IWV 40/100
Operating manual
Industrial vacuum cleaner
Read these
instructions carefully
before operating the
machine!
This machine is
intended for
industrial and
professional use
only!
09.2018
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2
Introduction
This manual provides all the information needed to use and service your vacuum cleaner. Good
operation and durability depend on proper maintenance and careful use.
Before leaving the factory, this particular model has undergone stringent tests to ensure utmost
reliability. Always check however to make sure the vacuum cleaner has not been damaged during
transport in such a way as to affect operation and safety.
This manual should be considered an integral part of the vacuum cleaner and must be kept together
with the unit until this is scrapped. In case of loss of or damage to the manual, ask columbus for a
new copy.
The technical details contained in this manual are the property of columbus and should be deemed of
a confidential nature.
Even partial reproduction of the graphic project, the text and the illustrations is legally forbidden.
Some details shown in the illustrations in this manual may be different from those of your vacuum
cleaner. Some component parts may have been removed for greater clarity.
For easier reference, this manual is split into sections, identifiable by specific graphic symbols.
The subjects dealt with in this manual are those expressly required by "Machine Directive
2006/42/CE" and the technical details shown are those provided by the manufacturer at the time of
compilation.
This manual must be kept in a place accessible to all the personnel charged with operating and
servicing the vacuum cleaner.
In case of any doubts, always immediately phone the After-Sales Service.
The competent Law Court for all disputes is that of Stuttgart.
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Contents
1 Information .......................................................................................................................................... 4
1.1 Identification of the main parts ....................................................................................................... 4
1.2 Accessories provided ..................................................................................................................... 5
1.3 Identification details of manufacturer ............................................................................................. 6
1.4 Type plate ...................................................................................................................................... 6
1.5 Intended uses ................................................................................................................................ 7
1.6 Allowed environmental conditions ................................................................................................. 7
1.7 Noise level ..................................................................................................................................... 7
1.8 Storage .......................................................................................................................................... 7
1.9 Scrapping ....................................................................................................................................... 7
1.10 Technical details .......................................................................................................................... 8
2 Safety ................................................................................................................................................... 9
2.1 Safety details ................................................................................................................................. 9
2.2 Safety warnings ........................................................................................................................... 10
2.3 Safety plates and symbols ........................................................................................................... 13
2.4 Outstanding risks ......................................................................................................................... 14
2.5 Applied directives ......................................................................................................................... 14
3 Installation ......................................................................................................................................... 15
3.1 Handling ....................................................................................................................................... 15
3.2 Installation .................................................................................................................................... 16
4 Operation ........................................................................................................................................... 18
4.1 Description of controls ................................................................................................................. 18
4.2 Work cycle ................................................................................................................................... 19
4.3 Releasing and removing the removable container ...................................................................... 21
5 Maintenance ...................................................................................................................................... 22
5.1 Informative notes ......................................................................................................................... 22
5.2 General safety warnings .............................................................................................................. 22
5.3 Maintenance operations .............................................................................................................. 23
5.4 Replacing the filters ..................................................................................................................... 24
5.5 Troubleshooting ........................................................................................................................... 26
6 Recommended spare parts ............................................................................................................. 27
7 Declaration of conformity ................................................................................................................ 28
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1 Information
1.1 Identification of the main parts
1) Suction unit
2) Release fastener
3) Push handle
4) Suction pipe coupling point
5) Filtering chamber
6) Level indicator
7) Castors
8) Fixed wheels
9) Container release lever
10) Container
7 8 1
2 4 5
6 3 9
10
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1.2 Accessories provided
21478300 – POLYESTER FILTER Ø500 H100
21495000 – OIL SIEVE GRID
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1.3 Identification details of manufacturer
G. Staehle GmbH u. Co. KG
columbus Reinigungsmaschinen
Mercedesstr.15
D - 70372 STUTTGART
Telefon +49(0)711 / 9544-950
Telefax +49(0)711 / 9544-941
info@columbus-clean.com
www.columbus-clean.com
1.4 Type plate
In compliance with the Machine Directive 2006/42/CE on vacuum cleaners, the machine is fitted with
CE plates.
When contacting the manufacturer or dealer, always quote the details shown on the vacuum cleaner
type plate.
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1.5 Intended uses
These specific vacuum cleaner models have been designed, built and protected for vacuuming dusts
and solid materials only, using special filters.
Warning!
Always use specific filters for the type of dust or materials to be vacuumed.
Any other use is considered IMPROPER.
The vacuum cleaner is in any case intended for professional industrial use.
1.6 Allowed environmental conditions
To ensure the correct operation of the vacuum cleaner, this must be positioned protected against
atmospheric agents (rain, hail, snow, fog, dusts in suspension, etc.) with an environmental running
temperature between 5°C and 45°C and relative humidity not above 70%.
The work environment must be clean, well-enough lit and devoid of explosive atmosphere.
1.7 Noise level
Noise level readings were taken in accordance with the provisions of Machine Directive 2006/42/CE
standards.
Sound tests performed on this specific vacuum cleaner model have been taken from a distance of 1
meter and from a height of 1,60 meters, showing an acoustic pressure no higher than:
76 dB (A)
The vibrations transmitted by the machine are lower than 2,5 m2/s.
Attention!
Pursuant to articles L.D. 81/08, workers exposed to sound pressure levels above 85 dB (A)
must be protected by special individual protection devices.
It is therefore necessary, if such working conditions exist, to provide workers with such
approved individual protection devices and to inform them of the risks relating to noise
exposure.
1.8 Storage
Remove the filter and clean it, empty the container and store the vacuum cleaner in a place protected
against atmospheric agents with a temperature between 0°C and 40°C. Cover with a nylon sheet to
prevent accumulation of dust.
1.9 Scrapping
In case of scrapping, all the component parts of the vacuum cleaner will have to be disposed of
through adequate disposal channels in accordance with applicable legislation.
Before scrapping, all plastic and rubber parts will have to be separated from the electrical material.
Parts made of plastic, aluminium and steel only may be recycled if collected by special centres.
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1.10 Technical details
Power
kW
3,45
Voltage
Volt
230-50/60
Max. vacuums rate
mm / H2O
2.300
Max. air flow rate
m³ / h
540
Noise level
dB (A)
76
Filter type
Polyester
Capacity (swarf)
l
40
Capacity (liquid)
l
100
Suction inlet
Ø
80
Dimensions
cm
58 x 60 x 110
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2 Safety
2.1 Safety details
The person in charge of safety shall be responsible for informing workers about the risks associated
with vacuum cleaner operation.
The obligation also exists of training workers so they are able to protect themselves and others.
Failure to observe basic safety regulations and Warnings could cause accidents during vacuum
cleaner operation, maintenance and repair. Accidents can often be avoided by recognising potentially
dangerous situations before these occur. Operators should be aware of potential hazards and be
trained and skilled enough. They should also have the tools necessary to perform these duties
properly.
columbus shall under no circumstances be deemed liable for accidents or damage caused by use of
the vacuum cleaner by personnel not properly trained or who use it in an improper manner, as well as
by even partial failure to comply with the safety regulations and intervention procedures indicated in
this manual.
The safety Warnings and warning notices are indicated in this manual and on the product.
Unless these hazard messages are heeded, the operator could become involved in accidents with
serious consequences for him/herself and for other people.
The safety messages are highlighted by the following symbols:
Attention!
Unless these messages are heeded, operator injuries could occur.
Warning!
Unless these messages are heeded, vacuum cleaner damage could occur.
columbus cannot foresee all possible circumstances capable of representing a potential hazard. The
warnings in this manual and on the products should not therefore be deemed exhaustive. In the event
of tools, procedures, work or machining methods being used that are not explicitly recommended by
columbus, make sure no hazards exist for operators and others.
Only ever use original columbus spare parts.
columbus declines all liability in the event of non-original spare parts being used.
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2.2 Safety warnings
Attention!
The following indications are, by themselves, not enough to fully protect against all the
hazards that could arise during vacuum cleaner operation. These will have to be integrated
with common sense and the experience of the operator, both of which are crucial factors for
preventing accidents. Each section of this manual lists further specific safety warnings for the
various operations.
Maintenance jobs must always be performed with the power plug detached from the power
point.
The employer must inform and train the user according to the provisions of applicable laws.
Before using the machine, prepare and train yourself by reading this manual carefully. Use of the
machine by untrained and unauthorised persons is forbidden.
Using the machine to vacuum toxic substances is forbidden unless this has been equipped with
special filters required for the specific type of dusts. Such filters must be explicitly requested by you.
If the machine is used to vacuum toxic-harmful substances, the container must be emptied and the
filters cleaned using adequate individual protection devices, selected according to the type of
substances to be vacuumed.
Do not vacuum flammable materials or substances or which could cause explosions (fuels, solvents,
etc.). To vacuum such materials, the machine must be built with Anti-explosion Motor and Electric
System and this must be requested by you explicitly.
Do not vacuum corrosive substances unless the machine is equipped with containers suitable for this
purpose (Stainless-steel AISI 304).
Use of the machine without the supplied filters is not recommended.
If the filters are correctly fitted, the machine will not eject any objects.
Never rest miscellaneous materials on the horizontal protection guard.
The machine casing containing moving parts must not be removed by the user.
When using the machine, mind other people, especially children.
Use the machine cautiously on slopes and ramps.
Do not change direction on gradients.
Make sure the parked machine remains stable by operating the braked wheel.
During cleaning operations, maintenance jobs or when changing parts, the starter switch must be off
and the machine must be disconnected from the power mains by removing the cable from the socket.
Only skilled persons should carry out repairs.
During use, mind the power supply cables and avoid crushing or pulling these.
Periodically check the mains power cable to ensure this is not damaged.
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In the event of the cable being damaged, the machine must not be used.
In the event of the cable, plugs or couplings being replaced, make sure these are protected against
water spray and check mechanical strength.
Never pull the machine by means of the power cable and the vacuum pipe.
Motor brushes and burnt-out fuses must be replaced by columbus or authorised dealers. Always use
original spare parts.
The user is responsible for disposing of vacuumed substances in accordance with applicable laws.
After 10 years of use, we recommend sending the machine for a complete overhaul to columbus.
The machine is supplied with: instruction manual, Exploded Spare Parts drawing, Declaration of
Conformity.
In the event of Customers fitting a tool to the machine not supplied by columbus, make sure the
safety conditions required by Machine Directive 2006/42/CE are complied with and in any event,
columbus is unable to accept liability for any problems arising from use of such tool.
The vacuum cleaner must not be operated in a corrosive or explosive environment.
Always make sure the vacuum cleaner is free of all foreign materials such as debris, oil, equipment
and other objects that could affect operation and cause injury to persons.
Avoid using flammable or toxic solvents such as petrol, benzene, ether and alcohol for cleaning.
Avoid prolonged contact with solvents and inhaling their vapours. Avoid use close to open flames or
sources of heat.
Never use the vacuum cleaner without the filter.
Do not vacuum lit cigarette ends. The filter could be damaged.
Do not vacuum petrol or flammable liquids in general.
Make sure all the guards and protection devices are in place and that all the safety devices are in
place and working properly.
Do not wear loose or hanging clothing such as ties, scarves or torn garments that could become
trapped and be sucked up by the cleaner
Do not open the vacuum container with the machine running.
The manual should always be kept handy for reference so the operating cycle can be checked every
time there are doubts.
In the event of this manual being lost or damaged, ask columbus for a new copy.
Structural damage and improper alterations or repairs could change the protection capacity of the
vacuum cleaner and therefore cancel this certification.
Any alterations to the appliance must only be made by columbus engineers.
During maintenance jobs, affix a notice to the appliance indicating "MACHINE BEING SERVICED,
DO NOT START".
.
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Climbing on the cleaner is forbidden.
Never touch electric wires, switches, buttons, etc. with wet hands.
Before connecting to the power mains, make sure the power voltage and frequency are those shown
on the machine plate.
Make power connections to a mains supply with efficient earth system.
In the event of an extension being used, make sure this is in perfect condition, marked CE and that the
cross section of the cable is suitable for the vacuum cleaner power input.
When restoring original working conditions, the appointed personnel should make sure that at the end
of the operating procedure, proper vacuum cleaner operation safety conditions are restored, especially
the safety devices and the protective guards.
Only adult persons should use the vacuum cleaner.
During vacuuming operations, always brake the vacuum cleaner using the special revolving wheel
lock.
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2.3 Safety plates and symbols
Plates are affixed to the vacuum cleaner showing safety symbols and/or messages.
Attention!
Make sure all the safety messages are legible.
Clean these with a cloth, soap and water. Do not use solvents, diesel fuel or petrol.
Replace the damaged plates with new ones supplied by columbus.
If a plate is affixed to a replaced part, make sure a new plate is affixed to the new part.
Attention!
Read the operator's and maintenance manual carefully before using the cleaner or doing any
maintenance jobs.
Warning!
Risk of crushing upper limbs while fitting and locking the material container on the vacuum
cleaner.
Never place hands between the material container and vacuum cleaner while locking.
Do not place hands on sides of container near the guide pins while locking.
Perform the container locking operation by means of the levers located on the side, USING
BOTH HANDS!
IMPORTANT
DO NOT BREATHE IN INFLAMMABLE AND / OR EXPLOSIVE
LIQUIDS
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2.4 Outstanding risks
Careful analysis of risks performed by the manufacturer and stored in the technical file has made it
possible to eliminate most of the risks associated with vacuum cleaner operation.
The manufacturer advises carefully following the instructions, procedures and advice contained in this
manual as well as applicable safety regulations, including the use of the envisaged protection devices,
both those integrated in the cleaner and individual.
Outstanding risks associated with the vacuum cleaner could be:
Electrical maintenance risks caused by the need to work under power.
Pursuant to Presidential Decree 81/08, only trained personnel should work on the machine with the
power supply connected and this must have double earth insulation.
Risk of improper use in the presence of explosive and flammable substances.
The vacuum cleaner must not be used in environments containing substances in the form of liquids
that could vaporise at room temperature and flammable dusts and gas.
Risks of operation in humid environments.
Keep to the limits shown in this manual at chap. 1.6 Allowed environmental conditions.
Risk of erroneous interpretation of the safety pictograms.
Having identified the various outstanding risks, the manufacturer has affixed to the cleaner a number
of hazard labels in compliance with regulations relating to the graphic symbols to be used. The user
must immediately replace any safety plates that become illegible due to wear or damage.
Attention!
Removing the safety plates on the vacuum cleaner is strictly forbidden. The manufacturer
declines all liability in relation to vacuum cleaner safety in the event of failure to comply with
the above indications.
2.5 Applied directives
The following directives apply to the vacuum cleaner described in this manual:
2006/42/CE Machine Directive
2014/30/EU Electromagnetic compatibility directive
2006/95/CE Low-voltage directive
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3 Installation
3.1 Handling
The machine is supplied in a strong cardboard box secured with straps.
Transport the package using a fork-lift truck of adequate lifting capacity and make sure it is stable and
that weight is properly distributed on the forks.
Before starting to move, make sure the transit area is free and that there are no moving objects on the
packaging.
During movement, keep the load low for greater stability and safety.
When starting up the vacuum cleaner, move this by means of the wheels supplied.
The appliance must never be moved using fork-lift trucks or other equipment that lifts it off the floor.
If for any reason the need arises to lift and transport the vacuum cleaner, this operation must be
performed under the responsibility of the user. The user is therefore invited to secure the load as he
best thinks fit to ensure the operation is performed in total safety.
A
(cm)
B
(cm)
H
(cm)
Weight
(incl. packaging)
kg
IWV 40/100
73
85
150
75
H B A
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3.2 Installation
Warning!
Before installing the vacuum cleaner, carefully make a sight check to pinpoint any damage
suffered during transport.
In the event of any component parts being damaged, do not proceed with installation. Notify the
manufacturer and reach an agreement on how to proceed.
The vacuum cleaner already features a suction filter.
Fit the accessory required for the type of vacuuming operation on the opposite end of the hose.
Note: No standard accessories (reducers, hoses, nozzles) are included with the vacuum;
accessories must be specified and ordered separately.
Contact your dealer for information relating to the different types of optional accessories available for
this specific vacuum cleaner model.
Fit the supplied connector on the pipe union
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Fit the supplied pipe on the connector.
Make sure the power supply corresponds to the voltage and frequency indicated on the vacuum
cleaner plate.
Warning!
Do not fit the plug in the power socket with wet hands.
In the event of an extension being used, make sure this is in perfect condition, in compliance with CE
standards and with cable cross section suitable for the power input of the vacuum cleaner.
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4 Operation
4.1 Description of controls
1) START / STOPP switch (Motor 1)
2) START / STOPP switch (Motor 2)
3) START / STOPP switch (Motor 3)
4) Power on – red light indicator
5) Vacuum meter
2
1
3 4 5
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4.2 Work cycle
Warning!
Before fitting the plug, make sure the power voltage corresponds to that on the CE marking
plate.
Make sure the power plug is correctly fitted in the power socket.
Make sure the flexible hose is properly fitted and locked in the vacuum pipe union.
Make sure the power cable and any extension used are integral and in perfect condition.
Block the vacuum cleaner by means of the retainer provided.
Grip one end of the flexible hose complete with selected accessory.
Press the Start button and start vacuuming.
To stop the vacuum cleaner, press the Stop button.
Warning!
Before switching the vacuum cleaner back on, make sure the motors have come to a complete
halt.
After finishing work, disconnect the vacuum cleaner from the power socket.
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To move the vacuum cleaner, use the large handle.
Warning!
The vacuum can be moved only on flat ground!
If the vacuum is moved on inclined grounds, you can risk to lose the control, because of the
weight and to damage persons or things.
Warning!
During vacuuming, avoid rolling up or bending the flexible hose.
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4.3 Releasing and removing the removable container
Stop the vacuum motors by pressing the relevant STOP buttons.
Warning!
Disconnect the plug from the power socket.
Lift the lever located in the bottom part of the cleaner to release and remove the container.
…..
Use the valve to empty the container.
Empty the contents oft he container and oft he sieve grid into a special waste disposal
container in accordance with laws applicable in the country where the vacuum cleaner is used.
Warning!
Perform the container release operation by means of the levers located on the sides or on the
handle with BOTH HANDS!
Danger of crushing upper limbs when fitting and locking the container on the vacuum cleaner.
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5 Maintenance
5.1 Informative notes
This section describes the control and special maintenance operations crucial for keeping the vacuum
cleaner in perfect working condition.
Any other jobs which might be necessary to eliminate operating faults must be expressly authorised by
the manufacturer. In such cases, always notify the identification details of the cleaner.
In the case of major repairs, it is best to contact an authorised dealer, whose skilled personnel, backed
by all the technological experience relating to the original factory construction methods, are always
available and ready to promptly intervene.
5.2 General safety warnings
Maintenance jobs must always be performed by skilled technicians, trained to carry out their specific
jobs. In the case of this machine, these are:
Mechanical maintenance
Electrical maintenance
The Safety Manager has the precise duty of determining the professional capacities and skills of such
persons.
Before doing any maintenance job, the safety manager must:
Make sure there are no unauthorised persons in the work area.
Make sure the necessary tools are on hand and that these are in good condition.
Make sure that lighting is adequate and, if necessary, provide 24-V portable lamps.
Make sure the maintenance engineer is equipped with all approved individual protection
devices needed for the specific operation (gloves, eyewear, shoes, etc.).
Make sure the maintenance engineer has carefully read the instructions contained in this
manual and knows how the vacuum cleaner works.
Before carrying out a maintenance job, the maintenance engineer must:
Disconnect the plug from the power socket.
Work done on motors or other electrical component parts must only be performed by a specifically
trained electrician, authorised by the Safety Manager.
Always use tools that are in perfect condition and specifically made for the operation to be done. The
use of unsuitable tools or tools not in good condition could cause serious damage.
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5.3 Maintenance operations
Attention!
All the described operations must be done with the plug disconnected from the power socket.
Before starting any maintenance or cleaning job, always wear adequate protective clothing,
eyewear and/or gloves according to the type of job to be done.
For smooth vacuum cleaner operation, a number of controls are best made periodically:
Check to see whether the filter is worn or has become too permeable.
Make sure the sealing gaskets of the motor head base, of the filter-holder ring and of the
container are working efficiently.
The electrical parts (plugs, switches, cables, etc.) must not be faulty.
The screws and nuts must always be tight.
Make sure the container is not overfull. This should be emptied when the vacuumed material
has reached 3/4 of maximum capacity.
Check the integrity of the flexible vacuum hose and accessories to be used.
If the flexible hose is perforated, the power of the cleaner will be reduced and dust and liquids
will leak into the environment.
Warning!
All maintenance and repair jobs must be performed directly by columbus or its authorised
dealers.
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5.4 Replacing the filters
To replace the filters, proceed as follows:
Turn off the vacuum cleaner by pressing the motor STOP buttons.
Disconnect the vacuum cleaner plug from the power socket.
Important!
Wear individual protection devices.
Block the vacuum cleaner by means of the retainer.
Release the retainers that hold the motor head. Lift the motor head and rest this on a flat
surface being careful not to damage the power cable.
Lift the filter with ist support.
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Loosen the clamp and remove the support ring with seal.
Fit the new filter and put everything back in place, locking the cap.
Important!
All the material trapped by the filter and the filter itself must be disposed of through authorised
channels in the country where the vacuum cleaner is used.
The container locking operation must be performed by one person only, who must lower the back side
lever with both hands.
Caution!
Hand crushing hazard!.
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5.5 Troubleshooting
Fault found
Possible fault
Recommended remedy
The cleaner fails to start
No power
Check the power mains supply.
Check the integrity of the plug
and power cable
Dust is leaking out
Perforated vacuum pipe
Replace the pipe
The vacuum cleaner does
not work as it should
Pipe perforated or blocked
Check the pipe and, if necessary,
replace it.
Container full
Empty container.
Filter blocked
Clean the filter and, if necessary,
change it.
Seals worn
Check the seals and, if
necessary, replace it.
Airleak
Check for any air leaks out of
closing fasteners, tightening
screws, container or filter
chamber.
Motor very noisy
Contact columbus after-sales.
Warning!
For any other problems, contact the columbus after-sales service.
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6 Recommended spare parts
Code
Description
21478300
POLYESTERFILTER Ø 500 H100
21479100
FILTERDICHTUNG Ø500
21487000
FILTERKLEMME Ø500
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7 Declaration of conformity
in accordance with the EC Directive on Machines 2006/42/EC
Manufacturer
G. Staehle GmbH u. Co. KG
columbus Reinigungsmaschinen
Mercedesstraße 15
D-70372 Stuttgart
hereby declares that the following product conforms to the regulations of the above mentioned
directive – as well as any modifications valid at the time the declaration was made.
Produkt:
Industrial vacuum cleaner
Typ:
IWV 40/100
The following related standards apply:
EN 13857
EN 60 204-1
EN 61000-3-2
EN 61000-3-3
EN 55 014
EN 60335-2-69
The following further EU Directive apply:
EMC-Directive
2014/30/EU
2014/35/EU
Stuttgart, 01.09.2018
Dipl. Ing.(BA) Erich Stockmann, Head of Design and Development
Authorised Documentation Representative: Dr. M. Baumgärtel
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Notes
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Notes
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31
G. Staehle GmbH u. Co. KG
columbus Reinigungsmaschinen
Mercedesstr.15
D - 70372 STUTTGART
Telefon +49(0)711 / 9544-950
Telefax +49(0)711 / 9544-941
info@columbus-clean.com
www.columbus-clean.com
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