The package electrical system incorporates a temperature switch to control the
fan. The following operating features will be noticed:
• The electric fan will not start to run immediately when the PTO is engaged.
• After a few minutes, when the compressor discharge air temperature has
Package
risen, the fan will start.
Junction Box
• At the end of the discharge, when the PTO is disengaged, the fan will
Figure 11a - Junction Box Location
continue to run for a few minutes.
These characteristics are normal.

Page 16 Bulkline 650/1000 LNC Package - Installation, Operating & Maintenance Instructions 4990877002 - 02/10
 Installation
2.10 Electrical connection (cont..)

30A

30A

Figure 11b. Electrical Circuit Diagram.

Figure 11c. Junction Box Connection Diagram

Figure 11d. Air Flow Direction

4990877002 - 02/10 Bulkline 650/1000 LNC Package - Installation, Operating & Maintenance Instructions Page 17
 Maintenance
Use alongside the Bulkline machine maintenance instructions
3.1 Package Maintenance Schedule
See Section 1.1 Health & Safety The package maintenance schedule below should be used alongside
the machine maintenance schedule in the Bulkline 650 & 1000 machine
maintenance instructions.
The maintenance intervals in the table below refer to intermittent operation
of around 3 hours every day at 2 barg working pressure.

Maintenance point Action Section Maintenance Interval

Replace/Clean the Signaled by Filter
Replace/Clean 3.3
Integral Air Filter Restriction Indicator
Clean the
Clean 3.4 Half-Yearly
Cooling Radiator

3.2 Replacing the drive belts

The Bulkline LNC package compressor is driven by a set of 4 off XPB drive
belts. Various lengths of belt are available as detailed in Figures 3c and 3d. If
belt replacement is necessary, replace all the belts as a set.
To replace the belts, follow the procedure below:
1. Ensure that the Package is isolated from the drive and that there is no
See Section 1.1 Health & Safety pressure in the system.
2. Release the belt tension – slacken the locknut and retaining nut on the
tensioner (Figures 2c, 3c and 3d).
3. Slacken the nut on the Drive Shaft Housing pivot bolt.
4. Swing the Drive Shaft Housing Assembly towards the mounting bracket
until the belts can be removed.
5. Remove the old belts.
6. Install the new belts.
7. Set the belt tension in line with the belt tensioning tables below.
8. Re-tighten the locknut on the tensioner.
9. Re-tighten the nut on the pivot pin (210Nm).
Belt Tension Values
F Package Input Speed = 1800 rpm Max. / Compressor Speed = 3600 rpm Max. (2:1 Step Up)
Installation Tension F = Force Applied to
Force per Belt (N) Tension Tester (N) D = Belt
D C R N Belt Length
Deflection
mm mm mm mm New Belt Used Belt New Belt Used Belt
R mm
Min. Max. Min. Max. Min. Max. Min. Max.
415 280 140 1500 744 797 638 691 31 33 27 29 4.1
440 280 140 1550 741 794 635 688 31 33 26 29 4.3
460 280 140 1590 738 791 633 686 31 33 26 29 4.5
C

N
Package Input Speed = 2015 rpm Max. / Compressor Speed = 3600 rpm Max. (1.786:1 Step Up)
Installation Tension F = Force Applied to
Ref. Description Force per Belt (N) Tension Tester (N) D = Belt
C R N Belt Length
Deflection
C Distance Between Pulley Centres mm mm mm mm New Belt Used Belt New Belt Used Belt
mm
Deflection of Belt When Pressure is Min. Max. Min. Max. Min. Max. Min. Max.
D
Applied to Tension Tester
F Force Applied to Tension Tester 415 250 140 1450 733 785 628 680 30 32 26 28 4.1
N Compressor Input Pulley Diameter 440 250 140 1500 730 782 626 678 30 32 26 28 4.4
R Package Input Pulley Diameter
465 250 140 1550 728 780 624 676 30 32 26 28 4.6
Figure 12. Belt Tension Testing

Page 18 Bulkline 650/1000 LNC Package - Installation, Operating & Maintenance Instructions 4990877002 - 02/10
 3 Maintenance
3.3 Replacing/cleaning the Integral Air Filter
Restriction Indicator
If the indicator has reached the red portion of the scale (See Figure 13a),
change/clean the filter element as follows:

Accessing the element (Figure 13b)

Key
1 - Filter Blocked • Remove the two cover retaining nuts (#1) and remove the filter housing
2 - Filter Clear cover (#2).
• Remove the filter clamp plate (#3).
• Remove the air filter element (#4).

Cleaning the element;

Figure 13a. Maintenance Indicator
Clean the element by lightly tapping the element or blowing compressed air
through it from the inside outwards.
Note: This will not return the element to new condition, but should prolong
the life until it can be replaced.
See Section 1.1 Health & Safety
Replacing the element:
This is a direct reversal of the “Accessing the element” section above. Lightly
lubricate the nuts and the grommets before re assembly.
After cleaning or replacing the element, reset the filter restriction indicator by
pressing the yellow button.

55

4
No. Description QTY
3 1 Cover Retaining Nuts 2
2 Filter Housing Cover 1
1 2 3 Filter Clamp Plate 1
4 Filter Element 1
5 Filter Spacer Studs 2
Figure 13b. Replacing the filter element

4990877002 - 02/10 Bulkline 650/1000 LNC Package - Installation, Operating & Maintenance Instructions Page 19
 Maintenance
3.4 Cleaning the cooling radiator
The radiator should be periodically cleared of debris to maintain efficiency.
To gain access to the radiator/fan assembly refer to Figure 14 and follow the
procedure below:

1. Remove the 5 off bottom cover retaining screws (#4).

2. Remove the bottom cover.
3. Remove the 2 off top retaining screws (#1), flanged bushes (#2) and
rubber washers (#3).
4. Release the hose clip (#6) retaining the connection hose to the
compressor inlet elbow. Access from below the package.
5. Lift the main enclosure (#7) clear.
6. Blow through the radiator fins with an air line. Access to the radiator can
No. Description QTY
be gained via the air outlet duct (#8), and also from the area between
1 Top Retaining Screws 4
the compressor and the radiator.
2 Top Flanged Bushes 4
3 Top Rubber Washers 2
7. Replace and re-fix the main cover by reversing the above steps. Ensure
that the connection hose is correctly engaged on the stub pipe in the
4 Underside Retaining Screws 5
cover and also on the compressor inlet elbow. Also ensure that the hose
5 Underside Cover 1
clips are secure. Re-fix the underside cover.
6 Air Inlet Elbow Hose Clip 1
7 Main GRP Enclosure 1
8 Air Outlet Duct 1

1
2
8
3

5
7
4
Figure 14 - Cleaning the radiator

Page 20 Bulkline 650/1000 LNC Package - Installation, Operating & Maintenance Instructions 4990877002 - 02/10
 Notes

4990877002 - 02/10 Bulkline 650/1000 LNC Package - Installation, Operating & Maintenance Instructions Page 21
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