Operator Manual: Screw Compressor M100

Operator Manual
Screw Compressor
M100
No.: 9_6999 23 USE
Manufacturer:
KAESER KOMPRESSOREN SE
96410 Coburg • PO Box 2143 • GERMANY • Tel. +49-(0)9561-6400 • Fax +49-(0)9561-640130
http://www.kaeser.com
Original instructions
/KKW/M100 2.03 en Z1 SBA-MOBILAIR
20150112 161243
Contents
1 Regarding this Document

1.1 Using this document ......................................................................................................... 1
1.2 Further Documents .......................................................................................................... 1
1.3 Copyright .......................................................................................................................... 1
1.4 Symbols and labels .......................................................................................................... 1
1.4.1 Warnings ............................................................................................................. 1
1.4.2 Potential damage warnings ................................................................................ 2
1.4.3 Other alerts and their symbols ............................................................................ 2
2 Technical Data
2.1 Nameplate ........................................................................................................................ 4
2.2 Options ............................................................................................................................. 4
2.2.1 Compressed air treatment devices ..................................................................... 5
2.2.2 Tool lubricator ..................................................................................................... 5
2.2.3 Compressed air distributor .................................................................................. 5
2.2.4 Check valve function ........................................................................................... 6
2.2.5 Proportional controller ......................................................................................... 6
2.2.6 Low temperature equipment ............................................................................... 6
2.2.7 Equipment for fire hazard areas ......................................................................... 6
2.2.8 Battery isolating switch ....................................................................................... 7
2.2.9 Chassis ............................................................................................................... 7
2.2.10 Lighting ............................................................................................................... 8
2.2.11 Generator ............................................................................................................ 8
2.2.12 Sealed floor pan .................................................................................................. 8
2.2.13 Anti-theft device .................................................................................................. 8
2.2.14 Pedestrian protection .......................................................................................... 8
2.2.15 Instrument panel cover ....................................................................................... 9
2.3 Machine (without options) ................................................................................................ 9
2.3.1 Sound pressure level .......................................................................................... 9
2.3.2 Tightening torques for screws ............................................................................. 9
2.3.3 Ambient conditions ............................................................................................. 9
2.3.4 Additional specifications ..................................................................................... 9
2.4 Chassis ........................................................................................................................... 10
2.4.1 Weight ................................................................................................................. 10
2.4.2 Tires .................................................................................................................... 10
2.4.3 Wheel nut/bolt tightening torque ......................................................................... 11
2.4.4 Towbar tightening torque .................................................................................... 11
2.5 Compressor ..................................................................................................................... 11
2.5.1 Working pressure and FAD ................................................................................ 11
2.5.2 Compressed air outlet ......................................................................................... 11
2.5.3 Safety relief valves .............................................................................................. 12
2.5.4 Temperature ....................................................................................................... 12
2.5.5 Cooling oil recommendation ............................................................................... 12
2.5.6 Cooling oil charge ............................................................................................... 14
2.6 Engine ............................................................................................................................. 14
2.6.1 Engine specification ............................................................................................ 14
2.6.2 Oil recommendation ............................................................................................ 14
2.6.3 Fuel recommendation ......................................................................................... 15
2.6.4 Recommended Cooling Fluid ............................................................................. 15
2.6.5 Fluid volumes ...................................................................................................... 15
2.6.6 Battery ................................................................................................................ 15
2.7 Options ............................................................................................................................ 16
2.7.1 Air treatment options ........................................................................................... 16
2.7.2 Low temperature equipment ............................................................................... 17
2.7.3 Generator (50 Hz version) .................................................................................. 18
Operator Manual Screw Compressor

No.: 9_6999 23 USE M100 i
Contents
2.7.4 Generator (60 Hz version) .................................................................................. 21

3 Safety and Responsibility
3.1 Basic instructions ............................................................................................................. 24
3.2 Specified use .................................................................................................................... 24
3.3 Incorrect Use .................................................................................................................... 24
3.4 User's Responsibilities ..................................................................................................... 24
3.4.1 Observe statutory and universally accepted regulations .................................... 24
3.4.2 Determining personnel ........................................................................................ 25
3.4.3 Adherence to inspection schedules and accident prevention regulations .......... 25
3.4.4 Attachment of a "Hazardous goods" label .......................................................... 25
3.5 Dangers ............................................................................................................................ 26
3.5.1 Safely dealing with sources of danger ................................................................ 26
3.5.2 Safe machine operation ...................................................................................... 29
3.5.3 Organizational Measures .................................................................................... 32
3.5.4 Danger areas ...................................................................................................... 33
3.6 Safety devices .................................................................................................................. 33
3.7 Safety signs ...................................................................................................................... 33
3.8 Noise control requirements .............................................................................................. 37
3.9 Generator operation ......................................................................................................... 37
3.9.1 Comply with the protective measures against dangerous electric current ......... 37
3.9.2 Safe generator operation .................................................................................... 37
3.9.3 Connecting extension cables .............................................................................. 38
3.9.4 Do not exceed the maximum supply system load .............................................. 38
3.9.5 Perform regular generator inspections ............................................................... 38
3.10 Emergencies .................................................................................................................... 39
3.10.1 Correct fire fighting ............................................................................................. 39
3.10.2 Injury from handling operating fluids/materials ................................................... 39
3.11 Warranty ........................................................................................................................... 40
3.11.1 Noise emissions warranty ................................................................................... 40
3.12 Identifying the effects of improper modifications .............................................................. 40
3.13 Environmental protection ................................................................................................. 41
4 Design and Function
4.1 Bodywork ......................................................................................................................... 42
4.2 Component identification .................................................................................................. 43
4.3 Machine function .............................................................................................................. 43
4.4 Operating modes and control mode ................................................................................. 45
4.4.1 Operating modes ................................................................................................ 45
4.4.2 MODULATING control ........................................................................................ 45
4.5 Safety devices .................................................................................................................. 46
4.5.1 Monitoring functions with shutdown .................................................................... 46
4.5.2 Further safety devices ........................................................................................ 47
4.6 Fuel level monitoring ........................................................................................................ 47
4.7 Options ............................................................................................................................. 47
4.7.1 Compressed air treatment options ...................................................................... 48
4.7.2 Low temperature equipment options .................................................................. 51
4.7.3 Optional battery isolating switch ......................................................................... 52
4.7.4 Options for operating in fire hazard areas .......................................................... 53
4.7.5 Generator option ................................................................................................. 54
4.7.6 Transport options ................................................................................................ 56
4.7.7 Sealed floor pan option ....................................................................................... 58
4.7.8 Optional anti-theft device ................................................................................... 59
4.7.9 Pedestrian protection option ............................................................................... 59
4.7.10 Instrument panel cover option ............................................................................ 60

ii M100 No.: 9_6999 23 USE
Contents
5 Installation and Operating Conditions

5.1 Ensuring safety ................................................................................................................ 61
5.2 Installation conditions ....................................................................................................... 61
6 Installation
6.1 Ensuring safety ................................................................................................................ 63
6.2 Reporting Transport Damage ........................................................................................... 63
6.3 Fitting the towbar .............................................................................................................. 63
6.3.1 Fitting the height adjustable towbar .................................................................... 64
6.3.2 Fitting a non-adjustable tow bar .......................................................................... 65
6.4 Adjusting the chassis ....................................................................................................... 67
6.4.1 Adjusting the towbar height ................................................................................ 68
6.4.2 Changing the towing eye/ball hitch ..................................................................... 68
7 Initial Start-up
7.1 Ensuring safety ................................................................................................................ 72
7.2 Before initial start-up (or recommissioning) ...................................................................... 72
7.2.1 Instructions to be observed before commissioning or recommissioning ............ 72
7.2.2 Special measures for re-commissioning after storage ........................................ 73
7.3 Checking installation and operating conditions ................................................................ 73
7.4 Low-temperature operation (winter) ................................................................................. 74
7.4.1 Starting assistance ............................................................................................. 74
7.4.2 Starting up low-temperature equipment .............................................................. 76
7.5 Activating the generator ................................................................................................... 78
8 Operation
8.1 Ensuring safety ................................................................................................................ 81
8.2 Starting and stopping ....................................................................................................... 82
8.2.1 Starting the machine ........................................................................................... 83
8.2.2 Engine pre-heating ............................................................................................. 83
8.2.3 Starting the machine ........................................................................................... 83
8.2.4 Allow the machine to run up to operating temperature ....................................... 83
8.2.5 Switching to LOAD ............................................................................................. 84
8.2.6 Manually setting the discharge pressure ............................................................ 84
8.2.7 Shutting down the machine ................................................................................ 85
8.3 Monitoring fuel level in the fuel tank ................................................................................. 86
8.4 Operating the tool lubricator ............................................................................................. 86
8.5 Using the low-temperature equipment ............................................................................. 87
8.5.1 Pre-warms the engine cooling water .................................................................. 87
8.5.2 Operating the machine with frost protector ......................................................... 88
8.6 Operating the battery isolating switch .............................................................................. 89
8.7 Generator operation ......................................................................................................... 89
8.7.1 Note when operating the generator .................................................................... 90
8.7.2 Switching in the generator .................................................................................. 90
8.7.3 Switching off the generator ................................................................................. 90
8.8 Cleaning the machine after operation .............................................................................. 91
9 Fault Recognition and Rectification
9.1 Basic instructions ............................................................................................................. 92
9.2 Engine faults and alarms .................................................................................................. 92
9.2.1 Engine refuses to start or comes to a stop ......................................................... 92
9.2.2 Engine does not reach full speed ....................................................................... 93
9.2.3 Indicator lamp remains on .................................................................................. 93
9.3 Compressor faults and alarms ......................................................................................... 94
9.3.1 Working pressure too high .................................................................................. 94
9.3.2 Working pressure too low. .................................................................................. 94

No.: 9_6999 23 USE M100 iii
Contents
9.3.3 Pressure relief valve blowing off ......................................................................... 95

9.3.4 Machine overheating .......................................................................................... 95
9.3.5 Too much oil residue in the compressed air ....................................................... 96
9.3.6 Oil flows from the compressor air filter after shutdown ....................................... 96
9.3.7 High moisture content in the compressed air ..................................................... 97
9.4 Generator faults and alarms ............................................................................................. 97
9.4.1 There is no voltage or too low a voltage from the generator .............................. 97
9.4.2 Generator voltage too high ................................................................................. 97
10 Maintenance
10.1 Ensuring safety ................................................................................................................ 99
10.2 Maintenance schedules ................................................................................................... 100
10.2.1 Logging maintenance work ................................................................................. 100
10.2.2 Maintenance tasks after commissioning ............................................................. 100
10.2.3 Regular maintenance tasks ................................................................................ 101
10.3 Engine maintenance ........................................................................................................ 106
10.3.1 Water cooler maintenance .................................................................................. 106
10.3.2 Engine air filter maintenance .............................................................................. 111
10.3.3 Fuel system maintenance ................................................................................... 114
10.3.4 Checking the engine oil level .............................................................................. 118
10.3.5 Engine oil filling and topping up .......................................................................... 119
10.3.6 Changing the engine oil ...................................................................................... 120
10.3.7 Replace the engine oil filter ................................................................................ 123
10.3.8 Drive belt maintenance ....................................................................................... 124
10.3.9 Battery maintenance ........................................................................................... 127
10.3.10 Checking the fastening of the fuel tank .............................................................. 130
10.4 Compressor Maintenance ................................................................................................ 130
10.4.1 Checking cooling oil level ................................................................................... 131
10.4.2 Cooling oil filling and topping up ......................................................................... 132
10.4.3 Changing the cooling oil ..................................................................................... 133
10.4.4 Replace the compressor oil filter ........................................................................ 137
10.4.5 Oil separator tank dirt trap maintenance ............................................................. 138
10.4.6 Changing the oil separator cartridge ................................................................... 139
10.4.7 Compressor air filter maintenance ...................................................................... 143
10.4.8 Checking safety relief valves .............................................................................. 146
10.5 Cleaning the cooler .......................................................................................................... 146
10.5.1 Cleaning the compressor cooler and engine radiator ......................................... 146
10.5.2 Cleaning the compressed air aftercooler ............................................................ 147
10.6 Maintenance of rubber sealing strips ............................................................................... 148
10.7 Chassis maintenance ....................................................................................................... 149
10.7.1 Wheel checks ..................................................................................................... 149
10.7.2 Towbar maintenance .......................................................................................... 149
10.7.3 Brake maintenance ............................................................................................. 152
10.8 Maintenance for Optional Items ....................................................................................... 155
10.8.1 Tool lubricator maintenance ............................................................................... 155
10.8.2 Cyclone separator maintenance ......................................................................... 157
10.8.3 Combination filter maintenance .......................................................................... 158
10.8.4 Fresh air filter maintenance ................................................................................ 162
10.8.5 Frost protector maintenance ............................................................................... 165
10.8.6 Spark arrestor maintenance ............................................................................... 166
10.8.7 Engine air intake shut-off valve maintenance ..................................................... 168
10.8.8 Generator drive belt maintenance ...................................................................... 169
10.8.9 Draining liquid accumulation within the machine ................................................ 172
10.9 Documenting maintenance and service work .................................................................. 174

iv M100 No.: 9_6999 23 USE
Contents
11 Spares, Operating Materials, Service

11.1 Note the nameplate .......................................................................................................... 175
11.2 Ordering consumable parts and operating fluids/materials .............................................. 175
11.3 KAESER AIR SERVICE .................................................................................................. 176
11.4 Service Addresses ........................................................................................................... 176
11.5 Replacement parts for service and repair ........................................................................ 176
12 Decommissioning, Storage and Transport
12.1 De-commissioning ............................................................................................................ 227
12.1.1 Temporary de-commissioning ............................................................................ 227
12.1.2 Long-term decommissioning and storage ........................................................... 228
12.2 Transport .......................................................................................................................... 229
12.2.1 Safety .................................................................................................................. 229
12.2.2 Towing the compressor on the road ................................................................... 229
12.2.3 Parking the machine ........................................................................................... 238
12.2.4 Transport with a crane ........................................................................................ 241
12.2.5 Transport with a forklift truck ............................................................................... 241
12.2.6 Transporting the machine as load ...................................................................... 242
12.3 Storage ............................................................................................................................. 243
12.4 Disposal ........................................................................................................................... 244
13 Annex
13.1 Identification ..................................................................................................................... 245
13.2 Pipeline and instrument flow diagram (P+I diagram) ....................................................... 245
13.3 Dimensional drawings ...................................................................................................... 251
13.3.1 Dimensional drawing, chassis options ................................................................ 251
13.3.2 Dimensional drawing, chassis options ............................................................... 253
13.3.3 Dimensional drawing, chassis options ............................................................... 255
13.3.4 Dimensional drawing, chassis options ................................................................ 257
13.3.5 Dimensional drawing, stationary version ............................................................ 259
13.3.6 Dimensional drawing, stationary version ............................................................ 261
13.4 Wiring diagrams .............................................................................................................. 263
13.4.1 Electrical Diagram ............................................................................................... 263
13.4.2 Lighting and signaling system connection .......................................................... 277
13.4.3 Lighting and signaling system connection .......................................................... 285
13.4.4 Generator electrical diagram, 400V, 3-ph ........................................................... 290
13.4.5 Generator electrical diagram, 230V, 3-ph ........................................................... 299
13.4.6 Generator electrical diagram, 115 V, 2-ph .......................................................... 308
13.4.7 Generator electrical diagram, 230 V, 2-ph .......................................................... 317
13.5 Fuel circulation diagram ................................................................................................... 326
13.6 Assembly diagrams - chassis ........................................................................................... 329
13.6.1 Assembly diagrams - chassis EU version ........................................................... 329
13.6.2 Assembly diagrams - chassis GB/US version .................................................... 331
13.6.3 Assembly diagram brake rod .............................................................................. 334
13.7 Operating instructions for compressed air filter (combination filter) ................................. 336
13.8 Operating instructions for compressed air filter (fresh air filter) ....................................... 357
13.9 Service tasks - Generator ................................................................................................ 371

No.: 9_6999 23 USE M100 v
Contents

vi M100 No.: 9_6999 23 USE
List of Illustrations
Fig. 1 Example for Tire information on the side wall ............................................................................ 10

Fig. 2 Location of safety signs .............................................................................................................. 34
Fig. 3 Overview Bodywork .................................................................................................................... 42
Fig. 4 Right-hand door opened ............................................................................................................. 43
Fig. 5 Left-hand door opened ............................................................................................................... 43
Fig. 6 Machine layout ........................................................................................................................... 44
Fig. 7 Stepless regulation of FAD (standstill) ....................................................................................... 46
Fig. 8 Fuel level monitoring .................................................................................................................. 47
Fig. 9 Compressed air options ............................................................................................................. 48
Fig. 10 Tool lubricator ............................................................................................................................. 50
Fig. 11 Principle tool lubricator ............................................................................................................... 50
Fig. 12 Coolant pre-heating .................................................................................................................... 51
Fig. 13 Frost protector ............................................................................................................................ 52
Fig. 14 Battery isolating switch ............................................................................................................... 53
Fig. 15 Instrument panel – generator control box, 400 V AC ................................................................. 55
Fig. 16 Instrument panel – generator control box, 230 V AC ................................................................. 55
Fig. 17 Generator instrument panel - control box, 115 V, single-phase (50 Hz) .................................... 56
Fig. 18 Generator instrument panel - control box, 230 V, single-phase (60 Hz) .................................... 56
Fig. 19 Position of service openings in the sealed floor pan .................................................................. 59
Fig. 20 Drain points for oil and coolant from engine and compressor .................................................... 59
Fig. 21 Minimum distance from excavations/slopes and walls ............................................................... 61
Fig. 22 Height adjustable towbar, fitted .................................................................................................. 64
Fig. 23 Fitting the height adjustable towbar ............................................................................................ 64
Fig. 24 Non-adjustable tow bar fitted ...................................................................................................... 65
Fig. 25 Fitting the overrun braking mechanism of the non-adjustable tow bar ....................................... 66
Fig. 26 Fitting the jockey wheel of the non-adjustable tow bar ............................................................... 67
Fig. 27 Towbar height adjustment .......................................................................................................... 68
Fig. 28 Changing the towing eye (height-adjustable drawbar) ............................................................... 69
Fig. 29 Changing the towing eye/ball hitch (fixed height towbar) ........................................................... 70
Fig. 30 Changing the towing eye (fixed height towbar, USA chassis version) ....................................... 71
Fig. 31 Jumper cable connection diagram ............................................................................................. 75
Fig. 32 Engine coolant pre-heating ........................................................................................................ 77
Fig. 33 Operating the frost protector ...................................................................................................... 77
Fig. 34 Insulation monitoring - 400 V AC, 3-phase generator ................................................................ 78
Fig. 35 Insulation monitoring - 230 V AC, 3-phase generator ................................................................ 78
Fig. 36 insulation monitoring - 115 V, single-phase generator ............................................................... 79
Fig. 37 insulation monitoring - 230 V, single-phase generator ............................................................... 79
Fig. 38 Starting instruments ................................................................................................................... 82
Fig. 39 Label referring to the warm-up period when ambient temperatures are below -50 °F ............... 84
Fig. 40 Proportional controller ................................................................................................................ 85
Fig. 41 Setting the tool lubricator ............................................................................................................ 86
Fig. 42 Frost protector on and off ........................................................................................................... 88
Fig. 43 Battery isolating switch ............................................................................................................... 89
Fig. 44 Checking coolant level ............................................................................................................... 107
Fig. 45 Draining the coolant from the radiator ........................................................................................ 110
Fig. 46 Draining the coolant from the radiator (closed floor pan - stationary machine) .......................... 111
Fig. 47 Engine air filter maintenance ...................................................................................................... 112
Fig. 48 Cleaning the filter element .......................................................................................................... 113
Fig. 49 Fuel system maintenance .......................................................................................................... 114
Fig. 50 Bleeding the fuel system ............................................................................................................ 115
Fig. 51 Fuel filter with water trap maintenance ....................................................................................... 116
Fig. 52 Changing the fuel pre-filter. ........................................................................................................ 117
Fig. 53 Fuel micro-filter maintenance ..................................................................................................... 117
Fig. 54 Checking the engine oil level ...................................................................................................... 119

No.: 9_6999 23 USE M100 vii
List of Illustrations
Fig. 55 Draining the engine oil ................................................................................................................ 121

Fig. 56 Draining the engine oil (closed floor pan - stationary machine) ................................................. 122
Fig. 57 Changing the oil filter .................................................................................................................. 123
Fig. 58 Belt guard attachment ................................................................................................................ 124
Fig. 59 Checking the drive belt seating .................................................................................................. 125
Fig. 60 Manually checking the belt tension ............................................................................................ 125
Fig. 61 Changing/tensioning the drive belt ............................................................................................. 126
Fig. 62 Safety signs - warning stickers on the battery. ........................................................................... 127
Fig. 63 Checking cooling oil level ........................................................................................................... 131
Fig. 64 Draining the compressor cooling oil ........................................................................................... 134
Fig. 65 Draining the oil from the heat exchanger ................................................................................... 135
Fig. 66 Draining the cooling oil (closed floor pan - stationary machine) ................................................. 136
Fig. 67 Changing the oil filter .................................................................................................................. 137
Fig. 68 Oil separator tank dirt trap maintenance .................................................................................... 138
Fig. 69 Changing the oil separator cartridge .......................................................................................... 140
Fig. 70 Changing the oil separator cartridge (Option ba) ....................................................................... 142
Fig. 71 Compressor air filter maintenance ............................................................................................. 144
Fig. 72 Cleaning the filter element .......................................................................................................... 145
Fig. 73 Cleaning the compressor cooler and engine radiator ................................................................. 147
Fig. 74 Cleaning the compressed air aftercooler .................................................................................... 148
Fig. 75 Towbar maintenance .................................................................................................................. 150
Fig. 76 Maintaining the fixed height towbar ............................................................................................ 150
Fig. 77 Ball coupling (EC version) .......................................................................................................... 151
Fig. 78 Ball coupling (USA version) ........................................................................................................ 152
Fig. 79 Checking the brake lining thickness ........................................................................................... 153
Fig. 80 Brake system adjustment ........................................................................................................... 153
Fig. 81 Brake rod adjustment ................................................................................................................. 154
Fig. 82 Tool lubricator maintenance ....................................................................................................... 156
Fig. 83 Cleaning the dirt trap .................................................................................................................. 157
Fig. 84 Filter combination ....................................................................................................................... 159
Fig. 85 Combination filter maintenance .................................................................................................. 159
Fig. 86 Fresh air filter maintenance ........................................................................................................ 162
Fig. 87 Filling the frost protector ............................................................................................................. 165
Fig. 88 Cleaning the spark arrestor (floor pan with service openings) ................................................... 166
Fig. 89 Cleaning the spark arrestor (sealed floor pan) ........................................................................... 167
Fig. 90 Engine air intake shut-off valve maintenance ............................................................................. 168
Fig. 91 Securing the belt guard at the generator .................................................................................... 170
Fig. 92 Generator belt tensioning ........................................................................................................... 171
Fig. 93 Towing position .......................................................................................................................... 231
Fig. 94 Ball coupling (ALKO-EU) ............................................................................................................ 232
Fig. 95 Wear alert, ball coupling (ALKO-EU) .......................................................................................... 233
Fig. 96 Ball coupling (ALKO-USA) ......................................................................................................... 234
Fig. 97 Release the parking brake. ........................................................................................................ 234
Fig. 98 Automatic jockey wheel in transport position ............................................................................. 235
Fig. 99 Safety sign - secure the chocks ................................................................................................. 236
Fig. 100 Breakaway cable attachment ..................................................................................................... 237
Fig. 101 ................................................................................................................................................... 237
Fig. 102 Warning "Injury can occur if the towbar is allowed to fall." ......................................................... 238
Fig. 103 Towbar with automatic jockey wheel .......................................................................................... 239
Fig. 104 Actuating the parking brake ........................................................................................................ 239
Fig. 105 Safety sign - secure the chocks ................................................................................................. 240
Fig. 106 Transporting using a forklift truck ............................................................................................... 242
Fig. 107 Guys to secure the freight .......................................................................................................... 243
Fig. 108 Identification ............................................................................................................................... 245

viii M100 No.: 9_6999 23 USE
List of Tables
Tab. 1 Danger levels and their definitions (personal injury) .................................................................. 1

Tab. 2 Danger levels and their definition (damage to property) ............................................................ 2
Tab. 3 Nameplate .................................................................................................................................. 4
Tab. 4 Options label .............................................................................................................................. 5
Tab. 5 Compressed air treatment options ............................................................................................. 5
Tab. 6 Tool lubricator option .................................................................................................................. 5
Tab. 7 Compressed air distributor option .............................................................................................. 5
Tab. 8 Check valve option ..................................................................................................................... 6
Tab. 9 Proportional controller option ..................................................................................................... 6
Tab. 10 Low temperature equipment options .......................................................................................... 6
Tab. 11 Optional equipment for fire hazard areas ................................................................................... 6
Tab. 12 Battery isolating switch option .................................................................................................... 7
Tab. 13 Chassis options .......................................................................................................................... 7
Tab. 14 Options, stationary frame ........................................................................................................... 7
Tab. 15 Lighting options .......................................................................................................................... 8
Tab. 16 Generator options ....................................................................................................................... 8
Tab. 17 Sealed floor pan option .............................................................................................................. 8
Tab. 18 Anti-theft device option ............................................................................................................... 8
Tab. 19 Pedestrian protection option ....................................................................................................... 8
Tab. 20 Instrument panel cover options .................................................................................................. 9
Tab. 21 Sound pressure level ................................................................................................................. 9
Tab. 22 Tightening torques for screws (property class 8.8, coefficient of friction µ = 0.12) .................... 9
Tab. 23 Ambient conditions ..................................................................................................................... 9
Tab. 24 Weight of the machine ................................................................................................................ 10
Tab. 25 Tires ........................................................................................................................................... 10
Tab. 26 Wheel nut/bolt tightening torque ................................................................................................. 11
Tab. 27 Towbar tightening torque ............................................................................................................ 11
Tab. 28 Working pressure and FAD ........................................................................................................ 11
Tab. 29 Compressed air distributor ......................................................................................................... 11
Tab. 30 Safety relief valve activating pressure ........................................................................................ 12
Tab. 31 Machine temperatures ................................................................................................................ 12
Tab. 32 Airend discharge temperature .................................................................................................... 12
Tab. 33 Cooling oil recommendations ..................................................................................................... 13
Tab. 34 Cooling oil recommendation (food processing) .......................................................................... 13
Tab. 35 Cooling oil charge ....................................................................................................................... 14
Tab. 36 Engine specification ................................................................................................................... 14
Tab. 37 Engine oil recommendation ........................................................................................................ 15
Tab. 38 Fluid volumes ............................................................................................................................. 15
Tab. 39 Battery ........................................................................................................................................ 15
Tab. 40 Road breaker lubricant recommendation ................................................................................... 16
Tab. 41 Fresh air filter conditions ............................................................................................................ 16
Tab. 42 Interrelation between compressed air treatment and compressed air quality ............................ 16
Tab. 43 Environmental conditions, low temperature equipment .............................................................. 17
Tab. 44 Coolant pre-heater ..................................................................................................................... 17
Tab. 45 Recommended antifreeze .......................................................................................................... 17
Tab. 46 Battery, low-temperature equipment .......................................................................................... 17
Tab. 47 Generator data ........................................................................................................................... 18
Tab. 48 Compressed air delivery with generator in operation (generator without FAD limitation) .......... 18
Tab. 49 Compressed air delivery with generator in operation (generator with FAD limitation) ............... 19
Tab. 50 Connection sockets .................................................................................................................... 19
Tab. 51 Circuit breaker ............................................................................................................................ 19
Tab. 52 Generator operating limits .......................................................................................................... 19
Tab. 53 Maximum three-phase mains loading ........................................................................................ 20
Tab. 54 Maximum single-phase mains loading ....................................................................................... 20

No.: 9_6999 23 USE M100 ix
List of Tables
Tab. 55 Power reduction at elevated ambient temperatures ................................................................... 20

Tab. 56 Generator data ........................................................................................................................... 21
Tab. 57 Compressed air delivery with generator in operation (generator without FAD limitation) .......... 21
Tab. 58 Compressed air delivery with generator in operation (generator with FAD limitation) ............... 22
Tab. 59 Connection sockets .................................................................................................................... 22
Tab. 60 Circuit breaker ............................................................................................................................ 22
Tab. 61 Generator operating limits .......................................................................................................... 22
Tab. 62 Maximum power supply load ...................................................................................................... 23
Tab. 63 Power reduction at elevated ambient temperatures ................................................................... 23
Tab. 64 Danger areas .............................................................................................................................. 33
Tab. 65 Safety signs ................................................................................................................................ 34
Tab. 66 Generator / Compressor operation ............................................................................................. 54
Tab. 67 Generator operating modes ....................................................................................................... 54
Tab. 68 Measures for re-commissioning the compressor after a long period of storage ........................ 73
Tab. 69 Positioning and operating conditions checklist ........................................................................... 73
Tab. 70 Low-temperature equipment checklist ........................................................................................ 77
Tab. 71 Test instructions for a generator with an ground short detection device. ................................... 80
Tab. 72 Alarm: Engine refuses to start or comes to a stop. .................................................................... 92
Tab. 73 Alarm: Engine does not reach full speed .................................................................................... 93
Tab. 74 Indicator lamp remains on .......................................................................................................... 93
Tab. 75 Fault: Working pressure too high ............................................................................................... 94
Tab. 76 Fault: Working pressure too low ................................................................................................. 94
Tab. 77 Fault: Pressure relief valve blowing off ....................................................................................... 95
Tab. 78 Fault: Machine overheating ........................................................................................................ 95
Tab. 79 Fault: Too much oil residue in the compressed air ..................................................................... 96
Tab. 80 Fault: Oil flows from the compressor air filter after shutdown .................................................... 96
Tab. 81 Fault: High moisture content in the compressed air ................................................................... 97
Tab. 82 There is no voltage or too low a voltage from the generator ...................................................... 97
Tab. 83 Generator voltage too high ......................................................................................................... 97
Tab. 84 Advise others that the machine is being serviced ...................................................................... 99
Tab. 85 Maintenance tasks after commissioning .................................................................................... 100
Tab. 86 Maintenance intervals and regular maintenance tasks .............................................................. 101
Tab. 87 Regular machine maintenance tasks ......................................................................................... 102
Tab. 88 Regular maintenance task options ............................................................................................. 104
Tab. 89 KAESER coolant mixture table ................................................................................................... 108
Tab. 90 Maintenance log ......................................................................................................................... 174
Tab. 91 Compressor consumables .......................................................................................................... 175
Tab. 92 Consumable engine parts .......................................................................................................... 175
Tab. 93 Replacement parts, combination filter ........................................................................................ 176
Tab. 94 Replacement parts, fresh-air filter .............................................................................................. 176
Tab. 95 "Temporarily decommissioned" information notice .................................................................... 227
Tab. 96 Long-term decommissioning and storage checklist ................................................................... 228
Tab. 97 Text for the long-term decommissioned and storage information notice .................................... 229
Tab. 98 Ball coupling wear indicator ........................................................................................................ 233

x M100 No.: 9_6999 23 USE
1.1 Using this document

1.1 Using this document
The operating manual is a component of the product. It describes the machine as it was at the time
of first delivery after manufacture.
➤ Keep the operating manual in a safe place throughout the life of the machine.
➤ Supply any successive owner or user with this operating manual.
➤ Please insert any amendment or revision of the operating manual sent to you.
➤ Enter details from the machine nameplate and individual items of equipment in the table in
chapter 2.
1.2 Further Documents

Further documents included with this operating manual are:
■ Certificate of acceptance / operating instructions for the pressure vessel
■ Manufacturer’s declaration / declaration of conformity in accordance with applicable directives
■ Engine documentation (compressors driven by internal combustion engine)
Missing documents can be requested from KAESER.

➤ Make sure all documents are complete and observe the instructions contained in them.
➤ Make sure you provide the data from the nameplate when ordering documents.
1.3 Copyright
This operator manual is copyright protected. Queries regarding use or duplication of the documen‐
tation should be referred to KAESER. Correct use of information will be fully supported.
1.4 Symbols and labels

➤ Please note the symbols and labels used in this document.
1.4.1 Warnings
Warning notices indicate dangers that may result in injury when disregarded.
Warning notices indicate three levels of danger identified by the corresponding signal word:
Signal term Meaning Consequences of ignoring the warning
DANGER Warns of an imminent danger Will result in death or severe injury
WARNING Warns of a potentially imminent danger May result in death or severe injury
CAUTION Warns of a potentially dangerous situation May result in a moderate physical injury
Tab. 1 Danger levels and their definitions (personal injury)
Warning notices preceding a chapter apply to the entire chapter, including all sub-sections.
For example,

No.: 9_6999 23 USE M100 1
These show the kind of danger and its source.

The possible consequences of ignoring a warning are shown here.
If you ignore the warning notice, the "DANGER" signal word indicates a lethal or severe in‐
jury will occur.
➤ The measures required to protect yourself from danger are shown here.
Warning notes referring to a sub-section or the subsequent action are integrated into the procedure
and numbered as an action.
For example,
1. These show the kind of danger and its source.
The possible consequences of ignoring a warning are shown here.
If you ignore the warning notice, the "WARNING" signal word indicates that death or severe
injury may occur.
➤ The measures required to protect yourself from danger are shown here.
2. Always read and comply with warning instructions.
1.4.2 Potential damage warnings

Unlike the warnings shown above, damage warnings do not indicate a potential personal injury.
Warning notices for damages are identified by their signal term.

Signal term Meaning Consequences of ignoring the warning
NOTE Warns of a potentially dangerous situation Damage to property is possible
Tab. 2 Danger levels and their definition (damage to property)
For example,
These show the kind of danger and its source.

Potential effects when ignoring the warning are indicated here.
➤ The protective measures against the damages are shown here.
➤ Carefully read and fully comply with warnings against damages.
1.4.3 Other alerts and their symbols

This symbol indicates particular important information.
Material Here you will find details on special tools, operating materials or spare parts.
Precondition Here you will find conditional requirements necessary to carry out the task.
The conditions relevant to safety shown here will help you to avoid dangerous situations.
➤ This symbol is placed by lists of actions comprising one stage of a task.

1. For instructions with several steps ...
2. ... the sequence of actions is numbered.

2 M100 No.: 9_6999 23 USE
Result Shows the expected conclusion of the previous action.
Option da ➤ Information relating to one option only is marked with an option code (e.g., "option da" means
that this section is only valid for machines with the air treatment components "aftercooler and
cyclone moisture separator"). Option codes used in this service manual are explained in chap‐
ter 2.2.
Information referring to potential problems are identified by a question mark.
The cause is named in the help text ...
➤ ... and a remedy given.
This symbol refers to important information or measures concerning environmental protec‐
tion.
Further information Further topics are introduced here.

No.: 9_6999 23 USE M100 3
2 Technical Data
2.1 Nameplate
2 Technical Data
2.1 Nameplate
The machine's nameplate provides the model designation and important technical information.
The nameplate is located on the outside of the machine (see illustration in chapter 13.1).
➤ Enter the nameplate data here as a reference:
Feature Value
Vehicle Identification No.
Permissible total weight
Permissible coupling load
Permissible axle load
Portable compressor
Part no.
Serial no.
Year of manufacture
Total weight
Lifting point load capacity
Rated engine power
Engine speed
Maximum working pressure
Tab. 3 Nameplate
2.2 Options
A list of the options fitted to your machine helps to relate the information in this service manual.
Options fitted to the machine are listed on the options label (as code letters).
The nameplate can be found:

■ On the outside of the machine
■ On the front of the machine (see chapter 13.1)
The following table lists all possible options.

Only the codes for those options fitted on the machine appear on the nameplate.

4 M100 No.: 9_6999 23 USE
2 Technical Data
2.2 Options
M100 Part Number Serial no.

Options fitted
da db dc dd
ea ec
fa fc
hc hd
ca cb
ba bb bc bd
la lb
ga gb
oa oe
r1= rb; rc; rd
r3= rm; ro
* r4= rr; rs; rt
r1 r3 r4 r5 r5= rw; rx
ta tb tc te
sf sg pa pb 02-M0277
*r1 - r5 = place holders for chassis options
Tab. 4 Options label
➤ Take note of fitted options from the options label and enter them here for reference.
2.2.1 Option da, db, dc, dd

Compressed air treatment devices
Option Option code Available?
Aftercooler and cyclone separator da
Heat exchanger db
Fresh air filter dc
Filter combination dd
Tab. 5 Compressed air treatment options
2.2.2 Option ea, ec

Tool lubricator
Tool lubricator (with option fa) ea
Tool lubricator (with option fc) ec
Tab. 6 Tool lubricator option
2.2.3 Option fa, fc

Compressed air distributor
Non-separated compressed air distribution line fa

No.: 9_6999 23 USE M100 5
2 Technical Data
2.2 Options

Separated compressed air distribution lines, down‐ fc
stream of the option
Tab. 7 Compressed air distributor option
2.2.4 Option hc, hd

Check valve function
Pressure/check valve (without option dd) hc
Pressure/check valve (with option dd) hd
Tab. 8 Check valve option
2.2.5 Option ca, cb

Proportional controller
Without manual adjustment (100 psi) ca
With manual adjustment (≥145 psi) cb
Tab. 9 Proportional controller option
2.2.6 Option ba
Low temperature equipment
Low temperature equipment ba
Engine coolant pre-heating bb
Frost protector bc
Stronger battery bd
Tab. 10 Low temperature equipment options
2.2.7 Option la, lb

Equipment for fire hazard areas
Spark arrestor la
Spark arrestor and engine air intake shut-off valve lb
(automatic)
Tab. 11 Optional equipment for fire hazard areas

6 M100 No.: 9_6999 23 USE
2 Technical Data
2.2 Options
2.2.8 Option oa
Battery isolating switch
Battery isolating switch oa
Tab. 12 Battery isolating switch option
2.2.9 Option rb/rk/rm/rs, rc/ro/rs, rd/ro/rs, rb/rl/rm/rs, rw, rx

Chassis
Chassis are defined by the combination of several option designations as follows:
Version/axle load/hight adjustment/service brake
Example: rb/rk/rm/rs means
EU chassis with low axle load, with height-adjustable tow bar and overrun brake
Chassis
Chassis Option code Available?

Model (rb, rc, rd):
EU chassis rb
GB chassis rc
US chassis rd
Axle load (rk, rl):
low axle load rk
higher axle load rl
Height adjustment (rm, ro):
With height adjustment rm
Without height adjustment ro
Service brake (rs):
With overrun brake rs
Tab. 13 Chassis options
Stationary frame
Chassis Option code Available?

Stationary (rw, rx):
on skids rw
on frame rx
Tab. 14 Options, stationary frame

No.: 9_6999 23 USE M100 7
2 Technical Data
2.2 Options
2.2.10 Option ta, tb, tc, te

Lighting
None (stationary) ta
Reflective warning triangle tb
EG - 12 V tc
USA - 12 V (DOT conformity) te
Tab. 15 Lighting options
2.2.11 Option ga, gb

Generator
Generator without FAD limitation ga
Generator with FAD limitation gb
Tab. 16 Generator options
2.2.12 Option oe
Sealed floor pan
Sealed floor pan oe
Tab. 17 Sealed floor pan option
2.2.13 Option sf
Anti-theft device
Anti-theft device sf
Tab. 18 Anti-theft device option
2.2.14 Option sg
Pedestrian protection
Pedestrian protection sg
Tab. 19 Pedestrian protection option

8 M100 No.: 9_6999 23 USE
2 Technical Data
2.3 Machine (without options)
2.2.15 Option pa, pb

Instrument panel cover
Instrument panel cover pa
Generator control box cover pb
Tab. 20 Instrument panel cover options
2.3 Machine (without options)

2.3.1 Sound pressure level
Sound pressure levels comply with the American EPA Standard.
Measurement distance: 23 ft
M100
Guaranteed sound pressure level [dB(A)] 76
Tab. 21 Sound pressure level
2.3.2 Tightening torques for screws

Recommended values for screws of property class 8.8
Thread M4 M5 M6 M8 M10 M12 M14 M16 M18 M20

Torque [lbf-in] 26.6 52.2 88.5 216.8 424.8 743.5 1177 1823 2611 3673
Tab. 22 Tightening torques for screws (property class 8.8, coefficient of friction µ = 0.12)
2.3.3 Ambient conditions

Positioning Limit value
Maximum altitude amsl* [ft] 3280
Minimum ambient temperature [°F] 14
Maximum ambient temperature [°F] 122
* Higher altitudes are permissible only after consultation with the manufacturer.
Tab. 23 Ambient conditions
2.3.4 Additional specifications

For specifications, according to the machine's operating license, such as:
■ dimensions,
■ track width,
■ footprint,
can be found in the dimensioned drawings in Chapter 13.3.

No.: 9_6999 23 USE M100 9
2 Technical Data
2.4 Chassis
The dimensional drawings also show the position of the following inlets and outlets:
■ Cooling air inlet
■ Cooling air outlet
■ Compressed air outlet
■ Exhaust
2.4 Chassis
2.4.1 Weight
The values given are the maximum in each case. Actual weight of individual machines is depend‐
ent on equipment fitted (see machine nameplate).
Feature Chassis Stationary

Height adjustment with without –
Axle load low high low –
Actual total weight [lb]*
Permissible axle load [lb] 3527 3968 3527 –
* Enter here for reference, the actual total weight taken from the machine nameplate.
Tab. 24 Weight of the machine
2.4.2 Tires
The tire's dimensions are shown on the side wall, see also Fig. 1.
Fig. 1 Example for Tire information on the side wall

1 Section, Tire side wall 5 Rim diameter [in]
2 Tire width [in] 6 Light truck Tires (commercial)
3 Ratio cross-section height to cross-section 7 Cross-section height
width [%] 8 Cross-section width
4 Radial design
Use the following table for detailed information regarding the tires of your machine:
Characteristic/marking Value
Axle load low high
Tire size 185 R 14C 195 R 14C

10 M100 No.: 9_6999 23 USE
2 Technical Data
2.5 Compressor
Characteristic/marking Value
Minimum and recommen‐ 65 65
ded tire pressure [psi]
Wheel nuts/bolts M 12 x 1.5 M 12 x 1.5
Tab. 25 Tires
Further information See tire side wall for maximum pressure.
2.4.3 Wheel nut/bolt tightening torque

Fixing medium Thread Wrench size Torque [lbf in]
Wheel bolt M 12 x 1.5 19 797
Tab. 26 Wheel nut/bolt tightening torque
2.4.4 Towbar tightening torque

Components Thread Strength category Torque [lbf in]
Ball coupling M16 8.8 1858
Towing eye M16 8.8 1858
Towbar M16 8.8 1858
M20 10.9 4778–4957
M24 8.8 5930–6107
Tab. 27 Towbar tightening torque
2.5 Compressor
2.5.1 Working pressure and FAD
Maximum working gauge pressure [psig] 100 145 175 205
SIGMA airend 27 G
Free air delivery [cfm] 360 300 254 226
FAD as per ISO 1217:2009. Annex D
Tab. 28 Working pressure and FAD
2.5.2 Compressed air outlet

Outlet valve ["] Number
G 3/4 3
G 1 1/2 1
Tab. 29 Compressed air distributor

No.: 9_6999 23 USE M100 11
2 Technical Data
2.5 Compressor
2.5.3 Safety relief valves

Maximum working pressure: see machine nameplate
Maximum working pres‐ Activating pressure [psig]

sure [psig] Safety relief valve * Safety relief valve **
100 138 –
145 205 175
175 232 205
205 232 225
* On the oil separator tank
** Upstream of the compressed air outlet (Option cb only)
Tab. 30 Safety relief valve activating pressure
2.5.4 Temperature
Machine temperatures Values
Recommended airend discharge temperature for 86
switching to load [°F]
Typical airend discharge temperature during opera‐ 167 ..... 212
tion [°F]
Maximum airend discharge temperature (automatic 239
safety shut-down) [°F]
Tab. 31 Machine temperatures
Temperature at the airend discharge port

Ambient temperature [°F] Combination valve (thermostatic valve)
with ambient temper‐ without ambient tem‐
ature acquisition [°F] perature acquisi‐
tion [°F]
(Option db)
50 194 –
68 – 194
77 140 –
Tab. 32 Airend discharge temperature
2.5.5 Cooling oil recommendation

A sticker showing the type of oil used is located near the oil separator tank filler.
Information on ordering cooling oil is found in chapter 11.

12 M100 No.: 9_6999 23 USE
2 Technical Data
2.5 Compressor
Cooling oils for general applications
SIGMA FLUID
MOL S-460 S-570
Description Mineral oil Silicone-free, Synthetic oil
synthetic oil
Application Standard oil for all appli‐ Standard oil for all applica‐ Special oil for ambient
cations except in con‐ tions except in connection conditions with high tem‐
nection with food prod‐ with food products peratures and humidity.
ucts. Particularly suitable for ma‐ Standard oil for all appli‐
Particularly suitable for chines with a high duty cy‐ cations except in connec‐
machines with a low duty cle. tion with food products.
cycle. Particularly suitable for
machines with a high duty
cycle.
Approval — — —
Viscosity at 44 mm /s
2
45 mm /s2
52.8 mm2/s
104°F (DIN 51562-1) (D 445; ASTM test) (D 445; ASTM test)
Viscosity at 6.8 mm2/s 7.2 mm2/s 8.0 mm2/s
212°F (DIN 51562-1) (D 445; ASTM test) (D 445; ASTM test)
Flash point 428°F 460°F 496°F
(ISO 2592) (D 92; ASTM test) (D 92; ASTM test)
Density at — 864 kg/m3 0.869 kg/l
59°F (ISO 12185) (D 1298; ASTM test)
Pour point –27°F −51°F -65°F
(ISO 3016) (D 97; ASTM test) (D 97; ASTM test)
Demulsibility — 40/40/0/10 min 15 min
at 129°F (D 1401; ASTM test) (D 1401; ASTM test)
Tab. 33 Cooling oil recommendations
Cooling oils for applications in food processing
SIGMA FLUID
FG-460 FG-680
Description Synthetic oil Synthetic oil
Application Specifically for machines in applica‐ Special oil for ambient conditions with
tions where the compressed air high temperatures and humidity.
may come into contact with food‐ Specifically for machines in applications
stuff. where the compressed air may come into
contact with foodstuff.
Approval USDA H-1, NSF USDA H-1, NSF
Approved for the manufacture of Approved for the manufacture of food
food packaging, meat and poultry packaging, meat and poultry processing
processing and other food process‐ and other food processing applications.
ing applications.
Viscosity at 50.7 mm2/s 70.0 mm2/s
104 °F (D 445; ASTM test) (D 445; ASTM test)

No.: 9_6999 23 USE M100 13
2 Technical Data
2.6 Engine
SIGMA FLUID
FG-460 FG-680
Viscosity at 8.2 mm /s
2
10.4 mm2/s
212 °F (D 445; ASTM test) (D 445; ASTM test)
Flash point 473 °F 473 °F
(D 92; ASTM test) (D 92; ASTM test)
Density at 59 °F — —
Pour point — —
Demulsibility at — —
130 °F
Tab. 34 Cooling oil recommendation (food processing)
2.5.6 Cooling oil charge

Cooling oil Fluid volume [gal]
Machine 5.8
Compressor unit + heat exchanger 6.6
(Option db)
Tab. 35 Cooling oil charge
2.6 Engine
2.6.1 Engine specification
Feature Specification
Make/Model Kubota / V 3800 DI-T
Engine control Mechanical
Fuel injection Mechanical
Rated engine power [hp] 97.6
Speed at LOAD mode [rpm] 2600
Speed at IDLE mode [rpm] 1800
Type of fuel Diesel
Fuel consumption under LOAD mode [gal/h] 4.89
Oil consumption relative to fuel consumption [%] approx. 0.5
Tab. 36 Engine specification
2.6.2 Oil recommendation

The engine oil must meet the following classification:
■ ACEA, class E4, E7

■ API, class CF, CI-4

14 M100 No.: 9_6999 23 USE
2 Technical Data
2.6 Engine
The engine is filled initially with engine oil of viscosity class SAE 10W–40 .
Ambient temperature [°F] Viscosity class

68 ..... 122 SAE 40
32 ..... 68 SAE 20W
5 ..... 32 SAE 10W
14 ..... 104 SAE 15W–40
−22 ..... 86 SAE 5W–30
−4 ..... 104 SAE 10W–40
Tab. 37 Engine oil recommendation
2.6.3 Fuel recommendation

The diesel fuel must meet the requirements of EN 590 and ASTM D975 respectively.
According to these standards a specific portion of bio-diesel is permitted in the fuel.
Depending on the country of origin, bio-diesel can be produced from different plant materials and
thus have different properties.
Affected by temperature, atmospheric oxygen, and time, these bio-diesel components in the fuel
may decompose in the fuel and thus cause damages within the fuel system.
The use of other fuels as well as the mixing with additives is only permitted after consultation
with the engine manufacturer.
The engine service manual gives further information on fuel use.
2.6.4 Recommended Cooling Fluid

The engine coolant must meet the requirements of specification ASTM D4985.
Do not use a common coolant / antifreeze that only meets the requirements of ASTM D3306.
Such coolants are intended only for light use in vehicles and could shorten the useful life of
the engine.
The engine service manual gives further information on coolant application.
2.6.5 Fluid volumes

Description Fluid volume [gal]
Engine oil 2.9
Fuel 39.63
Coolant 4.23
Tab. 38 Fluid volumes
2.6.6 Battery
Feature Value
Voltage [V] 12
Capacity [Ah] 80

No.: 9_6999 23 USE M100 15
2 Technical Data
2.7 Options
Feature Value
PTC testing current [A] 640
(according to EN 50342)
Tab. 39 Battery
Further information Depending on machine equipment, a higher capacity battery may be required. See chapter 2.7.2.
2.7 Options
2.7.1 Air treatment options
2.7.1.1 Option ea, ec
Tool lubricator
Name Temperature range [°F] Fluid volume [gal]

Special road breaker lubricant −13 ..... 122 2.64
Tab. 40 Road breaker lubricant recommendation
2.7.1.2 Option dc
Fresh air filter
Feature Value
Maximum working pressure [psig] 232
Minimum ambient temperature [°F] 34.7
Tab. 41 Fresh air filter conditions
2.7.1.3 Air quality at the compressed air outlets
Interrelation between compressed air treatment and compressed air quality:
Air Treatment Compressed air quality

Option designation Components Characteristics Abbreviation
da ■ After-cooler cool and condensate- A
■ Cyclone separator free
da + db ■ After-cooler dry and warmed B

■ Cyclone separator
■ Heat exchanger
da + dd ■ After-cooler dry and technically oil- F
■ Cyclone separator free
■ Filter combination
da + dd + db ■ After-cooler technically oil-free and G
■ Cyclone separator warmed
■ Filter combination
■ Heat exchanger

16 M100 No.: 9_6999 23 USE
2 Technical Data
2.7 Options
Air Treatment Compressed air quality

Option designation Components Characteristics Abbreviation
ea / ec Tool lubricator Lubricated E
Tab. 42 Interrelation between compressed air treatment and compressed air quality
The compressed air outlets at the air distributor are labelled with the identifiers of com‐
pressed air quality.
2.7.2 Option ba
Low temperature equipment
2.7.2.1 Ambient conditions
Installation Limit value

Maximum altitude amsl* [ft] 3280
Minimum ambient temperature [°F] −13
* Higher altitudes are permissible only after consultation with the manufacturer.
Tab. 43 Environmental conditions, low temperature equipment
2.7.2.2 Option bb
Engine coolant pre-heating
Coolant pre-heater Value

Voltage [V] 230
Power [W] 550
Tab. 44 Coolant pre-heater
2.7.2.3 Option bc
Compressed air line frost protection
Antifreeze Fluid volume [qt]

Antifreeze protection for air brake systems 0.32
(e.g., Wabcothyl)
Tab. 45 Recommended antifreeze
2.7.2.4 Option bd
Battery
Feature Value
Voltage [V] 12
Capacity [Ah] 100
PTC testing current [A] 850
(according to EN 50342)
Tab. 46 Battery, low-temperature equipment

No.: 9_6999 23 USE M100 17
2 Technical Data
2.7 Options
2.7.3 Option ga, gb

Generator (50 Hz version)
Generator specification:
Features Generator Generator Generator

400V, 3-ph 230V, 3-ph 115V, 2-
phase
Rated power [kVA] 13.0 8.5 13.0 8.5 7.0
3-phase/2-phase
Rated power [kVA] 7.0 5.0 7.5 5.0 5.0
single-phase
Voltage constant [%] ±5
balanced load
Voltage constant [%] +6/−10
single-phase, unbalanced
load
Rated power [kVA] 18.8 12.3 32.6 21.0 31.0
3-phase/2-phase
Rated current [A] 30.0 21.7 32.6 21.0 45.0
1-phase
Rated current [A] 300.0 260.0 330.0 330.0 420.0
short circuit ( 0.3 s/170
V)
Power factor (cos j) 0.8 – 1
Frequency [Hz] 50
Speed [rpm] 3000
Distortion factor [%] <5
Type Synchronous internal pole (electronically controlled)
Protection rating IP 54
Tab. 47 Generator data
Option ga Reduced compressed air delivery (generator without FAD limitation)
Features Generator Generator

13.0 [kVA] 8.5 [kVA]
Maximum working pres‐ 100 145 100 145 175
sure [psi]
FAD [cfm] − generator 215 194 300 254 226
OFF
FAD cfm] − generator ON 215 194 300 254 226
Tab. 48 Compressed air delivery with generator in operation (generator without FAD limitation)

18 M100 No.: 9_6999 23 USE
2 Technical Data
2.7 Options
Option gb Reduced compressed air delivery (generator with FAD limitation)
Features Generator Generator Generator

13.0 [kVA] 8.5 [kVA] 7.0 [kVA]
Maximum working pres‐ 100 145 100 145 100
sure [psi]
OFF
ON
Tab. 49 Compressed air delivery with generator in operation (generator with FAD limitation)
Connections:
Type Generator Generator Generator

400V, 3-ph 230V, 3-ph 115V, 2-phase
Power sockets Quantity:
16 A; 230 V/1~/N/PE 3 – –
16 A; 400 V/3~/N/PE 1 – –
16 A; 230 V/2~/PE – 2 –
32 A; 230 V/3~/PE – 1 –
16 A; 230 V/3~/PE – 1 –
32 A; 115 V/2~/PE – – 1
16 A; 115 V/2~/PE – – 2
Tab. 50 Connection sockets
Overload protection switch
Type Generator Generator Generator

400V, 3-ph 230V, 3-ph 115V, 2-phase
Miniature circuit breaker Quantity:
[A]
16 1 1 2
32 – 1 1
Tab. 51 Circuit breaker
Operating limits:
(to EN 60034-22, page 10, table)
Features Value
Design category G3
Voltage adjustment range [%] ±5
Static voltage deviation [%] 1
Maximum dynamic voltage drop [%] –15

No.: 9_6999 23 USE M100 19
2 Technical Data
2.7 Options
Features Value
Maximum dynamic voltage rise [%] 20
Maximum voltage settling time [ms] 1500
Maximum voltage asymmetry [%] 1
Tab. 52 Generator operating limits
Maximum power loading by consumers
Resistive consumers include lamps and heaters, for example.

Electric motors and transformers are inductive consumers.
Nominal rating conditions:

■ Ambient temperature: 77 °F
■ Max. height above sea level at the place of use: 328 ft
Three-phase power supply
Generator 400V, 3-ph 230V, 3-ph

Rated power [kVA] 13.0 8.5 13.0 8.5
Resistive consum‐ – 13.0 8.5 12.7 8.5
ers [kVA]
Inductive consumers [kW] Rated power 7.5 5.0 12.7 8.5
Tab. 53 Maximum three-phase mains loading
AC power:
Generator 400V, 3-ph 230V, 3-ph 115V, 2-

ph
Rated power [kVA] 13.0 8.5 13.0 8.5 7.0
Resistive consum‐ per phase 3.5 – 3.5 – –
ers [kVA] total 10.5 5.0 10.5 5.0 5.0
Inductive consumers [kW] Rated 3.5 – 3.5 – –
power
per phase
Rated 10.5 5.0 10.5 5.0 5.0
power
total
Tab. 54 Maximum single-phase mains loading
Power reduction at elevated ambient temperatures:
Ambient temperature Generator power

[°F]
≤86 Full power available
>86 Reduction of 10 % for each temperature rise of 50 °F.
Tab. 55 Power reduction at elevated ambient temperatures

20 M100 No.: 9_6999 23 USE
2 Technical Data
2.7 Options
2.7.4 Option ga, gb

Generator (60 Hz version)
Generator specification:
Features Generator
250V, 2-phase
Rated power [kVA] 13.0 8.0
2-phase
Rated power [kVA] 7.0 5.0
single-phase
Voltage [V] 250/125
Voltage constant [%] ±5
balanced load
Voltage constant [%] +6/−10
single-phase, unbalanced
load
Rated current [A] 56.0 35.0
2-phase ( 230V )
2-phase ( 115V )
short circuit ( 0.3 s/170
V)
Power factor (cos j) 0.8 – 1
Frequency [Hz] 50
Speed [rpm] 3600
Distortion factor [%] <5
Type Synchronous internal pole (electronically controlled)
Protection rating IP 54
Tab. 56 Generator data
Option ga Reduced compressed air delivery (generator without FAD limitation)
Features Generator
8.0 [kVA]
Maximum working pres‐ 100 145 175 205
sure [psig]
FAD with simultaneous 300 254 226 194
generator operation [cfm]
Tab. 57 Compressed air delivery with generator in operation (generator without FAD limitation)

No.: 9_6999 23 USE M100 21
2 Technical Data
2.7 Options
Option gb Reduced compressed air delivery (generator with FAD limitation)
Features Generator Generator

13.0 [kVA] 8.0 [kVA]
Maximum working pres‐ 100 145 100 145
sure [psig]
FAD with simultaneous 159 120 187 162
generator operation [cfm]
Tab. 58 Compressed air delivery with generator in operation (generator with FAD limitation)
Connections:
Power sockets Quantity:

30 A; 250 V/2~/PE 2
20 A; 125 V/2~/PE 2
Tab. 59 Connection sockets
Overload protection switch
Type Generator Generator

250V, 2-phase 125V, 1-phase
Miniature circuit break‐ Quantity:
er [A]
16 1 1
Tab. 60 Circuit breaker
Operating limits:
(to EN 60034-22, page 10, table)
Features Value
Design category G3
Voltage adjustment range [%] ±5
Static voltage deviation [%] 1
Maximum dynamic voltage drop [%] –15
Maximum dynamic voltage rise [%] 20
Maximum voltage settling time [ms] 1500
Maximum voltage asymmetry [%] 1
Tab. 61 Generator operating limits
Maximum power loading by consumers
Resistive consumers include lamps and heaters, for example.

Electric motors and transformers are inductive consumers.

22 M100 No.: 9_6999 23 USE
2 Technical Data
2.7 Options
Nominal rating conditions:

■ Ambient temperature: 77 °F
■ Max. height above sea level at the place of use: 328 ft
Generator [kVA] 13.0 8.0

Resistive consum‐ per phase 6.5 4.0
ers [kVA] total 13.0 8.0
Inductive consumers [kW] Rated power 5.0 5.0
Tab. 62 Maximum power supply load
Power reduction at elevated ambient temperatures:
Ambient temperature Generator power

[°F]
≤86 Full power available
>86 Reduction of 10 % for each temperature rise of 50 °F.
Tab. 63 Power reduction at elevated ambient temperatures

No.: 9_6999 23 USE M100 23
3.1 Basic instructions

The machine is manufactured to the latest engineering standards and acknowledged safety regula‐
tions. Nevertheless, dangers can arise through its operation:
■ danger to life and limb of the operator or third parties,
■ Impairments to the machine and other material assets.
Disregard of warning or safety instructions can cause serious injuries!
➤ Use this machine only if it is in a technically perfect condition and only for the purpose for
which it is intended; observe all safety measures and the instructions in the service manual!
➤ Immediately rectify (have rectified) any faults that could be detrimental to safety!
3.2 Specified use

The machine is intended solely for generating compressed air for industrial use. Any other use is
considered incorrect. The manufacturer is not liable for any damages that may result from incorrect
use. The user alone is liable for any risks incurred.
➤ Keep to the specifications listed in this service manual.
➤ Operate the machine only within its performance limits and under the permitted ambient condi‐
tions.
➤ Do not use compressed air for breathing purposes unless it is specifically treated.
➤ Do not use compressed air for any application that will bring it into direct contact with food
products unless it is specifically treated.
3.3 Incorrect Use

Improper usage can cause damage to property and/or (severe) injuries.
➤ Only use the machine as intended.
➤ Never direct compressed air at persons or animals.
➤ Do not use untreated compressed air for breathing purposes.
➤ Do not allow the machine to take in toxic, acidic, flammable, or explosive gases or vapors.
➤ Do not operate the machine in areas in which specific requirements with regard to explosion
protection are in effect.
3.4 User's Responsibilities

3.4.1 Observe statutory and universally accepted regulations
➤ Observe relevant statutory and accepted regulations during operation, transporting and main‐
tenance of the machine.

24 M100 No.: 9_6999 23 USE
3.4 User's Responsibilities
3.4.2 Determining personnel

Suitable personnel are experts who, by virtue of their training, knowledge, and experience as well
as their knowledge of relevant regulations can assess the work to be done and recognize the pos‐
sible dangers involved.
Authorized operators possess the following qualifications:

■ are of legal age,
■ are familiar with and adhere to the safety instructions and sections of the service manual rele‐
vant to operation,
■ have received adequate training and authorization to operate vehicles and electrical and com‐
pressed air devices.
Authorized maintenance personnel possess the following qualifications:

■ have read, are familiar with and adhere to the safety instructions and sections of the service
manual applicable to maintenance,
■ are completely familiar with the safety concepts and regulations of motor vehicle, electrical and
compressed air engineering,
■ are able to recognize the possible dangers of motor vehicle, electrical and compressed air de‐
vices and take appropriate measures to safeguard persons and property,
■ have received adequate training in and authorization for the safe installation and maintenance
of this machine.
Authorized transport personnel possess the following qualifications:

■ are familiar with and adhere to the safety instructions and sections of the service manual rele‐
vant to transporting,
■ are trained and authorized in safe vehicle transporting,
■ are familiar with the safety regulations relating to handling motor vehicles and transport goods,
■ are able to recognize the possible dangers of motor vehicles and take appropriate measures to
safeguard persons and property.
➤ Ensure that personnel entrusted with operation, maintenance and transporting are qualified
and authorized to carry out their tasks.
3.4.3 Adherence to inspection schedules and accident prevention regulations

The machine may be subject to local inspection schedules.
➤ Ensure that local inspection schedules are adhered to.
3.4.4 Attachment of a "Hazardous goods" label

The special regulation 363 "Transport of machines and equipment with liquid fluids" of the Europe‐
an regulations for the hazardous goods transport (ADR) has taken effect.
This regulation requires that machines filled with more than 0.26 gallons petrol or 1.32 gallons die‐
sel (in the fuel tank) during transport must be identified with hazardous goods labels on the ma‐
chine's exterior.

No.: 9_6999 23 USE M100 25
3.5 Dangers
Number of labels per machine:

■ Fuel tank content 16 - 119 gallons
─ ➤ Attach one label to the exterior.
■ Fuel tank content 120 gallons - 396 gallons
─ ➤ Attach one label on every exterior side.
The operator of the machine but also the authorised users and transport personnel are re‐
sponsible for compliance with this requirement. Please instruct your employees accordingly.
A violation of this regulation will be punished with a fine and the further machine transport will
be forbidden.
➤ Have a "Hazardous goods" label attached.
Further information Chapter CROSS_REFERENCE_FAILED “Safety signs” indicates the suggested position(s) for the
hazardous goods label(s).
3.5 Dangers
Basic instructions
The following describes the various forms of danger that can occur during machine operation.
Basic safety instructions are found in this service manual at the beginning of each chapter in the
section entitled 'Safety'.
Warning instructions are found before a potentially dangerous task.
3.5.1 Safely dealing with sources of danger

The following describes the various forms of danger that can occur during machine operation.
Exhaust fumes
Exhaust gases from combustion engines contain carbon monoxide, a color- and odor-less but high‐
ly toxic gas. The inhalation of minute quantities can be lethal.
Furthermore, diesel exhaust contains soot particles, some of which are noxious.
➤ Do not inhale exhaust fumes.
➤ Park the machine in such a manner that the exhaust cannot blow towards the operators.
➤ Never use the machine in enclosed spaces, only in the open.
Fire and explosion
Spontaneous ignition and combustion of fuel can result in serious injury or death.
➤ Allow no open flames or sparks at the place of use.
➤ Do not smoke while refueling.
➤ Never refuel the machine when it is running.
➤ Do not allow fuel to overflow.
➤ Wipe up spilled fuel immediately.
➤ Provide a fire extinguisher in the immediate vicinity.
➤ For operation in combustible environment, fit the machine with an exhaust silencer (Option la).

26 M100 No.: 9_6999 23 USE
3.5 Dangers
Hot coolant
The cooling system of a liquid-cooled engine at running temperature is under high pressure. If the
filler cap is unscrewed, hot coolant can spray out under pressure and cause severe scalding.
➤ Let the machine cool down before opening the cooling system.
➤ Unscrew the filler cap carefully by a quarter to half a turn at first. Remove the filler cap only
when pressure has escaped completely.
Electricity
Touching voltage-carrying components can result in electric shocks, burns, or death.

➤ Allow only qualified and authorized electricians or trained personnel under the supervision of a
qualified and authorized electrician to carry out work on electrical equipment according to elec‐
trical engineering regulations.
➤ Only qualified and authorized electricians may carry out work on the generator or generator
control box.
➤ Check regularly that all electrical connections are tight and in proper condition.
➤ Switch off any external power sources.
For example, the connections to the electrical engine cooling water pre-heater.
Forces of compression
Compressed air is contained energy. Uncontrolled release of this energy can cause serious injury
or death. The following information concerns work on components that could be under pressure.
➤ Wait until the compressor has automatically vented (check the pressure gauge: it must read
0 psig).
➤ Then open an outlet valve carefully to ensure that the line between the minimum pressure /
check valve and the compressed air outlet is vented.
➤ Do not carry out welding, heat treatment or mechanical modifications to pressurized compo‐
nents (e.g. pipes and vessels) as this influences the component's resistance to pressure. The
safety of the machine is then no longer ensured.
Compressed air quality
The composition of the compressed air must be suitable for the actual application in order to pre‐
clude health and life-threatening dangers.
➤ Use appropriate systems for air treatment before using the compressed air from this machine
as breathing air (fresh air reinforcement) and/or for the processing of foodstuffs.
➤ Use foodstuff-compatible cooling oil whenever compressed air is to come into contact with
foodstuffs.
Spring forces
Springs under tension or compression store energy. Uncontrolled release of this energy can cause
serious injury or death.
Minimum pressure / check valves, safety relief valves, and inlet valves are powerfully spring-loa‐
ded.
➤ Do not open or dismantle any valves.

No.: 9_6999 23 USE M100 27
3.5 Dangers
Rotating components
Touching the fan wheel, the coupling, or the drive while the machine is switched on can result in
serious injury.
➤ Do not open the service doors or panels while the machine is running.
➤ Prior to opening the service doors or the canopy, switch off the engine, disconnect from power
source and secure against unintended reactivation.
➤ Wear close-fitting clothes and a hair net if necessary.
➤ Ensure that all covers and safety guards are in place and secured before restarting.
Temperature
The operation of the combustion engine and the compression generate high temperatures. Touch‐
ing hot components may cause injuries.
➤ Avoid contact with hot components.
These include, for example, engine, compressor airend, oil and compressed air lines, coolers
and oil separator tank. Any objects in or near the flow of exhaust gas or discharged cooling air
will become very hot.
➤ Wear protective clothing.
➤ Wear protective gloves when connecting or disconnecting compressed air hoses.
➤ Allow the machine to cool down before commencing any maintenance work.
➤ If welding is carried out on or near the machine, take adequate measures to prevent sparks or
heat from igniting oil vapors or parts of the machine.
Noise
The enclosure absorbs the machine noise to a tolerable level. This function will be effective only if
the body is closed.
➤ Operate the machine only with closed body and intact sound insulation.
➤ Wear hearing protection if necessary.
The blowing-off of the safety relief valve can be particularly loud.
➤ Never generate compressed air without consumers being connected.
Operating fluids/materials
The used operating fluids and materials can cause adverse health effects. Suitable safety meas‐
ures must be taken in order to prevent injuries.
➤ Strictly forbid fire, open flame and smoking.
➤ Follow safety regulations when dealing with fuel, lubricants, antifreeze and chemical substan‐
ces.
➤ Avoid contact with skin and eyes.
➤ Do not inhale fumes or aerosols from fuel or oil.
➤ Do not eat or drink while handling fuel, cooling and lubricating fluids or antifreeze.
➤ Keep suitable fire extinguishing agents ready for use.
➤ Use only KAESER approved operating materials.
Unsuitable spare parts
Unsuitable spare parts compromise the safety of the machine.

28 M100 No.: 9_6999 23 USE
3.5 Dangers
➤ Use only spare parts approved by the manufacturer for use in this machine.
➤ Use only genuine KAESER pressure components.
Conversion or modification of the machine
Modifications, additions or conversions to or of the machine can result in unpredictable hazards.

➤ Do not convert or modify the machine!
➤ Do not install any non-approved additional components.
➤ Do not make any changes to the machine that will increase its weight beyond the permissible
limit and/or endanger its safe use or transportation. Any such changes invalidate the approval
to use the machine or tow it on the road.
➤ Prior to any technical modification and expansions of the machine, obtain the written approval
of the manufacturer.
3.5.2 Safe machine operation

The following is information supporting you in the safe handling of the machine during individual
product life phases.
Personal protective equipment
When working on the machine you may be exposed to dangers that can result in accidents with
severe adverse health effects.
➤ Wear protective clothing as necessary.
Suitable protective clothing (examples):

■ Safety work wear
■ Protective gloves
■ Safety boots
■ Eye protection
■ Ear protection
3.5.2.1 Transport
The weight and size of the machine require safety measures during its transport to prevent acci‐
dents.
➤ Allow transport only by personnel trained in safely dealing with motor vehicles and the trans‐
port of goods.
➤ Ensure that no persons are on the machine when transporting.
Transport as trailer
Non-compliance with the basic rules for a safe trailer operation may cause severe accidents during
machine transport.
➤ The maximum permissible load for the towing vehicle coupling and the maximum coupling load
given for the machine must not be exceeded.
➤ Avoid causing a shift in the centre of gravity by an excessive or incorrectly distributed load.
➤ Do not tow in such a way as to impose excessive stress on the machine or chassis.
➤ Adjust towing speed to accommodate ground and weather conditions. This applies particularly
to unpaved roads and when taking curves.

No.: 9_6999 23 USE M100 29
3.5 Dangers
➤ The towbar must be parallel with the ground otherwise towing instability can develop, resulting
in damage to the machine and/or towing vehicle.
➤ Before moving the machine, make sure any security devices (e.g. anti-theft chain) are re‐
leased.
Transport as trailer on public roads
➤ Do not tow machines without service brake on public roads.

➤ Do not tow machines without illumination and signaling equipment on public roads.
➤ Ensure all running gear, including chassis, wheels, brakes, signalling and lighting, is in safe
condition.
➤ The local laws and regulations regarding the use of public roads must be observed.
Transporting with a crane
Non-compliance with the safety regulations for load suspension and hoisting equipment may cause
severe accidents during lifting and moving the machine with cranes.
➤ Do not enter the danger zone while the machine is being lifted.
➤ Never lift and move the machine over people or occupied buildings.
➤ Avoid extreme weight shifting caused by additional loads or additions (tilting).
➤ Do not exceed the lifting capacity on the machine's lifting point (lifting eye).
➤ Only the designated lifting point should be used to attach lifting gear and under no circumstan‐
ces are handles, tow-bar or other components to be used.
➤ Use only hooks and shackles that comply with local safety regulations
➤ Do not attach cables, chains or ropes directly to the machine's lifting eye.
➤ Do not manipulate the crane suspension system, in particular the holding points of the crane
lifting eye.
➤ If screwed crane fixings had to be removed, please use only new self-locking nuts when instal‐
ling.
➤ Avoid jerking when lifting, as this may damage components.
➤ Loads must be slowly lifted and carefully set down.
➤ Never allow the load to hang from the crane longer than necessary.
The following are forbidden:
■ Air transport of the machine by slinging beneath a helicopter.

■ Dropping the machine by parachute.
3.5.2.2 Installation
The operator must ensure that only authorised personnel has access to the machine.
General instructions
A suitable installation location for the machine prevents accidents and faults.
➤ Do not position the machine directly against a wall. A build up of heat from the exhaust can
damage the machine.
➤ Ensure accessibility so that all work on the machine can be carried out without danger or hin‐
drance.

30 M100 No.: 9_6999 23 USE
3.5 Dangers
➤ Do not operate in areas in which specific requirements with regard to explosion protection are
in force.
For instance, the requirements of ATEX directive 94/9/EC "Equipment and Protective Systems
intended for use in Potentially Explosive Atmospheres".
➤ Ensure adequate ventilation.
➤ Place the machine in such a manner that the working conditions in its environment are not im‐
paired.
➤ Comply with limit values for ambient temperature and humidity.
➤ The intake air must not contain any damaging contaminants,
Damaging contaminants are for instance:

■ Exhaust gases from combustion engines,
■ Combustible, explosive or chemically unstable gases or vapours,
■ Acid- or base-forming chemicals such as ammonia, chlorine, or hydrogen sulphide.
➤ Do not position the machine in the warm exhaust air flow from other machines.
➤ Keep suitable fire extinguishing agents ready for use.
Parking the machine:
Improper parking and use of the parked machine endangers personnel and material.
➤ To park the machine, select an even and solid surface which is capable of bearing the ma‐
chine's weight.
➤ Move the machine only with a towing vehicle.
➤ Secure the parked machine:
■ Lower the prop stand / wind down the jockey wheel.

■ Chock the wheels to prevent unwanted movement.
─ Place chocks under the wheels.
─ Pull on the parking brake.
➤ Unauthorised persons must not be present in the parking area of the machine. The parking
area must be properly secured.
➤ The machine – the chassis and the towing mechanism in particular – must not be stepped on
or used for sitting.
➤ Do not place additional loads on the machine (e.g. excavator bucket as anti-theft measure).
3.5.2.3 Commissioning, operation and maintenance
During commissioning, operation and maintenance you may be exposed to dangers resulting from,
e.g., electricity, pressure and temperature. Careless actions can cause accidents with severe ad‐
verse effects for your health.
➤ Allow maintenance work to be carried out only by authorised personnel.
➤ Wear close-fitting, flame-resistant clothing. Wear protective clothing as necessary.
➤ Switch off the machine and lock out the supply disconnecting device.
➤ De-pressurise all pressurised components and enclosures.
■ Wait until the machine has automatically vented.

■ Carefully open the compressed air outlet valve.
■ Check: The pressure gauge must read 0 psig!

No.: 9_6999 23 USE M100 31
3.5 Dangers
➤ Allow the machine to cool down.

➤ Do not open the body while the machine is switched on.
➤ Use only spare parts approved by KAESER for use in this machine.
➤ Operate the machine only in technically sound condition.
➤ Carry out regular inspections:
■ for visible damage and leakage,

■ of safety devices,
■ of the EMERGENCY STOP devices (if present),
■ of parts needing monitoring.
➤ Pay particular attention to cleanliness during all maintenance and repair work. Cover compo‐
nents and openings with clean cloths, paper or tape to keep them clean.
➤ Do not leave any loose components, tools or cleaning rags on or in the machine.
➤ Components removed from the machine can still be dangerous.
Do not attempt to open or destroy any components taken from the machine.
➤ Self-locking nuts removed for the installation must not be reused but replaced by new nuts, be‐
cause the non-positive safety is no longer ensured.
➤ Use only suitable compressed air hoses.
Compressed air hoses must meet the following requirements:

■ they are of the right type and size for the highest permissible machine working pressure,
■ they are not damaged, worn or of reduced quality,
■ they have couplings and connections of the right type and size.
➤ Wear protective gloves when connecting or disconnecting compressed air hoses.

➤ Make sure compressed air hoses are de-pressurised before disconnecting from the machine.
➤ Secure the open end of an air hose before applying air pressure. An unsecured hose may whip
and cause injury.
➤ At working pressures>100 psi, compressed air hoses should be secured by a cable to their re‐
spective outlet valves.
➤ Connect and operate only suitable air tools.
■ The air tools must meet the set output pressure of the machine.
■ Use a pressure reducer for air tools requiring a lower pressure.
■ Use compressed air tools only with the pressure appropriate for its purpose (tool working pres‐
sure).
3.5.2.4 De-commissioning, storage and disposal
Improper handling of old operating fluids and components represent a danger for the environment.
➤ Drain off fluids and dispose of them according to environmental regulations.
These include, for example, fuel, engine oil and compressor cooling oil and engine coolant.
➤ Dispose of the machine in accordance with local environmental regulations.
3.5.3 Organizational Measures

➤ Designate personnel and their responsibilities.

32 M100 No.: 9_6999 23 USE
3.6 Safety devices
➤ Give clear instructions on reporting faults and damage to the machine.

➤ Give instructions on fire reporting and fire-fighting measures.
3.5.4 Danger areas

The table gives information on areas dangerous to personnel.
Only authorized personnel may enter these areas.
Task Danger area Authorized personnel

Transport Within a 10 ft radius of the machine. Operating personnel to prepare for trans‐
port.
No personnel during transport.
Beneath the lifted machine. No personnel!
Commissioning Within the machine. Maintenance personnel
Within a 3 ft radius of the machine.
Operation Within a 3 ft radius of the machine. Operating personnel
Maintenance Within the machine. Maintenance personnel
Within a 3 ft radius of the machine.
Tab. 64 Danger areas
3.6 Safety devices

Safety devices ensure safe working with the machine.
➤ Do not change, bypass or disable safety devices.
➤ Regularly check safety devices for their correct function.
➤ Do not remove or obliterate labels and notices.
➤ Ensure that labels and notices are clearly legible.
Further information More information on safety devices is contained in chapter 4.5.
3.7 Safety signs

The diagram shows the positions of safety signs on the machine. The table lists the various safety
signs used and their meanings.

No.: 9_6999 23 USE M100 33
3.7 Safety signs
Fig. 2 Location of safety signs
Item Sign Meaning

190* Wrong cooling oil level!
Risk of machine defects or rising oil consumption (oil content for pure air).
max.
➤ Check cooling-oil level.

min.
➤ Run the machine only with proper cooling-oil level.

282* Explosive hydrogen gas!
Severe injury or death could result from exploding gas.
➤ Keep flames, sparks and other sources of ignition away.
283* Battery contains acid!

Severe injury result from contact with battery acid.
➤ Do not allow battery acid to contact eyes, skin, clothing or painted surfa‐
ces.
➤ Do not attempt to jump-start if battery fluid is frozen.
➤ Bring temperature of battery up to at least 60°F before attempting to
jump-start or it may explode.
303* Fire or explosion caused by refueling!
Severe injury or death result from inflaming fuel.
➤ Use diesel fuel only.
➤ NEVER attempt to refuel the compressor while it is operating.
➤ Always replace fuel filter cap after refueling.
➤ Always wipe up fuel spills which may occur inside the compressor enclo‐
sure and allow the machine to ventilate.
* Location within the machine
** Only towable machines
*** Only machines with option dc
**** only machines with option ga, gb

34 M100 No.: 9_6999 23 USE
3.7 Safety signs
Item Sign Meaning

310 Injury or damage from open machine.
311 ➤ Operate the machine only when closed.
➤ Transport the machine only when closed.
320* Loud noise and oil mist when the safety relief valve opens.
Ear damage and burns can result.
➤ Wear ear protection and protective clothing.
➤ Close all maintenance doors and cover panels.
➤ Work carefully.
330 Hot surface can cause burns.
331 ➤ Let the machine cool down.
332 ➤ Work carefully.
➤ Wear protective clothing and gloves.
390* Rotating fan blades and V-belt drive!
391* Injury and machine damage possible. Severe injury could result from touch‐
ing the fan blades and v-belt drive while it is rotating.
➤ Never switch the machine on without guard in place over the fan blade.
➤ Switch off and lock out the power supply disconnecting device and
check that no voltage is present.
420** Injury or damage can result because tongue weight on this equipment may
be heavy.
➤ Do not lift towbar by hand if weight is more than you can safely handle.
➤ See safety section of service manual.
430 Connect air hoses only in full compliance with OSHA standard
29 CFR 1926,302 (bX7).
The required safety devices should be tested in accordance with their manu‐
facturer's recommendations to verify that they reduce pressure in case of
hose failure and will not nuisance trip with the hose and tool combinations in
use.
440 Compressed air quality.
Injury and/or contamination can result from breathing compressed air.
Contamination of food can result from using untreated compressed air for
food processing.
➤ Never breathe untreated compressed air!
➤ Air from this compressor must meet OSHA 29 CFR 1910.134 and
FDA 21 CFR 178.3570 standards, if used for breathing or food process‐
ing. Use proper compressed air treatment.
➤ Food grade coolant must be used for food processing.

No.: 9_6999 23 USE M100 35
3.7 Safety signs
Item Sign Meaning

500** Towbar load and ground clearance.
Danger of fishtailing, incorrect towing vehicle load, damage to the machine
caused by rollover or contact with the ground.
➤ Always line up the towbar so that the machine is level with the ground.
510** Malfunction due to lack of maintenance.
Accidents and machine damage possible.
➤ Maintain the chassis regularly.
➤ Follow instructions in the service manual.
540** Machine without breaks.
Serious injury or death may result from uncontrolled movement when the
unit is not safeguarded by chocks.
➤ Always use chocks before uncoupling and generally when the unit is not
in motion.
➤ Do not move unit manually.
541** Missing chock.
Serious injury or death may result from uncontrolled movement when the
unit is not safeguarded by chocks.
➤ Always fix chock for proper storage.
➤ Always replace missing chock immediately.
600* Pressure and spring force!
Serious injury or death can result from loosening or opening component that
is under pressure and heavily spring loaded.
➤ Never open (dismantle) valve.
➤ Contact an authorized KAESER service representative.
830**** There is danger of fatal injury touching electrically live components!
➤ Take protective measures.
➤ Switch off and lock out the power supply disconnecting device and
check that no voltage is present.
1222*** Danger!
Mortal danger from CO, CO₂ or toxic gas.
➤ Draw in only surrounding air of breathing quality.
Danger!
Danger to health from discharge of oily compressed air.
➤ Maintain surrounding air temperature between 34°F and 86°F.
➤ Check the oil indicator at least once a day.
Tab. 65 Safety signs

36 M100 No.: 9_6999 23 USE
3.8 Noise control requirements
3.8 Noise control requirements

Tampering with the noise control system is prohibited!
Federal law prohibits the following acts or causing thereof:

■ The removal or rendering inoperative by any persons, other than for purposes of maintenance,
repair, or replacement, of any devices or element of design incorporated into any new com‐
pressor for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or
while it is in use; or
■ the use of the compressor after such device or element of design has been removed or ren‐
dered inoperative by any person.
Among those acts included in the prohibition against tampering are the acts listed below:
■ Removing any facing (doors, hood, service panels).
■ Modifying the air inlet and outlet louvers.
■ Modifying the air intake channels or hoses (if applicable).
■ Modifying the air filter enclosure.
■ Modifying the exhaust air silencer.
■ Manipulating the machine's control and regulation system.
3.9 Option ga, gb

Generator operation
3.9.1 Comply with the protective measures against dangerous electric current
Protection against dangerous electric current is regulated by the "Low-voltage current generating
installations" directive IEC 60364–5–551 (DIN VDE 0100–551).
The protective measure concerning "isolation, insulation monitoring and shut-down" is applied. The
generator is equipped with an automatic mains cut-out with overcurrent release and insulation
monitoring in accordance with this protective measure.
➤ Observe and follow the regulations concerning protection against dangerous electric current
when using the generator.
3.9.2 Safe generator operation

Take note of the following to ensure the safe operation of the machine with a generator:
➤ Check correct function of the insulation monitoring device daily.
➤ Do not earth the neutral line (N) or connect it to the common protective earth/equipotential
bonding (PE).
➤ Make sure the equipotential bonding to earth is properly carried through (mains and machine
through cable to consumer).
➤ If the generator feeds a network (TN network), let the network's protective measures remain
effective or create another protective measure that is effective.
➤ Adjust the protective measures accordingly if the generator feeds a different network.
➤ Only a qualified electrician is allowed to carry out work on the generator or generator control
box. The electrician is responsible for the effectiveness of the protective measures provided.
➤ Do not use the generator for feeding the construction current distribution.

No.: 9_6999 23 USE M100 37
3.9 Generator operation
➤ A generator with insulation monitoring must not be connected to another insulation monitoring
device as these monitoring devices can then have counter effects.
➤ Ground fault current (F1) protection switches do not function in unearthed networks (IT network
such as provided by the generator). The isolation provided by the generator, however, makes a
further ground fault current protection switch unnecessary.
➤ Follow the regulations of the local electricity supply utility and obtain any necessary permits.
➤ When cleaning the inside of the machine do not direct water or steam jets directly at the gener‐
ator or terminal box.
➤ Check regularly that all electrical connections are tight and in proper condition.
3.9.3 Connecting extension cables

➤ When operating the generator, observe the regulations regarding the connection of extension
cables.
Bear in mind:
■ In IT networks, the total length of power cables may not exceed 0.16 miles (DIN VDE 0100,
Part 728 / IEC 60364-5-551).
■ Use at least H07RN-F cables to DIN VDE 0282 Part 4 (IEC 60245-4 / HD 22.4) as non-fixed
extension cables.
3.9.4 Do not exceed the maximum supply system load

➤ When operating the generator, do not exceed the maximum supply system load due to con‐
nected consumers.
Bear in mind:
■ The power consumption values of simultaneous consumers are added.
■ The maximum continuous power loading on the generator by the connected consumers is limi‐
ted by the safety cut-out.
3.9.5 Perform regular generator inspections

To ensure a safe operation, the machine must be subjected to regular inspections.
Daily inspection prior to activating the device by authorised operating personnel:
➤ Insulation monitor function check.
Annual inspection by trained and authorised electrician:
➤ Inspect the generator and generator control cubicle for mechanical damages.
➤ Inspect the protective conductor.
➤ Measure the dielectric resistance.
➤ Measure the substitute leakage current.
➤ Test the generator functionality.
➤ Test the proper functioning of the generator fan and clean, if required.
➤ Clean the cooling air openings.
➤ Check and tighten the screw connections at the generator and the generator control cubicle.
➤ Check covers and power socket caps for damage and good sealing.
➤ Check the completeness of labeling and warning labels.

38 M100 No.: 9_6999 23 USE
3.10 Emergencies
3.10 Emergencies
3.10.1 Correct fire fighting
Suitable measures
Calm and prudent action can safe lives in the event of a fire.
➤ Keep calm.
➤ Give the alarm.
➤ Shut down the machine from the instrument panel if possible.
➤ Warn and move endangered personnel to safety.
➤ Help incapacitated persons.
➤ Close the doors.
➤ When trained accordingly: Attempt to extinguish the fire.
Extinguishing substances
➤ Suitable extinguishing media:

Foam
Carbon dioxide
Sand or soil
➤ Unsuitable extinguishing media:
Strong jet of water
3.10.2 Injury from handling operating fluids/materials

The following operating fluids/materials are in the machine:
■ Fuel
■ Lubricating oil
■ Compressor cooling oil
■ Engine coolant
■ Battery electrolyte
■ Tool lubricant (option e)
■ Antifreeze (option ba)
Eye contact
Fuel, oil and other fluids/materials can cause irritation.

➤ Rinse open eyes thoroughly for a few minutes.
➤ Seek medical advice for persistent irritation.
Skin contact
Fuel, oil and other fluids/materials may irritate after prolonged contact.
➤ Wash thoroughly with skin cleaner, then with soap and water.
➤ Contaminated clothing should be intensively cleaned before reuse.

No.: 9_6999 23 USE M100 39
3.11 Warranty
Inhalation
Fuel and oil vapors impair breathing.

➤ Clear the respiratory tract from fuel or oil vapor.
➤ Seek medical help if difficulty with respiration continues.
Ingestion
➤ Wash out the mouth immediately.

➤ Do not induce vomiting.
➤ Seek medical aid.
3.11 Warranty
This operator manual contains no independent warranty commitment. Our general terms and con‐
ditions of business apply with regard to warranty.
A condition of our warranty is that the machine is used for the purpose for which it is intended un‐
der the conditions specified.
Due to the multitude applications for which the machine is suitable the obligation lies with the user
to determine its suitability for his specific application.
In addition, we accept no warranty obligation for:

■ the use of unsuitable parts or operating materials,
■ unauthorized modifications,
■ incorrect maintenance,
■ incorrect repair.
Correct maintenance and repair includes the use of original spare parts and operating materials.
➤ Obtain confirmation from KAESER that your specific operating conditions are suitable.
3.11.1 Noise emissions warranty

The manufacturer warrants to the ultimate purchaser and each subsequent purchaser that this air
compressor was designed, built, and equipped to conform, at the time of sale to the first retail pur‐
chaser, with all applicable American EPA noise control regulations.
This warranty is not limited to any particular part, component, or system of the air compressor.
Defects in the design, assembly, or in any part, component, or system of the compressor which, at
the time of sale to the first retail purchaser, caused noise emissions to exceed Federal standards
are covered by this warranty for the life of the air compressor.
3.12 Identifying the effects of improper modifications

The machine and various modules are designed according to applicable regulations and are sub‐
mitted for approval procedures by the relevant authorities (where applicable).
Concerned modules include:

■ Compressor drive motor
■ Fuel supply
■ Exhaust system

40 M100 No.: 9_6999 23 USE
3.13 Environmental protection
■ Chassis (if available)

■ Compressor unit
■ Pressure-bearing components (e.g., valves, vessels, pipelines)
Remodeling or modifications can have the result that the interaction of the individual modules ac‐
cording to regulations is no longer ensured. Thus, the prerequisites required for approval by the
authorities may no longer be given.
The concerned directives and regulations can be:

■ Machinery directive
■ Pressure vessel directive
■ EMC directive
■ Directive for environmental noise
In machines requiring a national road traffic permit, remodeling or modifications may adversely af‐
fect their approval for road traffic.
■ Exhaust emission limits may not be met.
■ The prerequisites for approval are no longer given.
Remodeling or modifications restrict the service work that can be performed for you. For example:
■ Warranty (if directly and originally affected by the remodeling or modification)
■ Reduced replacement part supply (scope, delivery times)
3.13 Environmental protection

The operation of this machine may cause dangers for the environment.
➤ Do not allow operating materials to escape into the environment or into the sewage system.
➤ Store and dispose of operating materials and replaced parts in accordance with local environ‐
mental protection regulations.
➤ Observe relevant regulations.
This applies particularly to parts contaminated with fuel, oil, coolants and acids.

No.: 9_6999 23 USE M100 41
4.1 Bodywork

4.1 Bodywork
Bodywork is understood to be the exterior of the machine mounted on the chassis.
Fig. 3 Overview Bodywork

1 Right-hand wing door 5 Lower body
2 Sound damping louver for cooler 6 Left-hand wing door
3 Snap fastener 7 Cover for lifting eye
4 Handle
The bodywork has several functions when it is closed:

■ Weather protection
■ Sound insulation
■ Guarding against touching
■ Cooling air flow
The bodywork is not suitable for the following uses:

■ Walking on, standing or sitting on.
■ Use as resting place or storage of any kind of load.
Danger of pinching!
Severe injuries of the fingers if they are caught when closing doors and covers.
➤ Work carefully.
➤ If necessary, wear protective gloves.
Safe and reliable operation is only ensured when the bodywork is closed.
The wing doors are provided with handles for opening. Release the doors by the snap fasteners.
The doors are held open by gas springs.

42 M100 No.: 9_6999 23 USE
4.2 Component identification
4.2 Component identification
Fig. 4 Right-hand door opened

1 Instrument panel 7 Fuel tank
2 Oil separator tank 8 Water cooler
3 Compressor air filter 9 Coolant expansion tank
4 Fuel filter with water trap 10 Engine air filter
5 Fuel filter 11 Proportional controller
6 Drive engine 12 Minimum pressure/check valve
Fig. 5 Left-hand door opened

13 Fan 17 Pressure relief valve
14 Tool box 18 Lifting eye cover
15 Airend 19 Lifting eye
16 Inlet valve
4.3 Machine function

Machine function (without options)
Item numbers correspond to the pipe and instrument flow diagram (P&ID) in chapter 13.2.

No.: 9_6999 23 USE M100 43
4.3 Machine function
Fig. 6 Machine layout

1 Compressor air filter 16 Oil return line
3 Inlet valve 19 Combination valve (thermostatic valve)
4 Airend 20 Oil cooler
5 Oil separator tank 21 Oil filter
7 Oil separator cartridge 23 Proportional controller
10 Compressed air distributor 24 Engine air filter
12 Temperature gauge switch 27 Venting valve
13 Pressure relief valve 28 Fan
14 Pressure gauge 37 Minimum pressure/check valve
15 Drive engine 52 Control valve
Ambient air is cleaned as it is drawn in through the filter 1 .

The air is then compressed in the airend 4 .
The airend is driven by an internal combustion engine 15 .
Cooling oil is injected into the airend. It lubricates moving parts and forms a seal between the ro‐
tors themselves and between them and the airend casing. This direct cooling in the compression
chamber ensures a very low airend discharge temperature.
Cooling oil recovered from the compressed air in the oil separator tank 5 gives up its heat in the oil
cooler 20 . The oil then flows through the oil filter 21 and back to the point of injection. Pressure
within the machine keeps the oil circulating. A separate pump is not necessary. A thermostatic
valve 19 automatically maintains optimum cooling oil temperature.
Compressed air, freed of cooling oil in the oil separator tank 5 , flows through the minimum pres‐
sure / check valve 37 into the air distributor 10 . The minimum pressure / check valve ensures that
there is always a minimum internal pressure sufficient to maintain cooling oil circulation in the ma‐
chine.
The cooling fan 28 ensures optimum cooling of all components within the enclosure.

44 M100 No.: 9_6999 23 USE
4.4 Operating modes and control mode
4.4 Operating modes and control mode

4.4.1 Operating modes
The machine operates in the following modes:
■ WARM UP
─ The inlet valve is nearly fully closed.
─ The minimum intake air volume escapes via the venting valve.
─ The engine runs at minimum speed.
■ LOAD
─ The inlet valve is open.
─ The engine runs at maximum speed.
─ The airend delivers compressed air.
■ MODULATING
─ With the help of a control valve (the proportional controller) the degree of opening of the
inlet valve is steplessly varied in response to the air demand.
─ The load and fuel consumption of the engine rises and falls with the air demand.
─ The airend delivers compressed air.
■ IDLE
─ The inlet valve is closed.
─ The control valve opens, allowing pressure in the oil separator tank to be applied to the inlet
valve.
─ Compressed air then flows in a closed circuit through the airend, the oil separator tank and
the control valve.
─ The pressure in the oil separator tank remains constant.
─ The engine runs at minimum speed.
■ RUN-ON PERIOD/STOPPED
─ The inlet valve closes.
─ The venting valve opens to de-pressurise the machine.
─ Machine cools down.
─ The engine stops.
4.4.2 MODULATING control

The control system regulates the volume of air generated to match the actual demand. The ma‐
chine keeps the working pressure constant by varying the volume of compressed air delivered,
thereby matching the air demand.
With the help of a mechanical control valve (the proportional controller), the opening and closing of
the inlet valve is continuously varied in relation to the actual air demand. The airend provides com‐
pressed air for connected consumers.
This stepless delivery regulation minimises fuel consumption of the engine. The load and fuel con‐
sumption of the engine rises and falls with the air demand.

No.: 9_6999 23 USE M100 45
4.5 Safety devices
Fig. 7 Stepless regulation of FAD (standstill)

3 Inlet valve 63 Control valve (proportional valve)
4 Airend 52 Control valve
5 Oil separator tank comprising the following components:
26 Engine speed control cylinder 23 Proportional controller (optionally adjusta‐
46 Nozzle ble)
27 Venting valve
62 Combined auxiliary valve (directional con‐
trol valve)
4.5 Safety devices

4.5.1 Monitoring functions with shutdown
The following functions are monitored automatically.
■ Engine oil pressure
■ Coolant temperature
■ Airend discharge temperature
■ Fuel level
■ Engine alternator

46 M100 No.: 9_6999 23 USE
4.6 Fuel level monitoring
The fuel stop device is activated when an alarm occurs. The engine comes to a stop and the
venting valve vents pressure from the machine.
4.5.2 Further safety devices

The following safety devices are provided and may not be modified in any way.
■ Safety relief valves
Safety relief valves protect the system against unacceptable pressure rise. They are factory
set.
■ Enclosures and guards for moving parts and electrical connections
protect against accidental contact.
4.6 Fuel level monitoring

The fuel level monitoring indicator lamp on the instrument panel is used for monitoring the fuel level
within the tank. This indicator lamp signals, when the fuel level in the fuel tank falls below the rec‐
ommended level.
Fig. 8 Fuel level monitoring

1 Instrument panel
2 Indicator lamp (LED yellow):
Fuel level monitoring
3 Group alarm lamp (red)
When the fuel level drops to a certain point, the fuel level indicator lamp (yellow) on the instrument
panel lights.
After about 20 minutes running on reserve, the fuel reaches the minimum level. So that no air is
drawn into the fuel line, the engine is automatically shut down when this point is reached.
The group alarm lamp lights (red) to indicate an alarm. The alarm is saved and the engine cannot
be restarted.
You can restart the machine only after deactivating and refilling the machine.
4.7 Options
The options available for your machine are described below.

No.: 9_6999 23 USE M100 47
4.7 Options
4.7.1 Option da, db, dc, dd, ea, ec

Compressed air treatment options
For some applications, the compressed air generated by this machine must be treated before use.
The following describes the possible air treatment options that may be fitted to the machine.
Fig. 9 Compressed air options

1 Fresh air filter (Option dc) 4 Cyclone separator (Option da)
2 Tool lubricator (option ea, ec) 5 Filter combination (Option dd)
3 Heat exchanger (Option db) 6 Compressed air aftercooler (Option da)
4.7.1.1 Option da
Compressed air aftercooler
The aftercooler lowers the compressed air temperature to only 9°F to 18°F above ambient. Most of
the moisture carried in the air is removed this way in the aftercooler.
4.7.1.2 Option da
Cyclone separator
Condensate accumulated during the air cooling process is separated, fed to the exhaust gas si‐
lencer and evaporated there.
4.7.1.3 Option db
Heat exchanger
The oil/air heat exchanger is fed with hot compressor cooling oil that warms the outgoing moisture-
reduced compressed air.
This warm, dry compressed air is ideal for sand blasting, for example.

48 M100 No.: 9_6999 23 USE
4.7 Options
4.7.1.4 Option dd
Filter combination
The dried compressed air passes through a pre-filter and micro-filter combination and emerges oil-
free.
4.7.1.5 Option dc
Fresh air filter
Compressed air from oil-injected compressors may not be used directly as breathing air.
The concentration of contaminants will increase during the compression of the intake ambient air
and cooling oil and abraded particles can enter the compressed air. This requires a subsequent
treatment of the pre-filtered compressed air.
Air must be filtered to remove all contaminants, such as fine dust and oil as well as odors, before it
can be used for breathing purposes.
To achieve this, part of the compressed air output from the compressor is passed through a combi‐
nation of micro-filter and activated carbon filter.
The connection to air treated in this way is specially marked. It is designed as a quick-release cou‐
pling next to the outlet valves on the compressed air distributor.
Danger from toxic air!

Danger of respiratory arrest because the filter does not remove CO/CO2, methane or other
toxic gasses or vapors.
➤ Never use the machine in enclosed spaces, only in the open.
➤ Clean inlet air without hazardous contaminants. Engine exhaust must not be drawn into
the compressor.
The treated air does not meet the local standards for “Compressed air for breathing appara‐
tus”. Therefore, it must not be used as pure breathing air but may be used to reinforce the
flow of fresh air when working in dusty or dirty conditions such as sand blasting.
Further information See chapter 2.7.1.2 for ambient conditions under which the fresh air filter can be used.
Further information See DIN EN 12021 for more information regarding permissible limit values for hazardous contami‐
nants in breathing air.
4.7.1.6 Option ea, ec

Tool lubricator
Compressed air containing lubricating oil is needed for the lubrication of certain air tools. The tool
lubricator introduces a fine oil mist into the compressed air for this purpose.
A metering valve on the lubricator regulates the amount of oil in the compressed air:
■ minimum oil to lubricate the tools and prevent corrosion,
■ more oil for cleaning and to prevent wear in the tools.
The oil flow can be stopped by a shut-off valve.

The oil flow adjusts automatically to changes in air demand (one or more tools/consumers on line).

No.: 9_6999 23 USE M100 49
4.7 Options
Fig. 10 Tool lubricator

1 Tool lubricator 4 Oil tank
2 Air line 5 Metering knob
3 Shut-off ball valve
Fig. 11 Principle tool lubricator

1 Compressed air inlet 4 Tool lubricator upper part with oil filling port
2 Oil tank 5 Filler plug with dipstick and integrated riser
3 Tool oil outlet tube
6 Metering knob

50 M100 No.: 9_6999 23 USE
4.7 Options
Option fc Points to be observed with separate compressed air lines:
Lubrication with tool oil.

Air tools that must not be lubricated can be damaged.
➤ Blow any residual oil out of the line before connecting such an air tool.
4.7.2 Option ba
Low temperature equipment options
Special equipment is provided for operation in extremely low temperatures.
This equipment guarantees machine operation at temperatures from -13°F to 122°F .
The electrical system enables trouble-free engine starting at ambient temperatures down to -4°F.
4.7.2.1 Option bb
Coolant pre-heating
The engine coolant can be pre-heated to improve starting under cold conditions.
The power supply to the coolant pre-heater takes place via a separate network connector. A flexi‐
ble power cable (supplied) connects the machine's power plug to the user's power socket.
The coolant pre-heater works according to the principle of self-circulation.
Fig. 12 Coolant pre-heating

1 Operating panel 3 Engine block
2 Connection for the coolant pre-heater 4 Coolant pre-heating
The ideal coolant pre-heating period is 2-3 hours before the machine is started. A pre-heating peri‐
od of more than 3 hours is not necessary, as the maximum effect has already been achieved within
this period (thermal balance).
Continuous operation of maximum 6 hours must be followed by a rest of approximately 3 hours.
4.7.2.2 Option bc
Frost protection
Control air is mixed with an alcohol-based antifreeze to prevent control and regulating devices
freezing. This considerably lowers the freezing point of any moisture in the air.

No.: 9_6999 23 USE M100 51
4.7 Options
Fig. 13 Frost protector

1 Control line (frost protection) 3 Shut-off ball valve
2 Frost protector 4 Control line (bypass line)
Operating the machine in cold temperatures
The frost protector is activated when the machine is started or stopped in ambient temperatures
below freezing. Due to the antifreeze in the air flow, valves and control lines in the interior are
moistened preventing a freezing of the control and regulating system.
During machine operation, the generated innate heat counteracts a potential freezing of individual
components.
Machine operation in summer
Antifreeze is not required for the regulating air at ambient temperatures of more than 32°F.
4.7.3 Option oa
Optional battery isolating switch
The «battery isolating switch» disconnects the battery completely from the machine's electrical sys‐
tem (fire protection, battery discharge protection).
Danger of short circuit!

Damage to the machine’s electrical components is possible.
➤ Use the «battery isolating switch» only when the machine is shut down.
➤ Do not use the «battery isolating switch» as a main or emergency switch.

52 M100 No.: 9_6999 23 USE
4.7 Options
Fig. 14 Battery isolating switch

1 «Battery isolating switch»
4.7.4 Option la, lb

Options for operating in fire hazard areas
Diesel engines represent a potential source of ignition in environments with concentrations of gas,
vapour or dust, and may cause major fires with disastrous consequences for people, the environ‐
ment and the production.
For the operation in fire hazard areas, the machine is equipped with the following accessories:
■ Engine air intake shut-off valve
■ Spark arrestor
4.7.4.1 Option lb
Engine air intake shut-off valve
If flammable gases and vapours are drawn by the Diesel engine from the environment into the air
intake, they will act like catalytic converters. This causes a sudden and uncontrolled increase in en‐
gine speed that can result in serious mechanical damage. Without appropriate preventive meas‐
ures, the engine and compressor can be destroyed. Explosion or fire are also possible.
When flammable gas is drawn into the engine, shutting off the fuel supply will not stop the engine
right away. In order to shut down the engine quickly and reliably in these events, the intake of the
combustion air must be interrupted.
If a certain engine speed is exceeded, the engine controller closes the engine air shut-off valve for
intake air. This brings the engine to an immediate stop.
4.7.4.2 Option la
Spark arrestor
Sparks in exhaust fumes represent a considerable risk in environments with flammable materials.
Flying sparks combined with flammable materials may cause fires and explosions.
A spark arrestor on the exhaust silencer is required when operating a diesel engine in a fire hazard
area and in forestry and agricultural applications. In such applications, a spark may ignite flamma‐
ble materials.
The spark arrestor prevents the exhaust silencer emitting any glowing fuel residue.

No.: 9_6999 23 USE M100 53
4.7 Options
4.7.5 Option ga, gb

Generator option
A generator is installed to provide a power supply to electrical consumers. The generator is driven
from the engine by a drive belt. A tensioning device automatically ensures optimum belt tension.
Option ga Version without FAD limitation
Activating the generator does not influence the volume of compressed air delivered. The compres‐
sor delivers its full capacity regardless of current being drawn from the generator. The maximum
FAD of versions without limitation is less, however, than versions where the FAD is linked inversely
to current draw. See chapter 2.7.3 for reduced FAD by generator (50 Hz) and chapter 2.7.4 by gen‐
erator (60 Hz) operation.
Option gb Version with FAD limitation
When the generator is activated, the air intlet at the inlet valve is limited. The compressor delivers
less compressed air. The engine is protected from overloading. The volume of compressed air
available is dependent on the generator operating mode and the power taken.
4.7.5.1 Operating modes
The compressor works with the normal air delivery regulation and generates electrical power at the
same time.
The generator can work in two modes. These are selected by the mode switch:
■ Automatic cut-in
■ Continuous load
Generator main switch Mode selector switch What is provided?

OFF - Compressed air
ON Position 1 Compressed air and electrical power
(automatic start mode)
Position 2 Electrical power and compressed air
(continuous load)
Tab. 66 Generator / Compressor operation
Operating mode Automatic cut-in Continuous load

Switch position Position 1 Position 2
Engine speed Electrical power input > 100 VA: Permanent maximum speed (en‐
automatic maximum speed gine under full load)
Power consumption below minimum value:
Engine run-on time of approximately 2 mi‐
nutes at maximum speed
Advantages Fuel saving Continuous generator power
Constant oscillation between maximum and available without delay
minimum speed avoided
Tab. 67 Generator operating modes

54 M100 No.: 9_6999 23 USE
4.7 Options
4.7.5.2 Operating controls
The switches, fuses and outlet sockets for electrical consumers are located on the generator con‐
trol box. Individual consumers are connected only by these outlet sockets.
Fig. 15 Instrument panel – generator control box, 400 V AC

1 «Mode selector switch» 4 Generator control box
2 Three-phase power sockets 5 «Generator main switch»
3 Single-phase power sockets 6 «Safety cut-out» (with overcurrent release)
Fig. 16 Instrument panel – generator control box, 230 V AC

2 32 A three-phase power socket 6 «Generator main switch»
3 Single-phase power sockets 7 «Safety cut-out»
4 16 A three-phase power socket 8 «Safety cut-out» (with overcurrent release)

No.: 9_6999 23 USE M100 55
4.7 Options
Fig. 17 Generator instrument panel - control box, 115 V, single-phase (50 Hz)
1 Generator control box 5 «Generator main switch»
2 Power socket, 32 A 6 «Safety cut-out»
3 Power socket, 16 A 7 «Safety cut-out»
4 «Mode selector switch» 8 «Safety cut-out» (with overcurrent release)
Fig. 18 Generator instrument panel - control box, 230 V, single-phase (60 Hz)
2 Power socket, 250 V 5 «Generator main switch»
3 Power socket, 125 V 6 «Safety cut-out» (with overcurrent release)
4.7.6 Option rb/rk/rm/rs, rc/ro/rs, rd/ro/rs, rb/rl/rm/rs, rw, rx

Transport options
4.7.6.1 Option rb/rk/rm/rs
Chassis
Option rb - chassis EU version

Option rk - Chassis with low axle load
Option rm - chassis with height-adjustable tow bar
Option rs - chassis with overrun brake

56 M100 No.: 9_6999 23 USE
4.7 Options
The chassis has the following features:

■ permissible axle load: 3527 lb
■ Single-axle chassis
■ Towbar, height adjustable
■ Rubber-spring axle
■ with service brake
■ May be operated on public roads
4.7.6.2 Option rc/ro/rs

Chassis
Option rc - chassis GB version

Option ro - chassis with fixed height tow bar

■ Fixed height towbar
4.7.6.3 Option rd/ro/rs

Chassis
Option rd - chassis USA version

Option ro - chassis with fixed height tow bar

■ Fixed height towbar
■ without parking brake
4.7.6.4 Option rb/rl/rm/rs

Chassis
Option rb - chassis EU version

Option rl - Chassis with higher axle load
Option rm - chassis with height-adjustable tow bar

No.: 9_6999 23 USE M100 57
4.7 Options

■ Towbar, height adjustable
4.7.6.5 Option rw
Stationary frame
Option rw - Skid frame on runners
The frame has the following features:

■ Body as skid
■ Use as stationary machine
■ Mounted on truck/trailer platform
4.7.6.6 Option rx
Stationary frame
Option rx - Frame
The frame has the following features:

■ Frame
■ Use as stationary machine
■ Mounted on truck/trailer platform
4.7.7 Option oe
Sealed floor pan option
The machine is fitted with a sealed floor pan catching liquids in the event of leaks. Thus, direct con‐
tamination of the floor is prevented.
The sealed floor pan:
■ Cannot catch all liquids contained in the machine, but is intended only to capture small
leaks in the vicinity of endangered components.
■ Is equipped with service openings which are closed with plugs. These openings must be
tightly re-closed after performing any cleaning work.
When other components are removed from the sealed floor pan, (for example the sheet metal
cover) they must be properly re-sealed prior to installation.

58 M100 No.: 9_6999 23 USE
4.7 Options
Position of service openings in the sealed floor pan
Fig. 19 Position of service openings in the sealed floor pan

1 Central drain point for oil/coolant 3 Access to the storage box of the anti-theft
2 Cleaning opening closed with plug chain
4 Spark arrestor in the service opening,
closed with plug
The drain points for compressor cooling oil and engine coolant are led to a central point outside.
Drain points for oil and coolant from engine and compressor
Fig. 20 Drain points for oil and coolant from engine and compressor
1 Engine oil drain 3 Coolant drain - water cooler, engine
2 Coolant drain - oil cooler, compressor 4 Coolant oil drain - oil separator tank, com‐
pressor
4.7.8 Option sf
Optional anti-theft device
The machine is fitted with a security chain as theft protection.
4.7.9 Option sg
Pedestrian protection option
The machine is fitted with a special protective guard that prevents pedestrians from being run over.

No.: 9_6999 23 USE M100 59
4.7 Options
4.7.10 Option pa, pb

Instrument panel cover option
To prevent unauthorized use and as protection during transport the machine is fitted with instru‐
ment panel cover(s).
■ Instrument panel cover (option pa)

■ Generator control box cover (option ga)

60 M100 No.: 9_6999 23 USE
5.1 Ensuring safety

5.1 Ensuring safety
The conditions in which the machine is installed and operated effect the safety of personnel and
surroundings.
Warning instructions are located before a potentially dangerous task.
Disregard of warning instructions can cause serious injuries!
Complying with safety warnings
Disregard of safety warnings can cause unforeseeable dangers!

➤ Strictly forbid fire, open flame and smoking.
➤ If welding is carried out on or near the machine, take adequate measures to prevent sparks or
heat from igniting fuel or oil vapors or parts of the machine.
➤ Do not store any flammable materials in the vicinity of the machine.
➤ The machine is not explosion-proof!
Do not operate in areas in which specific requirements with regard to explosion protection are
applied.
➤ Keep suitable fire extinguishing agents on hand and ready for use.
➤ Ensure that required ambient conditions are maintained.
Required ambient conditions may be:

■ A specific ambient temperature range
■ Air composition at the installation site:
─ clean with no damaging contaminants (e.g., dust, fibers, fine sand)
─ free of explosive or chemically-unstable gases or vapors
─ free of acid/alkaline forming substances, particularly ammonia, chlorine or hydrogen sulfide.
5.2 Installation conditions

Precondition The floor must be level, firm and capable of bearing the weight of the machine.
Fig. 21 Minimum distance from excavations/slopes and walls

W Wind direction

No.: 9_6999 23 USE M100 61
5.2 Installation conditions
1. Keep sufficient distance (at least 5 ft) from the edges of excavations and slopes.
2. Ensure that the machine is as level as possible.
The machine can be temporarily operated on a slope of not more than 15°.
3. Ensure accessibility so that all work on the machine can be carried out without danger or hin‐
drance. The operator panel must be accessible and within reach at any time.
4. Fire hazard from build-up of heat and hot exhaust system!
Insufficient distance from a wall may well cause heat build-up that could damage the machine.
➤ Do not position the machine directly against a wall.
➤ Ensure always sufficient ventilation space around the machine.
5. Position the machine as far as possible from any wall.
6. Ensure there is enough free space all round and above the machine.
7. Keep air inlet and outlet openings free of obstructions so that the cooling air can flow freely
through the machine.
8. Install the machine ensuring that
■ exhaust gases and heated exhaust air can escape freely.
■ Do not allow exhaust gases and heated cooling air to be drawn into the compressor.
Note the wind direction! (see figure 21)
■ Ensure the unimpeded intake of fresh air (air intake, cooling air).
9. Ambient temperature too low!
Frozen condensate and highly viscous engine or compressor cooling oil can cause damage
when starting the machine.
➤ Use winter grade engine oil.
➤ Use winter diesel fuel.
➤ Use low viscosity compressor cooling oil.
10. At ambient temperatures below 32 °F, follow the instructions in chapter 7.4.

62 M100 No.: 9_6999 23 USE
6 Installation
6.1 Ensuring safety
6 Installation
6.1 Ensuring safety
Follow the instructions below for safe installation.

➤ Follow the instructions in chapter 3 “Safety and Responsibility”.
➤ Installation work may only be carried out by authorized personnel.
➤ Replace self-locking nuts that have been removed, do not reuse old ones. The nut is no longer
self-locking once it has been unscrewed.
Further information Details of authorized personnel are found in chapter 3.4.2.

Details of dangers and their avoidance are found in chapter 3.5.
6.2 Reporting Transport Damage

1. Check the machine for visible and hidden transport damage.
2. Inform the carrier and the manufacturer in writing of any damage found.
6.3 Fitting the towbar

If the machine is shipped on a transport frame, it is necessary to dismantle the towbar to save
space. The towbar must be re-assembled before removing the transport frame.
Material Protective gloves

Wrench
Hard rubber hammer
Precondition The machine is standing firm and level.

The machine is switched off.
Danger of pinching!
Severe pinching injury to fingers is possible.
➤ Always wear protective gloves.
➤ Work carefully.

No.: 9_6999 23 USE M100 63
6 Installation
6.3.1 Option rb/rk/rm/rs, rb/rl/rm/rs

Fitting the height adjustable towbar
Option rb/rk/rm/rs,
rb/rl/rm/rs
Fig. 22 Height adjustable towbar, fitted

1 Overrun braking mechanism 4 Locking lever with split pin
2 Handle 5 Hand brake lever, parking brake
3 Tie bar 6 Fixing with bolt and nut
Option rb/rk/rm/rs,
rb/rl/rm/rs
Fig. 23 Fitting the height adjustable towbar
1. Remove all transport securing items (duct tape, foam pads) from the towbar components.
2. Undo the self-locking nut and remove the tie bar fixing bolt.
3. Bring the overrun braking mechanism into the horizontal position.
4. Push the tie bar end between the cheeks of the overrun braking mechanism and align the fix‐
ing holes.
5. Push in the securing bolt, using light hammer blows if necessary.
6. Secure the bolt with the self-locking nut (see chapter 2.4.4 for tightening torque).
7. Release the parking brake by pushing the hand brake down.
8. Pull out the split pin and unscrew the locking lever to the stop.
9. Use the positioning handle to push the towbar to the required height.
10. Tighten the locking lever:
■ Make sure the teeth in the adjustment joint mesh together.
■ Manually tighten the locking lever.
■ Use a hammer to hit the locking lever to further tighten the lower serrated joint until the
bore and the groove for the splint pin are aligned

64 M100 No.: 9_6999 23 USE
6 Installation
11. Insert the splint pin.

12. Pull up the parking brake (pull the hand brake lever up).
6.3.2 Option rc/ro/rs, rd/ro/rs

Fitting a non-adjustable tow bar
Option rc/ro/rs, rd/ro/rs
Fig. 24 Non-adjustable tow bar fitted

1 Overrun braking mechanism 5 Jockey wheel
2 Brake transfer cable 6 Breakaway cable
3 Brake rod 7 Parking brake
4 Tow bar * not for USA type chassis
1. Open the doors.

2. Remove the bag with the brake transfer cable and fastenings, unpack and lay out ready.
3. Close the doors.
4. Remove all transport securing items (screw fastenings, duct tape, foam pads) from the tow bar
components.

No.: 9_6999 23 USE M100 65
6 Installation
Fitting the overrun braking mechanism of the non-adjustable tow bar:
Fig. 25 Fitting the overrun braking mechanism of the non-adjustable tow bar
1 Overrun braking mechanism 8 Pivot mount
2 Tow bar 9 Hexagonal locking nut
3 Fixing bolt 10 Hexagon nut (locknut)
4 Washer 11 Turnbuckle
5 Hexagon nut (self locking) 12 Hexagonal locking nut
6 Brake transfer cable (Bowden) A Front screw fastening brake transfer cable
7 Brake rod B Rear screw fastening brake transfer cable
1. Push the overrun braking mechanism onto the tow bar and position so that the securing bolts
can be pushed on.
2. Push in the securing bolts (using light hammer blows if necessary) and push on U-washers.
3. Secure the bolts with the self-locking nuts (see chapter 2.4.4 for tightening torque).
4. Screw in the front screw fastening of the brake transfer into the pivot mount of the overrun
braking mechanism and secure with a lock nut.
5. Suspend the brake transfer cable in each of the two fastening lugs on the tow bar and tighten
the clamping nuts.
6. Screw the the brake-rod linkage onto the rear screw fastening of the brake transfer cable and
secure with a lock nut.
Further information Further information on setting the brake actuating rod is to be found in chapter 10.7.3.3.

66 M100 No.: 9_6999 23 USE
6 Installation
6.4 Adjusting the chassis
Fitting the jockey wheel of the non-adjustable tow bar:
Fig. 26 Fitting the jockey wheel of the non-adjustable tow bar

1 Overrun braking mechanism 4 Washer
2 Jockey wheel 5 Hexagon nut (self locking)
3 Fastening screw
1. Place a U-washer on each securing screw and insert each of these into the top four securing
holes on the jockey wheel mounting plate.
2. Raise the overrun braking mechanism and position such that the securing holes of the jockey
wheel mounting plate and the overrun braking mechanism coincide.
3. Push through the securing screws and push on the U-washers.
4. Secure the bolts with self-locking nuts.

Material Pliers
Hard rubber hammer
Precondition The machine is shut down.

The machine is disconnected from the towing vehicle and safely parked.
Danger of pinching!
Severe injury to fingers is possible if they become trapped in the adjusting mechanism.
➤ Work carefully.

No.: 9_6999 23 USE M100 67
6 Installation
6.4.1 Option rb/rk/rm/rs, rb/rl/rm/rs

Adjusting the towbar height
Option rb/rk/rm/rs,
rb/rl/rm/rs
Fig. 27 Towbar height adjustment

1 Locking lever 3 Split pin properly inserted
2 Split pin 4 Handle
1. Pull out the split pin and unscrew the locking lever to the stop.
2. Adjust the towbar with the handle until it is horizontal with the coupling on the towing vehicle
and parallel to the ground.
The parallel tie bar ensures that the overrun braking mechanism stays horizontal (Fig. 27.
The centre-piece can be moved up to 50° upwards and 10° downwards for height adjustment.
3. Tighten the locking lever:
■ Make sure the teeth in the adjustment joint mesh together.
■ Manually tighten the locking lever.
■ Use a hammer to hit the locking lever to further tighten the lower serrated joint until the
bore and the groove for the splint pin are aligned
4. Insert the splint pin.
5. Check if:
■ the teeth in the adjustment joint are fully engaged.
■ The locking lever is tight.
■ The split pin is correctly inserted to secure the locking lever (see 3 in Fig. 27).
6. Tighten the locking lever again after 30 miles.
The serrated joint will not disengage. The serrations are corroded together.
➤ Free the serrations by jerking the towbar horizontally and vertically.
6.4.2 Changing the towing eye/ball hitch

The towbar can be fitted with various towing eyes or couplings.

68 M100 No.: 9_6999 23 USE
6 Installation
Material Protective gloves

Wrench
Hammer

➤ Ascertain which towbar is fitted to the machine.
6.4.2.1 Option rb/rk/rm/rs, rb/rl/rm/rs

Changing the towing eye/ball hitch on a height-adjustable towbar
The following alternative tasks must be carried out to change the towing eye or coupling.
Option rb/rk/rm/rs,
rb/rl/rm/rs
Fig. 28 Changing the towing eye (height-adjustable drawbar)

1 Self-locking hexagon nut 4 Protective sleeve
2 Hex-head screw 5 Ball coupling
3 Towbar 6 Towing eye
Remove the ball coupling Removing the towing eye

1. Unscrew the nuts 1 of both screw connec‐ 1. Push back the protective sleeve 4 .
tions and withdraw the bolts 2 . 2. Unscrew the nuts 1 of both screw connec‐
2. Remove the coupling 5 from the towbar 3 . tions and withdraw the bolts 2 .
3. Remove the towing eye 6 from the tow‐
bar 3 .

No.: 9_6999 23 USE M100 69
6 Installation
Fitting the ball coupling Fitting the towing eye

1. Fit the new ball coupling 5 to the towbar. 1. Slide the towing eye 6 into or onto the tow‐
2. Position the various parts so that the bolts bar 3 .
can be freely inserted. 2. Position the various parts so that the bolts
3. Insert the bolts 2 through the correspond‐ can be freely inserted.
ing fixing holes of both screw connections 3. Insert the bolts 2 through the correspond‐
and secure with self-locking nuts 1 . ing fixing holes of both screw connections
and secure with self-locking nuts 1 .
4. Draw the protective sleeve 4 over the fix‐
ings.
6.4.2.2 Option rc/ro/rs, rd/ro/rs

Changing the towing eye/ball hitch on a fixed-height towbar
The shock absorber is secured in the rear fixing screw. The shock absorber extends automatically.
Use a mounting pin (thin metal rod with ø 0.3 – 0.4 inches) to facilitate the installation.
Material Mounting pin (thin metal rod ø 0.3 – 0.4 inches)
Option rc/ro/rs
Fig. 29 Changing the towing eye/ball hitch (fixed height towbar)

1 Self-locking hexagon nut 6 Towbar
2 Hex-head screw 7 Shock absorber
3 Shock absorber fixing eye 8 Mounting pin
5 Protective sleeve 10 Towing eye

70 M100 No.: 9_6999 23 USE
6 Installation
Option rd/ro/rs
Fig. 30 Changing the towing eye (fixed height towbar, USA chassis version)
1 Self-locking hexagon nut 6 Towbar
2 Hex-head screw 7 Shock absorber
3 Shock absorber fixing eye 8 Mounting pin
5 Protective sleeve 10 Towing eye
1. Push back the protective sleeve 5 .

2. Unscrew and remove the nuts 1 of both screw connections.
3. Use the mounting pin 8 to beat out the rear screw 4 . Do not remove the pin in order to retain
the centring of the shock absorber in the towbar tube.
4. Remove the front screw 2 .
5. Remove the ball coupling 9 or towing eye 10 from the towbar tube 6 .
6. Push the new ball coupling 9 or towing eye 10 onto the towbar 6 until the fixating holes
match.
7. Use the screw 4 at the rear fixating hole of the towing eye/ball coupling to beat out the mount‐
ing and pin and to thread the shock absorber.
8. Insert the screw 2 through the front fixating hole.
9. Thread self-locking nuts 1 on both screws and tighten with torque wrench (see chapter 2.4.4).
10. Draw the protective sleeve over the fixings.
Checking the overrun braking mechanism
➤ Push the towbar tube in and out by hand.

If resistance is felt, the shock absorber is properly connected.

No.: 9_6999 23 USE M100 71
7 Initial Start-up
7.1 Ensuring safety
7 Initial Start-up
7.1 Ensuring safety
Follow the instructions below for safe commissioning of the machine.

➤ Commissioning work may only be carried out by authorized personnel!
➤ Make sure that no one is working on the machine.
➤ Ensure that all service doors and panels are locked.

7.2 Before initial start-up (or recommissioning)

Incorrect or improper commissioning can cause injury to persons and damage to the machine.
7.2.1 Instructions to be observed before commissioning or recommissioning

The initial start-up of every machine takes place at the factory. Every machine is also given a
trial run and passes a careful check.
➤ Commissioning may only be carried out by authorized installation and service personnel who
have been trained on this machine.
➤ Remove all packing materials on and in the machine.
➤ Observe the machine during the first few hours of operation to ensure that it is operating cor‐
rectly.

72 M100 No.: 9_6999 23 USE
7 Initial Start-up
7.3 Checking installation and operating conditions
7.2.2 Special measures for re-commissioning after storage

➤ Carry out the following before every start-up after long period of storage:
Storage Remedy
period longer
than:
5 months ➤ Remove the desiccant from the openings in the air intake filters of the engine
and compressor.
➤ Check the air and oil filters.
➤ Drain the preserving oil from the separator tank.
➤ Fill with cooling oil.
➤ Drain the preserving oil from the engine.
➤ Fill with engine oil.
➤ Check the engine coolant
➤ Check the battery charge state.
➤ Reconnect the battery.
➤ Check all fuel lines, engine oil lines and compressor cooling oil lines for leaks,
loose connections, wear and damage.
➤ Clean the bodywork with a grease and dirt dissolving agent.
➤ Check the tire pressures.
36 months ➤ Have the overall technical condition checked by an authorised KAESER Serv‐
ice Technician.
Tab. 68 Measures for re-commissioning the compressor after a long period of storage
7.3 Checking installation and operating conditions

➤ Check and confirm all the items in the checklist before starting the machine.
Check See chapter Confirmed?

➤ Are the operators fully conversant with safety regulations? –
➤ Have all the positioning conditions been fulfilled? 5
➤ Is there sufficient cooling oil in the separator tank? 10.4.1
➤ Is there sufficient oil in the engine? 10.3.4
➤ Is the maintenance indicator on the air intake filters (engine and 10.3.2,
compressor) OK? 10.4.7
➤ Is there sufficient coolant in the coolant expansion tank? 10.3.1
➤ Is there sufficient fuel in the fuel tank? –
➤ Is there sufficient tool oil in the tool lubricator? (option ea, ec) 10.8.1
➤ Is there enough antifreeze in the frost protector? (Option ba) 10.8.5
➤ Are the access doors closed and all body panels in place? –
➤ Are the tire pressures OK? –
Tab. 69 Positioning and operating conditions checklist

No.: 9_6999 23 USE M100 73
7 Initial Start-up
7.4 Low-temperature operation (winter)

The machine's electrical equipment is designed for starting at ambient temperatures as low as
14°F.
➤ In temperatures below 32°F, use the following operating materials/components:
■ Winter-grade engine oil,
■ Low viscosity cooling oil for the compressor
■ Winter-grade diesel fuel
■ Stronger battery
Use air hoses that are as short as possible under extremely cold conditions.
Allow the engine to warm up:
1. Problems with pneumatic control at low temperatures.

Damage to the machine may be caused by ice particles in the pneumatic control and feedback
systems.
➤ Let the machine warm up in IDLE to ensure trouble-free regulation.
2. Allow the machine to warm up in idle with open air outlet valves until an airend discharge tem‐
perature of 86°F is reached. The airend discharge temperature is shown at the remote ther‐
mometer contact on the instrument panel.
7.4.1 Starting assistance

If the machine's starter battery is discharged, it can be started with the battery of another vehicle or
engine-driven machine.
Material Jumper cables
Precondition The machine is disconnected from the towing vehicle and safely parked.
Fire and explosion hazard.

High currents can flow if the battery is short-circuited. A shorted battery can catch fire or ex‐
plode.
Battery casing may crack and allow acidic fluid to spray out.
➤ Observe the instructions provided with the battery jumper cables.
➤ Do not connect the battery jumper cables to the negative pole of the discharged battery
or to the bodywork of the machine.
➤ Work with caution.

74 M100 No.: 9_6999 23 USE
7 Initial Start-up
Fig. 31 Jumper cable connection diagram

A Engine battery (receiving battery) 3 Positive pole clamp (red) on engine battery
B Assisting vehicle battery (external donor 4 Negative pole clamp (black/blue) on engine
battery) battery
1 Negative pole clamp (black/blue) on bat‐ 5 Bare metal point on the engine block
tery of assisting vehicle (ground)
2 Positive pole clamp (red) on battery of as‐
sisting vehicle
1. Fault in starting aid process!

➤ Connect batteries of the same voltage only.
➤ Ensure that machine and assisting vehicle do not touch.
➤ Switch off all consumers prior to connecting and disconnecting the batteries.
➤ Only use battery jumper cables of sufficient diameter and with insulated terminal clamps.
➤ Observe the instructions provided with the battery jumper cables.
➤ Keep jumper cables away from rotating parts.
➤ Avoid short-circuits due to incorrect poling and/or bridging with tools.
➤ Do not bend over the batteries when attaching jumper cables.
➤ Do not attempt to start the machine if its battery is frozen. Allow the battery to thaw first.
➤ Do not try to start the machine with a boost charger.
2. Comply with the safety instruction shown when using starting aids and starter batteries.
Preparations:
1. Park the assisting vehicle in close distance to the engine, without their bodywork touching each
other.
2. Stop the engine of the assisting vehicle.
3. Open the accesses to the batteries (remove maintenance panels/bonnet and pole caps).
4. Switch off all power consumers.

No.: 9_6999 23 USE M100 75
7 Initial Start-up
Connecting the battery jumper cables
1. Clamp the first terminal clamp 3 of the red jumper cable to the positive pole of the engine's
battery.
2. Clamp the second terminal clamp 2 of the red jumper cable to the positive pole of the assist‐
ing vehicle's battery.
3. Explosion hazard!
A spark may ignite an explosive gas mixture.
➤ Do not, under any circumstances, connect the negative pole of the assisting machine to
the negative pole of the battery in the machine to be started.
This can cause sparks when connecting and disconnecting.
4. Connect the first pole clamp 4 of the black jumper cable to the engine block or a connected,
solid and unpainted metal component of the engine 5 (as distant as possible to the batteries).
5. Clamp the second terminal clamp 1 of the black jumper cable to the negative pole of the as‐
sisting vehicle's battery.
Starting the engine
1. Start the engine of the assisting vehicle and run at high speed.
2. Start the compressor engine.
Upon a successful start, run both engines run for approximately 10 - 15 minutes.
This is important, in particular for fully discharged battery. The battery will pick up only little
current in the beginning and has a high internal resistance. Any voltage peaks occurring in
the engine generator in this state can be attenuated only by the battery of the assisting vehi‐
cle. The engine electronics in particular, of the machine is sensitive to high voltages and
could be damaged easily.
Disconnecting the battery jumper cables
1. Stop the engine of the assisting vehicle.

2. Disconnect the jumper cables in the reverse order, first negative (-) then positive (+).
3. Place the pole caps.
4. Close the maintenance panels and/or bonnet.
A stop of the compressor engine as soon as the cables are disconnected could indicate ma‐
jor damage to the alternator or battery to be repaired by a specialized workshop.
7.4.2 Option ba
Starting up low-temperature equipment
➤ Ascertain which low temperature equipment is fitted to the machine.
Option bb Operating the engine cooling water pre-heater
The engine coolant can be pre-heated to improve starting under cold conditions.
The connection for the power supply is located on the machine's instrument panel.

76 M100 No.: 9_6999 23 USE
7 Initial Start-up
Option bb
Fig. 32 Engine coolant pre-heating

1 Operating panel 4 Coolant pre-heating
2 Connection for the coolant pre-heater 5 Engine block
3 Power cable
1. Danger of fatal injury from electric shock!

Serious injury or death can result from a short-circuit in the electric coolant pre-heater.
➤ The power cable for the coolant pre-heater may only be plugged into an electrical socket
fitted with a protective ground.
➤ Have the coolant pre-heating and associated wiring checked according to the maintenance
schedule.
2. Connect the coolant pre-heater to the user's power socket with the power cable supplied.
Option bc Operating the frost protector
Fig. 33 Operating the frost protector

1 Frost protector
2 Ball valve (closed)
3 Level of antifreeze
➤ Use the checklist when initially starting the frost protector.
To be checked see chapter Confirmed?

Level of antifreeze in the frost protector. 10.8.5

No.: 9_6999 23 USE M100 77
7 Initial Start-up
7.5 Activating the generator
To be checked see chapter Confirmed?

Close the tap on the frost protector. 8.5
Tab. 70 Low-temperature equipment checklist
7.5 Option ga, gb

Activating the generator
The generator can be operated without grounding.
Test the insulation monitor daily with the engine running before activating the generator.
Fig. 34 Insulation monitoring - 400 V AC, 3-phase generator
Fig. 35 Insulation monitoring - 230 V AC, 3-phase generator

1 «Main switch» 4 «Main circuit breaker»
2 «Mode selection switch» («Circuit breaker» designed as automatic
3 Test button «Insulation monitor» with indi‐ circuit-breaker with shunt trip)
cator light for ground short 5 Three-phase AC power sockets
6 Single-phase AC power sockets

78 M100 No.: 9_6999 23 USE
7 Initial Start-up
Fig. 36 insulation monitoring - 115 V, single-phase generator
Fig. 37 insulation monitoring - 230 V, single-phase generator

1 «Main switch» 4 «Main circuit breaker»
2 «Mode selection switch» («Circuit breaker» designed as automatic
3 Test button «Insulation monitor» with indi‐ circuit-breaker with shunt trip)
cator light for ground short 5/6 AC power sockets
1. Activate the machine.

2. Danger of fatal injury caused by contact with live components!
➤ The generator may only be used if the «circuit breaker» («main circuit breaker») has trip‐
ped during the test!

No.: 9_6999 23 USE M100 79
7 Initial Start-up
3. Check the insulation monitor according to instructions:

Test instructions are provided on the label attached to the generator control box.
DANGER!
Electrical power.
Danger of fatal injury caused by contact with live components!
▶Test the «main circuit breaker» each day while the machine is running.
▶ The generator may only be operated if the main circuit breaker is functioning correctly.
Checking the safety cut-out:
➤ Turn on «main circuit breaker» 4 for the generator.
➤ Press and hold the «test button» 3 for 3 seconds.
The «main circuit breaker» 4 trips.
Problem: The «main circuit breaker» does not trip out?
➤ Shut down the generator and call your authorized KAESER service representative.
Tab. 71 Test instructions for a generator with an ground short detection device.

80 M100 No.: 9_6999 23 USE
8 Operation
8.1 Ensuring safety
8 Operation
8.1 Ensuring safety
Follow the instructions below for safe operation.

➤ Ensure that all service doors and panels are closed and secured.
Preventing accidental contact
Intensely heated, rotating, or electrically-live components can cause severe injuries.

➤ Ensure that all doors, canopy and panels are closed.
➤ Do not carry out any checks or settings while the machine is running.
➤ Shut down the machine before opening any doors/canopy.
When working on live components
Touching voltage-carrying components can result in electric shocks, burns or death.

➤ Work on electrical equipment may only be carried out by authorized electricians.
Safe working with compressed air tools and hoses
Open pressurized compressed air hoses move erratically and can cause serious injury to people.
➤ Pressurize compressed air hoses only after the tool has been connected.
➤ Do not pressurize open compressed air hoses.
➤ Detach compressed air hoses only after the hose has been purged of compressed air.
➤ At working pressures >100 psig, compressed air hoses should be secured by a cable to their
respective outlet valves.
Condensate formation in compressed air hoses
Use the shortest possible compressed air hoses to minimize the temperature difference between
the machine's compressed air outlet and the air tool. The hose length represents a cooling section.
With increasing cooling, the compressed air gives off moisture capable of damaging the air tool.
➤ Use short compressed air hoses.

No.: 9_6999 23 USE M100 81
8 Operation
8.2 Starting and stopping
Condensate formation in compressed air receivers
Compressed air stored in a containers will cool down. The compressed air precipitates moisture
that collects at the container's bottom. Corrosion may damage the container.
➤ Regularly drain the condensate.


Precondition No personnel are working on the machine.
All doors and siding panels are closed.
Serious damage to engine from cold starting sprays.

Cold-start assists, such as ether or other sprays, can cause severe engine damage.
➤ Do not use cold start sprays.
Fig. 38 Starting instruments

1 «Controller on» switch 6 Compressed air outlet pressure gauge
2 «Starter switch» 7 Temperature gauge switch
– STOP/Off 8 Operating hours counter
– On 9 – Fuel level monitoring light
– Preheat
– START
3 – «Load On» key with integrated LOAD
mode indicating light
4 – Back-pressure indicating light
5 Charging indicating light, group alarm
lamp

82 M100 No.: 9_6999 23 USE
8 Operation
Notes concerning snow and ice
Considerable snow or ice may build up on the machine under low temperature conditions.
➤ Remove any snow and ice from the machine before operating.
8.2.1 Starting the machine

1. Open the right-hand access door.
2. Switch «On» the Controller.
3. Close the door.
4. Turn the« starter switch» to "ON".
The generator indicator lamp must light.
8.2.2 Engine pre-heating

The preheating period should be between 5 and a maximum of 10 seconds depending on ambient
temperature. Low ambient temperatures require a longer preheating period.
The electric fuel pump starts automatically during pre-heating. This vents the fuel line before
each start.
1. Destruction of the glow plug

Excessive pre-heating can cause severe damage to the glow plug.
➤ Never allow the glow plugs to operate for longer than 10 seconds.
2. Turn the «starter switch» to the “Pre-heat” position and hold for 8 to 10 seconds.
The engine's glow plugs are energised and the engine pre-heated.
8.2.3 Starting the machine

1. Destruction of the starter!
Improper operation could destroy the starter.
➤ As long as the engine is running, do not actuate the starter switch.
➤ Do not turn and hold the starter switch for longer than 30 seconds.
➤ Wait for a few minutes after each attempt to start the engine.
➤ The starter switch must be returned to the neutral position before each start attempt (re‐
start protection).
2. Turn the «starter switch » to "START" and release it as soon as the engine starts.
The charging indicator lamp extinguishes as soon as the engine is running.
If the Back pressure lamp lights, there is back pressure in the system and the start is preven‐
ted. Only when the back-pressure lamp extinguishes has the pressure in the system fallen
sufficiently to allow the machine to be restarted.
8.2.4 Allow the machine to run up to operating temperature

To avoid unnecessary wear, the engine should be run in IDLE until the airend discharge tempera‐
ture reaches +86 °F. The airend discharge temperature is shown at the remote thermometer con‐
tact on the instrument panel.

No.: 9_6999 23 USE M100 83
8 Operation
Option ba
Fig. 39 Label referring to the warm-up period when ambient temperatures are below -50 °F
➤ Allow the machine to warm up in IDLE (low speed).
8.2.5 Switching to LOAD

Precondition The airend discharge temperature must be at least +86 °F.
1. Compressed air can cause serious injuries.

➤ Never direct compressed air at persons or animals.
➤ Ensure that all panels are in place.
➤ Ensure that all machine doors are closed.
2. Press the «Load On » button.
Result The integrated LOAD indicator lights and the engine accelerates to maximum speed.
8.2.6 Manually setting the discharge pressure
Danger from incorrectly set pressure!

Danger from malfunctioning or not functioning compressed air tools when the machine's dis‐
charge pressure is set incorrectly.
➤ Use connected compressed air tools only with the pressure appropriate for its purpose
(tool working pressure).
➤ Comply with the information and notes provided in the compressed air tool's operating
instruction.
Discharge pressure is adjusted manually on the proportional controller. The proportional controller
is located on the machine's oil separator tank cover. The required pressure can be seen on the
gauge on the instrument panel.
The pressure setting on the proportional controller can only be lower than the maximum
working pressure of the machine.
Precondition The machine is switched off.

84 M100 No.: 9_6999 23 USE
8 Operation
Fig. 40 Proportional controller

1 Oil separator tank 3 Adjusting knob lock
2 Proportional controller 4 «Pressure setting» knob

2. Unlock the «pressure setting» knob by turning counter-clockwise.
3. Set the required pressure with the «pressure adjusting» knob.
■ Turn the know to the right side in order to increase the discharge pressure.
■ Turn the know to the left side in order to decrease the discharge pressure.
4. Tighten the adjustment knob lock.
5. Close the door.
6. Start the machine and switch to LOAD mode.
7. Open the «compressed air outlet valve» on the air distributor slightly.
8. Check the pressure set on the instrument panel gauge.
If the indicated pressure is not the discharge pressure required, the machine should be shut
down and the setting procedure repeated.
8.2.7 Shutting down the machine

Operating the machine in the cool-down phase
1. Thermal overload of the turbocharger!

Abrupt stopping of the engine under load can cause a fault or damage to the turbo charger.
➤ Run the engine a few minutes in idle before shutting down to allow the turbocharger to
cool.
2. Close all «compressed air outlet valves» on the air distributor.
The engine runs in IDLE and the turbo charger can cool down.
3. After approx. 2 to 3 minutes, switch the «starter switch» to the "STOP/Off" position.
The engine turns off.
Shutting down the machine:

No.: 9_6999 23 USE M100 85
8 Operation
8.3 Monitoring fuel level in the fuel tank
2. Switch off the «» controller.

3. Close the door.
Secure both doors with locks as necessary.
8.3 Monitoring fuel level in the fuel tank

The fuel tank is fitted with a fuel level monitor.
When the fuel level drops to a certain point, the fuel level warning lamp (yellow) on the instrument
panel lights.
➤ Check the indicator lamp fuel level.
Indicator lights.
➤ Fill the fuel tank immediately.
Further information Further information on the fuel tank monitoring can be found in chapter 4.6.
8.4 Option ea, ec

Operating the tool lubricator
Tool lubricator is filled with oil
Fig. 41 Setting the tool lubricator

1 Shut-off valve
I – open
0 – closed
2 Metering knob
➤ Open the right-hand access door.

86 M100 No.: 9_6999 23 USE
8 Operation
8.5 Using the low-temperature equipment
Adding lubricating oil
1. Open the shut-off valve.

2. Close the access door.
Setting the oil flow
The amount of oil the compressed air should contain depends on the application and must be de‐
termined by the user. It depends on the nature of the air consumers and the supply hoses.
The metering valve controls the flow of oil into the air.
■ Clockwise adjustment reduces the oil flow.
■ Counter-clockwise adjustmen: increases the oil flow.
1. Set the required oil flow.

Further information Fill the tool lubricator with suitable oil (see chapter 10.8.1)
Shutting off lubricating oil
1. Close the shut-off valve.

8.5 Option ba
Using the low-temperature equipment
➤ Ascertain which low temperature equipment is fitted to the machine.
8.5.1 Option bb
Pre-warms the engine cooling water
➤ Start the engine coolant pre-heating as described in chapter 7.4.2.

No.: 9_6999 23 USE M100 87
8 Operation
8.5 Using the low-temperature equipment
8.5.2 Option bc
Operating the machine with frost protector
Fig. 42 Frost protector on and off

1 Shut-off valve
I – open
0 – closed
2 Frost protector tank
Using with the frost protector switched on
Operation at temperatures below 32 °F (winter operation).
Precondition Frost protector filled with antifreeze
1. Keep the frost protector shut-off valve permanently closed (position 0).
2. Close the door.
Result The machine is ready for winter operation.
Further information See chapter 10.8.5 for filling the frost protector with antifreeze.
Using with the frost protector switched off
Operating at temperatures above 32 °F (summer operation).

1. Leave the frost protector shut-off valve open permanently (position I).
2. Close the door.

88 M100 No.: 9_6999 23 USE
8 Operation
8.6 Operating the battery isolating switch
8.6 Option oa
Operating the battery isolating switch
Fig. 43 Battery isolating switch

1 «Battery isolating switch»
I – on
0 – off
➤ Open the left-hand door.
Start the machine
1. Switch the «battery isolating switch» on.

The battery is now connected to the machine's electrical system. The machine can now be
started.
Shutting down the machine:
1. Switch the «battery isolating switch» to the “off” position

The battery is disconnected from the machine's electrical system.
8.7 Option ga, gb

Generator operation
The generator may be operated immediately after the activation of the machine, during the warm-
up phase.
Risk of fatal injury caused by contact with live components!

➤ Check correct function of the insulation monitoring device daily (see chapter 7.5).
➤ Have the generator and control box checked annually by a qualified electrician (see
chapter 13.9).
➤ Follow instructions in chapter 3.9.

No.: 9_6999 23 USE M100 89
8 Operation
8.7 Generator operation
8.7.1 Note when operating the generator

Do not exceed the maximum supply system load:
➤ When operating the generator, do not exceed the maximum supply system load due to con‐
nected consumers.
Bear in mind:
■ The power consumption values of simultaneous consumers are added.
■ The maximum continuous power loading on the generator by the connected consumers is
limited by the safety cut-out.
8.7.2 Switching in the generator

1. Turn the «generator main switch »to the "l" position.
2. Set the «automatic circuit-breaker(s)» to the "l" position.
3. Turn the mode selector switch to the required mode of operation.
Result The engine runs at maximum speed and the generator generates power.
Further information See chapter 4.7.5.2 for generator controls.

See chapter 4.7.5.1 for generator operating modes.
Connect electrical consumers
1. Devices start automatically without warning.

Serious injury and damage to property is possible.
➤ Make sure that electric consumers are switched off.
2. Before connecting electrical consumers, carry out the following:
■ Determine the consumption values of the electric consumers.
■ Do not exceed the maximum system load caused by electric consumers. If necessary, re‐
duce the number of connected consumers.
■ Read the technical specification for the generator before connecting voltage-sensitive
equipment.
■ Check that electrical consumers and their connecting cables are in perfect condition.
■ Plug in and switch on consumers one-by-one.
■ Consumers with unfavourable on/off characteristics (e.g. high starting current) should be
started first.
Do not allow the rated current for each electrical socket and for the generator to be excee‐
ded.
8.7.3 Switching off the generator

Before deactivating the generator, carry out the following:
■ Switch off electrical consumers and unplug them one-by-one.
■ Switch off consumers drawing the highest current last.
■ Check that the protective covers on the power sockets are correctly closed.

90 M100 No.: 9_6999 23 USE
8 Operation
8.8 Cleaning the machine after operation
Thermal overload of the turbo generator.

Stopping the machine abruptly after the generator has been in operation for some time can
cause heat damage to the generator.
➤ Allow the engine to run for about 2 minutes in idle before shutting down to allow the gen‐
erator to cool down.
1. Set the «automatic circuit breaker(s)» to the "0" position.

2. Turn the «generator main switch» to the "0" position.
3. Close all «compressed air outlet valves» on the air distributor.
The engine runs in IDLE and the generator can cool down.
After running about 2 minutes in IDLE, the generator has cooled down sufficiently for the en‐
gine to be stopped.
8.8 Cleaning the machine after operation

Material High-pressure cleaner

The machine has cooled down.
The machine is fully vented, the pressure gauge reads 0 psig.
All compressed air consumers are disconnected and the air outlet valves are open.
Maintain the following minimum distances to the object to be cleaned in order to prevent damages
to the machine when cleaning with the high-pressure cleaner.
■ Circular section jets: approximately 2.3 ft

■ Fan jets: approximately 1 ft
■ Dirt blasters: approximately 1 ft
Keep the water jet in permanent motion during the cleaning process. You prevent thus dam‐
age.
Cleaning with dry-ice jets is strictly forbidden as it could cause unforeseeable damages.
1. Machine damage caused by strong water jet!

Direct water jets can damage or even destroy sensitive components.
➤ Do not directly focus a strong water jet towards sensitive components.
➤ Work carefully.
2. Carefully clean the machine with the high-pressure cleaner.
Water has accumulated in the sealed floor pan.
➤ Drain the water.
Catch the liquid and dispose in accordance with applicable environmental regulations.
Further information See chapter 10.8.9 for information to the draining of liquids within the machine.

No.: 9_6999 23 USE M100 91

The following tables are intended to assist in fault finding and rectification.
1. Do not attempt fault rectification measures other than those given in this manual!
2. In all other cases:
Have the fault rectified by an authorized KAESER service representative.
Further information Observe the instructions in chapter 3 "Safety and Responsibility" and prevailing local safety regula‐
tions when rectifying faults and malfunctions.
Comply with local applicable safety provisions!
9.2 Engine faults and alarms

Further information The engine service manual provides further information.
9.2.1 Engine refuses to start or comes to a stop

Possible cause Remedy Where can I get help?
Special‐ KAESER Engine
ized Service service
work‐ manual
shop
Defective starter. Have replaced. X – –
The fuel cut-off device has not Check the coil and electrics and X – –
opened. have replaced if necessary.
Fuel tank empty. Fill up the fuel tank – – –
Airlock in the fuel line between Bleed the fuel line (see chap‐ – – X
fuel tank and injector pump. ter 10.3.3).
Fuel filter clogged. Clean or replace, see chap‐ – – X
ter 10.3.3.
Fuel line broken. Have replaced. X X –
Defective control fuse or relay. Have repaired or replaced if X X –
necessary.
Airend discharge temperature Have checked. – X –
too high.
Defective temperature gauge Have repaired or replaced if – X –
switch giving no enable signal necessary.
Ignition switch defective. Have repaired or replaced if – X –
necessary.
Electrical connections and/or ca‐ Tighten the connection or have X X –
bles loose or broken the cable replaced.
Defective battery or low charge. Maintain battery, see chap‐ – – –
ter 10.3.9.

92 M100 No.: 9_6999 23 USE
9.2 Engine faults and alarms

work‐ manual
shop
Defective alternator. Have repaired or replaced if X X –
necessary.
Defective alternator regulator. Have repaired or replaced if X X –
necessary.
Oil pressure switch indicating in‐ Check engine oil level, see – – X
sufficient oil pressure. chapter 10.3.4.
Have the engine repaired or re‐ X X –
placed.
Tab. 72 Alarm: Engine refuses to start or comes to a stop.
9.2.2 Engine does not reach full speed

work‐ manual
shop
Airlock in the fuel line between Bleed the fuel line (see chap‐ – – X
fuel tank and injector pump. ter 10.3.3).
Fuel filter clogged. Clean or replace, see chap‐ – – X
ter 10.3.3.
Fuel line broken. Have replaced. X X –
Speed adjustment cylinder mal‐ Have repaired or replaced if X X –
adjusted or defective. necessary.
Tab. 73 Alarm: Engine does not reach full speed
9.2.3 Indicator lamp remains on

work‐ manual
shop
Electrical connections and/or ca‐ Tighten the connection or have X X –
bles loose or broken the cable replaced.
Defective alternator. Have repaired or replaced if X X –
necessary.
Defective alternator regulator. Have repaired or replaced if X X –
necessary.

No.: 9_6999 23 USE M100 93
9.3 Compressor faults and alarms

work‐ manual
shop
Engine oil pressure too low. Check engine oil level, see – – X
chapter 10.3.4.
Check the engine and have re‐ X X –
paired if necessary.
Tab. 74 Indicator lamp remains on

9.3.1 Working pressure too high
Specialized KAESER
workshop Service
Proportional controller maladjus‐ Have repaired or replaced if – X
ted or defective. necessary.
Inlet valve does not close. Check the controller, the control – X
air line and the inlet valve and
replace if necessary.
Pressure gauge indicating false Have repaired or replaced if – X
pressure. necessary.
Venting valve does not blow off. Check the connections and – X
function and have repaired or
replaced as necessary.
Tab. 75 Fault: Working pressure too high
9.3.2 Working pressure too low.

Specialized KAESER
workshop Service
Proportional controller maladjus‐ Have repaired or replaced if – X
ted or defective. necessary.
Inlet valve not opening or only Repair or have replaced if nec‐ – X
opening partially. essary.
Pressure gauge indicating false Have repaired or replaced if – X
pressure. necessary.
Pressure relief valve maladjus‐ Have repaired or replaced if – X
ted and/or leaking. necessary.
Venting valve does not close. Check the connections and – X
function and have repaired or
replaced as necessary.

94 M100 No.: 9_6999 23 USE

Specialized KAESER
workshop Service
The engine runs at maximum See chapter 9.2. X X
speed (LOAD).
Engine air filter and/or compres‐ Clean or change, see chap‐ – –
sor air filter clogged. ters 10.3.2 and 10.4.7.
Oil separator cartridge heavily Change, see chapter 10.4.6. – –
clogged.
Tab. 76 Fault: Working pressure too low
9.3.3 Pressure relief valve blowing off

Specialized KAESER
workshop Service
Oil separator cartridge heavily Change, see chapter 10.4.6. – –
clogged.
Inlet valve does not close. Check the controller, the control – X
air line and the inlet valve and
replace if necessary.
Pressure relief valve maladjus‐ Adjust or have replaced if nec‐ – X
ted and/or leaking. essary.
Tab. 77 Fault: Pressure relief valve blowing off
9.3.4 Machine overheating

Specialized KAESER
workshop Service
Defective cooling fan. Have the blades or the complete – X
fan wheel replaced.
Oil cooler clogged. Clean surface, see chap‐ – –
ter 10.5.
Defective working element in the Have repaired or replaced if – X
combination valve. necessary.
Gauge working pressure too Reset to the permissible value – X
high (proportional controller mal‐ or have replaced.
adjusted).
Oil separator cartridge heavily Measure the pressure differen‐ – X
clogged. tial and change the cartridge if
greater than 1 psi. See chap‐
ter 10.4.6 for changing.
Compressor oil filter clogged. Change, see chapter 10.4.4. – –
Compressor cooling oil level too Topping up, see chapter 10.4.2. – –
low.

No.: 9_6999 23 USE M100 95

Specialized KAESER
workshop Service
Oil pipes leaking. Seal leaks or have pipes X X
changed.
Engine cooling system or cool‐ Have repaired. X X
ing fan defective.
Ambient temperature too high. See installation conditions in – –
chapter 5.2.
Tab. 78 Fault: Machine overheating
9.3.5 Too much oil residue in the compressed air

Specialized KAESER
workshop Service
Oil separator cartridge scavenge Clean the oil separator cartridge – X
line clogged. dirt trap or replace the strainer
and nozzle if necessary. See
chapter 10.4.5.
Fractured oil separator car‐ See chapter 10.4.6 for chang‐ – –
tridge. ing.
Oil level in the oil separator tank Reduce to maximum level, see – –
too high. chapters 10.4.1 and 10.4.3.
Tab. 79 Fault: Too much oil residue in the compressed air
9.3.6 Oil flows from the compressor air filter after shutdown
Specialized KAESER
workshop Service
Defective non-return function of Repair or have replaced if nec‐ – X
the inlet valve. essary.
Tab. 80 Fault: Oil flows from the compressor air filter after shutdown

96 M100 No.: 9_6999 23 USE
9.4 Generator faults and alarms

High moisture content in the compressed air
Specialized KAESER
workshop Service
Blocked condensate drain on Clean the cyclone separator dirt – X
the cyclone separator. trap or replace the strainer and
nozzle if necessary. See chap‐
ter 10.8.2.
Tab. 81 Fault: High moisture content in the compressed air
9.4 Option ga, gb

Generator faults and alarms
9.4.1 There is no voltage or too low a voltage from the generator
Specialized KAESER-
workshop Service
Defective drive belt. Have replaced. X X
Generator / regulator defective Have repaired. X X
Overload protection switch trig‐ Check the power requirement of X –
gered because of overload or the connected consumers and
defect. reduce if necessary; check the
consumers for short circuits.
Check the overload protection X X
switch and have replaced if nec‐
essary.
Engine speed too low. Have reset to rated speed. X X
Generator not switched on. Switch on the generator. – –
The compressor's working pres‐ Have the working pressure ad‐ X X
sure is set too high, engine justed.
overloaded, speed drops off
The engine power is reduced Keep the generator and com‐ – –
because of climatic conditions or pressor load below the rated
other effects. power
Tab. 82 There is no voltage or too low a voltage from the generator
9.4.2 Generator voltage too high

Specialized KAESER-
workshop Service
Generator / regulator defective Have repaired. X X

No.: 9_6999 23 USE M100 97
9.4 Generator faults and alarms

Specialized KAESER-
workshop Service
Engine speed too high. Have reset to rated speed. X X
Tab. 83 Generator voltage too high

98 M100 No.: 9_6999 23 USE
10 Maintenance
10.1 Ensuring safety
10 Maintenance
10.1 Ensuring safety
Follow the instructions below to ensure safe machine maintenance.

➤ Maintenance work may only be carried out by authorized personnel.
➤ Do not reuse removed self-locking nuts but replace with new ones. The non-positive safety
against loosening is no longer ensured when the nut is unscrewed.
➤ Use one of the safety signs below to advise others that the machine is currently being serv‐
iced:
Sign Meaning
Do not activate the machine.
Warning:
The machine is being serviced.
Tab. 84 Advise others that the machine is being serviced
➤ Before switching on, make sure that:
■ no personnel is working on the machine,

■ all protective guards and cover panels are attached,
■ all doors, canopy, and panels are closed,
■ all tools have been removed from the machine.
➤ Do not perform any checks or maintenance while the machine is running.

The access doors are held up by gas struts.
➤ Check that the doors remain open.
If door does not remain opened: Have the gas-filled spring changed.
When working on the compressed air system
Compressed air is contained energy. Uncontrolled release of this energy can cause serious injury
or death. The following safety concerns relate to any work on components that could be under
pressure.
➤ Disconnect the air consumers.
➤ Depressurize all pressurized components and enclosures.
■ Wait until the machine has automatically vented.

No.: 9_6999 23 USE M100 99
10 Maintenance
10.2 Maintenance schedules
■ Carefully open the compressed air outlet valve.

■ Check: The pressure gauge must read 0 psig!
When working on the drive system
Touching rotating, very hot, or electrically-live components can result in serious injury.
➤ Shut down the machine before opening any doors/canopy.
➤ Disconnect the negative terminals on the batteries.
➤ Ensure that the machine has cooled down.


10.2.1 Logging maintenance work
The maintenance intervals given are those recommended for KAESER original components
with average operating conditions.
➤ In adverse conditions, perform maintenance work (e.g. oil and filter changes) at shorter
intervals.
Adverse conditions are, e.g.:

■ poor fuel quality
■ high/low temperatures
■ much dust
■ frequent use
➤ Adjust the maintenance intervals with regard to local installation and operating condi‐
tions.
➤ Logging all maintenance work.
This enables the frequency of individual maintenance tasks and deviations from our recom‐
mendations to be determined.
Further information A list is given in chapter 10.9.
10.2.2 Maintenance tasks after commissioning

The table below lists maintenance tasks required after commissioning (initial start-up).
➤ Carry out maintenance tasks according to the following schedule.
After the first
After the first
See chapter
Component:
Note
10 h
50 h
Task
Engine
h = operating hours; Engine-SM = manufacturer's engine service manual

100 M100 No.: 9_6999 23 USE
10 Maintenance
After the first
After the first
See chapter
Component:
Note
10 h
50 h
Task
Change oil. X 10.3.6 Engine
SM
Change the oil filter. X 10.3.7 Engine
SM
Check the fuel lines and clamps. X Engine
SM
Wheels/chassis:
Re-tighten the wheel nuts/bolts. X
Option ga, gb – generator:
Check the generator-drive belt X 10.8.8
tension and re-tension if neces‐
sary.
h = operating hours; Engine-SM = manufacturer's engine service manual
Tab. 85 Maintenance tasks after commissioning
10.2.3 Regular maintenance tasks

The following table lists the various maintenance intervals.
Maintenance interval Short description

Daily –
Every 250 h, at least annually. A250
Every 2000 h, at least every two years. A2000
Every 3000 operating hours A3000
Every 20000 operating hours A20000
Every 36000 h, at least every six years. A36000
Tab. 86 Maintenance intervals and regular maintenance tasks
The table below lists regular maintenance tasks.

1. Carry out maintenance tasks punctually taking ambient and operating conditions into consider‐
ation.
2. Change consumables and operating fluids according to each site.

No.: 9_6999 23 USE M100 101
10 Maintenance
10.2.3.1 Machine maintenance schedule
A36000
chapter
Component
A1000
A1500
A2000
A3000
A250
A500
Daily
Note
See
Function
Engine
Check inlet air filter mainte‐ X 10.3.2
nance indicator
Check engine oil level. X 10.3.4 Engine
SM
Clean the engine air filter X 10.3.2
Change the engine oil X 10.3.6
Replace the engine oil filter. X 10.3.7 Engine
SM
Check/adjust the drive belt ten‐ X 10.3.8 Engine
sion. SM
Replace the drive belt. X 10.3.8 SW
Engine
SM
Change engine air filter. X 10.3.2
Have the valve clearance adjus‐ X SW
ted. Engine
SM
Have the turbocharger checked. X SW
Check the engine coolant level. X 10.3.1 Engine
SM
Clean the cooler. X 10.5
Check antifreeze concentration. X 10.3.1 Engine
SM
Check radiator hose and hose X SW
clips, have replaced if necessa‐ Engine
ry. SM
Change the coolant. X 10.3.1 Engine
SM
Fill up the fuel tank X
Check/empty the water trap. X 10.3.3
Check fuel lines and hose X SW
clamping bands, have replaced
if necessary.
Have fuel lines and clamps re‐ X SW
placed.
Engine SM = engine manufacturer's service manual; SW = specialized workshop.

102 M100 No.: 9_6999 23 USE
10 Maintenance
A36000
chapter
Component
A1000
A1500
A2000
A3000
A250
A500
Daily
Note
See
Function
Clean the fuel microfilter. X 10.3.3 Engine
SM
Change the fuel prefilter. X 10.3.3
Replace the fuel microfilter. X 10.3.3 Engine
SM
Cleaning the fuel tank. X
Clean the tank fuel strainer. X
Have the fuel injectors checked. X SW
Have the fuel injector pump X SW
checked.
Check the battery electrolyte X 10.3.9
level and connections.
Check fuel tanks for secure fix‐ X 10.3.10
ing.
Compressor:
Check inlet air filter mainte‐ X 10.4.7
nance indicator.
Check the cooling oil level. X 10.4.1
Clean the compressor air filter. X 10.4.7
Clean the oil cooler. X 10.5
Have the pressure relief valve(s) X 10.4.8
checked.
Check/clean the oil separator X 10.4.5
tank dirt trap.
Change compressor air filter. X 10.4.7
Change the cooling oil. X 10.4.3
Change the compressor oil filter. X 10.4.4
Change the separator cartridge X 10.4.6
in the oil separator tank.
Chassis/bodywork
Check the tire pressures. X
Check wheel bolts and nut for X
tightness.
Carry out chassis maintenance. X 10.7
Grease the ball coupling, joints X 10.7.2
and towbar.
Brake maintenance X 10.7.3

No.: 9_6999 23 USE M100 103
10 Maintenance
A36000
chapter
Component
A1000
A1500
A2000
A3000
A250
A500
Daily
Note
See
Function
Check wear on the brake lin‐ X 10.7.3.2
ings.
Have the wheel brakes adjus‐ X SW
ted.
Check all screw connections, X
hinges, locks, handles and snap
fasteners of the doors for wear
and secure fixing.
Grease the door hinges. X
Carry out rubber sealing strip X 10.6
maintenance.
Have the lifting point checked. X SW
Other maintenance tasks
Check all accessible fittings, X
pipes and clamps for wear and
tightness.
Check hoses for leaks and X
wear.
Have hose lines replaced. X SW
Check that all electrical connec‐ X
tions are tight.
Tab. 87 Regular machine maintenance tasks
10.2.3.2 Maintenance schedule for options

A20000
chapter
Option:
A1000
A2000
A250
A500
Daily
Note
See
Function
Option ea, ec – tool lubricator
Check the oil level in the tool lu‐ X 10.8.1
bricator.
Option da, db, dc, dd – cyclone separator
Clean and check the dirt trap. X 10.8.2
Options da, db, dc, dd – compressed air aftercooler
Clean the cooler. X 10.5.2
EL = qualified electrician; SW = specialist workshop

104 M100 No.: 9_6999 23 USE
10 Maintenance
A20000
chapter
Option:
A1000
A2000
A250
A500
Daily
Note
See
Function
Option dd – filter combination
Drain condensate. X 10.8.3
Change the filter elements. X 10.8.3
Option dc – fresh air filter
Drain condensate. X 10.8.4
Check the oil indicator. X 10.8.4
Change the filter elements. X 10.8.4
Option ba – frost protector
Winter operation X 10.8.5
Check the level of antifreeze in
the frost protector.
Engine coolant pre-heater (Option bb)
Have the coolant pre-heating X SW
and associated wiring checked.
Option la – spark arrester
Clean the spark arrestor. X 10.8.6
Blow out the spark arrester with X
compressed air.
Option lb - engine air intake shut-off valve
Clean/check the engine air in‐ X 10.8.7
take shut-off valve.
Option ga, gb – generator
Check/adjust belt tension. X 10.8.8
Carry out visual check of drive X 10.8.8
belt.
Have the generator and control X 13.9 EL
box checked.
Replace the drive belt. X 10.8.8
Have the generator bearings X SW
checked.
Have the generator bearings X SW
changed.
Option oe – sealed floor pan
Check the machine interior for X 10.8.9
liquid accumulations and drain,
if required.
EL = qualified electrician; SW = specialist workshop
Tab. 88 Regular maintenance task options

No.: 9_6999 23 USE M100 105
10 Maintenance
10.3 Engine maintenance

➤ Perform maintenance tasks according to the schedule in chapter 10.2.3.1.
10.3.1 Water cooler maintenance

Material Coolant
Coolant tester
Oil receptacle
Drain hose with hose coupling is disconnectedly laying at the machine
Funnel
Cleaning cloths

The machine is standing level.
Danger of scalding by hot coolant!

Serious injuries can be caused by hot coolant.
➤ Let the machine cool down before opening the cooling system.
Risk of chemical burns from coolant containing antifreeze!

➤ Avoid eye and skin contact with coolant. If the eyes are affected, rinse immediately with
running water.
➤ Wear protective glasses and gloves.
Insufficient coolant can damage the engine.

Insufficient coolant will cause the engine to overheat. Overheating can cause serious dam‐
age to the engine.
➤ Check the coolant level daily.
➤ Top up the coolant as necessary.
10.3.1.1 Checking coolant level
The coolant level in the engine cooling circuit must be checked daily prior to startup.
The level is checked on the coolant expansion tank.
■ The tank is semi-transparent so the coolant level can be seen from outside.
■ The level should be between the minimum and maximum markings when the engine has
cooled down.

106 M100 No.: 9_6999 23 USE
10 Maintenance
Fig. 44 Checking coolant level

1 Coolant level 3 Water cooler
A Maximum mark (FULL) 4 Overflow
B Minimum mark (LOW) 5 Filler neck with cap
2 Coolant equalising tank
1. Check the level of coolant in the expansion tank.

Top up when the coolant level falls below the minimum level B . Replenish the coolant.
2. Close the door.
Have the cause for the coolant loss determined and rectified.
10.3.1.2 Checking the coolant
The coolant should be checked according to the maintenance schedule to ensure quality and op‐
erational life.
Coolant quality can be determined by the following parameters:

■ Visual check
■ Antifreeze concentration measurement
➤ Unscrew and remove the expansion tank filler cap.
Visual check
The coolant should be checked for its colour and any particles or sediments floating in it.
➤ Take a coolant sample and analyze.
The coolant is discoloured and/or has contains floating particles. Change the coolant.
Antifreeze concentration measurement
An instrument (e.g. refractometer) is used to check antifreeze concentration.

Maximum frost protection is ensured with an antifreeze concentration of 55% by volume, as frost
protection and heat transfer properties deteriorate beyond this point. Higher concentration also
leads to higher operating temperature.

No.: 9_6999 23 USE M100 107
10 Maintenance
1. The engine can be damaged if the antifreeze concentration is insufficient.

Corrosion
Damage to the cooling system.
Engine casing fracture
➤ Check coolant.
➤ Protect the coolant against frost.
➤ Top up as necessary.
2. Use the coolant tester as instructed by the manufacturer to test the coolant.
Concentration of antifreeze is too low: Change the coolant.
Performing final work steps:
1. Screw on the filler cap.

2. Close the door.
10.3.1.3 Mixing coolant
Do not use water without coolant additive. Water alone is corrosive at engine operating tempera‐
ture. Water alone does not offer sufficient protection from boiling or freezing.
The coolant is a mixture of clean, fresh water and antifreeze with corrosion inhibitor.
For reasons of corrosion protection and the need to raise the boiling point, the coolant must remain
in the cooling system throughout the year.
The maximum permissible coolant life is 2 years.
➤ Follow coolant recommendations in chapter 2.6.4.
Preparing coolant
Precondition Coolant must meet the specification of ASTM D4985.
➤ The coolant should be mixed in the proportions given by the manufacturer.
KAESER coolant mixture table

Antifreeze Water Frost protection to [°F]
1 part 2 parts −0.4
1 part 1.5 parts −13
1 part 1 part −34.6
Tab. 89 KAESER coolant mixture table
The concentration of antifreeze should not be less than 33% for ensured corrosion protection.
10.3.1.4 Filling and topping up the coolant
The proportion of antifreeze in the coolant should not fall below 33% to ensure frost and corrosion
protection and prevent the build up of deposits in the cooling circuit. Topping up with water alone
dilutes the antifreeze concentration and is forbidden.
Make sure that there is sufficient room for hot coolant to expand without overflowing.

108 M100 No.: 9_6999 23 USE
10 Maintenance
Precondition The negative cable to the battery is disconnected.
1. Twist and remove the expansion tank filler cap.

2. Mix a quantity of coolant according to the table and replenish to the mark.
Replenish the coolant just below the maximum mark A .
4. Reconnect the negative battery terminal.
5. Close the door.
6. Start the engine and allow to IDLE for about 1 minute.
7. Stop the motor.
9. Check the coolant level.
If the coolant level in the expansion tank has decreased: Replenish the coolant.
10. Visually inspect for leaks.
11. Close the door.
If the coolant has been changed, check the level of the new coolant frequently at first as it
can decrease due to the escape of air locks in the cooling circuit.
10.3.1.5 Draining the coolant
Precondition The machine has cooled down.

The negative cable to the battery is disconnected.
Draining the cooling oil (machine with chassis)
In machines with chassis (no closed floor pan, no stationary machine), the entire cooling oil of the
cooling circuit is drained directly at the engine's water cooler. This is done from a drain valve with
the aid of a separate drain hose.

No.: 9_6999 23 USE M100 109
10 Maintenance
Fig. 45 Draining the coolant from the radiator

1 Filler cap 5 Drain hose with male fitting
2 Coolant equalising tank 6 Quick-release coupling
3 Water cooler 7 Shut-off valve (ball valve)
4 Fuel tank I - open
0 - closed
1. Unscrew and remove the expansion tank filler cap 1 .

2. Position a receptacle beneath the water cooler drain point (accessible through a hole in the
floor panel).
3. Connect a suitable drain hose 5 to the radiator quick-release coupling 6 .
4. Suspend the free end of the hose in the receptacle and secure.
5. Open the shut-off valve 7 and catch the draining coolant.
6. Close the shut-off valve and remove the drain hose.
8. Close the door.
Option oe, rw, rx Draining the coolant (closed floor pan - stationary machine):
Compressor cooling oil and engine coolant drain lines are led to a central point outside the ma‐
chine on stationary machines and machines with closed floor pan. The cooling oil is drained via a
pipe which is screwed into the drain opening of the cooler and closed with a shut-off valve. The
pipe is sealed with a screwed sealing plug at the drain end.

110 M100 No.: 9_6999 23 USE
10 Maintenance
Option oe, rw, rx
Fig. 46 Draining the coolant from the radiator (closed floor pan - stationary machine)
1 Screwed sealing cap - coolant drain 4 Coolant equalising tank
2 Water cooler 5 Shut-off valve (ball valve)
3 Filler cap I - open
0 - closed
1. Unscrew and remove the expansion tank filler cap.

2. Position a receptacle beneath the drainage location of the water cooler.
3. Unscrew the filler plug 1 at the coolant drain.
4. Open the shut-off valve 5 at the water cooler and catch any draining coolant.
5. Close the shut-off valve and replace the screwed sealing cap.
6. Screw in the filler cap.
7. Close the door.
➤ Dispose of used coolant in accordance with environmental protection regulations.
Further information The operating manual supplied by the motor manufacturer provides further information on coolant
change and cleaning the cooling system.
10.3.2 Engine air filter maintenance

Clean the filter according to the maintenance schedule or if the maintenance indicator shows this to
be necessary.
Renew the air filter element after 2 years at the latest or after it has been cleaned 5 times.
■ Using the engine without an air filter element is not permitted!
■ Do not use an air filter element with damaged folds or gasket.
■ The use of an unsuitable air filter can permit dirt to ingress the engine and cause prema‐
ture wear and damage.

No.: 9_6999 23 USE M100 111
10 Maintenance
Material Compressed air for blowing out

Spare parts (as required)
Cleaning cloth

Machine is cooled down.
Damaged air filter element.

Wear in the engine from intake of contaminated air.
➤ Do not try to clean the filter element by striking or knocking it.
➤ Do not wash the filter element.
Fig. 47 Engine air filter maintenance

1 Maintenance indicator 5 Filter element
2 Red zone indicator scale 6 Retaining clip
3 Indicating piston of the maintenance indi‐ 7 Filter cap
cator
4 Reset knob for the maintenance indicator

112 M100 No.: 9_6999 23 USE
10 Maintenance
Fig. 48 Cleaning the filter element

1 Compressed air gun with blast pipe bent to 90° at the end
2 Filter element
➤ Open both doors.
Checking contamination of the air filter:
Air filter maintenance is necessary when the yellow piston inside the maintenance indicator rea‐
ches the red zone.
➤ Check the air filter maintenance indicator.
If the yellow piston reaches the red zone, clean or renew the filter element.
Cleaning the air filter:
1. Release the retaining clamps, lift off the cap an extract the air filter.
2. Carefully clean the inside of the housing, the cover and sealing faces with a damp cloth.
3. Cleaning the filter element:
■ Use dry compressed air (≤ 73 psi!) at an angle to blow dust from the element from inside to
outside until no further dust develops.
■ The blast pipe must be long enough to reach the bottom of the element.
■ The tip of the blast pipe must not touch the element.
■ Cleaning sealing faces.
4. Inspect the element carefully for any damage.
Replace any damaged filter element.
5. Insert the cleaned or new filter element into the filter housing. Make sure it is properly in place
and sealed by its gaskets.
6. Replace the cap and secure with the clip.
Resetting the maintenance indicator:
➤ Repeatedly press the reset knob on the maintenance indicator.

The yellow piston within the indicator is reset and the maintenance indicator is ready for use
again.
Dispose of old parts and contaminated materials according to environmental regulations.

No.: 9_6999 23 USE M100 113
10 Maintenance
10.3.3 Fuel system maintenance

Make sure no dirt enters the fuel system during maintenance. Clean components and their sur‐
roundings before dismounting.
Material Spare parts

Oil receptacle
Cleaning cloths

Danger of fire from spontaneous ignition of fuel!

Serious injury or death could result from the ignition and combustion of fuel.
➤ Allow no open flames or sparks at the place of use.
➤ Ensure that the maximum ambient temperature is not exceeded at the place of use.
➤ Stop the motor.
➤ Wipe up escaped fuel.
➤ Keep fuel away from hot machine parts.
Fig. 49 Fuel system maintenance

1 Fuel pump 4 Fuel tank
2 Fuel de-watering filter 5 Fuel strainer
3 Fuel pre-filter 6 Fuel fine filter

114 M100 No.: 9_6999 23 USE
10 Maintenance
10.3.3.1 Bleeding the fuel system
Air can enter the fuel system if the fuel tank is empty after a fuel filter change or when carrying out
work on the fuel lines.
If the motor refuses to start despite a full tank, bleed the fuel system.
Precondition Battery connected.
Fig. 50 Bleeding the fuel system

1 Fuel fine filter
2 Bleed screw
1. Place a receptacle beneath the fuel fine filter housing.

2. Loosen the micro-filter bleed screw.
3. Close the door.
4. Turn the «starter switch» (operator panel) to the "On" position.
The fuel pump runs and air is bled out of the fuel system.
5. After approx. 10 to 15 minutes, switch the «starter switch» to the "STOP/Off" position.
7. Tighten the bleed screw again.
8. Remove the receptacle.
9. Close the door.
Start the motor as soon as the fuel system has been bled and allow to run for at least 5 mi‐
nutes in IDLE.

11. Visually check the fuel system for leaks. If required, re-tighten all fittings.
12. Close the door.
10.3.3.2 Fuel filter with water trap maintenance
A water trap is installed between the tank and the fuel pump. The separator tank is semi-transpar‐
ent so the fuel level can be seen from outside.

No.: 9_6999 23 USE M100 115
10 Maintenance
Fig. 51 Fuel filter with water trap maintenance

1 Bleed screw
I ‑ open
0 ‑ close
2 Separator tank
3 Drain plug
I ‑ open
0 ‑ close
Checking the fuel water trap
Water, being denser than diesel fuel, sinks to the bottom of the separator tank. The water impurity
also differs in colour from the fuel. A check should be made daily as to whether water and dirt has
accumulated.
➤ Check the fuel in the transparent water trap.
Fuel contaminated: Eemptying the water trap immediately.
Emptying the fuel water trap
Precondition Water and/or contamination are visible in the water trap.
1. Place a receptacle beneath the fuel micro-filter housing.

2. Loosen the bleed screw 1 in the filter head.
3. Loose the drain screw 3 and allow water and dirt to drain out into the receptacle.
5. Reconnect the battery.
6. Close the door.
The mixture of fuel and water and any materials contaminated with fuel must be disposed of
in accordance with environment protection regulations.

116 M100 No.: 9_6999 23 USE
10 Maintenance
10.3.3.3 Fuel filter maintenance
Changing the fuel prefilter:
Fig. 52 Changing the fuel pre-filter.

1 Fuel hose
2 Hose clamp
3 Fuel pre-filter
1. Place a receptacle beneath the fuel pre-filter housing.

2. Loosen the hose clamps, carefully pull the fuel hoses from the connection at the fuel pre-filter.
Capture and wipe off any escaping fuel.
3. Install a new fuel pre-filter between the plastic hoses and secure using hose clamps, taking
care the flow is in the right direction.
Replacing the fuel microfilter:
Fig. 53 Fuel micro-filter maintenance

1 Turn in this direction to unscrew the filter cartridge.
2 Filter holder
3 Filter cartridge
1. Place a receptacle beneath the fuel fine filter housing.

2. Use a filter wrench to loosen then unscrew the filter cartridge. Catch fuel in the receptacle.
3. Clean the sealing faces of the micro-filter cartridges and the opposite site of the filter mount
with lint-free cloth.

No.: 9_6999 23 USE M100 117
10 Maintenance
4. Mount the micro-filter cartridges on the filter mount:

■ Moisten the rubber seals of the filter mount and the sealing faces of the new filter cartridge
with some fuel.
■ Manually screw the filter cartridge to the filter head (clockwise), until seal is tight.
6. Close the door.
The fuel system must be bled after the filter cartridges have been changed.
Dispose of fuel and any materials and components contaminated with it in accordance with
environmental protection regulations.
Starting the machine and performing a test run:
1. Switch the machine on and run it in IDLE mode for approx. 1 minute.
2. Shut down the machine.
4. Visually check the fuel system for leaks.
5. Tighten all fittings.
6. Close the door.
Further information The engine service manual provides further information on fuel system maintenance.
10.3.4 Checking the engine oil level

The engine oil is indicated by a dipstick in the oil sump. The oil level should ideally be between the
two marks on the dipstick. The oil level should not be allowed to fall below the minimum level.
Material Cleaning cloth

Engine cooled down.

118 M100 No.: 9_6999 23 USE
10 Maintenance
Fig. 54 Checking the engine oil level

1 Engine oil filler cap A Mark for maximum oil level
2 Oil dipstick B Mark for minimum oil level

2. Withdraw the dipstick, wipe with a lint-free cloth and replace fully.
3. Withdraw the dipstick once more and read off the oil level.
The level should be between the maximum and minimum markings.
Top up if the level has reached or fallen below the minimum level mark.
The marked maximum oil level should not be exceeded in order for the level of oil in the
crankcase not to reach the crankshaft. If this occurs, it could create oil bubbles that would
reduce the oil's lubricating capability and impair engine performance.
10.3.5 Engine oil filling and topping up

Material Engine oil
Cleaning cloth
Funnel

Filling with engine oil
See chapter 2.6.5 for engine oil filling volume.

The oil dipstick is marked with the «maximum oil level».

2. Remove the filler cap and fill with fresh oil.

No.: 9_6999 23 USE M100 119
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3. Wait 5 minutes then check the oil level.

It takes a few minutes for oil to reach the sump.
Top up if the level is too low.

4. Replace the plug in the filler port.
1. Switch the machine on and run it in IDLE mode for approx. 5 minutes.
3. Wait until the machine has automatically vented.
Pressure gauge reads 0 psig!
5. Check the oil level after about 5 minutes.
10.3.6 Changing the engine oil

The engine oil should be changed:
■ according to the maintenance schedule,
■ according to the degree of contamination of the intake air,
■ at least once a year.
Check the operating manual of the motor manufacturer for information on oil change in very
dusty environments.
Material Engine oil

Oil receptacle
Wrench
Cleaning cloths

Engine at operating temperature.
Danger of burns from hot components and escaping engine oil!

➤ Wear long-sleeved clothing and protective gloves.

120 M100 No.: 9_6999 23 USE
10 Maintenance
Draining the engine oil (machines with chassis)
In machines with chassis (no sealed floor pan, not stationary machine), the engine oil is drained
directly at the machine's oil pan. For this purpose, a drainage outlet is provided in the floor pan.
Fig. 55 Draining the engine oil

1 Oil filler neck cover, engine oil 4 Drain hole in the floor pan
2 Engine oil sump 5 Engine oil drain plug
3 Oil collection box (in floor pan) 6 Sealing ring

2. Remove the oil filler cover.
3. Place the oil receptacle below the drain hole in the floor pan.
4. Unscrew the drain plug and allow the engine oil to drain into the receptacle.
5. Clean the drain plug and screw in with a new gasket.
7. Close the door.
Option oe, rw, rx Draining the engine oil (sealed floor pan, stationary machine)
chine on stationary machines and machines with sealed floor pan. The engine oil is drained via a
pipe which is screwed into the drain opening of the engine block and closed with a shut-off valve.
The pipe is sealed with a screwed sealing plug at the drain end.

No.: 9_6999 23 USE M100 121
10 Maintenance
Option oe, rw, rx
Fig. 56 Draining the engine oil (closed floor pan - stationary machine)
1 Screwed sealing cap, engine oil drain 3 Engine oil sump
2 Oil filler neck cover, engine oil 4 Shut-off valve (ball valve)
I - open
0 - closed

2. Remove the oil filler cover.
3. Place the oil receptacle below the drain point.
4. Unscrew the filler plug 1 at the oil drain.
5. Open the shut-off valve 4 at the engine's oil pan and catch the engine oil.
8. Close the door.
Dispose of old oil and oil-soaked working materials according to environmental protection
regulations.
Further information See chapter 10.3.5 for engine oil filling.

Further information regarding changing the engine oil is provided in the engine manufacturer's op‐
erating manual.

122 M100 No.: 9_6999 23 USE
10 Maintenance
10.3.7 Replace the engine oil filter

Material Spares
Filter wrench
Cleaning cloth
Receptacle

Engine cooled down.
Danger of burns from hot components and escaping engine oil!

➤ Wear long-sleeved clothing and gloves.
Fig. 57 Changing the oil filter

1 Direction of rotation to unscrew the filter
2 Oil filter
3 Engine block

2. Prepare a receptacle.
3. Use a filter wrench to loosen and unscrew the filter. Catch any escaping oil.
4. Carefully clean sealing surfaces using lint-free cloth.
5. Lightly oil the new filter's gasket.
6. Turn the oil filter clockwise by hand to tighten.
7. Check the engine oil level.
9. Close the door.
Further information The engine service manual gives further information on oil filter changing.
Dispose of old oil filters, old oil and materials contaminated with oil according to environmen‐
tal protection regulations.

No.: 9_6999 23 USE M100 123
10 Maintenance
10.3.8 Drive belt maintenance

The lifespan of the drive belts is affected by belt tension.
■ Slack belts can slip and become damaged and may result in engine overheating.
■ Over-tight belts stretch and fatigue quicker. Over-tight belts also place unnecessary stress on
bearings and shorten their life.
Material Wrench
Suitable clamping lever (short, thin rod)
Spare part

Beware of rotating pulleys and moving belts.

There is danger of serious injury from pinching.
➤ Never check the drive belt unless the engine is at standstill.
➤ Never run the machine without a belt guard.
Removing the belt guard:
Fig. 58 Belt guard attachment

1 Belt guard 3 Washer
2 Hexagon bolt 4 Hexagon socket screw
1. Unscrew the securing screws of the belt guard and remove the belt guard.

124 M100 No.: 9_6999 23 USE
10 Maintenance
10.3.8.1 Carry out visual check
Visual inspection for damages:
➤ Check the belt thoroughly for cracks, fraying or stretching.

When damaged or worn: Replace the drive belt immediately.
Check the belt seating
Fig. 59 Checking the drive belt seating

1 Belt pulley
2 Drive belt
3 Pulley guidance groove
➤ Check the drive belt seating.

Belt is positioned too deeply in the guidance groove: Replace the drive belt immediately.
1. Replace the belt guard.
3. Close the doors.
10.3.8.2 Checking belt tension
Check belt tension when they are warm, not hot, to avoid length variations through temperature.
The belt tension can be checked by hand: To check the tension, press the belt inwards with the
thumb at the mid-point between pulleys.
Fig. 60 Manually checking the belt tension

A Drive belt testing position
* - Compressive load approximately: 22 Kg
Play approximately: 0.28 – 0.35 in

No.: 9_6999 23 USE M100 125
10 Maintenance
1. Check belt tension by hand (see Fig. 60).

2. Increase the tension on a loose belt.
5. Close the doors.
10.3.8.3 Changing/tensioning the drive belt
The drive belt is tensioned via the screw fastening of the alternator.
Fig. 61 Changing/tensioning the drive belt

1 Engine block 4 Hexagon nut (locknut)
2 Hexagon screw (securing screw) 5 Alternator
3 Lever 6 Drive belt
Tensioning the drive belt:
1. Loosen the alternator securing screw and clamping nut.

2. Place a suitable lever between the alternator and engine block.
3. Gently push the alternator in the direction of the arrow (outwards) using the lever until the drive
belt is tensioned.
4. Re-tighten the securing screw and clamping screw.
5. Remove the lever.
6. Check the belt tension (see Fig. 60).
Belt tension too low: Press the alternator further into arrow direction.
Belt tension too high: Slightly swivel the alternator against the arrow direction.
Changing the belts
1. Loosen the alternator securing screw and clamping nut until the drive belt can be taken off the
pulleys.
2. Take off the belt.
3. Check the pulleys for dirt and wear.
Dirty pulley: Clean pulley.
Worn pulley: Have the pulley changed.

126 M100 No.: 9_6999 23 USE
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4. Manually route the new drive belt over the pulleys without using force.
5. Tension the drive belt. Ensure that the drive belt is correctly positioned in its guide.
A belt that has been replaced may not be used again.
After running for two to three hours, check the belt tension again.
Old belts should be disposed of in accordance with the latest environmental regulations.
Putting in operation:

3. Close the doors.
Further information The operating manual of the engine manufacturer provides further information on removing, chang‐
ing and tensioning drive belts.
10.3.9 Battery maintenance

➤ Check the charging system if the battery discharges without reason.
10.3.9.1 Safety
Danger of acid burns from escaping electrolyte!

➤ Wear appropriate protective clothing including acid-proof rubber gloves.
➤ Always wear eye and face protection.
➤ Do not tip the battery. Electrolyte may run out of the vent holes.
When working on the battery comply with the following safety signs:
A warning label with safety signs is attached to the battery.
Fig. 62 Safety signs - warning stickers on the battery.

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10 Maintenance
➤ Take heed of any safety signs on the battery warning labels.

The individual safety signs have the following meaning:
■ 1 – Fire, sparks, open flame and smoking are forbidden!
■ 2 – Eye and face protection must be worn because of the danger of acid burns.
■ 3 – Keep children well away from batteries and electrolyte.
■ 4 – Wear protective gloves, batteries are filled with caustic electrolyte!
■ 5 – Observe the battery manufacturer's instructions!
■ 6 – Follow the safety rules, explosion hazard!
Further instructions on working with batteries:
➤ Do not remove battery terminal covers unnecessarily.

➤ Do not place tools on the battery. This can lead to short-circuiting, overheating and bursting of
the battery!
➤ Take particular care when the battery has been in service for a long time or has just been
charged as highly explosive gas is emitted!
Ensure adequate ventilation!
10.3.9.2 Battery checking and care
Even so-called 'maintenance-free' batteries need a degree of care to obtain their maximum opera‐
tional life.
The outside of the battery and the terminals should be cleaned regularly with a soft cloth.
This avoids current leaks and minimises the discharge rate.
Material Terminal grease

Distilled water
Cleaning cloth
Protective gloves
Eye protection


1. Clean the casing and terminals. Do not use a wire brush!
2. Lightly grease the terminals to prevent corrosion.
3. Check that the batteries and cable connections are properly seated and tighten if necessary.
Check the battery electrolyte level
The acid quantity is generally sufficient for the life of the battery. Nevertheless, the fluid level
should be checked annually. The level should be up to the mark, 0.4 inches above the plates.
Replace the battery immediately if the casing leaks.

128 M100 No.: 9_6999 23 USE
10 Maintenance
1. Battery destruction!
Topping up with pure acid will increase the electrolyte concentration and can destroy the bat‐
tery.
➤ Top up only with distilled water.
2. Check the electrolyte level.
If the level does not reach the mark:
➤ Top up with distilled water.
➤ Close the access door.
Winter operation:
The battery is especially stressed during the winter. Only a fraction of the normal starting energy is
available at low temperatures.
1. Danger of batteries freezing!
A discharged battery is endangered by freezing temperatures and could freeze at a tempera‐
ture of 14 °F.
➤ Check battery charge with a acid density tester.
➤ Recharge the battery.
➤ Clean the cable connections and apply terminal grease.
2. Check the battery charge weekly.
Recharge as necessary.
3. If the machine is to be unused for a number of weeks, remove the battery and store in a frost-
proof room.
In extreme cases, the use of a heavy-duty cold-start battery and/or an additional booster bat‐
tery is recommended.
10.3.9.3 Battery removal and installation

The machine is fully vented, the pressure gauge reads 0psig.
1. There is danger of batteries bursting!

A short circuited batty heats up quickly and can burst.
➤ Never short-circuit a battery (e.g. with a hand tool).
➤ Wear gloves and eye protection.
2. Excessive voltage produced by the alternator.
Voltage peaks can destroy the alternator regulator and diodes.
➤ The battery serves as a buffer and must not be disconnected while the engine is running.
➤ Carry out work on batteries only with the machine shut down.
3. Open the left-hand door.
4. Disconnect the negative cable first, then the positive cable.
5. Unscrew the battery fixing clamp.
6. Replace in the reverse order.

No.: 9_6999 23 USE M100 129
10 Maintenance
10.4 Compressor Maintenance
7. Make sure the battery is properly secured.

Battery replacement:
If the battery is to be replaced, the new battery should have the same capacity, current rating and
shape as the original battery.
➤ Always replace a battery with one of the same type.
The old battery is hazardous waste and must be disposed of in accordance with local envi‐
ronment protection regulations.
10.3.10 Checking the fastening of the fuel tank

The machine is equipped with a fuel tank or tanks. These are fastened with lashing strips and
ratchets.

The machine is cooled down.
The lashing strip of the fuel tank is overly tightened.

The plastic tank can be damaged by excessive tightening of the lashing strips.
The fuel tank may burst and spill.
➤ Do not overtighten the lashing strips.
➤ Slightly hand-tighten the lashing strips.
Carry out visual check
1. Check the lashing strips for tears and fraying in the fabric, and for damages to the ratchet.
Change any damaged lashing strip immediately.
2. Check whether the lashing strips are tight with the tank and that the ratchet is closed.
If the lashing strips sits loose, or the ratchet is not closed properly, tighten the fastening.
Tightening the fastening of the fuel tank
The lashing strips are tensioned via the integrated ratchet.

The lashing strips must fit closely around the fuel tank. The tensioning force of the strips must not
exceed 10 daN (approx. 25 lbf), slightly hand-tighten only.
➤ Hand-tighten the lashing strip with the integrated ratchet and push the ratchet to the strip.


130 M100 No.: 9_6999 23 USE
10 Maintenance
10.4.1 Checking cooling oil level

The oil level is checked at the oil separator tank filling port. Oil must be visible in the port when the
filler plug is removed.
Material Wrench
Cleaning cloth

Fig. 63 Checking cooling oil level

1 Oil separator tank A Minimum level
2 Oil filler port B Maximum level
3 Filler plug

2. Slowly unscrew and withdraw the plug from the oil filler port.
3. Check the cooling oil level.
Top up if no oil is visible.

No.: 9_6999 23 USE M100 131
10 Maintenance
10.4.2 Cooling oil filling and topping up

Material Cooling oil
Funnel
Cleaning cloth
Wrench

Filling with cooling oil
A sticker on the oil separator tank specifies the type of oil used.
1. The machine could be damaged by unsuitable oil.
➤ Never mix different types of oil.
➤ Never top up with a different type of oil than that already used in the machine.
3. Slowly unscrew and withdraw the plug from the oil filler port.
4. Top up the cooling oil to the maximum level B with the help of a funnel.
5. Check the oil level.
6. Check the filler plug gasket for damage.
Change a damaged gasket.
1. Start the machine and run in IDLE until the operating temperature is reached.
2. Close the outlet valves.
5. Open the outlet valves.
Top up if necessary.

132 M100 No.: 9_6999 23 USE
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10.4.3 Changing the cooling oil

Drain the oil completely from the following components:
■ Oil separator tank
■ Oil cooler
■ Oil pipes
■ Heat exchanger (Option db)
➤ Always change the oil filter when changing the oil.
Material Cooling oil

Receptacle
Drain hose with hose coupling is disconnectedly laying at the machine
New gasket for the drain plug
Funnel
Cleaning cloth
Wrench

The machine is at operating temperature.
There is risk of burns from hot components and escaping oil.

10.4.3.1 Draining the cooling oil (machine with chassis)
In machines with chassis (no closed floor pan, no stationary machine), the cooling oil is drained
directly at the oil separator tank and the oil cooler.

No.: 9_6999 23 USE M100 133
10 Maintenance
Fig. 64 Draining the compressor cooling oil

1 Oil separator tank 6 Drain hose with male coupling
2 Oil separator tank drain plug 7 Oil cooler
3 Oil filler plug 8 Fuel tank
4 Shut-off ball valve 9 Water-cooler, motor
5 Quick-release coupling
➤ Remove the plug 3 from the oil separator tank filling port.
Draining the cooling oil from the oil separator tank:
The oil separator tank can be drained from a point accessible through a hole in the floor panel.
1. Place the oil receptacle below the corresponding drain hole in the floor pan.
2. Unscrew the drain plug 2 and allow the cooling oil to drain into the receptacle.
3. Fit a new gasket on the drain plug and screw it back in again.
Draining the oil from the oil cooler
This is done from a drain valve with the aid of a separate drain hose.
1. Position a receptacle beneath the oil cooler drain point (accessible through a hole in the floor
panel).
2. Connect the drain hose 6 to the oil cooler quick-release coupling 5 .
3. Lead the hose through the hole in the floor panel and into the receptacle, securing it in place.
4. Slowly open the shut-off valve 4 and catch the draining cooling oil.
5. Close the shut-off valve and remove the drain hose.
Performing final work steps:
1. Replace the plug in the oil separator tank filling port.

2. Close the door.
Dispose of used oil and oil-contaminated working materials according to environmental pro‐
tection regulations.
Further information See chapter 10.4.2 for cooling oil filling.

134 M100 No.: 9_6999 23 USE
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Option db Draining the oil from the heat exchanger:
The heat exchanger can be drained by a separate oil drain plug at the heat exchanger (accessible
from underneath through the access hole in the floor pan).
Option db
Fig. 65 Draining the oil from the heat exchanger

1 Oil separator tank 12 Heat exchanger drain plug
10 Heat exchanger 13 Gasket
11 Floor pan 14 Underside of floor pan
1. Position the receptacle below the heat exchanger drain plug 12 .

2. Unscrew the drain plug and allow the cooling oil to drain into the receptacle.
3. Fit a new gasket on the drain plug and screw it back in again.
4. Replace the plug in the oil separator tank filling port.
5. Close the door.
10.4.3.2 Option oe, rw, rx

Draining the cooling oil (closed floor pan - stationary machine):
chine on stationary machines and machines with closed floor pan. The cooling oil is drained via
pipes which are screwed into the drain openings of the oil separator tank and the airend and are
closed with a shut-off valve. The pipes are sealed with a screwed sealing plug at the drain end.

No.: 9_6999 23 USE M100 135
10 Maintenance
Option oe, rw, rx
Fig. 66 Draining the cooling oil (closed floor pan - stationary machine)
1 Oil separator tank 6 Screwed sealing cap - cooling oil drain
2 Oil filler plug 7 Oil cooler drain
3 Oil cooler 8 Oil separator tank drain
4/5 Shut-off ball valve
I – open
0 – closed
➤ Remove the plug 2 from the oil separator tank filling port.
Draining the oil from the separator tank
1. Position a receptacle beneath the oil drainage point for the oil separator tank's cooling oil 8 .
2. Unscrew the corresponding screwed sealing cap at the cooling oil drain.
3. Open the shut-off valve 5 at the oil separator tank and catch any draining cooling oil.
Draining the oil from the oil cooler
1. Position a receptacle beneath the oil drainage point for the oil cooler's cooling oil 7 .
2. Unscrew the corresponding screwed sealing cap at the cooling oil drain.
3. Open the shut-off valve 4 at the oil cooler and catch any draining cooling oil.
Perform final work steps:
1. Replace the plug 2 in the oil separator tank filling port.

2. Close the door.
Further information See chapter 10.4.2 for oil filling.

136 M100 No.: 9_6999 23 USE
10 Maintenance
10.4.4 Replace the compressor oil filter

Material Spares
Receptacle
Cleaning cloth

There is risk of burns from hot components and escaping oil.

Fig. 67 Changing the oil filter

1 Oil filter 3 Combination valve
2 Direction of rotation to unscrew the oil fil‐ 4 Ambient temperature sensor (not with Op‐
ter. tion db)
Changing the oil filter:

2. Prepare a receptacle.
3. Loosen the filter by turning counter-clockwise and catch any escaping oil.
4. Carefully clean sealing surfaces using lint-free cloth.
5. Lightly oil the new filter's gasket.
6. Turn the oil filter clockwise by hand to tighten.
7. Check the oil level in the oil separator tank.
Dispose of old cooling oil and any materials or parts contaminated with oil according to envi‐
ronment protection regulations.

No.: 9_6999 23 USE M100 137
10 Maintenance
Oil level too low: top up if necessary.
10.4.5 Oil separator tank dirt trap maintenance

Wrench
Small screwdriver
Maintenance kit, control valve
Petroleum ether or spirit

Fig. 68 Oil separator tank dirt trap maintenance

1 Oil separator tank cover 5 Nozzle
2 Control valve 6 Screw-in connector
3 Union nut 7 Gasket
4 Oil return line 8 Strainer

138 M100 No.: 9_6999 23 USE
10 Maintenance
Dirt trap maintenance:
1. Undo the union nut and bend the oil return line to one side.
2. Unscrew the screw-in connector.
3. Unscrew the strainer from the screw-in connector.
4. Use a screwdriver to unscrew the nozzle from the screw-in connector.
5. Clean the housing, strainer and sealing ring with cleaning solvent or spirit.
6. Check the nozzle, strainer and sealing ring for wear.
Replace components if they are heavily worn.
7. Fit the nozzle and strainer to the screw-in connector.
8. Screw in the connector making sure the sealing ring seats properly.
9. Refit the oil scavenge line.
Making operational:

10.4.6 Changing the oil separator cartridge

The oil separator element cannot be cleaned.
The life of the oil separator cartridge is influenced by:

■ contamination in the air drawn into the compressor,
■ and adherence to the changing intervals for:
─ Cooling oil
─ Oil filter
─ Air filter

No.: 9_6999 23 USE M100 139
10 Maintenance
Material Spares
Cleaning cloth
Wrench

The machine is fully vented, the pressure gauge reads 0 psig
10.4.6.1 Changing the oil separator cartridge
Fig. 69 Changing the oil separator cartridge

1 Control air line union nut 8 Fixing screw
2 Oil scavenge pipe (screwed to the cover) 9 Control valve
3 Oil scavenge pipe union nut (screwed to 10 Solenoid valve plug
the dirt trap) 11 Gasket
5 Air pipe 12 Metal clip
6 Pipe fitting 13 Oil separator cartridge
7 Cover
Changing the oil separator cartridge
1. Unscrew the union nuts 1 and 3 and place the components with connections carefully to one
side.
2. Pull out the plug to the solenoid valve 10 and withdraw the cable.
3. Unscrew the fitting 6 and turn the air pipe 5 to one side.
4. Remove the screws 8 securing the cover 7 to the tank.

140 M100 No.: 9_6999 23 USE
10 Maintenance
5. Carefully lift the cover and put to one side.

Take care that the oil scavenge pipe 2 screwed to the underside of the cover is not bent in
the process.
6. Take out the old cartridge 13 and gaskets 11 .

7. Clean all sealing surfaces, taking care that no foreign bodies (dirt particles) fall into the oil sep‐
arator tank.
Do not remove the metal clips!
The metal parts of the oil separator cartridge are electrically interconnected. The gaskets 11
are fitted with metal clips 12 that fulfil this requirement and provide an electrical path to the
oil separator tank and to the frame of the machine.
8. Insert the new oil separator cartridge with gaskets and screw down the cover.
9. Re-position the air pipe 5 .
10. Replace and tighten all loosened fittings.
11. Reconnect cables.
Maintenance of the control valve dirt trap must be carried out whenever the oil separator car‐
tridge is changed.
Further information Information on control valve dirt trap maintenance is given in chapter 10.4.5.
Making operational:


No.: 9_6999 23 USE M100 141
10 Maintenance
10.4.6.2 Option ba
Changing the oil separator (machine with low-temperature equipment)
Option ba
Fig. 70 Changing the oil separator cartridge (Option ba)

1 Control air line union nut 9 Control valve
2 Oil scavenge pipe (screwed to the cover) 10 Solenoid valve plug
3 Oil scavenge pipe union nut (screwed to 11 Gasket
the dirt trap) 12 Metal clip
5 Air pipe 13 Oil separator cartridge
6 Pipe fitting 14 Frost protector
7 Cover
8 Fixing screw
1. Unscrew the union nuts 1 and 3 and place the components with connections carefully to one
side.
2. Pull out the plug to the solenoid valve 10 and withdraw the cable.
3. Unscrew the fitting 6 and turn the air pipe 5 to one side.
4. Loosen the frost protector clamp ring 14 and empty the bowl. See chapter 10.8.5 on frost pro‐
tector maintenance.
5. Remove the screws 8 securing the cover 7 to the tank.
6. Carefully lift the cover and put to one side.
Take particular care with the following components:
■ The frost protector 14 connected to the control line,

■ The oil scavenge line 2 screwed to the underside of the cover.
7. Take out the old cartridge 13 and gaskets 11 .

142 M100 No.: 9_6999 23 USE
10 Maintenance
8. Clean all sealing surfaces, taking care that no foreign bodies (dirt particles) fall into the oil sep‐
arator tank.
Do not remove the metal clips!
The metal parts of the oil separator cartridge are electrically interconnected. The gaskets 11
are fitted with metal clips 12 that fulfil this requirement and provide an electrical path to the
oil separator tank and to the frame of the machine.
9. Insert the new cartridge and gaskets.
10. Carefully replace the cover on the tank and the frost protector with holder on the cover.
11. Screw down the cover.
12. Re-position the air pipe 5 .
13. Replace and tighten all loosened fittings.
Maintenance of the control valve dirt trap must be carried out whenever the oil separator car‐
tridge is changed.
Further information Information on control valve dirt trap maintenance is given in chapter 10.4.5.
Making operational:

10.4.7 Compressor air filter maintenance

Clean the filter according to the maintenance schedule or if the maintenance indicator shows this to
be necessary.
Renew the air filter element after 2 years at the latest or after it has been cleaned 5 times.

No.: 9_6999 23 USE M100 143
10 Maintenance
■ Using the machine without an air filter element is not permitted!

■ Do not use an air filter element with damaged folds or gasket.
■ The use of an unsuitable air filter can permit dirt to ingress the pressure system and
cause premature wear and damage to the machine.

Spare parts (as required)
Cleaning cloth

Damaged air filter element.

Machine damage due to contaminated intake air.
➤ Do not try to clean the filter element by striking or knocking it.
➤ Do not wash the filter element.
Fig. 71 Compressor air filter maintenance

1 Maintenance indicator 5 Filter element
2 Red zone indicator scale 6 Retaining clip
3 Indicating piston of the maintenance indi‐ 7 Filter cap
cator
4 Reset knob for the maintenance indicator

144 M100 No.: 9_6999 23 USE
10 Maintenance
Fig. 72 Cleaning the filter element

1 Compressed air gun with blast pipe bent to 90° at the end
2 Filter element
Checking contamination of the air filter:
Air filter maintenance is necessary when the yellow piston inside the maintenance indicator rea‐
ches the red zone.
➤ Check the air filter maintenance indicator.
If the yellow piston reaches the red zone, clean or renew the filter element.
Cleaning the air filter:
1. Release the retaining clamps, lift off the cap an extract the air filter.
2. Carefully clean the inside of the housing, the cover and sealing faces with a damp cloth.
3. Cleaning the filter element:
■ Use dry compressed air (≤ 73 psi!) at an angle to blow dust from the element from inside to
outside until no further dust develops.
■ The blast pipe must be long enough to reach the bottom of the element.
■ The tip of the blast pipe must not touch the element.
■ Cleaning sealing faces.
4. Inspect the element carefully for any damage.
Replace any damaged filter element.
5. Insert the cleaned or new filter element into the filter housing. Make sure it is properly in place
and sealed by its gaskets.
6. Replace the cap and secure with the clip.
Resetting the maintenance indicator:
➤ Repeatedly press the reset knob on the maintenance indicator.

The yellow piston within the indicator is reset and the maintenance indicator is ready for use
again.

No.: 9_6999 23 USE M100 145
10 Maintenance
10.5 Cleaning the cooler
10.4.8 Checking safety relief valves

➤ Have safety relief valves checked by KAESER Service in accordance with the maintenance
schedule.

The frequency of cleaning is mainly dependent on local operating conditions.
Severe clogging of the coolers causes overheating and machine damage.
Check coolers regularly for clogging.
Avoid creating dust eddies. Wear breathing protection if necessary.
Do not clean the coolers/radiators with a sharp instrument as they may be damaged.
A severely contaminated cooler should be cleaned by KAESER Service.
Material Compressed air

Breathing mask (if necessary)
Water or steam jet blaster
Precondition The machine is placed over a washing station equipped with an oil separator.
The machine is switched off.
Damage to the machine can be caused by water or steam jets.

Direct water or steam jets can damage or destroy electrical components and indicating in‐
struments.
➤ Cover up electrical components such as the control cabinet, alternator, starter and in‐
struments.
➤ Do not direct water or steam jets at sensitive components such as alternator, starter or
indicating instruments.
➤ Deploy the extension pole of the pressure washer at a distance of at least 20 inches and
an approximately 90° angle to the cooler/radiator surface.
10.5.1 Cleaning the compressor cooler and engine radiator

The compressor oil cooler and engine coolant radiator are combined in a single cooler block.

146 M100 No.: 9_6999 23 USE
10 Maintenance
Fig. 73 Cleaning the compressor cooler and engine radiator

1 Front end of machine, sound insulation 4 Radiator (engine)
(radiator grill) removed 5 Sound damping louvres
2 Direction of impacting water or steam jet
(from outside to inside).
3 Compressor oil cooler
Cooler cleaning
1. Seal off the air intakes of the engine and compressor air filters before starting cleaning.
2. Remove the sound damping louver in front of the cooler/radiator.
3. Clean the cooling fins with compressed air, water or steam jet in the opposite direction to the
cooling air flow (from inside to outside).
4. Replace the sound damping louver.
5. Remove the protective coverings from the air filters.
7. Close the doors.
8. Start the machine and run up to operating temperature so that excess water is evaporated.
Check the cooler for leaks
1. Open both doors.

2. Visually inspect for leaks. Does oil or cooling water escape?
Is a cooler leaking?
➤ Have the defective cooler repaired or replaced immediately by KAESER Service.

Clean the cooler blades only in a washing area equipped with an oil separator.

Cleaning the compressed air aftercooler
The compressed air aftercooler is located near the air treatment devices.

No.: 9_6999 23 USE M100 147
10 Maintenance
10.6 Maintenance of rubber sealing strips
Option da, db, dc, dd
Fig. 74 Cleaning the compressed air aftercooler

1 After-cooler
2 Direction of impacting water or steam jet (from inside to outside).
1. Seal off the air intakes of the engine and compressor air filters before starting cleaning.
2. Clean the aftercooler with compressed air, water or steam jet in the opposite direction to the
cooling air flow (from inside to outside).
3. Remove the protective coverings from the air filters.
5. Close the doors.
6. Start the machine and run up to operating temperature so that excess water is evaporated.
Clean the cooler blades only in a washing area equipped with an oil separator.
10.6 Maintenance of rubber sealing strips

The rubber sealing strips between the body panels and the access doors serve both as a sound‐
proofing measure and to prevent ingress of rain water.
Care of the rubber sealing strips is especially necessary in winter to prevent the strips from sticking
and tearing when the access panels are opened.

Silicone or Vaseline

1. Open all the doors.

2. Clean the rubber sealing strips with a lint-free cloth and check for cracks, holes and other dam‐
age.
Have any damaged gasket replaced.
3. Properly grease the rubber strips.
4. Close the doors.

148 M100 No.: 9_6999 23 USE
10 Maintenance
10.7 Chassis maintenance

10.7.1 Wheel checks

Check the wheels for tightness, visible damage and tire pressures:
■ after the first 30 miles
■ after every wheel change
■ at least every six months
Material Torque wrench

tire pressure gauge
Precondition Machine shut down and secured against restarting.
1. Check/adjust for wheel fixing torques.

2. Check the tires and wheels for any defect.
Replace any damaged or worn tires.
3. Check the tire treads for sufficient depth.
According to local roadworthy regulations, at least 63 mil in most countries.
Profile depth too low: change tires.

4. Check the tire pressures.
Result tire pressure too low: pump tires.
Further information See chapter 2.4.3 for wheel fixing torques.

See chapter 2.4.2 for tire pressures.
A sticker is found on each wheel arch giving the recommended tire pressure.
10.7.2 Towbar maintenance

Clean and lubricate all sliding and rotating bearings as necessary but at least every 6 months.
Material Lithium-enriched multi-purpose grease

Acid-free oil
Cleaning cloth


No.: 9_6999 23 USE M100 149
10 Maintenance
Option rb/rk/rm/rs,
rb/rl/rm/rs
Fig. 75 Towbar maintenance

1 Handle 3 Lubricating points
2 Transfer cable 4 Greasing points
Fig. 76 Maintaining the fixed height towbar

4 Greasing points
10.7.2.1 Checking the tow bar
1. Check the towbar for correct function and movement.

2. Clean and oil all sliding and rotating bearings.
Option rb/rk/rm/rs, Check the height setting of the towbar

rb/rl/rm/rs
➤ Check the towbar height adjustment function.
The locking teeth on the towbar height adjustment joint are corroded and jammed and the
towbar height cannot be adjusted.
➤ If necessary, free the teeth by jerking the towbar horizontally and vertically.
➤ Clean the toothed coupling and smear with water-repellent grease.
Further information See chapter 6.4.1 for towbar height adjustment.

150 M100 No.: 9_6999 23 USE
10 Maintenance
Option rb/rk/rm/rs, Maintaining the parking brake

rb/rl/rm/rs, rc/ro/rs
➤ Lightly lubricate the pins and adjustment joints.
10.7.2.2 Option rb/rk/rm/rs, rb/rl/rm/rs, rc/ro/rs, rd/ro/rs

Overrun braking mechanism maintenance
Greasing the overrun mechanism:
➤ Pump fresh grease into the nipple until old grease is squeezed out.
Further information For the lubricating points of the height-adjustable tow mechanism (Option rb/rm/rs) see illustra‐
tion 75.
Lubricating points of a tow mechanism non-adjustable in height (Option rc/ro/rs) see illustration 76.
Checking the shock absorber:
1. Loosen the transfer cable one side.

2. Press in the shock absorber against its damping force.
Have the shock absorber replaced by a specialist workshop if:
■ There is little resistance to pushing in,
■ Air has entered the device,
■ there is little resistance to pulling out the shock absorber.
■ Oil leaks out.
10.7.2.3 Ball coupling maintenance
Option rb/rk/rm/rs,
rb/rl/rm/rs, rc/ro/rs
Fig. 77 Ball coupling (EC version)

1 Lubricating points
2 Greasing points

No.: 9_6999 23 USE M100 151
10 Maintenance
Option rd/ro/rs
Fig. 78 Ball coupling (USA version)

1 Lubricating points
2 Greasing points
1. Check the ball coupling for correct function and movement.

2. Clean the ball coupling. Grease or oil the ball cup, joints, and bearings.
10.7.3 Brake maintenance

The brake adjusting procedure ensures even wear on the brake linings by adjusting the brake
shoes.
The following points must be observed:

■ Carry out the adjustment procedure on all wheel brakes, one after the other.
■ During adjustment, turn the wheel in the 'forward' direction only.
Material Screwdriver
Wrench
Inspection lamp or torch
Cleaning cloths
Lithium-enriched multi-purpose grease
1. Jack up the machine and lower it onto supports.

2. Release the parking brake and completely pull out the overrun braking mechanism.
The brake cables are not tensioned.
10.7.3.1 Checking brake system settings
1. Pull up the parking brake to first notch.

2. Turn the wheels in the forward direction.
3. Check that there is the same braking resistance on both wheels.
Brake resistance not even: adjust brake system.
4. Release the parking brake.

152 M100 No.: 9_6999 23 USE
10 Maintenance
10.7.3.2 Checking wheel brake lining wear
Fig. 79 Checking the brake lining thickness

1 Inspection hole
2 Brake linings
1. Remove the plug from the inspection hole.

2. With the aid of a torch, check the brake lining thickness.
Brake lining thickness less than 0.1 inch: Have the brake shoes replaced in a specialist work‐
shop.
3. Replace the plug in the inspection hole.
10.7.3.3 Brake system adjustment
There is an arrow pressed into the brake back plate near the adjustment hole.
■ Turn in the direction of the arrow: Adjust the brake.
■ Turn against the direction of the arrow: Loosen the brake.
Fig. 80 Brake system adjustment

1 Brake rod 4 Screwdriver as adjusting tool
2 Equaliser 5 Adjusting wheel
3 Brake support
1. Remove the plug from the inspection hole.

2. Use a screwdriver to turn the adjusting wheel 5 until the wheels no longer turn in the forward
direction.
3. Apply the parking brake a number of times to centre the brake linings.
4. Use the screwdriver to turn the adjusting wheel back (3 to 5 notches) until there is no more
braking resistance to the wheels turning forward.

No.: 9_6999 23 USE M100 153
10 Maintenance
5. Pull on the parking brake.

6. Check the position of the equaliser 2 on the brake rod 1 .
If the equaliser is perpendicular to the brake rod, the brake clearance is the same on each
wheel.
If the equaliser is oblique to the brake rod, adjust the brake rod.
7. Pull the parking brake lightly on and compare the braking force on the wheels.
If the braking force on the wheels is not equal, re-adjust brake system.
8. Replace the plug in the inspection hole.
A light rubbing sound when the wheels turn is permissible if it does not affect free turning.
Brake rod adjustment
Fig. 81 Brake rod adjustment

1 Brake rod 6 Hexagonal nut
2 Equaliser 7 Hexagonal nut
3 Brake cable (Bowden) 8 Axle abutment
4 Spacer 9 Axle (cross-section)
5 Connecting sleeve
1. To free the brake rod, remove the hexagon nut 2 at the equaliser 6 and loosen the sleeve 5 .
2. Clean and grease the brake rod threads.
3. Manually tighten the connecting sleeve.
4. Pull and release the parking brake three times.

154 M100 No.: 9_6999 23 USE
10 Maintenance
10.8 Maintenance for Optional Items
5. Turn the wheel in forward direction and simultaneously tighten the connecting sleeve up to a
clearly experienced braking resistance.
You must still be able to manually turn the wheel in forward driving direction.
6. Screw the hexagon nut 6 onto the brake rod and lock the connecting sleeve.
Further information For more information, see the assembly illustration in chapter 13.6.3.
➤ Test by applying the brake a number of times.
10.7.3.4 Greasing the brake rods
Grease the brake rods when necessary (stiff movement) but at least annually.
Material Lithium-enriched multi-purpose grease

Cleaning cloths

➤ Clean and grease the brake rod’s sliding and adjustment joints.

10.8.1 Option ea, ec

Tool lubricator maintenance
Material Tool oil (special lubricant for road breakers),
Funnel
Cleaning cloths


No.: 9_6999 23 USE M100 155
10 Maintenance
Fig. 82 Tool lubricator maintenance

1 Filler plug with dipstick and integrated riser 3 Oil tank
tube 4 O-ring
A Minimum and recommended oil level 5 Tool oil
2 Tool lubricator upper part with oil filling
port
Checking the tool lubricator oil level
Check the oil level daily.

A dip stick is attached to the underside of the oil filler plug with which to measure the oil level.
The oil level should be in the upper third of the dipstick.
1. Slowly unscrew and withdraw the oil filler plug.
2. Wipe off the dipstick with a lint-free cloth or rag and screw the plug fully in again.
3. Unscrew and withdraw the plug once more and read off the oil level on the dipstick.
Oil level at the upper third of the dip stick: Oil level is correct.
If oil does not reach this level: Immediately replenish tool oil.
4. Close the door.
Filling and topping up with tool lubricator oil
1. Slowly unscrew and withdraw the oil filler plug.

2. Use a funnel to pour in the oil to the maximum level (0.4 – 0.6 inches below the top of the
tank).
3. Check the oil level.
4. Check the filler plug O-ring for external damage.
Skadet O-ring: replace the O-ring.

156 M100 No.: 9_6999 23 USE
10 Maintenance
5. Insert the plug in the filler port.

6. Close the door.
Further information See chapter 2.7.1.1 for suitable oil grade and volume.

Cyclone separator maintenance
Clean the cyclone separator dirt trap if the moisture content in the compressed air is too high.

Wrench
Small screwdriver
Dirt trap maintenance kit

Fig. 83 Cleaning the dirt trap

1 Cyclone separator 6 Strainer
2 Dirt trap 7 Condensate drain hose union nut
3 Condensate drain hose 8 Nozzle
4 Filler plug 9 Dirt trap housing
5 O-ring
Cleaning the dirt trap:
1. Unscrew the plug 4 and remove the strainer.

2. Loosen the union nut 7 and detach the condensate drain hose 3 from the dirt trap.
3. Use the small screwdriver to unscrew the nozzle 8 from the dirt trap housing.

No.: 9_6999 23 USE M100 157
10 Maintenance
4. Clean the nozzle, strainer, screw plug, O-ring 5 and dirt trap housing 9 with cleaning solvent
or spirit.
5. Check the nozzle, strainer and O-ring for wear.
Replace components if they are heavily worn.
6. Place the strainer on the screw plug.
7. Screw in the plug making sure the O-ring seats properly.
8. Screw in the nozzle and re-attach the condensate drain hose.
Making operational:

6. Check the cyclone separator housing and hose line for leaks.
10.8.3 Option dd
Combination filter maintenance
Danger of injury from compressed air!

Filter combination is pressurised during operation. Serious injury can result from loosening
or opening components under pressure.
➤ Wait until the machine has automatically vented (check: pressure gauge reads 0 psig!
➤ De-pressurise the combination filter.

158 M100 No.: 9_6999 23 USE
10 Maintenance
Option dd
Fig. 84 Filter combination

1 Filter combination
2 Shut-off valve condensate drain
Option dd
Fig. 85 Combination filter maintenance

1 Filter combination 5 Pressure differential gauge (check fittings
a Microfilter for Service personnel)
b Pre-filter 6 Filter head
2 Cyclone separator 7 Casing gasket
3 Condensate drain hose fittings 8 Filter element
4 Shut-off ball valve for condensate drain‐ 9 Filter housing
age

No.: 9_6999 23 USE M100 159
10 Maintenance
10.8.3.1 Drain condensate
Material Oil receptacle

Cleaning cloths
1. Place the receptacle under the combination filter hose lines.

2. Open the pre-filter and micro-filter condensate drain shut off valves.
3. Close the door.
4. Start up the machine and run in IDLE.
The condensate collecting in the filter housings is blown out.
5. Stop the compressor as soon as air escapes.
7. Close the shut-off valve.
8. Close the door.
Condensate must be stored in suitable containers and disposed of in accordance with local
environmental regulations.
10.8.3.2 Changing the filter elements
The pre-filter and microfilter contain different elements and these must be changed as a pair. Note
location!
Using the combination filter without an element installed is not permitted.
Handle new filter elements only with clean fabric gloves. Do not touch the new filter elements
with bare fingers – Contamination risk!

Filter wrench
Wrench
Cleaning cloths
Clean fabric gloves
Precondition The machine has cooled down.

Ensure that the combination filter is not under pressure.
➤ Slowly open the pre-filter and micro-filter condensate drain shut off valves.
Remaining pressure escapes.
Gaining access to the filter housing
➤ Loosen the screw fitting of the condensate drain hoses from the filter housings of pre-filter and
micro-filter and remove the drain hoses.
Changing the prefilter element
1. Unscrew the filter housing counter-clockwise.

2. Draw the filter element down and out.
3. Clean the filter head, housing and sealing surface with a lint-free cloth.

160 M100 No.: 9_6999 23 USE
10 Maintenance
4. Check the housing gasket.

Housing gasket is damaged: replace gasket.
5. Insert a new filter element.
Wear gloves!
6. Screw on the filter housing clockwise.
Changing the pre-filter element
1. Unscrew the filter housing counter-clockwise.

3. Clean the filter head, housing and sealing surface with a lint-free cloth.
Housing gasket is damaged: replace gasket.
Wear gloves!
6. Screw on the filter housing clockwise.
Putting in operation:
1. Screw the condensate drain hoses to the housings of the pre-filter and the micro-filter.
2. Close the condensate drain shut-off valves.
3. Tighten the filter combination fittings.
4. Reconnect the negative cable to the batteries.
5. Close the door.
Further information Further information on changing elements can be found in the filter instructions in chapter 13.7.
6. Check the combination filter housing and hose lines for leaks.
7. Close the door.

No.: 9_6999 23 USE M100 161
10 Maintenance
10.8.4 Option dc
Fresh air filter maintenance
Before commencing work on the fresh air filter, read and understand the operating instructions giv‐
en in chapter 13.8.

Option dc
Fig. 86 Fresh air filter maintenance

1 Fresh air filter 5 Lower filter element (high capacity ele‐
2 Upper housing ment)
3 Upper element (adsorption element) 6 Lower housing
4 Body 7 Condensate drain (tap for manual draining)
0 - closed
I - open
8 Oil indicator
10.8.4.1 Draining condensate
Material Receptacle
Cleaning cloth
1. Place the receptacle below the fresh air filter condensate drain point.
2. Open the condensate drain valve.
3. Close the doors.
The condensate collecting in the filter housings is blown out.

162 M100 No.: 9_6999 23 USE
10 Maintenance

6. Open both doors.
7. Close the drain valve.
8. Carefully remove the receptacle.
9. Close the doors.
Condensate must be stored in suitable containers and disposed of in accordance with local
environmental regulations.
10.8.4.2 Check the oil indicator
The fresh air filter is fitted with an oil indicator. When the indicator is blue, the filtration function can
no longer be ensured and the filter must not be used. Both filter elements and the oil indicator must
be changed (regardless of the maintenance schedule).
The oil indicator must be checked at least once daily.
The oil indicator does not give information on the filter element changing interval.
➤ Check the oil indicator.

Indicator blue - change both filter elements and the indicator.
10.8.4.3 Changing consumable parts
The fresh air filter contains two different element and both must be changed as a pair. Note loca‐
tion!
Using the fresh air filter without an element installed is not permitted!
Handle new filter elements only with clean fabric gloves. Do not touch the new filter elements
with bare fingers – Contamination risk!

Filter wrench
Wrench
Cleaning cloth
Clean fabric gloves
Precondition Machine is cooled down.

Ensuring the fresh air filter is depressurized:
➤ Open the fresh air filter drain tap to release any remaining pressure.
Change the lower filter element (high performance element):
1. Unscrew the lower housing counter-clockwise.

3. Clean the lower housing and sealing surface with a lint-free cloth.
When damaged, replace the housing gasket.

No.: 9_6999 23 USE M100 163
10 Maintenance
5. Insert a new lower filter element.

Wear gloves!
6. Screw on the lower housing clockwise.
Change the upper filter element (adsorption insert).
1. Unscrew the upper housing counter-clockwise.

2. Draw the filter element up and out.
3. Clean the lower housing and sealing surface with a lint-free cloth.
When damaged, replace the housing gasket.
Wear gloves!
6. Screw on the upper housing clockwise.
Change the oil indicator:
1. Unscrew the oil indicator.

2. Clean the housing and sealing surface with a lint-free cloth.
3. Screw in the new oil indicator.
Making operational:
1. Close the drain valve.

3. Close the doors.
Further information Further information on changing elements can be found in the operating instructions for pressur‐
ised air filters (fresh air filters) in chapter 13.8.
5. Open both doors.
6. Check the fresh air filter housing and hose line for leaks.
7. Close the doors.

164 M100 No.: 9_6999 23 USE
10 Maintenance
10.8.5 Option ba
Frost protector maintenance
At temperatures under 41 °F, the level of antifreeze in the protector must be checked daily before
starting the compressor.
Material Antifreeze: Antifreeze protection for air brake systems

z. B. Wabcothyl (part no. 9.5400.0)
Cleaning cloths

Spontaneous ignition of anti-freeze!

Risk of fire and explosion caused by spontaneous ignition can cause severe injury.
➤ Never top up antifreeze unless the machine is stopped and cooled down.
Danger of injury from compressed air!

The frost protector is pressurised during operation. Serious injury can result from loosening
or opening components under pressure.
➤ Wait until the machine has automatically vented (check: pressure gauge reads 0 psig!
Option ba
Fig. 87 Filling the frost protector

1 Frost protector clamp ring
2 Frost protector bowl
3 Antifreeze container
1. Open both doors.

2. Unscrew the clamp ring and remove the bowl.
3. Fill the bowl ¾ full with antifreeze.

No.: 9_6999 23 USE M100 165
10 Maintenance
4. Screw the bowl carefully back into place.

5. Close the doors.
10.8.6 Option la
Spark arrestor maintenance
The spark arrestor must be cleaned of any soot residue every two months to prevent the emission
of glowing particles from the exhaust silencer.
Material Suitable rubber hose

Soot receptacle
Cleaning cloth
Protective gloves
Eye protection

Danger of suffocation from toxic exhaust fumes.

Exhaust fumes from internal combustion engines contain carbon monoxide, which is odor‐
less and deadly.
➤ Never use the machine in enclosed spaces, only in the open!
➤ Do not inhale exhaust fumes.
Danger of burns from hot components and sparks.

➤ Wear eye protection.
Cleaning the spark arrestor (floor pan with service openings)
Fig. 88 Cleaning the spark arrestor (floor pan with service openings)
1 Exhaust silencer end pipe 3 Soot drain port with plug
2 Opening in floor panel to access drain port 4 Exhaust silencer with integrated spark ar‐
restor

166 M100 No.: 9_6999 23 USE
10 Maintenance
1. Unscrew the soot drain plug.

2. Push one end of the hose over the drain port and place the other end in the receptacle.
4. In order to increase the pressure in the exhaust system, partially cover the exhaust discharge
pipe with a fire-proof object.
Soot will drain through the hose into the receptacle.
5. Shut down the engine.
6. Remove the hose and replace the plug.
It is recommended to blow out the spark arrestor with compressed air once a year.
Dispose of soot according to environmental protection regulations.
Option oe Cleaning the spark arrestor (sealed floor pan)
In machines with a sealed floor pan, the service openings are closed with plugs. In order to access
the port of the soot drain, you must remove the appropriate plug.
Option oe
Fig. 89 Cleaning the spark arrestor (sealed floor pan)

1 Exhaust silencer end pipe 3 Exhaust silencer with integrated spark ar‐
2 Soot drain port with plug restor
4 Service opening, closed with plug (access
to drain port)
1. Unscrew the service opening plug.

2. Unscrew the soot drain plug.
3. Push one end of the hose over the drain port and place the other end in the receptacle.
5. In order to increase the pressure in the exhaust system, partially cover the exhaust discharge
pipe with a fireproof covering.
Soot will drain through the hose into the receptacle.
6. Shut down the engine.
7. Remove the hose and replace the plug.
8. Screw the service plug back into the floor pan.
It is recommended to blow out the spark arrestor with compressed air once a year.

No.: 9_6999 23 USE M100 167
10 Maintenance
Dispose of soot according to environmental protection regulations.
10.8.7 Option lb
Engine air intake shut-off valve maintenance
Cleaning cloth

Engine air intake shut-off valve

The engine air intake shut-off valve does not close when flammable gas is drawn into the
engine:
The machine does not shut down? Destruction of the engine and explosion and/or fire are
possible!
➤ Do not move the valve adjusting screw.
➤ Have the valve set by a specialist workshop or KAESER Service.
Fig. 90 Engine air intake shut-off valve maintenance

1 Engine air intake 4 Air intake hose (filter side)
2 Engine air filter 5 Engine air intake shut-off valve
3 Air intake hose (engine side) 6 Hose clamp

168 M100 No.: 9_6999 23 USE
10 Maintenance
Cleaning the engine air intake shut-off valve:
1. The engine air intake shut-off valve does not close fully.
The machine does not shut down? Destruction of the engine and explosion and/or fire are pos‐
sible!
➤ Do not grease the valve, as this may cause a build up of dust and valve sticking.
2. Loosen the hose clamp on the filter side of the valve and turn the air intake hose to one side.
3. Check if the interior of the shut-off valve is clean.
Blow out any dirt with compressed air.
If necessary, clean the valve with petroleum ether or spirit and allow to dry.
Refer to a specialised workshop or KAESER Service if dirt cannot be removed.
Checking the engine air intake shut-off valve for correct function and movement:
1. Check the valve for signs of excessive wear.

2. Check that the valve plate closes fully and easily.
Result Have the valve changed if it is heavily worn or malfunctions in any way.
1. Reposition the air intake hose and tighten the clamp.

2. Close the doors.
3. Start the machine and switch to LOAD.
If the engine stops on switching to LOAD, have the valve adjusted by a specialist workshop or
KAESER Service.
10.8.8 Option ga, gb

Generator drive belt maintenance
Correct belt tension is extremely important for the function of the generator and the operational life
of the belts themselves. The lifespan of the drive belts is affected by belt tension.
■ Slack V-belts can cause belt slip and damage to the belts.
■ Over-tight belts stretch and wear quicker. Over-tight belts also place unnecessary stress on
bearings and shorten their life.
Material Wrench
Spare parts (if required)


No.: 9_6999 23 USE M100 169
10 Maintenance
Beware of rotating pulleys and moving belts.

Touching the moving drive belt may result in severe bruising or even loss of limb or extremi‐
ties.
➤ Check the belt only when the compressor is shut down.
➤ Never run the machine without a belt guard.
Removing the belt guard:
Fig. 91 Securing the belt guard at the generator

1 Hex-head screw 4 Belt guard
2 Washer 5 Generator belt
3 Rubber pad 6 Support for belt tensioner
➤ Unscrew the securing screws of the belt guard and remove the belt guard.
10.8.8.1 Visual check
1. Check the drive belt for cracks, frays or stretching.

Change the belt immediately if any damage or wear is found.
4. Close the doors.
10.8.8.2 Checking belt tension
Check belt tension when they are warm, not hot, to avoid length variations through tempera‐
ture.

170 M100 No.: 9_6999 23 USE
10 Maintenance
The tensioning device uses spring force to apply correct tension to the belts over a certain range.
The tensioning dimension A is controlled by adjusting the belt (see fig. 92).
Tensioning dimension:
■ Adjusting distance: 0.39 in
■ Minimum distance: 0.2 in
1. Check the tensioning distance A on the belt adjustment 9 .

Re-tension the belts if the tensioning dimension is below the minimum.
3. Close the door.
10.8.8.3 Changing/tensioning the drive belt
Fig. 92 Generator belt tensioning

1 Support for belt tensioner 8 Generator swing frame
2 Hexagon nut 9 Belt adjustment
3 Spherical seat washer 10 Compression spring
4 Conical seat washer 11 Hexagon nut (self-locking)
5 Hexagon nut (locknut) 12 Generator
6 Drive belt A Tensioning dimension
7 Generator drive pulley
Tensioning the drive belt:
1. Loosen the locking nut 2 .

2. Turn the tensioning nut 5 to tighten the belt 6 until the tensioning dimension A corresponding
to the set distance is reached.
3. Tighten the locknuts 2 and 5 .
6. Close the doors.

No.: 9_6999 23 USE M100 171
10 Maintenance
Changing the belts
1. Undo the nut 5 until the belt 6 can be slipped off the pulleys.
2. Take off the belt.
3. Check the pulleys for dirt and wear.
Clean the pulleys.
Worn pulley: Have the pulley replaced.
4. Without using force, place the new belt over the engine and generator pulleys.
5. Turn the tensioning nut 5 to tighten the belt 6 until the tensioning dimension A corresponding
to the set distance is reached.
6. Tighten the locknuts 2 and 5 .
9. Close the doors.
10. Run the compressor under LOAD operation for 15–20 minutes.
11. Check the belt again and re-tension if necessary.
■ Check the belt again after a further 2 operating hours.
■ A belt that has been replaced may not be used again.
Old belts should be disposed of in accordance with the latest environmental regulations.
10.8.9 Option oe
Draining liquid accumulation within the machine
The so-called "closed floor pan" contributes to the protection of the environment by preventing a
contamination of the soil in the event of leaking operating fluids.
Liquid accumulations within the machine's body can also cause corrosion or electrical faults.
Liquid accumulations must be removed as quickly as possible in order to avoid potential machine
faults.
For draining the liquid, maintenance openings have been added to the floor panel of the machine
which are closed with bungs.
Material Receptacle
Cleaning cloth

The machine is secured against moving.
The machine is cooled down.
1. Place a receptacle underneath the maintenance opening(s).

2. Unscrew and remove the bung(s) from the maintenance openings.
The liquid will drain.
3. Clean the bungs and maintenance openings.

172 M100 No.: 9_6999 23 USE
10 Maintenance
4. Close all maintenance openings with bungs.

The machine body is sealed.
5. Using the cleaning cloth, remove any dirt within the machine.
Dispose of collected liquid and contaminated working materials according to environmental
protection regulations.

No.: 9_6999 23 USE M100 173
10 Maintenance
10.9 Documenting maintenance and service work
10.9 Documenting maintenance and service work

Machine model/part number:
➤ Enter maintenance and service work carried out in this list.
Date Maintenance task carried out Operating hours Signature
Tab. 90 Maintenance log

174 M100 No.: 9_6999 23 USE
11.1 Note the nameplate

11.1 Note the nameplate
The nameplate contains all information to identify your machine. This information is essential to us
in order to provide you with optimal service.
➤ Please give the information from the nameplate with every inquiry and order for spares.
11.2 Ordering consumable parts and operating fluids/materials

KAESER consumable parts and operating materials are original Kaeser products. They are match‐
ed to application in our machines and ensure trouble-free operation.
Unsuitable or poor quality consumable parts and operating fluids/materials may damage the ma‐
chine or impair its proper function.
Personal injury may result from machine damage.
There is risk of personal injury or damage to the machine resulting from the use of unsuita‐
ble spares or operating fluids/materials.
➤ Use only original KAESER parts and operating fluids/materials.
➤ Do not use alternative consumable parts and operating fluids and materials.
Compressor
Name Quantity Number

Air filter element 1 1260
Compressor oil filter 1 1210
Oil separator cartridge 1 1450
(complete set)
Cooling oil 1 1600
Tab. 91 Compressor consumables
Kubota engine parts

Air filter element 1 1280
Fuel prefilter 1 1910
Fuel fine filter (cartridge) 1 1920
Fuel de-watering filter 1 1980
Motor oil filter (cartridge) 1 1905
Oil drain seal 1 4496
Injector nozzle 1 4475
Injector nozzle seal 1 4476
Motor belt 1 4470

No.: 9_6999 23 USE M100 175
11.3 KAESER AIR SERVICE

Glow plug 1 4466
Engine oil 1 1925
Tab. 92 Consumable engine parts
Option dd Filter combination

Filter element for pre-filter 1 1550
Filter element for micro-filter 1 1551
Casing gasket 2 1548
Tab. 93 Replacement parts, combination filter
Option dc Fresh air filter

Filter elements, fresh-air filter 1 1549
(filter kit)
Indicator insert 1 3930
Tab. 94 Replacement parts, fresh-air filter
11.3 KAESER AIR SERVICE

KAESER AIR SERVICE offers:
■ Authorized service technicians with KAESER factory training.
■ Increased operational reliability ensured by preventive maintenance.
■ Energy savings achieved by avoidance of pressure losses.
■ The security of genuine KAESER spare parts.
■ Increased legal certainty as all regulations are kept to.
➤ Why not sign a KAESER AIR SERVICE maintenance agreement.

The advantages:
Lower costs and higher compressed air availability.
11.4 Service Addresses

Addresses of KAESER representatives are given at the end of this manual.
11.5 Replacement parts for service and repair

With the help of the parts list you can plan your material requirement according to operating condi‐
tions, and order the spare parts you need.

176 M100 No.: 9_6999 23 USE
Personal injury or machine damage due to incorrect working on the machine!

Incorrect inspection, service or repair can damage the machine or severely impair its func‐
tion. Personal injury may result from damage.
➤ Inspections, preventive maintenance or repair tasks not described in this manual must
not be carried out by unqualified personnel.
➤ Have further tasks, not described in this service manual, carried out by motor vehicle
workshops or KAESER Service.

No.: 9_6999 23 USE M100 177

178 M100 No.: 9_6999 23 USE

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180 M100 No.: 9_6999 23 USE

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182 M100 No.: 9_6999 23 USE

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184 M100 No.: 9_6999 23 USE

No.: 9_6999 23 USE M100 185

186 M100 No.: 9_6999 23 USE

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188 M100 No.: 9_6999 23 USE

No.: 9_6999 23 USE M100 189

190 M100 No.: 9_6999 23 USE

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192 M100 No.: 9_6999 23 USE

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194 M100 No.: 9_6999 23 USE

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196 M100 No.: 9_6999 23 USE

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198 M100 No.: 9_6999 23 USE

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200 M100 No.: 9_6999 23 USE

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202 M100 No.: 9_6999 23 USE

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204 M100 No.: 9_6999 23 USE

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206 M100 No.: 9_6999 23 USE

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208 M100 No.: 9_6999 23 USE

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210 M100 No.: 9_6999 23 USE

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212 M100 No.: 9_6999 23 USE

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214 M100 No.: 9_6999 23 USE

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216 M100 No.: 9_6999 23 USE

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218 M100 No.: 9_6999 23 USE

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220 M100 No.: 9_6999 23 USE

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222 M100 No.: 9_6999 23 USE

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224 M100 No.: 9_6999 23 USE

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226 M100 No.: 9_6999 23 USE
12.1 De-commissioning

De-commissioning is necessary, for example, under the following circumstances:
■ The machine is temporarily not needed
■ The machine will not be needed for a considerable time.
■ The machine is to be scrapped.

Machine dry and cool.
1. Carry out the following de-commissioning procedures.

2. Place a notice on the instrument panel describing the de-commissioning procedures carried
out.
12.1.1 Temporary de-commissioning

Decommissioning for about 4 months.
Material Plastic sheeting

Moisture-resistant adhesive tape
1. Disconnect the battery (the minus terminal first and then the plus terminal).
2. Close off the following openings with plastic foil and moisture-resistant adhesive tape.
■ Engine air inlet
■ Compressor air inlet
■ Exhaust silencer
3. Attach the following notice on the instrument panel showing the decommissioning measures
taken.
Attention!
1. The machine is temporarily decommissioned.
2. The following machine openings have been covered:

3. Recommission according to service manual.
Date / signature
Tab. 95 "Temporarily decommissioned" information notice
Decommissioning of the compressor for several weeks during severe frost
1. Danger of batteries freezing!

Discharged batteries are subject to frost damage and can freeze at 14 °F.
➤ Store batteries in a frost-free place.
➤ Store batteries preferably fully charged.

No.: 9_6999 23 USE M100 227
2. Remove the battery (batteries) and store in a frost-free room.

3. Make sure batteries are fully charged.
12.1.2 Long-term decommissioning and storage

Decommissioning the machine for 5 months or longer.
Material Receptacle
Preserving oil
Preservative
Desiccant
Plastic sheeting
Moisture-resistant adhesive tape
➤ The following measures must be taken for long-term decommissioning and storage:
Long-term decommissioning and storage tasks See Confirmed?

chapter
➤ Check engine coolant. 10.3.1
➤ Drain the engine oil. 10.3.6
➤ Drain the oil from the oil separator tank and the oil cooler. 10.4.3
➤ Fill the separator tank and engine with preserving oil. 10.4.2
10.3.5
➤ Run the machine for about 10 minutes to coat all parts with a protec‐ –
tive oil film.
➤ Disconnect the battery, the minus terminal first and then the plus ter‐ –
minal, and store in a frost-free room.
➤ Check the battery fluid level. 10.6
➤ Check the battery charge monthly and recharge if necessary to pre‐ –
vent the battery fluid freezing.
➤ Clean the battery terminals and coat with acid-resistant grease. –
➤ Close the compressed air outlet valves. –
➤ Use plastic sheeting and moisture-resistant adhesive tape to seal off –
the following openings:

➤ Clean the bodywork and treat with preservative. –
➤ Hang a notice on the instrument panel to inform of the decommis‐ –
sioning measures taken.
Tab. 96 Long-term decommissioning and storage checklist

228 M100 No.: 9_6999 23 USE
12.2 Transport
➤ Attach the following notice on the instrument panel to inform of the decommissioning measures
taken.
Attention!
1. The machine is decommissioned.
2. It is filled with preserving oil.
3. For recommissioning:
■ Take measures for recommissioning the compressor after a long period of storage.
■ Recommission according to service manual.
Date / signature
Tab. 97 Text for the long-term decommissioned and storage information notice
➤ Store in a dry place with even temperatures.
12.2 Transport
Precondition Machine switched off and locked off.
All compressed air consumers are disconnected.
All connecting lines and hoses disconnected and removed.
Any loose or movable parts that may fall when transporting are removed or secured.
12.2.1 Safety
Allow transportation only by personnel trained in safely dealing with motor vehicles and the
transporting of goods.
1. There is danger of being run over or crushed by an overturning vehicle.

Death or serious injury can result from being crushed or run-over by a machine under tow.
➤ Riding on the machine while it is under tow is strictly forbidden.
2. Make sure the danger area is clear of personnel.
12.2.2 Towing the compressor on the road

The portable machine can be transported as trailer by a towing vehicle.
Machines without lighting system and service brake must not be towed on public roads.
Prerequisites for the towing on public roads:

■ Chassis with overrun brake
■ Lighting and signaling system.
All other machines may be transported only on non-public roads!
National and local regulations must be observed when towing the machine on public high‐
ways.

No.: 9_6999 23 USE M100 229
12.2 Transport
1. Risk of accident when towing non-roadworthy machines on public roads.

Death or severe injury possible due to accidents with unbraked and/or unilluminated trailer.
➤ Do not tow machines without service brake and/or illumination equipment on public roads.
➤ Transport only an illuminated machine equipped with a service brake on public roads.
2. Observe the safety instructions in chapter 3.5.2 "Safe machine operation".
12.2.2.1 Preparing for transport
Stowing payload:
Do not exceed the permissible loading (overall mass, coupling load, axle load).
Observe national traffic laws. If additional loading is not permitted, the load must be transported in
the towing vehicle.
1. Check that loading the machine with tools or accessories during transport is permissible.
2. Place additional loads only in the spaces provided (if available) and secure carefully.
Additional precautions for a very dirty machine:
The machine can become very dirty after prolonged use on a construction site. A machine in such
condition is not suitable for towing on public roads.
1. Clean the machine, in particular around the chassis and the lighting and signaling equipment.
2. Check the function of wheels, brakes, lights and signaling equipment.
Correct any defects before towing.
Additional precautions for conditions of snow and ice:
1. Accident hazard due to snow or ice falling off the machine.
Snow or ice falling from the towed machine can endanger following vehicles.
Problems with driving dynamics and damage to the machine could occur.
The maximum permissible axle load could be exceeded.
➤ Do not transport the machine if it is covered by snow or ice.
2. Remove any snow or ice before towing.
Perform the following tasks prior to transporting the machine:
1. Make sure the towing hitch is compatible with the ball or eye coupling on the towed machine.
2. Check that the machine is shut down and secured against accidental restarting.
3. Detach all connecting lines and hoses.
4. Make sure there are no unsecured tools lying on or in the machine.
5. Close and lock the access doors.
Option rb/rk/rm/rs, Adjust the towing bar to suit the height of the towing vehicle hitch.
rb/rl/rm/rs
When the machine is coupled up, the towing bar must be parallel with the ground.

230 M100 No.: 9_6999 23 USE
12.2 Transport
Fig. 93 Towing position
1. Danger from problematic driving dynamics!

The permissible loading range may be exceeded or undercut.
Personal injury may result from towing.
Damage to the machine and/or towing vehicle is possible.
➤ Do not couple up the machine at an angle to the towing vehicle.
➤ Ensure that the towing bar is horizontal when coupled to the towing vehicle.
2. Adjust the towing bar height to suit the height of the hitch on the towing vehicle.
Further information See chapter 6.4.1 for towing bar height adjustment.
12.2.2.2 Coupling-up
1. Slowly and carefully approach the machine with the towing vehicle.
2. Position and park the towing vehicle with coupling in front of the machine's towing eye.
Coupling a machine with towing eye:
1. Open the towing coupling of the towing vehicle.

2. Slowly and carefully approach the machine with the towing vehicle until the trailer coupling au‐
dibly latches.
3. Danger of accident from an incorrectly attached coupling.
If the coupling is not fully closed, the trailer can become uncoupled from the towing vehicle and
cause an accident.
➤ Check correct coupling.
4. Check the locking mechanism of the trailer coupling and re-couple if required.
Option rb/rk/rm/rs, Coupling machine with ball coupling (EC version):

rc/ro/rs, rb/rl/rm/rs
To hitch up the machine, lower the open coupling onto the ball of the towing vehicle so that it clicks
into place.
The coupling is fully locked when the green locking indicator protrudes and is visible from the side.

No.: 9_6999 23 USE M100 231
12.2 Transport
Fig. 94 Ball coupling (ALKO-EU)

1 Coupling handle 3 Towing vehicle ball hitch
2 Ball coupling 4 Locking indicator (protruding)
1. There is considerable danger of injury caused by trapped fingers.

They can be trapped in the spring-loaded closing mechanism.
➤ Never place your fingers inside an open ball coupling.
2. Pull up the coupling handle.
The coupling opens.
3. Risk of accident due to unhitching of the ball coupling during transport.
If the coupling is not fully closed the compressor can become uncoupled from the towing vehi‐
cle and cause an accident.
4. Place the open coupling over the towing vehicle ball hitch.
The weight on the coupling will cause it to audibly close. The coupling locks automatically.
Closing and locking is automatic.
5. Push the handle down to be certain of locking.
The coupling is fully locked when the handle is fully down and can be pushed no further.
6. Check correct coupling.
■ Check that the coupling handle cannot be pushed further down.
■ Check that the locking indicator is protruding and visible.
The locking indicator is not visible.
➤ Lift the handle and uncouple.
➤ Set the coupling back on the towing vehicle ball hitch and push down.
Checking the ball coupling wear indicator (EU version):
The ball coupling is equipped with a wear indicator.
The wear indicator shows:

■ Wear on the ball hitch.
■ Wear on the coupling.

232 M100 No.: 9_6999 23 USE
12.2 Transport
Fig. 95 Wear alert, ball coupling (ALKO-EU)

1 Ball coupling + Green zone (OK)
2 Wear indicator – Red zone (wear tolerance exceeded)
1. Danger of accident from worn coupling!

The machine may detach from the towing vehicle.
➤ Do not tow the machine.
➤ Have the ball coupling and ball hitch checked.
➤ Replace worn parts.
2. Couple-up the machine and tow slowly and carefully for about 0.5 miles.
The action of towing sets the coupling mechanism to maximum closure and gives a true read‐
ing on the wear indicator.
3. Interpret the wear indicator as follows:
Wear indicator Meaning

Green zone showing ■ Coupling in new condition.
■ Towing vehicle ball hitch wear within acceptable limits.
➤ No action necessary.
Red zone showing ■ Ball hitch wear at acceptable limit, ball coupling unworn.
■ Ball hitch in new condition; ball coupling showing increased wear.
■ Both ball and coupling showing increased wear.
■ Ball coupling damaged.
➤ Have the ball coupling and ball hitch checked by a specialist workshop.
➤ Replace worn parts.
Tab. 98 Ball coupling wear indicator
Option rd/ro/rs Coupling machine with ball coupling (US version):
To couple up the compressor, lower the open coupling onto the ball hitch of the towing vehicle so
that it clicks into place.

No.: 9_6999 23 USE M100 233
12.2 Transport
Fig. 96 Ball coupling (ALKO-USA)

1 Coupling handle 4 Safety pin
2 Ball coupling 5 Fixing hole for the security pin
3 Towing vehicle ball hitch 6 Ball coupling properly secured
1. There is considerable danger of injury caused by trapped fingers.

They can be trapped in the spring-loaded closing mechanism.
➤ Never place your fingers inside an open ball coupling.
2. Check if the security pin is removed from the coupling and draw it out if not.
3. Pull up the coupling handle.
The coupling opens.
4. Risk of accident due to unhitching of the ball coupling during transport.
If the coupling is not fully closed the compressor can become uncoupled from the towing vehi‐
cle and cause an accident.
➤ Check correct location of the security pin.
5. Place the open coupling over the towing vehicle ball hitch.
The weight on the coupling will cause it to audibly close. The coupling locks automatically.
Closing and locking is automatic.
6. Push the handle down to be certain of locking.
The coupling is fully locked when the handle is fully down and can be pushed no further.
7. Insert the security pin in the ball coupling fixing opening.
12.2.2.3 Ensure transport readiness of the coupled machine.
Fig. 97 Release the parking brake.

a Parking brake with gas spring assistance b Parking brake with ratchet and spring load‐
1 Parking brake lever ing
2 Dead point zone 3 Brake lever release button

234 M100 No.: 9_6999 23 USE
12.2 Transport
Fig. 98 Automatic jockey wheel in transport position
Option rb/rk/rm/rs, Preparing the machine for transport (height-adjustable chassis):

rb/rl/rm/rs
1. Check that the tow bar is adjusted to the correct height. See also chapter 6.4.1.
Check if:
■ The teeth in the tow bar height adjusting joints are fully engaged.
■ The locking levers are tightened
■ The security pin is fully inserted.
2. Wind the jockey wheel to its uppermost position.
The free jockey wheel automatically moves in transport position (see Ill. 98).
3. Check that the wheels are securely fitted and the tires are in good condition.
5. Connect the cable for the lighting and indicator systems and carry out a function check.
6. Release the parking brake:
(see Ill. 97, figure a).
■ Pull the brake lever a little further on and press the release button.
■ Hold the release button in and push the lever down past the dead point zone.
7. Remove the chocks.
Option rc/ro/rs Preparing the machine for transport (fixed-height chassis):

4. Connect the cable for the lighting and indicator systems and carry out a function check.
5. Release the parking brake:
(see Ill. 97, figure b).
■ Pull the brake lever a little further on and press the release button.
■ Hold in the release button and push the lever fully down.
6. Remove the chocks.

No.: 9_6999 23 USE M100 235
12.2 Transport
Option rd/ro/rs Preparing the machine for transport (fixed-height chassis, without parking brake):
Option rd/ro/rs
Fig. 99 Safety sign - secure the chocks
1. Missing chocks
Serious injury or death can result from an unsecured machine rolling away.
➤ Secure the chocks in the transport securing device before transporting the machine.
➤ Replace missing chocks immediately.
5. Attach the lighting and indicator systems and carry out a function check.
6. Remove the chocks and secure them in the transport securing device.
Replacement chocks can be purchased from KAESER representatives. A list is given at the
end of this manual. The part number of the chock is 5.1325.0.
Option rb/rk/rm/rs, Ensuring emergency braking in the case of breakaway from the towing vehicle:
rc/ro/rs, rb/rl/rm/rs
If the compressor breaks away from the towing vehicle, the cable tightens and pulls on the emer‐
gency brake (parking brake).
It is essential that the breakaway cable is threaded through its guides for correct emergency brak‐
ing.

236 M100 No.: 9_6999 23 USE
12.2 Transport
Fig. 100 Breakaway cable attachment

1 Breakaway cable
2 Breakaway cable guide (eye)
3 Connection (spring clip)
1. Unintentional brake application.

If the breakaway cable is too short it can apply the brakes when rounding a curve. This impo‐
ses high wear on the braking system.
➤ Make sure the breakaway cable is long enough.
2. Thread the breakaway cable through the guide welded on the side of the towing bar.
3. Loop the end of the cable round the towing vehicle hitch and secure with the spring clip.
Option rd/ro/rs Attach safety chains
Always use safety chains.

Chains hold the towed machine if connections fails.
Fig. 101
1 Coupling vehicle 3 Safety chains, crossed
2 Towbar 4 Fixing hook
➤ Attach safety chains to the towing vehicle.

■ Both chains must be crossed under the ball coupling/towing eye.
■ Allow slack for towed machine to turn.
■ Attach chain hooks securely to tow vehicle frame.

No.: 9_6999 23 USE M100 237
12.2 Transport
12.2.3 Parking the machine

The machine is generally only moved by being coupled to a towing vehicle.
The parking brake is not a running brake and is used only to lock the wheels when the machine is
positioned.
The towing mechanism of the machine is fitted with an "automatic jockey wheel".
In a parked machine which is separated from the towing vehicle, the machine's bearing load
affects the jockey wheel.
For this reason, the jockey wheel of a separated machine must be wound down until the
cam 2 no longer touches the bead 1 . The automatic folding of the wheel suspension is
thus blocked (see Ill. 103, figure a).
When the jockey wheel of a separated machine is wound up further, the bead pushes
against the cam of the retaining pin (see Ill. 103, figure b). The retaining pin 3 unlocks the
wheel suspension 4 which will abruptly fold (see Ill. 103, figure c), and drop the towing
mechanism to the ground.
A folding wheel suspension during winding up causes the towing device to suddenly crash
onto the ground,
potentially causing severe injuries to legs and/or feet.
➤ The operator must ensure that only authorised personnel has access to the machine.
➤ Wind the automatic jockey wheel only up when the machine is coupled to a towing vehi‐
cle.
➤ Wind the automatic jockey wheel up only as far as the bead does not touch the cam.
➤ Do not place your feet beneath the towing device.
Fig. 102 Warning "Injury can occur if the towbar is allowed to fall."

238 M100 No.: 9_6999 23 USE
12.2 Transport
Fig. 103 Towbar with automatic jockey wheel

1 Bead 3 Retaining pin
2 Cam 4 Wheel suspension
Fig. 104 Actuating the parking brake

a Parking brake with gas spring assistance b Parking brake with ratchet and spring load‐
1 Parking brake lever ing
2 Gas spring 4 Ratchet
3 Dead point zone 5 Spring loading device
Parking the machine (towing eye coupling):
1. Use a coupled towing vehicle to move the machine into position.

2. Disconnect the lighting and signaling cable (if provided).
3. Strongly pull the parking brake (if provided) upward past the dead point zone (see Ill.104, fig‐
ure a).
The gas spring holds the brake under tension.
4. Remove the cap nut (if fitted).
5. Lower the jockey wheel until the towing mechanism is stress-free.
6. Place chocks under the wheels.
7. Uncouple the compressor from the towing vehicle:
■ Open the towing coupling of the towing vehicle.
■ Slowly forward the towing vehicle to separate from the parked machine.
Option rb/rk/rm/rs, Parking the machine (height-adjustable chassis):

rb/rl/rm/rs
2. Disconnect the lighting and signaling cable.

No.: 9_6999 23 USE M100 239
12.2 Transport
3. Strongly pull the parking brake upward past the dead point zone (see Ill.104, figure a).
The gas spring holds the brake under tension.
4. Detach the breakaway cable.
■ Pull up the coupling release lever.
■ Lift the coupling off the towing hitch ball.
8. Slowly remove the towing vehicle from the parked machine.
The gas spring automatically increases parking brake force if the machine rolls backwards or
when parked on a slope.
Option rc/ro/rs Parking the machine (fixed-height chassis):

2. Disconnect the lighting and signaling cable.
3. Strongly pull the lever of the parking brake upward to the last ratchet tooth (see Ill. 104, figure
b).
When the hand brake lever is horizontal, the brake is under spring loading.
If the lever is not horizontal, the brake is not fully applied and the machine may roll away.
4. Detach the breakaway cable.
Option rd/ro/rs Parking the machine (fixed-height chassis, without parking brake):
Fig. 105 Safety sign - secure the chocks
1. Machine without parking brake.

Serious injury or death can result from an unsecured machine rolling away.
➤ Securely chock the machine before uncoupling.
➤ As a general rule, the machine should always be blocked with chocks when it is not being
moved.
➤ The machine should not be manoeuvred by hand.

240 M100 No.: 9_6999 23 USE
12.2 Transport

5. Remove the lighting and signaling system.
■ Withdraw the security pin from the ball coupling.
■ Insert the security pin in the ball coupling fixing opening.
12.2.4 Transport with a crane

Additional precautions for conditions of snow and ice:
This may adversely effect the machine's centre of gravity.
It is possible that the permissible loading on the crane or lifting eye is exceeded.
➤ Perform the following tasks in snow and ice conditions:
■ Remove any snow and ice from the machine before lifting by a crane.
■ Make sure the lifting eye cover plate is freely accessible and can be opened.
Perform the following tasks prior to moving the machine by crane:
A lifting eye is provided for transporting with a crane. The lifting eye is located beneath a lift-up cov‐
er in the centre of the canopy.
1. Unlock the cover from inside and lift up.
2. Position the crane hook vertically over the lifting eye.
3. Engage the hook in the eye.
4. Close and lock the access doors.
5. Lift and transport carefully.
Take care when setting down the machine
1. Incorrect setting down can damage the machine.

Machine components, particularly the chassis, can be damaged by incorrectly setting down.
➤ Set the machine down carefully.
➤ Do not set down unevenly.
2. Set the machine down slowly and carefully.
12.2.5 Option rw
Transport with a forklift truck
All connecting lines and hoses disconnected and removed.

No.: 9_6999 23 USE M100 241
12.2 Transport
Damage to the machine by incorrect lifting with a fork truck.

The machine may fall or be damaged by the forks.
➤ Do not use a fork truck to lift towable machines.
➤ Only stationary machines with skids may be transported with a fork truck.
➤ Pick up the machine only from the side with the forks through the lifting lugs.
Option rw
Fig. 106 Transporting using a forklift truck

1 Skids
2 Lifting lugs
1. Close and lock the access doors or canopy.

2. Position the fork truck to the side of the machine with the forks lined up with the lifting lugs.
3. Drive the forks fully through the lifting lugs as far as possible.
The forks are fully under the machine.
4. Lift the machine carefully.
12.2.6 Transporting the machine as load

The medium of transport determines the type of packing and securing.
Packing and securing methods must be such that, assuming proper handling, the goods arrive in
perfect condition at the destination.
Additional measures must be taken for the transport of machines by sea or air. Please contact
KAESER SERVICE for more information.
Material Chocks
Drag shoes or squared timber
Straps
Carry out a freight securing:
■ National directives and regulations for securing loads should be followed.

■ Load securing is taken to mean that by full braking or sudden turning the load will not
slide, fall, roll or cause unnecessary noise. Accepted technical regulations should be ob‐
served (e.g. VDI directive 2700 ff in Germany).
■ Responsibility for properly secured loads falls on the driver, the vehicle keeper and the
carrier.
Use chocks, restrainers or timber balks for securing the load.
If necessary, use straps across the chassis and the towbar.

242 M100 No.: 9_6999 23 USE
12.3 Storage
Fig. 107 Guys to secure the freight
1. Straps can damage the bodywork.

Movement during transportation can damage the bodywork.
➤ Do not use straps over the bodywork.
➤ Use straps only over the chassis.
2. Always observe valid accident and safety regulations when transporting.
3. The loads must be secured against rolling, tipping, slipping and falling.
Contact KAESER Service with any questions regarding transporting or load securing.
KAESER accepts no liability and provides no guarantee for damage arising from incorrect
transport or insufficient or incorrect load securing provisions.
For hire, rental and trade fair plant, any transport safety devices used for the delivery must
also be used for the return transport.
Before shipment as air freight
The machine is designated as dangerous goods for air freight purposes; any disregard can result in
a heavy fine.
1. Danger of fire or explosion from operating fluids/materials.
The machine incorporates an internal combustion engine.
➤ Any dangerous fluids/materials contained within the machine must be removed before
transport.
2. Remove all dangerous fluids/materials.
These include:
■ Residues of fuel or fuel vapours
■ Lubricants in engine and compressor.
■ Battery electrolyte
■ Residual quantities of tool lubricating oil in the tool lubricator (option ea, ec)
■ Residual quantities of antifreeze in the frost protector (Option ba)
12.3 Storage
Moisture can lead to corrosion, particularly in the engine, airend and oil separator tank.
Frozen moisture can damage components, valve diaphragms and gaskets.
The following measures also apply to machines not yet commissioned.

No.: 9_6999 23 USE M100 243
12.4 Disposal
Please consult with KAESER if you have questions to the appropriate storage and commis‐
sioning.
Moisture and frost can damage the machine!

➤ Prevent ingress of moisture and formation of condensation.
➤ Maintain a storage temperature of >32 °F.
➤ Store the machine in a dry place, free from frost if possible.
12.4 Disposal
When disposing of a machine, drain out all liquids and remove old filters.
Precondition The machine is decommissioned.
1. Completely drain the fuel from the machine.

2. Completely drain the cooling oil and engine oil from the machine.
3. Remove used filters and the oil separator cartridge.
4. Drain the coolant from water-cooled engines and systems.
5. Remove the battery.
6. Hand the machine over to an authorized disposal expert.
➤ Operating materials and components contaminated with fuel, cooling oil or engine oil
must be disposed of in accordance with local environmental protection regulations.
➤ The old battery is hazardous waste and must be disposed of correctly in accordance with
local environmental protection regulations.

244 M100 No.: 9_6999 23 USE
13 Annex
13.1 Identification
13 Annex
13.1 Identification
Fig. 108 Identification

1 Machine nameplate with serial number 3 Options label
2 VIN* (stamped in the bodywork) 4 Engine nameplate with serial number
*Vehicle Identification Number
13.2 Pipeline and instrument flow diagram (P+I diagram)

No.: 9_6999 23 USE M100 245
13 Annex

246 M100 No.: 9_6999 23 USE
13 Annex

No.: 9_6999 23 USE M100 247
13 Annex

248 M100 No.: 9_6999 23 USE
13 Annex

No.: 9_6999 23 USE M100 249
13 Annex

250 M100 No.: 9_6999 23 USE
13 Annex
13.3 Dimensional drawings

13.3.1 Option rb/rm/rs
Dimensional drawing, chassis options
■ Option rb - Chassis EU version
■ Option rm - Chassis with height-adjustable towbar
■ Option rs - Chassis with overrun brake

No.: 9_6999 23 USE M100 251
No.: 9_6999 23 USE M100 252
Screw Compressor Operator Manual
Die Zeichnung bleibt unser ausschließliches Eigentum. Sie wird nur zu dem vereinbarten Zweck anvertraut und darf zu keinem anderen Zweck verwendet werden. Drawings remain our exclusive property. They are entrusted only for the agreed purpose. Copies or any other reproduction, including storage, treatment and Entwicklungsbedingte Änderungen
Kopien oder sonstige Vervielfältigungen einschließlich Speicherung, Verarbeitung oder Verbreitung unter Verwendung elektronischer Systeme dürfen nur zu dem dissemination by use of electronic systems must not be made for any other than the agreed purpose. Neither originals nor reproductions may be given to or made vorbehalten. Zeichnung darf nur über CAD
vereinbarten Zweck angefertigt werden. Weder Original noch Vervielfältigungen dürfen Dritten ausgehändigt oder in sonstiger Weise zugänglich gemacht werden. available to third parties. geändert werden.
R 3
8 5/
8
88 1/4
70 1/16
61 7/16
Track width
Cooling air inlet
without towbar 40.80 feet²

Area covered by the vehicle,
15 3/8 44 11/16
82 1/2
Retracted lifting eye
Control panel
Compressed air outlet

min. 171 3/16
max. 186 3/8
min. 118 1/8
Cooling air outlet
Optional pedestrian protectors
max. 132 1/16
Engine exhaust
Status
30451
Änderungs-Nr.
Dokument TZD
Dokument TZM
FREIGEGEBEN
10227568 D 00
53 3/16
10227568 USE 00
Projektion
16 5/8
A3
1:25
9 7/16
Original
42 5/16
Maßstab
Bezeichnung
104 5/16
Gez.
Bearb.
Dimension and connection dim.

Datum
51 1/8
Freigeg. 20.07.2012 SCHMIDT8

20.07.2012 BOSSECK2
19.07.2012 BOSSECK2
Name
51 3/16
M 80/100.1 1600 rb rk rm rs
USE
Sprache
Generator option
Blatt
60 1/16
1 von 1
02.02.2012
Dimensional drawings 13.3
Annex 13
13 Annex
13.3.2 Option rc/ro/rs

■ Option rc - Chassis GB version
■ Option ro - Chassis with fixed height towbar

No.: 9_6999 23 USE M100 253
No.: 9_6999 23 USE M100 254
R 3
8 5/
8
88 1/4
70 1/16
61 7/16
Track width
Cooling air inlet

15 3/8 44 11/16
82 1/2
Control panel
max. 166 1/4

min. 158 7/16
max. 111 15/16
Cooling air outlet
min. 105 7/8
Engine exhaust
Status
30451
Änderungs-Nr.
Dokument TZD
Dokument TZM
17 15/16 u 1 2/8
FREIGEGEBEN
10227570 D 00
53 3/16
10227570 USE 00
Projektion
A3
1:25
9 7/16
Original
Maßstab
Bezeichnung
104 5/16
Gez.
Bearb.

Datum
51 1/8

20.07.2012 BOSSECK2
19.07.2012 BOSSECK2
Name
51 3/16
M 80/100.1 1600 rc ro rs
USE
Sprache
Generator option
Blatt
60 1/16
1 von 1
02.02.2012
Annex 13
13 Annex
13.3.3 Option rd/ro/rs

■ Option rd - Chassis USA version
■ Option ro - Chassis with fixed height towbar

No.: 9_6999 23 USE M100 255
No.: 9_6999 23 USE M100 256
R 3
8 5/
8
88 1/4
70 1/16
61 7/16
Track width
Cooling air inlet

15 3/8 44 11/16
82 1/2
Control panel
max. 166 1/4

min. 158 7/16
max. 111 15/16
Cooling air outlet
min. 105 7/8
Engine exhaust
Status
30451
Änderungs-Nr.
Dokument TZD
Dokument TZM
17 15/16 u 1 2/8
FREIGEGEBEN
10227571 D 00
53 3/16
10227571 USE 00
Projektion
A3
1:25
9 7/16
Original
Maßstab
Bezeichnung
104 5/16
Gez.
Bearb.

Datum
51 1/8

20.07.2012 BOSSECK2
19.07.2012 BOSSECK2
Name
51 3/16
M 80/100.1 1600 rd ro rs
USE
Sprache
Generator option
Blatt
60 1/16
1 von 1
02.02.2012
Annex 13
13 Annex
13.3.4 Option rb/rl/rm/rs

■ Option rb - Chassis EU version
■ Option rl - Chassis with higher axle load
■ Option rm - Chassis with height-adjustable towbar

No.: 9_6999 23 USE M100 257
No.: 9_6999 23 USE M100 258
R 3
8 5/
8
88 1/4
70 1/16
61 7/16
Track width
Cooling air inlet

16 5/16 44 11/16
83 7/16
Control panel

min. 171 3/16
max. 186 3/8
Cooling air outlet
min. 118 11/16

max. 132 11/16
Engine exhaust
Status
30451
Änderungs-Nr.
Dokument TZD
Dokument TZM
FREIGEGEBEN
53 3/4
10227569 D 00
10227569 USE 00
Projektion
17 5/16
A3
1:25
9 7/16
Original
43
Maßstab
Bezeichnung
104 5/16
Gez.
Bearb.

Datum
50 9/16

20.07.2012 BOSSECK2
19.07.2012 BOSSECK2
Name
51 3/16
59 3/16
M 80/100.1 1800 rb rl rm rs
USE
Sprache
Generator option
Blatt
61
1 von 1
02.02.2012
Annex 13
13 Annex
13.3.5 Option rw
Dimensional drawing, stationary version
■ Option rw - Skid frame on runners

No.: 9_6999 23 USE M100 259
No.: 9_6999 23 USE M100 260
51 3/16
59 3/16
54 1/2
Cooling air inlet
Drain
3 9/16
21 1/4
Control panel
103 1/8
99 3/16
CG: Centre of gravity

CG
CG

48 13/16
position marginally dependent on design

Engine exhaust
Cooling air outlet
Status
30451
Änderungs-Nr.
Dokument TZD
Dokument TZM
FREIGEGEBEN
10227572 D 00
R 3
10227572 USE 00
Projektion
8 3/
4
A3
1:25
Original
Maßstab
Bezeichnung
50
88 9/16
Gez.
Generator option
Bearb.

87
M 80/100.1 rw
.5
Datum
°
13 3/417 11/1613 3/4

23.07.2012 BOSSECK2
19.07.2012 BOSSECK2
23 5/16
Name
9 13/16 44 11/16
28 15/16
77
USE
Sprache
Blatt
1 von 1
02.02.2012
Annex 13
13 Annex
13.3.6 Option rx
Dimensional drawing, stationary version
■ Option rx - On frame

No.: 9_6999 23 USE M100 261
No.: 9_6999 23 USE M100 262
O 5 1/2
9/
16
51 3/16
59 3/16
6 11/16

* +2.36" if fitted with rubber pads
50 9/16 *
Cooling air inlet
Drain
Choice of rubber pads or machine mountings
17 5/16 *
Control panel
6 11/16
Anchor the machine only with machine mountings

82 11/16
99 3/16
CG: Centre of gravity

CG
CG

48 13/16
position marginally dependent on design

Engine exhaust
Cooling air outlet
Status
30451
Änderungs-Nr.
Dokument TZD
Dokument TZM
FREIGEGEBEN
10227573 D 00
R 3
10227573 USE 00
Projektion
8 3/
4
A3
1:25
Original
Maßstab
Bezeichnung
47 7/16
88 9/16
Gez.
Generator option
Bearb.

87
M 80/100.1 rx
.5
Datum
°

23.07.2012 BOSSECK2
19.07.2012 BOSSECK2
19 3/8 *
Name
5 7/8 * 44 11/16
73 1/16 *
USE
Sprache
Blatt
1 von 1
02.02.2012
Annex 13
13 Annex
13.4 Wiring diagrams

13.4.1 Electrical Diagram

No.: 9_6999 23 USE M100 263
13 Annex

264 M100 No.: 9_6999 23 USE
13 Annex

No.: 9_6999 23 USE M100 265
13 Annex

266 M100 No.: 9_6999 23 USE
13 Annex

No.: 9_6999 23 USE M100 267
13 Annex

268 M100 No.: 9_6999 23 USE
13 Annex

No.: 9_6999 23 USE M100 269
13 Annex

270 M100 No.: 9_6999 23 USE
13 Annex

No.: 9_6999 23 USE M100 271
13 Annex

272 M100 No.: 9_6999 23 USE
13 Annex

No.: 9_6999 23 USE M100 273
13 Annex

274 M100 No.: 9_6999 23 USE
13 Annex

No.: 9_6999 23 USE M100 275
13 Annex

276 M100 No.: 9_6999 23 USE
13 Annex
13.4.2 Option tc
Lighting and signaling system connection

No.: 9_6999 23 USE M100 277
13 Annex

278 M100 No.: 9_6999 23 USE
13 Annex

No.: 9_6999 23 USE M100 279
13 Annex

280 M100 No.: 9_6999 23 USE
13 Annex

No.: 9_6999 23 USE M100 281
13 Annex

282 M100 No.: 9_6999 23 USE
13 Annex

No.: 9_6999 23 USE M100 283
13 Annex

284 M100 No.: 9_6999 23 USE
13 Annex
13.4.3 Option te
Lighting and signaling system connection

No.: 9_6999 23 USE M100 285
13 Annex

286 M100 No.: 9_6999 23 USE
13 Annex

No.: 9_6999 23 USE M100 287
13 Annex

288 M100 No.: 9_6999 23 USE
13 Annex

No.: 9_6999 23 USE M100 289
13 Annex
13.4.4 Option ga
Generator electrical diagram, 400V, 3-ph

290 M100 No.: 9_6999 23 USE
13 Annex

No.: 9_6999 23 USE M100 291
13 Annex

292 M100 No.: 9_6999 23 USE
13 Annex

No.: 9_6999 23 USE M100 293
13 Annex

294 M100 No.: 9_6999 23 USE
13 Annex

No.: 9_6999 23 USE M100 295
13 Annex

296 M100 No.: 9_6999 23 USE
13 Annex

No.: 9_6999 23 USE M100 297
13 Annex

298 M100 No.: 9_6999 23 USE
13 Annex
13.4.5 Option ga
Generator electrical diagram, 230V, 3-ph

No.: 9_6999 23 USE M100 299
13 Annex

300 M100 No.: 9_6999 23 USE
13 Annex

No.: 9_6999 23 USE M100 301
13 Annex

302 M100 No.: 9_6999 23 USE
13 Annex

No.: 9_6999 23 USE M100 303
13 Annex

304 M100 No.: 9_6999 23 USE
13 Annex

No.: 9_6999 23 USE M100 305
13 Annex

306 M100 No.: 9_6999 23 USE
13 Annex

No.: 9_6999 23 USE M100 307
13 Annex
13.4.6 Option ga
Generator electrical diagram, 115 V, 2-ph

308 M100 No.: 9_6999 23 USE
13 Annex

No.: 9_6999 23 USE M100 309
13 Annex

310 M100 No.: 9_6999 23 USE
13 Annex

No.: 9_6999 23 USE M100 311
13 Annex

312 M100 No.: 9_6999 23 USE
13 Annex

No.: 9_6999 23 USE M100 313
13 Annex

314 M100 No.: 9_6999 23 USE
13 Annex

No.: 9_6999 23 USE M100 315
13 Annex

316 M100 No.: 9_6999 23 USE
13 Annex
13.4.7 Option ga
Generator electrical diagram, 230 V, 2-ph

No.: 9_6999 23 USE M100 317
13 Annex

318 M100 No.: 9_6999 23 USE
13 Annex

No.: 9_6999 23 USE M100 319
13 Annex

320 M100 No.: 9_6999 23 USE
13 Annex

No.: 9_6999 23 USE M100 321
13 Annex

322 M100 No.: 9_6999 23 USE
13 Annex

No.: 9_6999 23 USE M100 323
13 Annex

324 M100 No.: 9_6999 23 USE
13 Annex

No.: 9_6999 23 USE M100 325
13 Annex
13.5 Fuel circulation diagram

326 M100 No.: 9_6999 23 USE
13 Annex

No.: 9_6999 23 USE M100 327
13 Annex

328 M100 No.: 9_6999 23 USE
13 Annex
13.6 Assembly diagrams - chassis

13.6.1 Assembly diagrams - chassis EU version

No.: 9_6999 23 USE M100 329
13 Annex

330 M100 No.: 9_6999 23 USE
13 Annex
13.6.2 Assembly diagrams - chassis GB/US version

No.: 9_6999 23 USE M100 331
13 Annex

332 M100 No.: 9_6999 23 USE
13 Annex
Verschraubung K26 – Bowdenzug - Gestänge

No.: 9_6999 23 USE M100 333
13 Annex
13.6.3 Assembly diagram brake rod

334 M100 No.: 9_6999 23 USE
No.: 9_6999 23 USE
A A
1
2 8 7 A-A (1 : 1)
13
13.6
M100
Operator Manual
3 5
Annex
Screw Compressor
4
Assembly diagrams - chassis
1. Bowdenzüge (2) am Achswiderlager (7) einstecken

694917 / Mittwoch, 15. Oktober 2014 15:44:01
und mit Skt.-Mutter M12x1,5 (8) kontern. 9

Anziehdrehmoment 40-45 Nm.
1. Insert bowden cables (2) into abutment (7)
and counter with hex. nut M12x1,5.
Schutzvermerk nach DIN ISO 16016 beachten

torque to 40-45 Nm.
2. Ausgleichsprofil (1) auf Bremsgestänge (3) aufschieben.
Ausgleichsprofil (1) in Bowdenzüge (2) einfädeln.
2. Put the balance bar (1) on the push brake rod (3).
PDM-
Arrange the balance bar (1) into the bowden cables (2) . Status:
3. Distanzstück (5) auf Bremsgestänge (3) schieben.

(Rundung zum Ausgleichsprofil)
3. Fit the distance plate on to the push brake rod.
(with the curve to the balance bar)
Vers. RevS Änderungstext
4. Langmutter M10 (4) aufschrauben und anziehen Oberfläche Zul. Abweichung Werkstoff Norm Halbzeug Norm Materialnr.
bis kein Spiel mehr vorhanden ist. nach nach
Mit Skt.-Mutter M10 (6) kontern. EN ISO 1302 DIN ISO 2768 m - - - - -
Anziehdrehmoment 20-25Nm Vers. RevS Änd.-Nr. Datum Name Gewicht KG Bearb. Name: MUSKIETORZ Datum: 10.10.2014
© Alle Rechte bei AL-KO, auch für Schutzrechtsanmeldungen. Alle Verfügungbefugnisse, wie Kopie- und Weitergaberechte, bei uns.
4. Srew the long nut M10 (4) and fix it Projekt: -
Benennung
until no tolerance is available.
Counter with hex. nut M10 (6) MONTPLAN AUSGLEICHSPR R13 EA1636G-2361
torque to 20-25Nm. -
Materialnr. Klass.-Nr.
5. Gestängehalter (9) wahlweise
5. Brake rod rear (9) optional 694917 904050
ALOIS KOBER GMBH Maßstab Bl.-Nr. Bl.-Anz. Format
D-89359 Kötz 1:4 1 1 A3
Vorlage Vers. 4.3.1 / 14.07.2005
Urspr. Ers. f. Ers. d.
335
13 Annex
13.7 Operating instructions for compressed air filter (combination filter)
13.7 Option dd
Operating instructions for compressed air filter (combination filter)

336 M100 No.: 9_6999 23 USE
13 Annex
Bedienungsanleitung
Instruction Manual
Hochleistungs - Druckluftfilter
Compressed-air filters
Serie / Series
FA (D), FB (D&E), FC (D&E), FD (E), FE (D&E), FF (D&E), FG
STANDARD D-Pack D-PACK E-PACK

Basic
(OPTION) (OPTION) (OPTION)
Kaeser Kompressoren GmbH

Postfach 2143
96410 Coburg
Tel.: 09561/640-0
Fax: 09561/640130
http://www.kaeser.com
A Kap. 9.2, 9.3 Wartungsintervalle 04.12.08 SK
Änd. Mittlg. Datum Bearb.
gültig ab 01.04.2007 F0507 05.03.07 KC 05.03.07 KC F0412

-1-
D-Name erstellt Name gepr. Name ersetzt f. ersetzt d.
FI HANK-MOB_02 D E

No.: 9_6999 23 USE M100 337
13 Annex
Materialkennzeichnung Sign of material
Filter: Standard Filter: D-Pack Filter: Element/Cartrigde

Typ/Type Nr./No. Typ/Type Nr./No. Typ/Type Nr./No.
FA-6 9.4600.0 FA-6 D 9.4600.00110 E-A-6 9.4800.0
FA-10 9.4601.0 FA-10 D 9.4601.00110 E-A-10 9.4801.0
FA-18 9.4602.0 FA-18 D 9.4602.00110 E-A-18 9.4802.0
FA-28 9.4603.0 FA-28 D 9.4603.00110 E-A-28 9.4803.0
FA-48 9.4604.0 FA-48 D 9.4604.00010 E-A-48 9.4804.0
FA-71 9.4605.0 FA-71 D 9.4605.00010 E-A-71 9.4805.0
FA-107 9.4606.0 FA-107 D 9.4606.00010 E-A-107 9.4806.0
FA-138 9.4607.0 FA-138 D 9.4607.00010 E-A-138 9.4807.0
FA-177 9.4608.0 FA-177 D 9.4608.00010 E-A-177 9.4808.0
FA-221 9.4609.0 FA-221 D 9.4609.00010 E-A-221 9.4809.0
FA-185 9.4610.0 FA-185 D 9.4610.00010 E-A-185 9.4810.0
FA-283 9.4611.0 FA-283 D 9.4611.00010 E-A-283 9.4811.0
FA-354 9.4612.0 FA-354 D 9.4612.00010 E-A-185 9.4810.0
FA-526 9.4613.0 FA-526 D 9.4613.00010 E-A-185 9.4810.0
FA-708 9.4614.0 FA-708 D 9.4614.00010 E-A-185 9.4810.0
FA-885 9.4615.0 FA-885 D 9.4615.00010 E-A-185 9.4810.0
FA-1420 9.4616.0 FA-1420 D 9.4616.00010 E-A-185 9.4810.0
FA-1950 9.4617.0 FA-1950 D 9.4617.00010 E-A-185 9.4810.0
FA-2480 9.4618.0 FA-2480 D 9.4618.00010 E-A-185 9.4810.0
D-Pack: Filter mit ECO-DRAIN / D-Pack: Filter with ECO-DRAIN
Filte r: Sta nda rd Filte r: D-Pa ck Ba sic Filte r: D-Pa ck Filte r: E-Pa ck Filte r: Ele m e nt/Ca rtrigde
Typ/Type Nr./No. Typ/Type Nr./No. Typ/Type Nr./No. Typ/Type Typ/Type Nr./No.
FB-6 9.4620.0 FB-6 B 9.4620.00110 FB-6 D 9.4620.00120 FB-6 E E-B-6 9.4812.0
FB-10 9.4621.0 FB-10 B 9.4621.00110 FB-10 D 9.4621.00120 FB-10 E E-B-10 9.4813.0
FB-18 9.4622.0 FB-18 B 9.4622.00110 FB-18 D 9.4622.00120 FB-18 E E-B-18 9.4814.0
FB-28 9.4623.0 FB-28 B 9.4623.00110 FB-28 D 9.4623.00120 FB-28 E E-B-28 9.4815.0
FB-48 9.4624.0 FB-48 B 9.4624.00110 FB-48 D 9.4624.00120 FB-48 E E-B-48 9.4816.0
FB-71 9.4625.0 FB-71 B 9.4625.00110 FB-71 D 9.4625.00120 FB-71 E E-B-71 9.4817.0
FB-107 9.4626.0 FB-107 B 9.4626.00110 FB-107 D 9.4626.00120 FB-107 E E-B-107 9.4818.0
FB-138 9.4627.0 FB-138 B 9.4627.00110 FB-138 D 9.4627.00120 FB-138 E E-B-138 9.4819.0
FB-177 9.4628.0 FB-177 B 9.4628.00110 FB-177 D 9.4628.00120 FB-177 E E-B-177 9.4820.0
FB-221 9.4629.0 FB-221 B 9.4629.00110 FB-221 D 9.4629.00120 FB-221 E E-B-221 9.4821.0
FB-185 9.4630.0 - - FB-185 D 9.4630.00120 FB-185 E E-B-185 9.4822.0
FB-283 9.4631.0 - - FB-283 D 9.4631.00120 FB-283 E E-B-283 9.4823.0
FB-354 9.4632.0 - - FB-354 D 9.4632.00120 FB-354 E E-B-185 9.4822.0
FB-526 9.4633.0 - - FB-526 D 9.4633.00120 FB-526 E E-B-185 9.4822.0
FB-708 9.4634.0 - - FB-708 D 9.4634.00120 FB-708 E E-B-185 9.4822.0
FB-885 9.4635.0 - - FB-885 D 9.4635.00120 FB-885 E E-B-185 9.4822.0
FB-1420 9.4636.0 - - FB-1420 D 9.4636.00020 FB-1420 E E-B-185 9.4822.0
FB-1950 9.4637.0 - - FB-1950 D 9.4637.00020 FB-1950 E E-B-185 9.4822.0
FB-2480 9.4638.0 - - FB-2480 D 9.4638.00020 FB-2480 E E-B-185 9.4822.0
D-Pack: Filter mit Differenzdruckmanometer und ECO-DRAIN D-pack: Filter with differential pressure gauge and ECO-DRAIN
D-Pack-Basic: Filter mit Differenzdruckmanometer und ECO-DRAIN 30 D-pack-basic: Filter with differential pressure gauge and ECO-DRAIN 30
E-Pack: Filter mit Filtermonitor und ECO-DRAIN E-pack: Filter with filtermonitor and ECO-DRAIN
Anzahl Filterelemente siehe Kapitel 3. „Technische Daten“. Quantity of filter cartridges see chapter 3. „Technical data“.
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338 M100 No.: 9_6999 23 USE
13 Annex
Filte r: Sta ndard Filter: D-Pa ck Basic Filter: D-Pack Filter: E-Pack Filte r: Elem ent/Cartrigde
Typ/Type Nr./No. Typ/Type Nr./No. Typ/Type Nr./No. Typ/Type Typ/Type Nr./No.
FC-6 9.4640.0 FC-6 B 9.4640.00110 FC-6 D 9.4640.00120 FC-6 E E-C-6 9.4824.0
FC-10 9.4641.0 FC-10 B 9.4641.00110 FC-10 D 9.4641.00120 FC-10 E E-C-10 9.4825.0
FC-18 9.4642.0 FC-18 B 9.4642.00110 FC-18 D 9.4642.00120 FC-18 E E-C-18 9.4826.0
FC-28 9.4643.0 FC-28 B 9.4643.00110 FC-28 D 9.4643.00120 FC-28 E E-C-28 9.4827.0
FC-48 9.4644.0 FC-48 B 9.4644.00110 FC-48 D 9.4644.00120 FC-48 E E-C-48 9.4828.0
FC-71 9.4645.0 FC-71 B 9.4645.00110 FC-71 D 9.4645.00120 FC-71 E E-C-71 9.4829.0
FC-107 9.4646.0 FC-107 B 9.4646.00110 FC-107 D 9.4646.00120 FC-107 E E-C-107 9.4830.0
FC-138 9.4647.0 FC-138 B 9.4647.00110 FC-138 D 9.4647.00120 FC-138 E E-C-138 9.4831.0
FC-177 9.4648.0 FC-177 B 9.4648.00110 FC-177 D 9.4648.00120 FC-177 E E-C-177 9.4832.0
FC-221 9.4649.0 FC-221 B 9.4649.00110 FC-221 D 9.4649.00120 FC-221 E E-C-221 9.4833.0
FC-185 9.4650.0 - - FC-185 D 9.4650.00120 FC-185 E E-C-185 9.4834.0
FC-283 9.4651.0 - - FC-283 D 9.4651.00120 FC-283 E E-C-283 9.4835.0
FC-354 9.4652.0 - - FC-354 D 9.4652.00120 FC-354 E E-C-185 9.4834.0
FC-526 9.4653.0 - - FC-526 D 9.4653.00120 FC-526 E E-C-185 9.4834.0
FC-708 9.4654.0 - - FC-708 D 9.4654.00120 FC-708 E E-C-185 9.4834.0
FC-885 9.4655.0 - - FC-885 D 9.4655.00120 FC-885 E E-C-185 9.4834.0
FC-1420 9.4656.0 - - FC-1420 D 9.4656.00020 FC-1420 E E-C-185 9.4834.0
FC-1950 9.4657.0 - - FC-1950 D 9.4657.00020 FC-1950 E E-C-185 9.4834.0
FC-2480 9.4658.0 - - FC-2480 D 9.4658.00020 FC-2480 E E-C-185 9.4834.0
Filte r: S ta nda rd Filte r: E-Pa ck Filte r: Ele m e nt/Ca rtrigde

Typ/Type Nr./No. Typ/Type Typ/Type Nr./No.
FD-6 9.4660.0 FD-6 E E -D-6 9.4836.0
FD-10 9.4661.0 FD-10 E E -D-10 9.4837.0
FD-18 9.4662.0 FD-18 E E -D-18 9.4838.0
FD-28 9.4663.0 FD-28 E E -D-28 9.4839.0
FD-48 9.4664.0 FD-48 E E -D-48 9.4840.0
FD-71 9.4665.0 FD-71 E E -D-71 9.4841.0
FD-107 9.4666.0 FD-107 E E -D-107 9.4842.0
FD-138 9.4667.0 FD-138 E E -D-138 9.4843.0
FD-177 9.4668.0 FD-177 E E -D-177 9.4844.0
FD-221 9.4669.0 FD-221 E E -D-221 9.4845.0
FD-185 9.4670.0 FD-185 E E -D-185 9.4846.0
FD-283 9.4671.0 FD-283 E E -D-283 9.4847.0
FD-354 9.4672.0 FD-354 E E -D-185 9.4846.0
FD-526 9.4673.0 FD-526 E E -D-185 9.4846.0
FD-708 9.4674.0 FD-708 E E -D-185 9.4846.0
FD-885 9.4675.0 FD-885 E E -D-185 9.4846.0
FD-1420 9.4676.0 FD-1420 E E -D-185 9.4846.0
FD-1950 9.4677.0 FD-1950 E E -D-185 9.4846.0
FD-2480 9.4678.0 FD-2480 E E -D-185 9.4846.0
E-Pack: Filter mit Filtermonitor E-Pack: Filter with filtermonitor
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No.: 9_6999 23 USE M100 339
13 Annex
Filter: Standard Filter: D-P ack Bas ic Filter: D-P ack Filter: E-Pac k Filter: Element/Cartrigde
Typ/Type Nr./No. Typ/Type Nr./No. Ty p/Type Nr./No. Typ/Type Typ/Type Nr./No.
FE-6 9.4700.0 FE-6 B 9.4700.00110 FE-6 D 9.4700.00120 FE-6 E E-E -6 9.4860.0
FE-10 9.4701.0 FE-10 B 9.4701.00110 FE-10 D 9.4701.00120 FE-10 E E-E -10 9.4861.0
FE-18 9.4702.0 FE-18 B 9.4702.00110 FE-18 D 9.4702.00120 FE-18 E E-E -18 9.4862.0
FE-28 9.4703.0 FE-28 B 9.4703.00110 FE-28 D 9.4703.00120 FE-28 E E-E -28 9.4863.0
FE-48 9.4704.0 FE-48 B 9.4704.00110 FE-48 D 9.4704.00120 FE-48 E E-E -48 9.4864.0
FE-71 9.4705.0 FE-71 B 9.4705.00110 FE-71 D 9.4705.00120 FE-71 E E-E -71 9.4865.0
FE-107 9.4706.0 FE-107 B 9.4706.00110 FE-107 D 9.4706.00120 FE-107 E E-E -107 9.4866.0
FE-138 9.4707.0 FE-138 B 9.4707.00110 FE-138 D 9.4707.00120 FE-138 E E-E -138 9.4867.0
FE-177 9.4708.0 FE-177 B 9.4708.00110 FE-177 D 9.4708.00120 FE-177 E E-E -177 9.4868.0
FE-221 9.4709.0 FE-221 B 9.4709.00110 FE-221 D 9.4709.00120 FE-221 E E-E -221 9.4869.0
FE-185 9.4710.0 - - FE-185 D 9.4710.00120 FE-185 E E-E -185 9.4870.0
FE-283 9.4711.0 - - FE-283 D 9.4711.00120 FE-283 E E-E -283 9.4871.0
FE-354 9.4712.0 - - FE-354 D 9.4712.00120 FE-354 E E-E -185 9.4870.0
FE-526 9.4713.0 - - FE-526 D 9.4713.00120 FE-526 E E-E -185 9.4870.0
FE-708 9.4714.0 - - FE-708 D 9.4714.00120 FE-708 E E-E -185 9.4870.0
FE-885 9.4715.0 - - FE-885 D 9.4715.00120 FE-885 E E-E -185 9.4870.0
FE-1420 9.4716.0 - - FE-1420 D 9.4716.00020 FE-1420 E E-E -185 9.4870.0
FE-1950 9.4717.0 - - FE-1950 D 9.4717.00020 FE-1950 E E-E -185 9.4870.0
FE-2480 9.4718.0 - - FE-2480 D 9.4718.00020 FE-2480 E E-E -185 9.4870.0
Filter: Standard Filter: D-Pack Bas ic Filter: D-P ack Filter: E-Pack Filter: Element/Cartrigde
Typ/Ty pe Nr./No. Typ/Ty pe Nr./No. Typ/Ty pe Nr./No. Typ/Type Typ/Ty pe Nr./No.
FF-6 9.4720.0 FF-6 B 9.4720.00110 FF-6 D 9.4720.00120 FF-6 E E -F-6 9.4872.0
FF-10 9.4721.0 FF-10 B 9.4721.00110 FF-10 D 9.4721.00120 FF-10 E E -F-10 9.4873.0
FF-18 9.4722.0 FF-18 B 9.4722.00110 FF-18 D 9.4722.00120 FF-18 E E -F-18 9.4874.0
FF-28 9.4723.0 FF-28 B 9.4723.00110 FF-28 D 9.4723.00120 FF-28 E E -F-28 9.4875.0
FF-48 9.4724.0 FF-48 B 9.4724.00110 FF-48 D 9.4724.00120 FF-48 E E -F-48 9.4876.0
FF-71 9.4725.0 FF-71 B 9.4725.00110 FF-71 D 9.4725.00120 FF-71 E E -F-71 9.4877.0
FF-107 9.4726.0 FF-107 B 9.4726.00110 FF-107 D 9.4726.00120 FF-107 E E -F-107 9.4878.0
FF-138 9.4727.0 FF-138 B 9.4727.00110 FF-138 D 9.4727.00120 FF-138 E E -F-138 9.4879.0
FF-177 9.4728.0 FF-177 B 9.4728.00110 FF-177 D 9.4728.00120 FF-177 E E -F-177 9.4880.0
FF-221 9.4729.0 FF-221 B 9.4729.00110 FF-221 D 9.4729.00120 FF-221 E E -F-221 9.4881.0
FF-185 9.4730.0 - - FF-185 D 9.4730.00120 FF-185 E E -F-185 9.4882.0
FF-283 9.4731.0 - - FF-283 D 9.4731.00120 FF-283 E E -F-283 9.4883.0
FF-354 9.4732.0 - - FF-354 D 9.4732.00120 FF-354 E E -F-185 9.4882.0
FF-526 9.4733.0 - - FF-526 D 9.4733.00120 FF-526 E E -F-185 9.4882.0
FF-708 9.4734.0 - - FF-708 D 9.4734.00120 FF-708 E E -F-185 9.4882.0
FF-885 9.4735.0 - - FF-885 D 9.4735.00120 FF-885 E E -F-185 9.4882.0
FF-1420 9.4736.0 - - FF-1420 D 9.4736.00020 FF-1420 E E -F-185 9.4882.0
FF-1950 9.4737.0 - - FF-1950 D 9.4737.00020 FF-1950 E E -F-185 9.4882.0
FF-2480 9.4738.0 - - FF-2480 D 9.4738.00020 FF-2480 E E -F-185 9.4882.0
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340 M100 No.: 9_6999 23 USE
13 Annex
Filter: Standard Filter: Element/Cartrigde

Typ/Type Nr./No. Typ/Type Nr./No.
FG-6 9.4740.0 E-G-6 9.4884.0
FG-10 9.4741.0 E-G-10 9.4885.0
FG-18 9.4742.0 E-G-18 9.4886.0
FG-28 9.4743.0 E-G-28 9.4887.0
FG-48 9.4744.0 E-G-48 9.4888.0
FG-71 9.4745.0 E-G-71 9.4889.0
FG-107 9.4746.0 E-G-107 9.4890.0
FG-138 9.4747.0 E-G-138 9.4891.0
FG-177 9.4748.0 E-G-177 9.4892.0
FG-221 9.4749.0 E-G-221 9.4893.0
FG-185 9.4750.0 E-G-185 9.4894.0
FG-283 9.4751.0 E-G-283 9.4895.0
FG-354 9.4752.0 E-G-185 9.4894.0
FG-526 9.4753.0 E-G-185 9.4894.0
FG-708 9.4754.0 E-G-185 9.4894.0
FG-885 9.4755.0 E-G-185 9.4894.0
FG-1420 9.4756.0 E-G-185 9.4894.0
FG-1950 9.4757.0 E-G-185 9.4894.0
FG-2480 9.4758.0 E-G-185 9.4894.0
Filte r: Sta nda rd Filte r: D-Pa ck Ba sic Filte r: D-Pa ck Filte r: E-Pa ck
Typ/Type Nr./No. Typ/Type Nr./No. Typ/Type Nr./No. Typ/Type
FFG-6 9.4760.0 FFG-6 B 9.4760.00110 FFG-6 D 9.4760.00120 FFG-6 E
FFG-185 9.4770.0 - - FFG-185 D 9.4770.00120 FFG-185 E
FFG-283 9.4771.0 - - FFG-283 D 9.4771.00120 FFG-283 E
FFG-354 9.4772.0 - - FFG-354 D 9.4772.00120 FFG-354 E
FFG-526 9.4773.0 - - FFG-526 D 9.4773.00120 FFG-526 E
FFG-708 9.4774.0 - - FFG-708 D 9.4774.00120 FFG-708 E
FFG-885 9.4775.0 - - FFG-885 D 9.4775.00120 FFG-885 E
FFG-1420 9.4776.0 - - FFG-1420 D 9.4776.00020 FFG-1420 E
FFG-1950 9.4777.0 - - FFG-1950 D 9.4777.00020 FFG-1950 E
FFG-2480 9.4778.0 - - FFG-2480 D 9.4778.00020 FFG-2480 E
Filterkombination bestehend aus Serie FF & FG Filter combination consist of series FF & FG
E-Pack: Filter Serie FF mit Filtermonitor und ECO-DRAIN E-pack: Filter series FF with filtermonitor and ECO-DRAIN
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No.: 9_6999 23 USE M100 341
13 Annex
Inhaltsverzeichnis Contents
1. Einleitung 1. Introduction
2. Sicherheitsregeln, Warnhinweise 2. Safety rules, warnings
3. Technische Daten 3. Technical data
4. Funktionsbeschreibung 4. Description of functions
5. Kondensatableiter 5. Condensate discharger
6. Transport, Wareneingangskontrolle 6. Transportation, checking of goods

received
7. Montage 7. Assembly
8. Inbetriebnahme, Betrieb 8. Start up, operation
9. Wartung, Austausch der Filterelemente 9. Servicing, filter cartridge replacement
10. Garantiebedingungen 10. Guarantee conditions
11. Maßzeichnung 11. Dimensional drawing
12. Anhang (ECO-DRAIN) 12. Annex (ECO-DRAIN)
13. Einteilung nach Druckgeräterichtlinie 13.Grading of filters according to pressure

equipment directive (PED)
Wir haben den Inhalt der Bedienungsanleitung auf Übereinstim- We have examined the content of the operating instructions for
mung mit dem beschriebenen Gerät geprüft. conformity with the appliance described.
Dennoch können Abweichungen nicht ausgeschlossen werden, so Inconsistencies cannot be ruled out, however, with the result that
daß wir für die vollständige Übereinstimmung keine Gewähr über- we do not guarantee complete conformity
nehmen.
We reserve the right to alter the specifications without prior notice
Technische Änderungen vorbehalten.
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342 M100 No.: 9_6999 23 USE
13 Annex
1. Einleitung 1. Introduction
1.1 Allgemeines 1.1 General remarks

Die in dieser Betriebsanleitung dokumentierten Druckluftfilter erfül- The compressed air filters documented in these instruction manual
len alle Anforderungen, die an moderne Filtersysteme gestellt wer- has all requirements that can be expected from a modern filter/ -
den. system.
Um Sie optimal nutzen zu können, benötigt der Anwender ausführ- In order to obtain maximum benefit from using the filters/ -system
liche Informationen. the user should have sufficient information.
In der vorliegenden Betriebsanleitung haben wir diese Informationen These instruction manual gave the user this information which has
möglichst vollständig und in entsprechende Kapitel gegliedert zu- been divided into separate sections for easy reference.
sammengestellt.
Please read carefully before installing and operating the filter/ -system.
Lesen und beachten Sie diese Informationen.
Sie helfen Ihnen auch Unfälle zu vermeiden.
1.2 Erklärung der Symbole in der 1.2 Explanation to the symbols in the
Bedienungsanleitung instruction manual
• Aufzählungen werden mit diesem Punkt oder Sternchen • Technical data or instructions.
∗ gekennzeichnet. ∗
Mit diesem Symbol werden Textstellen gekennzeichnet, die Parts that require absolute attention
unbedingt zu beachten sind.
• Wichtige Sicherheitshinweise • Vital safety instructions

• Wichtige Bedienungs-/Wartungshinweise • Essential operation and maintenance instructions
• Warnung vor möglichen Fehlbedienungen • Warnings on handling or moving the dryer
• Warnung vor Gefahren • Danger areas
Elektrisches Gefahrensymbol Electrical danger symbol
Ausführende Tätigkeit. Changes sequence of operation

Vom Bediener auszuführende Bedienschritte.
1.3 Erklärung der Symbole am Gerät 1.3 Symbols used in the filter
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No.: 9_6999 23 USE M100 343
13 Annex
2. Sicherheitsregeln, 2. Safety rules,

Warnhinweise warnings
2.1 Bestimmungsgemäßer Gebrauch 2.1 Use of filter/ -system
Achtung! Achtung!
• Die Filter dürfen nur für die in dieser Bedienungsanleitung • The filter must only be used for the purpose as designated
vorgesehenen Einsatzfälle zur Aufbereitung von Druckluft in the instruction manual to upgrading the compressed air.
verwendet werden.
• To obtain maximum efficiency and operation of the filter/ -
• Der einwandfreie und sichere Betrieb der Produkte erfordert system ensure all sections of the manual are read
sachgerechten Transport, Lagerung, Aufstellung und Mon- carefully.
tage, sowie sorgfältige Bedienung und Instandhaltung.
2.2 Sicherheitsregeln 2.2 Safety rules
Warnung! Warning!
• Die Filter dürfen nur von qualifiziertem Personal genutzt, • The filter/ -system must only be used, operated, inspected
bedient, gewartet oder instandgesetzt werden. and repaired by trained personnel.
• Qualifiziertes Personal im Sinne der sicherheitsbezogenen • Trained personnel are defined as follws:
Hinweise in dieser Dokumentation oder auf dem Produkt
selbst, ist Personal das: ∗ Operating staff who are skilled in the field of compressed air
engineering and who are familiar with the filter/ -system and
∗ im Umgang mit Einrichtungen der Druckluft vertraut und un- possible dangers in unauthorised operation or service.
terwiesen sowie über die damit verbundenen Gefahren un-
terrichtet ist. ∗ Who can interpret and action the contents of this operation
instruction manual.
∗ Den auf die Bedienung bezogenen Inhalt dieser Dokumen-
tation kennt. ∗ Who have had the appropriate training and qualified as being
competent in these fields.
∗ Es besitzt als solches eine zur Inbetriebnahme und War-
tung derartiger Einrichtungen befähigende Ausbildung bzw.
Berechtigung.
F0507 05.03.07 KC 05.03.07 KC F0412

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FI HANK-MOB_02 D E

344 M100 No.: 9_6999 23 USE
13 Annex
2. Sicherheitsregeln, 2. Safety rules,

Warnhinweise warnings
2.3 Warnhinweise 2.3 Security-warnings
Warnung! Warning!
Das (die) Filter beinhalten unter erhöhtem Druck stehende The filter/ -system contains components under high pressure.
Systeme. Before starting any service work turn off compressed air
Vor Servicearbeiten sind sie drucklos zu machen. supply to the dryer and depressurise the system.
Warnung! Warning!
Filtersysteme mit elektrisch gesteuerten Kondensatableitern The filter/ -systems with electrical condensate discharger
enthalten unter elektrischer Spannung stehende Bauteile. contains components that are electrically live and which can
Vor Servicearbeiten sind diese allpolig vom elektrischen cause danger to life.
Spannungsversorgungsnetz zu trennen. Before starting any service work ensure all power is isolated
(Netzstecker ziehen, Hauptschalter ausschalten) from the filter/ -system, mains isolator to be off, mains plug if
fitted to be removed.
ACHTUNG!
Alle Arbeiten am elektrischen System dürfen nur von ATTENTION!
elektrotechnisch geschultem Fachpersonal, oder unter Any electrical work on the dryer must only be carried
Aufsicht von diesem, durch Unterwiesene ausgeführt out by skilled staff - qualified electricians, or persons
werden. under supervision of qualified staff.
Hinweis! Remark!
Die Filter sind ausschließlich zur Aufbereitung von Druckluft Use filter for compressed air applications only.
einzusetzen.
ACHTUNG! Attention!
Die Verwendung in Verbindung mit brennbaren Gasen The use of combustible gases is prohibited.
ist verboten!
ACHTUNG! ATTENTION!
Filter/ -systeme zur Aufbereitung von Atemluft dürfen nur nach Filter/ -systems for breathing air applications must be
Genehmigung des Herstellers der Filter/ -systeme eingesetzt approved from manufacturer.
und betrieben werden.
F0507 05.03.07 KC 05.03.07 KC F0412

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FI HANK-MOB_02 D E

No.: 9_6999 23 USE M100 345
346
MODELL BEZEICHNUNG / Volumenstrom Anschluß Betriebsduck Abmessungen Gewicht AUSTAUSCH-FILTERELEMENTE
MODEL DESIGNATION Capacity Connection Working Dimensions Weight FILTER REPLACEMENT CARTRIDGE
Pressure
FILTER- FILTER- Höhe / Breite / FILTER- FILTER- Anzahl
GRAD / GRADE GEHÄUSE / Hight Width GRAD / GRADE GEHÄUSE / Quantity
HOUSING [m³/min] [] [max] [mm] [mm] [kg] HOUSING
13
MODUL-BAUWEISE / MODULAR SYSTEM

13.7
M100
-6 0,58 3/8“ 16 105 -6 1
-10 1,00 1/2“ 16 siehe 105 -10 1
FA -18 1,75 1/2“ 16 Kapitel 105 siehe Kapitel E-A- -18 1
-28 2,83 3/4“ 16 „Maßzeich- 133 „Maßzeichnung -28 1
FB -48 4,83 1“ 16 nung 133 E-B- -48 1
Operator Manual
-71 7,10 1-1/2“ 16 164 see chapter -71 1
Annex
FC -107 10,7 1-1/2“ 16 see chapter 164 „dimensional E-C- -107 1

-138 13,8 2 16 „dimensional 194 drawing“ -138 1
FD -177 17,7 2-1/2“ 16 drawing“ 194 E-D- -177 1
-221 22,1 2-1/2“ 13 194 -221 1
FE BEHÄLTER-BAUWEISE / PRESSURE VESSEL E-E-
3. Technische Daten
-185 18,5 DN80 16 1025 350 -185 1

FF -283 28,3 DN80 16 1045 400 siehe Kapitel E-F- -283 2
-354 35,4 DN80 16 1045 400 „Maßzeichnung -185 2
Screw Compressor
FG -526 52,6 DN100 16 1085 440 E-G- -185 3
-708 70,8 DN100 16 1105 535 see chapter -185 4
-885 88,5 DN100 16 1105 535 „dimensional -185 5
142 DN150 16 1215 600 drawing“ 8
- 10 -
-1420 -185
-1950 195 DN150 16 1245 720 -185 11
-2480 248 DN150 16 1245 750 -185 14
• Volumenstrom m³/h bezogen auf +20°C und 1 bar absol ut, bei Betriebsüberdruck 7 bar / Air flow m³/h based on +20°C and 1 bar absolute, at working pressure 7 bar
• Größere Betriebsdrücke auf Anfrage / Contact factory for dryers with a higher working pressure
• Filtergehäuse F-185 – F-2480: Konstruktion der Behälter entspricht der EG-Richtlinie 87/404/EEC für einfache Druckbehälter und ist mit CE-Zeichen versehen /
Filter bowls F-185 – F-2480: Vessel construction complies with directive 87/404/EEC, simple pressure vessels, and is marked with the EC symbol
F0507
Volumenstrom - Korrekturtabelle / Sizing
D-Name
Minimaler Betriebsdruck / Minimum working pressure
erstellt
bar 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Korrekturfaktor / Correction factor 0,38 0,52 0,63 0,75 0,88 1,00 1,13 1,26 1,38 1,52 1,65 1,76 1,87 2 2,14
05.03.07 KC
Name
Auslegung
Bei Drücken abweichend von 7 bar berechnet sich der max. Volumenstrom wie folgt:
gepr.
den Korrekturfaktor des entsprechenden minimalen Betriebsdruckes mit dem gewählten Volumenstrom aus o.g. Tabelle multiplizieren.
Based on
To find the maximum flow at pressures other than 7 bar:
05.03.07 KC
3. Technical data
Name
multiply the flow (from table above) by the correction factor corresponding to the minimum working pressure of the filter.
Operating instructions for compressed air filter (combination filter)
F0412
Betriebsbedingungen: Working conditions:
ersetzt f.
Min. Betriebstemperatur: +1°C Min. Working temperature: +1°C
Max. Betriebstemperatur: 66°C. Max. Working temperature: 66°C
Min. Betriebsdruck mit automatischem Kondensatableiter: 2,0 bar Min. working pressure with automatic condensate drain: 2,0 bar
ersetzt d.
FI HANK-MOB_02 D E
No.: 9_6999 23 USE

13 Annex
4. Funktionsbeschreibung 4. Description of operation
4.3 Serie FC 4.3 Series FC

1-MIKRON-COALESCING-FILTER 1-MICRON-COALESCING-FILTER
• Zweistufige Tiefenfiltration bewirkt hervorragende Leistung • Two in-depth filter beds offer superior performance and ex-
und höhere Standzeiten des Filterelementes tended cartridge life
• Entfernt 100% des Kondensats • Removes 100% of liquid water
• Entfernt Feststoffpartikel bis herunter zu 1 Mikron • Removes solid particles down to 1 micron
• Restölgehalt < 1 ppm w/w • Oil content < 1 ppm w/w
• Automatischer Kondensatableiter • Automatic condensate drain
• Differenzdruckanzeige am Filtergehäuse • Differential pressure indicater at the filter housing
• max. Flüssigkeitsbeladung: 2g/m³ • max. liquid load: 2g/m³
Anwendungen: Application:
• Allgemeine Filter für Werkstattluft • General filter for shop air
• Vorfilter für Hochleistungsfilter • Prefilter for high efficiency filters
• Nachfilter für Adsorptionstrockner • Afterfilter for pressure-swing desiccant dryers
• Endstellenfiltration bei Einsatz von Nachkühlern oder • Point-of-use filter on systems utilising aftercoolers or dryers
Trocknern
Funktion: Operation:
Die Luft tritt von oben in das Filterelement FC ein und strömt radial Air enters the inside of the cartridge FC and flows outwardly
durch den perforierten inneren Stützmantel zur 1. Filtrationsstufe. through two in-depth beds of glass fibres. Larger particles are
Diese Stufe besteht aus mehreren Lagen Glasfiber und einer stüt- collected in the first bed while all remaining particles one micron
zenden Glasfasermatte. Gröbere Feststoffteilchen werden hier zu- and larger are collected in the second bed. A combination of large
rückgehalten. Die Luft gelangt nun in die 2. Filtrationsstufe, beste- void areas and stabilized media allows heavy particulate loading
hend aus einer mehrlagigen Mischung von imprägnierten Glasfa- and low pressure drop resulting in a long service life for the
sern und Mikrofibern. In beiden Stufen werden Feststoffpartikel und cartridge. Throughout both stages, liquid aerosols are captured
Flüssigkeiten nach dem Prinzip der Tiefenfiltration sowie des and coalesced. The coalesced liquids then drain to the bottom of
Coalescings ausgefiltert. Die Luft tritt durch den perforierten äuße- the cartridge for removal.
ren Stützmantel aus.
F0507 05.03.07 KC 05.03.07 KC F0412

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FI HANK-MOB_02 D E

No.: 9_6999 23 USE M100 347
13 Annex
4. Funktionsbeschreibung 4. Description of operation
4.5 Serie FE 4.5 Series FE

0,01-MIKRON-COALESCING-FILTER 0,01-MICRON-COALESCING-FILTER
(bei 0,01 ppm w/w max. Ölgehalt) (at 0,01 ppm w/w max. oil content)
DUO-System Abscheidung DUO-system separation

1. Stufe: flüssige Bestandteile 1. Stage: liquid particles
2. Stufe: Ölbestandteile 2. Stage: oil particles
• Entfernt mehr als 99,99% der Öl-Aerosole • Removes more than 99,99% of oil aerosols
• Entfernt Feststoffpartikel bis herunter zu 0,01 Mikron • Removes solid particles down to 0,01 microns
• Restölgehalt < 0,01 ppm w/w • Oil content < 0,01 ppm w/w
• Automatischer Kondensatableiter • Automatic condensate drain
• Differenzdruckanzeige am Filtergehäuse • Differential pressure indicater at the filter housing
• max. Flüssigkeitsbeladung: 1g/m³ • max. liquid load: 1g/m³
Anwendungen: Application:
• Vorfilter für Membrantrockner • Prefilter for membrane dryers
• Vorfilter für Adsorptionstrockner • Prefilter for pressure-swing desiccant dryers
• Endstellenfiltration (falls geringfügige Feuchtigkeit vorhan- • Point-of-use filter (may be used if light liquid load is present)
den ist)
Funktion: Operation:
Die Luft tritt von oben in das Filterelement FE ein und strömt durch Air enters the inside of the cartridge FE and flows through an
den inneren Stützmantel, radial durch verschiedenartige Lagen Fiber- inner foam sleeve, radially outward through various layers of
glas. Dann strömt die Luft durch ein weiteres Sieb. In dieser 1. glass fibers. Then the air flows through another screen. In the
Filtrationsstufe werden größere Partikel entfernt. In der zweiten first stage filter section the larger solid particles are trapped. In
Filtrationsstufe werden Aerosole und feste Bestandteile durch eine the second stage filter section aerosols and solid particles are
Mehrschicht-Membranwand aus epoxidharz verstärktem Fiberglas trapped using a multi-layered membrane wall made of epoxy
gefiltert, daß speziell für feinste Aerosole geeignet ist. Das Filter- resin-reinforced glass fibres which was especially designed for
medium ist ein Bett aus submikrofeinen Glasfasern und wirkt nach the finest aerosols.
dem Prinzip des Coalescings sowie der Tiefenfiltration. Der innere The filter media is a bed of submicronic glass fibers and works to
Schaumstoffmantel gleicht Luftschwankungen und Aerosolkon- the principle of coalescing and in-depth filtration. The inner foam
zentrationen aus und gewährleistet eine gleichmäßige Vertei- sleeve compensates air cycling and aerosol concentrations and
lung. Im äußeren Schaumstoffmantel werden die Öltröpfchen maintains uniform distribution. The outer foam sleeve collects the
gesammelt, fließen durch Schwerkraft in den unteren Teil des coalesced oil droplets which then, due to gravity, travel
Filters und tropfen dann in den Filterbehälter ab. downstream to the bottom of the sleeve and drain to the bottom
of the filter bowl.
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FI HANK-MOB_02 D E

348 M100 No.: 9_6999 23 USE
13 Annex
7. Montage 7. Mounting
7.1 Montageort 7.1 Location of mounting

Das Filter/ -system sollte in einem trockenen, frostfreien Innenraum The filter/ -system should be installed in a dry and frost-proof room
installiert werden. indoors.
Zur Wartung ist genügend Freiraum vorzusehen. Ample free, space should be allowed for the maintenance.
7.2 Montage 7.2 Mounting

Das Filter/ -system ist senkrecht so zu montieren, daß der Druckluft- Mount the filter/ -system so that inlet and outlet connections are
ein- und austritt waagerecht erfolgt. horizontal (filter bowl vertical).
Im Filtergehäuse eingebaute Filterelemente können sich während Cartridges installed in the filter housing may become dislodged during
des Transportes lösen. transport.
Prüfen Sie den richtigen Sitz der Filterelemente vor der Inbetrieb- Make sure that the cartidge is correctly installed before use.
nahme.
ACHTUNG! ATTENTION!
Achten Sie bei der Montage darauf, daß keine Zug- und When installing the filter/ -system ensure all
Druckkräfte auf die Geräteanschlüsse übertragen connections are even and no pressure is placed on
werden. inlet and outlet connections.
Hinweis! Remark!
Bei den Standard-Filtern FB, FC, FE und FF der Größe By the standard-filter FB,FC,FE and FF with the size
-185 & -283 ... -2480, den D-Pack-Basic-Filtern FB, FC, -185 & -283 ... -2480, by the D-pack-basic-filter FB, FC,
FE und FF, sowie den E-Pack-Filtern FA, FB, FC, FE FE, FF and by the E-pack-filter FA, FB, FC, FE and FF
und FF sind die Kondensatableiter beigepackt und the condensate drains are attached and must
müssen wie in Kapitel 11. „Maßzeichnung“ ange- mount as shown in chapter 11. „Dimensional
baut werden. drawing“.
7.3 Anschluß an das Druckluftnetz

7.3 Connection to the compressed air system
Die Druckluftein und -austrittsleitung sollte für Servicezwecke
mit einem Bypass versehen werden. The compressed air inlet and outlet line should be equipped with
Die Dimensionierung der Anschlüsse entnehmen Sie bitte dem a by-pass system for the maintenance.
Kapitel 3. „Technische Daten“. For the sizing of the connections please see chapter 3. „Technical
data“.
ACHTUNG!
Durchflußrichtung beachten. ATTENTION!
Druckluftein- und austritt dürfen nicht vertauscht Pay attention to the flow direction.
werden. Do not exchange the compressed air inlet and outlet.
7.4 Kondensatableitung
7.4 Condensate drain
Für die automatische Kondensatableitung ist bei den Filtern (FA,
FB, FC, FE, FF) ein Anschluß vorhanden. The filters (FA, FB, FC, FE, FF) are equipped with one connection
Die Dimensionierung des Anschlusses entnehmen Sie bitte for the automatically condensate drain.
Kapitel 5. „Kondensatableiter“. For the sizing of the connection please see chapter
5. „Condensate discharger“.
Achten Sie bei der Montage der Kondensatableitung

darauf, daß das abgeschiedene Kondensat ungehindert When fitting the drains please see to it, that the
abfließen kann. condensate separated is drained off into a system that
does not create a back pressure.
HINWEIS!
Bei der Entsorgung des Kondensats ist der Schmutzan- Instruction!
teil zu berücksichtigen. When disposing of the condensate the amount of
Beachten Sie die jeweils geltenden gesetzlichen Vor- pollution has to be taken into consideration. Please act
schriften. according to the prevailing regulations of law.
Bei den Filtern FD, FG entfällt der Kondensatableitungsanschluß. Condensate drain does not exist in filters FD, FG.
F0507 05.03.07 KC 05.03.07 KC F0412

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FI HANK-MOB_02 D E

No.: 9_6999 23 USE M100 349
13 Annex
8. Inbetriebnahme, Betrieb 8. Start-up, operation
8.1 Bereitschaft zur Inbetriebnahme 8.1 Preconditions for starting the dryer
Druckluftfilter/ -systeme sind bereit zur The filter/ -system is ready for starting when:
Inbetriebnahme, wenn:
• Der auf dem Typenschild angegebene Druck dem maxima- • Check unit serial number tag to verify working pressure.
len Betriebsdruck entspricht.
• They has been installed in accordance with section 7.
• Sie entsprechend Kapitel 7. „Montage“ installiert wurden. „Mounting“.
• Alle Zu- und Ableitungen sachgerecht angeschlossen sind. • All inlet and outlet lines have been correctly connected.
• Die erforderlichen Energien (Druckluft) verfügbar sind. • The required forms of energy (compressed-air) are available.
• Absperrorgane (z.B. Ventil, Kugelhahn) in der Druckluftein- • The shut-off devices (e.g. ball valve) in the compressed-air
und austrittsleitung geschlossen sind. inlet and outlet lines are closed.
• Kondensat durch die Kondensatableitung ungehindert ab- • The condensate is able to flow through the condensate
fließen kann. discharger without obstruction.
• Der elektrisch gesteuerte Kondensatableiter an das elektri- • The electrical condensate drain has been connected to the
sche Spannungsversorgungsnetz mit der richtigen Betriebs- electric power supply system with the correct operating
spannung angeschlossen ist. (Nur bei elektrisch gesteuer- voltage (only electrical condensate drains).
ten Kondensatableitern)
• The filter/ -system is equipped with the right cartridges.
• Das Filter/ -system mit den richtigen Filterelementen aus-
gerüstet ist.
8.2 Inbetriebnahme, Betrieb 8.2 Start up, operation
Vor der Inbetriebnahme ist sicherzustellen, daß Before starting the dryer, ensure that all the
alle Bedingungen des Abschnittes 8.1 „Bereitschaft requirements specified in section 8.1 „Precondi-
zur Inbetriebnahme“ erfüllt sind. tions for starting the dryer“ have been fulfilled.
Setzen Sie das Filter/ -system durch langsames Öffnen Place filter/ -system under pressure gradually by
der Drucklufteintritts- und austrittsleitung unter Druck. slowly opening the compressed air inlet/outlet.
Schließen Sie das Absperrorgan im Bypass

(falls vorhanden). Close the shut-off device in the bypass (if installed).
Das Filter/ -system ist nun in BETRIEB. The filter/ -system is now OPERATIVE.
F0507 05.03.07 KC 05.03.07 KC F0412

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FI HANK-MOB_02 D E

350 M100 No.: 9_6999 23 USE
13 Annex
8. Inbetriebnahme, Betrieb 8. Start-up, operation
8.3 Differenzdruckanzeige-Standard und 8.3 Differential pressure indicator-

D-Pack (OPTION) standard and D-Pack (OPTION)
Die Differenzdruckanzeige informiert als Störanzeige über eine The differential pressure indicator indicates atypical
atypische Verschmutzung. contamination.
Unabhängig von der Differenzdruckanzeige We recommend installing a new filter cartridge

müssen die Filterelemente gemäß der Wartungs- according to the maintenance periods. (See chapter
intervalle gewechselt werden. (Siehe Kapitel 9) 9)
The FG filter does not require a differential pressure

Das Filter FG benötigt keine Differenzdruckanzeige. gauge.
F0507 05.03.07 KC 05.03.07 KC F0412

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FI HANK-MOB_02 D E

No.: 9_6999 23 USE M100 351
13 Annex
9. Wartung 9. Servicing, filter cartridge

Austausch der Filterelemente replacement
9.1 Standzeit der Filterelemente 9.1 Serviceable life of cartridge

Die Standzeit der Filterelemente ist abhängig von der Beladung. Mit The cartridge’s serviceable life depends upon the degree of
steigender Beladung der Elemente erhöht sich der Differenzdruck contamination. As the cartridge becomes more contaminated,
über den Filter. the differential pressure above the filter increases.
Die Filterelemente müssen gemäß unten stehender Tabelle ge- The filterelements must be changed according to the table below.
wechselt werden.
9.2 Austausch der Filterelemente 9.2 Replacing the cartridge

Filtergehäuse -6 bis -221 Filter housing -6 to -221
Anzahl der Filterelemente siehe Kapitel 4. „Technische Daten“. Number of cartridges see chapter 4. „Technical data“.
WARNUNG! CAUTION!
• Verwenden Sie keine Werkzeuge! (Filtergehäuse -6 bis -48) • Do not use any tools (filter housings -6 to -48)
• Öffnen und Schließen Sie das Filter nicht mit Gewalt. • Do not force the filter open or closed.
• Das (die) Filter beinhaltet(n) unter erhöhtem Druck stehen- • The filter(s) contain(s) systems under high pressure.
de Systeme. All pressure must be let off before servicing.
Vor Servicearbeiten sind sie drucklos zu machen.
Close the shut-off device in the compressed air inlet/outlet.

Absperrvorrichtung im Druckluftein- und -austritt
schließen.
Loosen condensate drain hose at (1) (only on FB, FC, FE, FF
Kondensatableitungsschlauch an (1) lösen. models).
(Nur bei FB, FC, FE, FF).
Slowly turn the knurled screw (1) clockwise. This will release
Rändelschraube (1) langsam im Uhrzeigersinn lösen. the air from the housing.
Das Filtergehäuse wird entlüftet.
Wartungsintervalle / Maintenance-intervals
Wartungsteil
Anwendung Wartungs-Intervall
Part of Type
Application Maintenance-interval
maintenance
Vorfilter 6.000 Bh, max. 1 Jahr /

FB, FC
Pre-filter 6.000 Bh, max. 1 year
3.000 Bh, max. 1 Jahr/

FE, FF Microfilter
3.000 Bh, max. 1 year
3.000 Bh, max. 1 Jahr (Type FE)

3.000 Bh, max. 1 year Type (FE)
FEG
Filter-Elemente / Filterkombination 1.000 Bh, max. 1 Jahr (Type FG)
filter car tridges Filter combination 1.000 Bh, max. 1 year Type (FG)
1.000 Bh, max. 1 Jahr/

FFG
1.000 Bh, max. 1 year
Nachfilter 6.000 Bh, max. 1 Jahr/

FD
After-filter 6.000 Bh, max. 1 year
Aktivkohlefilter
FG 1.000 Bh
Act.carbon filter
Vorfilter
Service-unit 6.000 Bh
Pre-filter 1
Kondensatableiter /
Service-unit Microfilter 6.000 Bh
condensate drain
Filterkombination
Service-unit 6.000 Bh
Filter combination
Bh = Kompressor-Betriebsstunden / Working hours
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FI HANK-MOB_02 D E

352 M100 No.: 9_6999 23 USE
13 Annex

Filtergehäuse entfernen. Remove housing.
• Filtergehäuse -6 bis -48 (Bajonett-Verschluß) • Housing -6 to -48 (bayonet-style head)

∗ Das Filtergehäuse nach oben, gegen den Filterkopf drük- ∗ Push housing upwards against the filter head.
ken. ∗ Then slowly turn the housing clockwise to the stop (about
∗ Dann das Filtergehäuse im Uhrzeigersinn langsam gegen 1/8 of a turn) and remove by pulling downwards.
den Anschlag drehen (etwa 1/8 Drehung) und nach unten
abziehen.
• Housing -71 to -221 (threaded head)
∗ Screw off the housing counter-clockwise (by hand or using
• Filtergehäuse -71 bis -221 (Gewinde-Verschluß) a filter wrench).
∗ Schrauben Sie das Filtergehäuse gegen den Uhrzeigersinn
(per Hand oder mit Hilfe eines Filterschlüssels) auf. Remove and replace cartridge as shown below.
Filterelement gemäß unten stehender Skizze abziehen, Please note: Do not touch the foam sleeves of the cartridges
bzw. wechseln. from the FE, FF and FG series with your fingers.
Hinweis: Die Schaumstoffummantelung der Re-assemble the housing in the reverse order.
Filterelemente Serie FE, FF und FG dürfen nicht mit den Fin-
gern angefaßt werden.
Place filter under pressure again by slowly opening the
Filtergehäuse in umgekehrter Reihenfolge shut-off device.
zusammenbauen.
Filter durch langsames Öffnen der Absperrvorrichtung

wieder mit Druck beaufschlagen.
Filtergehäuse -185 bis -2480 Housing -185 to -2480
Anzahl der Filterelemente siehe Kapitel 3. „Technische Daten“. Number of cartridges see chapter 3. „Technical data“.
WARNUNG! CAUTION!
• Das (die) Filter beinhaltet(n) unter erhöhtem Druck ste- • The filter(s) contain(s) systems under high pressure.
hende Systeme. Alle pressure must be let off before servicing
Vor Servicearbeiten sind sie drucklos zu machen.
F0507 05.03.07 KC 05.03.07 KC F0412

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FI HANK-MOB_02 D E

No.: 9_6999 23 USE M100 353
13 Annex

Absperrvorrichtung im Druckluftein- und -austritt Close shut-off device in compressed air inlet/outlet.
schließen.
Kondensatableitungsschlauch an (1) lösen. Loosen condensate drain hose at (1) (only on FB, FC, FE,
(Nur bei FB, FC, FE, FF). FF models).
Um das Filtergehäuse zu entlüften müssen Sie beim: Follow these steps to release the air from the housing:
- Kondensatableiter Nr. 30505 und Nr. 30506 die Entlüf- - for condensate drain no. 30505 and no. 30506, loosen
tungsschraube (3) entgegen dem Uhrzeigersinn lösen. the bleed screw (3) in counter-clockwise direction.
- FG den Kugelhahn (5) öffnen. - on FG models, open the ball valve (5).
Schrauben der Flanschverbindung am Boden des Gently loosen the screws at the bottom flange of the
Filtergehäuses vorsichtig lösen, da evtl. noch ein geringer housing. Caution is necessary as the system may still be
Restdruck im System vorhanden ist. under slight residual pressure.
Schrauben bis auf eine entfernen und Flansch zur Remove all screws except one and swing flange to the
Seite schwenken. side.
Filterelemente entgegen dem Uhrzeigersinn Screw out cartridge counter-clockwise.

herausschrauben.
Neue Filterelemente ohne Werkzeug „fingerfest“ Screw in new cartridge by hand until „handtight“.
einschrauben. Do not use a wrench.
Hinweis: Die Schaumstoffummantelung der Please note: Do not touch the foam sleeves of the
Filterelemente Serie FE, FF, FG dürfen nicht mit den Fingern cartridges from the FE, FF, FG series with your fingers.
angefaßt werden.
Close housing in reverse order.
Filtergehäuse in umgekehrter Reihenfolge schließen.
Place filter under pressure again by slowly opening the

Filter durch langsames Öffnen der Absperrvorrichtungen shut-off device.
wieder mit Druck beaufschlagen.
3
1
1 3
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354 M100 No.: 9_6999 23 USE
13 Annex

9.3 Austausch der 9.3 Changing of

Schwimmerableiter / Float drain /
ECO-DRAIN Service-unit / ECO-DRAIN Service-unit /
ECO-DRAIN Membransätze ECO-DRAIN membrane set
Die Kondensatableiter / Wartungspakete sind gemäß The condensate drains / service packages must be
unten aufgeführter Tabelle regelmäßig zu wechseln. changed according to the table below.
Wartungsteil Wartungs-Intervall
Part of maintenance Maintenance-interval
Schwimmer-Kondensatableiter/
3.000 Bh
Float drain
Ser vice-Unit
6.000 Bh
(ECO DRAIN 30/31)
ECO DRAIN Verschleißteilsatz

(ECO DRAIN 13/14)
6.000 Bh
ECO DRAIN wearing par t set
(ECO DRAIN 13/14)
Nähere Informationen finden Sie auch im Anhang ECO DRAIN. For more details please see annexe ECO DRAIN.
F0507 05.03.07 KC 05.03.07 KC F0412

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No.: 9_6999 23 USE M100 355
13 Annex
10. Garantiebedingungen 10. Guarantee conditions
10.1 Allgemeines 10.1 General

Die Garantie erstreckt sich, im Rahmen unserer allgemeinen Liefer- The guarantee covers the delivered device with regard to our general
bedingungen, auf das gelieferte Filter/-system. terms of delivery.
10.2 Garantieausschluß 10.2 Exclusion from guarantee coverage

Garantieansprüche bestehen nicht, No guarantee claims shall be assertible,
• wenn das Filter/ -system durch Einfluß höherer Gewalt oder • if the filter/ -system is damaged or destroyed due to force
durch Umwelteinflüsse beschädigt oder zerstört wird. majeurs or environmental effects.
• bei Schäden, die durch unsachgemäße Behandlung, ins- • for damage resulting from incorrect handling, in particular
besondere Nichtbeachtung der Betriebs- und Wartungsan- failure to comply with the operating and maintenance
leitung aufgetreten sind (regelmäßige Kontrolle des instructions (regular inspection of the condensate
Kondensatableiters / regelmäßiger Wechsel der Filter- discharger, regular change of the filter cartridges).
elemente).
• if the filter/ -system has not been used in accordance with
• falls das Filter/ -system nicht seinen Bestimmungen ent- its specifications (see section 3. „Technical data“).
sprechend eingesetzt war (siehe Kapitel 3. „Technische
Daten“). • if the filter/ -system has been opened or repaired by
workshops or other persons unauthorised for this purpose
• falls das Filter/ -system durch nicht hierfür autorisierte Werk- and/or reveals any type of mechanical damage.
stätten oder andere Personen unsachgemäß geöffnet oder
repariert wurde und/oder mechanische Beschädigungen
irgendwelcher Art aufweist.
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356 M100 No.: 9_6999 23 USE
13 Annex
13.8 Operating instructions for compressed air filter (fresh air filter)
13.8 Option dc
Operating instructions for compressed air filter (fresh air filter)

No.: 9_6999 23 USE M100 357
13 Annex
dh
domnick hunter
AC010 - AC030
Original Language EN OIL VAPOUR & ODOUR REMOVAL FILTERS
NL OLIEDAMP & GEUR VERWIJDERINGSFILTERS DE FILTER ZUM ENTFERNEN VON ÖLNEBEL UND GERÜCHEN
FR FILTRES D'ÉLIMINATION DES ODEURS ET DES VAPEURS D'HUILE FI ÖLJYHÖYRYN JA HAJUN POISTOSUODATTIMET
SV FILTER FÖR AVLÄGSNING AV OLJEÅNGOR OCH LUKT NO OLJEDAMP- OG OLJELUKTFJERNINGSFILTRE
DA FILTER FÖR AVLÄGSNING AV OLJEÅNGOR OCH LUKT EL ΦΙΛΤΡΑ ΑΦΑΙΡΕΣΗΣ ΑΤΜΩΝ & ΟΣΜΩΝ ΛΑ∆ΙΟΥ
ES FILTROS DE ELIMINACIÓN DE OLORES Y VAPORES DE ACEITE PT VAPOR DO ÓLEO E FILTROS DE REMOÇÃO DOS CHEIROS
IT FILTRI PER L'ELIMINAZIONE DEGLI ODORI E DEI VAPORI D'OLIO PL FILTRY DO USUWANIA OPARÓW I ZAPACHU OLEJU
SK FILTRE NA ODSTRAŇOVANIE OLEJOVÝCH VÝPAROV A ZÁPACHU CS OLEJOVÉ A PROTIPACHOVÉ FILTRY
ET ÕLISUDU JA -HAISU EEMALDUSFILTRID HU OLAJGŐZ- ÉS SZAGELTÁVOLÍTÓ SZŰRŐK
LV EĻĻAS TVAIKU UN AROMĀTA NOVĒRŠANAS FILTRI LT ALYVOS GARŲ IR KVAPO ŠALINIMO FILTRAI
RU ФИЛЬТРЫ ДЛЯ УСТРАНЕНИЯ ЗАПАХА И ПАРОВ МАСЛА SL FILTRI ZA ODSTRANJEVANJE OLJNIH HLAPOV IN VONJAV
TR YAĞ BUHARI VE KOKUSU GİDERİCİ FİLTRELER MT FILTRI LI JNE{{U L-FWAR TA}-}JUT U L-IRWEJJA{
1 FILTER-DH-OIL-XEVOLUTION 01

358 M100 No.: 9_6999 23 USE
13 Annex

No.: 9_6999 23 USE M100 359
13 Annex
AC010 - AC030
• Highlights actions or procedures, which if not performed correctly, may lead to personal injury or death.
• Benadrukt de acties of procedures die, indien niet juist uitgevoerd, lichamelijk letsel of de dood kunnen veroorzaken.
• Weist auf Aktionen oder Verfahren hin, die bei fehlerhafter Durchführung zu Verletzungen und tödlichen Unfällen führen können.
• Met en relief les actions ou procédures qui, si elles ne sont pas exécutées correctement, peuvent entraîner des dommages
corporels ou la mort.
Warning • Osoittaa toimenpiteitä tai menettelytapoja, jotka väärin suoritettuina saattavat aiheuttaa henkilövahingon tai kuoleman.
• Anger åtgärder och metoder som kan orsaka personskador eller dödsfall om de inte utförs korrekt.
• Fremhever handlinger eller prosedyrer som kan føre til personskade eller dødsfall hvis de ikke utføres på korrekt måte.
• Fremhæver handlinger eller fremgangsmåder, som kan medføre personskade eller dødsfald, hvis de ikke udføres korrekt.
• Επισηµαίνει τις ενέργειες ή τις διαδικασίες, οι οποίες αν δεν πραγµατοποιηθούν σωστά, µπορεί να οδηγήσουν σε
τραυµατισµ( προσωπικού ή σε θάνατο
• Destaca acciones o procedimientos que, de no realizarse correctamente, pueden ocasionar daños personales o la muerte.
• Realça as acções ou procedimentos que, se não forem executados correctamente, poderão provocar danos pessoais ou morte.
• Segnala azioni o procedure che, se non eseguite correttamente, comportano il rischio di infortuni o morte.
• Wskazuje działania i procedury, które w razie niewłaściwego wykonania mogą prowadzić do obrażeń ciała lub śmierci.
• Zvýrazňuje činnosti alebo postupy, ktoré môžu v prípade nesprávneho vykonania viesť zraneniu alebo usmrteniu.
• Upozornění na činnosti nebo postupy, jejichž nesprávné provádění může vést ke zranění nebo usmrcení osob.
• Tõstab esile toimingud või protseduurid, mis väära teostamise korral võivad põhjustada kehavigastusi või surma.
• Olyan műveleteket vagy eljárásokat jelöl, amelyek nem megfelelő módon történő végrehajtása súlyos vagy végzetes személyi
sérülést okozhat.
• Uzsver darbības vai procedūras, kuru rezultātā, ja tās neveic pareizi, var izraisīt ievainojumus vai nāvi.
• Žymi veiksmus ar procedūras, kuriuos atlikus neteisingai, galima susižeisti ar mirti.
• Указывает на действия, ненадлежащее выполнение которых может привести к нанесению вреда здоровью или
смерти
• Označuje dejanja ali postopke, ki lahko ob nepravilnem izvajanju poškodujejo človeka ali povzročijo smrt.
• Doğru bir şekilde yerine getirilmediği takdirde bu ürüne hasar verebilecek işlem ve süreçleri vurgular.
• Tissottolinea l-azzjonijiet jew il-pro/eduri, li jekk ma jsirux kif suppost, jista’ jkun hemm korriment jew mewt
• Highlights actions or procedures, which if not performed correctly, may lead to damage to this product.
• Benadrukt de acties of procedures die, indien niet juist uitgevoerd, schade kunnen berokkenen aan dit product.
• Weist auf Aktionen oder Verfahren hin, die bei fehlerhafter Durchführung zu Schäden am Gerät führen können.
• Met en relief les actions ou procédures qui, si elles ne sont pas exécutées correctement, peuvent endommager ce produit.
• Osoittaa toimenpiteitä tai menettelytapoja, jotka väärin suoritettuina saattavat vaurioittaa tätä laitetta.
Caution • Anger åtgärder och metoder som kan orsaka skador på den här produkten om de inte utförs korrekt.
• Fremhever handlinger eller prosedyrer som kan føre til skade på produktet hvis de ikke utføres på korrekt måte.
• Fremhæver handlinger eller fremgangsmåder, som kan medføre beskadigelse af dette produkt, hvis de ikke udføres korrekt.
• Επισηµαίνει τις ενέργειες ή τις διαδικασίες, οι οποίες αν δεν πραγµατοποιηθούν σωστά, µπορεί να προκαλέσουν
ζηµιά στο προϊ(ν αυτ(
• Destaca acciones o procedimientos que, de no realizarse correctamente, pueden ocasionar el deterioro del producto.
• Realça as acções ou procedimentos que, se não forem executados correctamente, poderão danificar este produto.
• Segnala azioni o procedure che, se non eseguite correttamente, comportano il rischio di danneggiare il prodotto.
• Wskazuje działania i procedury, które w razie niewłaściwego wykonania mogą powodować uszkodzenie produktu.
• Zvýrazňuje činnosti alebo postupy, ktoré v prípade nesprávneho vykonania môžu viesť k poškodeniu tohto výrobku.
• Upozornění na činnosti nebo postupy, jejichž nesprávné provádění může vést k poškození tohoto výrobku.
• Tõstab esile toimingud või protseduurid, mis väära teostamise korral võivad käesolevat toodet kahjustada.
• Olyan műveleteket vagy eljárásokat jelöl, amelyek nem megfelelő módon történő végrehajtása a termék károsodásához
vezethet.
• Uzsver darbības vai procedűras, kuru rezultātā, ja tās neveic pareizi, var sabojāt šo izstrādājumu.
• Žymi veiksmus ar procedūras, kuriuos atlikus neteisingai, galima sugadinti šį gaminį.
• Указывает на действия, ненадлежащее выполнение которых может привести к повреждениям данного изделия
• Označuje dejanja ali postopke, ki lahko ob nepravilnem izvajanju poškodujejo izdelek.
• Doğru bir şekilde yerine getirilmediği takdirde yaralanma ya da ölüme yol açabilecek işlem ve süreçleri vurgular
• Tissottolinea l-azzjonijiet jew il-pro/eduri, li jekk ma jsirux kif suppost, tista’ ssir [sara lil dan il prodott
• Suitable gloves must be worn. • Altijd geschikte handschoenen dragen.
• Geeignete Schutzhandschuhe tragen. • Le port de gants adaptés est obligatoire.
• Käytettävä asianmukaisia käsineitä. • Använd lämpliga handskar.
• Bruk egnede hansker. • Der skal anvendes egnede handsker.
• Απαιτείται να φοράτε κατάλληλα γάντια • Se deben llevar puestos guantes apropiados.
• Devem ser utilizadas luvas adequadas. • Indossare guanti di protezione.
• Należy zakładać odpowiednie rękawice • Je nutné použít vhodné rukavice.
• Kohustuslik kanda sobivaid kaitsekindaid • Viseljen megfelelő védőkesztyűt.
• Jāvalkā piemēroti cimdi. • Reikia mūvėti tinkamas pirštines.
• Работы должны проводиться в соответствующих перчатках • Uporabiti je treba ustrezne rokavice.
• Uygun eldiven giyilmelidir • G[andhom jintlibsu ingwanti adatti
• Highlights the requirements for disposing of used parts and waste.
• Benadrukt de vereisten voor het weggooien van gebruikte onderdelen en afval.
• Weist auf die Anforderungen zur Entsorgung gebrauchter Teile und Abfall hin.
• Met en relief les consignes de mise au rebut des pièces usagées et des déchets.
• Osoittaa käytettyjen osien ja jätteen hävittämistä koskevia vaatimuksia.
• Anger de krav som ställs på bortskaffande av gamla delar och avfall.
• Fremhever kravene for avhending av brukte deler og avfall.
• Fremhæver kravene til bortskaffelse af udtjente dele og affald.
• Επισηµαίνει τις απαιτήσεις απ(ρριψης των χρησιµοποιηµένων εξαρτηµάτων και των απορριµµάτων
• Destaca los requisitos para desechar las piezas usadas y los residuos.
• Realça os requisitos para eliminar as peças utilizadas e os desperdícios.
• Segnala i criteri per lo smaltimento di componenti usati e rifiuti.
• Wskazuje wymagania dotyczące usuwania zużytych części i odpadów.
• Zvýrazňuje požiadavky pre zneškodňovanie použitých dielov a odpadu.
• Upozornění na požadavky týkající se likvidace použitých dílů a odpadu.
• Tõstab esile kasutatud osade ja jääkide utiliseerimisele esitatavad nõuded
• A használt alkatrészek és a hulladék megfelelő módon történő elhelyezésére hívja fel a figyelmet.
• Uzsver prasības tam, kā atbrīvoties no lietotajām detaļām un atkritumiem.
• Žymi panaudotų dalių ir atliekų išmetimo reikalavimus.
• Указывает на требования по уничтожению использованных деталей и отходов
• Označuje zahteve za odlaganje rabljenih delov in odpadkov.
• Kullanılmış parçaların ve atıkların atılmasına ilişkin gereklilikleri vurgular
• Tissottolinea l-kundizzjonijiet biex wie[ed jarmi l-partijiet u]ati u l-iskart
1

360 M100 No.: 9_6999 23 USE
13 Annex
AC010 - AC030
• Pressure. • Druk • Druck. • Pression.
• Paine. • Tryck • Trykk • Tryk
• Πίεση • Presión. • Pressão. • Pressione.
• Ciśnienie • Tlak.. • Tlak. • Surve.
• Nyomás alatt. • Spiediens. • Slėgis. • Давление
• Tlak • Basınç • Pressjoni
• Release Pressure. • Druk aflaten. • Druck ablassen.
• Évacuation de pression. • Vapauta paine. • Tryckutsläpp.
• Avlast trykk • Aflast tryk • Εκτ(νωση πίεσης
• Despresurizar. • Liberta Pressão. • Scaricare la pressione.
• Ciśnienie spustowe • Uvoľnite tlak. • Uvolnění tlaku.
• Surve väljalase • Engedje ki a nyomást. • Pazeminiet spiedienu.
• Išleiskite slėgį. • Стравить давление • Sprostitev tlaka.
• Basıncı Kaldırın • Ne[[i l-pressjoni
• Replace every year • Elk jaar vervangen • Jährlich austauschen
• Remplacer tous les ans. • Vaihda vuosittain. • Byt varje år
• Skift ut hvert år • Udskift en gang om året • Αντικατάσταση κάθε χρ(νο
• Sustituir anualmente • Substituir todos os anos • Sostituire ogni anno
• Należy wymieniać raz w roku • Každý rok vymieňajte • Nutná výměna každý rok.
• Asendage igal aastal • Évente cserélje • Nomainiet reizi gadā
• Keiskite kartą per metus • Заменять каждый год. • Zamenjajte vsako leto.
• Her yıl değiştirin • Ibdel kull sena
• Filter housing / Model • Filterhuis / Model • Filtergehäuse / Modell
• Logement du filtre/modèle. • Suodatinkotelo/-malli • Filterhus/modell
• Filterhus/-modell • Filterhus/modell • Υποδοχή/µοντέλο φίλτρου
• Caja de filtro/modelo. • Caixa / Modelo do filtro • Corpo del filtro / Modello
• Obudowa filtra / model. • Kryt filtra / Model • Kryt filtru / Model
• Filtri korpus/mudel • Szűrőház / típus • Filtra korpuss / modelis
• Filtro korpusas / modelis • Корпус фильтра / модель • Ohišje filtra / Model
• Filtre muhafazası / Model • Kontenitur tal-filtru - Mudell
• High efficiency filter element • Zeer efficiënt filterelement
• Hochleistungsfilterelement • Cartouche filtrante haute efficacité.
• Tehokas suodatinelementti • Högeffektivt filterelement
• Høyeffektivt filterelement • Högeffektivt filterelement
• Φίλτρο υψηλής απ(δοσης • Elemento filtrante de gran eficiencia.
• Elemento do filtro de elevado rendimento • Elemento filtrante ad alta efficienza
• Wysokowydajny wkład filtra • Vysoko účinný filtračný článok
• Vysoce účinný filtrační prvek • Kõrgtootlik filterelement
• Nagy hatékonyságú szűrőelem • Augstas produktivitātes filtra elements
• Labai efektyvus filtravimo elementas • Высокоэффективный фильтрующий элемент
• Visoko učinkovit filtrirni element • Yüksek etkinlikli filtre öğesi
• Element tal-filtru b’effi/jenza kbira
• Adsorption filter cartridge - Granular carbon • Adsorptiefilter cartridge - korrelvormige actieve kool
• Adsorptionsfiltereinsatz - Granulatkohle • Cartouche filtrante d'adsorption - Charbon en granulés.
• Adsorptiosuodatinelementti – rakeinen hiili • Adsorptionsfilterkassett – Kornigt kol
• Adsorpsjonsfilterpatron – Karbon i kornform • Adsorptionsfilterkassett – Kornigt kol
• Φυσίγγιο φίλτρου προσρ(φησης - Κοκκώδης άνθρακας • Cartucho filtrante de adsorción, gránulos de carbón.
• Cartucho do filtro de absorção - Carvão granular • Filtro a cartuccia ad adsorbimento - granuli di carbone
• Adsorpcyjny wkład filtrujący z węgla ziarnistego • Adsorpčná filtračná kazeta – Granulovaný uhlík
• Adsorpční filtrační prvek – granulovaný uhlík • Adsorptsioonfiltri kassett – teraline süsi
• Adszorpciós szűrőbetét – granulált szén • Absorbējoša filtra kasetne – graudains ogleklis
• Adsorbcinio filtro kasetė – anglies granulės • Адсорбционный фильтрующий элемент –
гранулированный уголь
• Kaseta adsorpcijskega filtra – zrnasti ogljik • Adsorpsiyon filtresi kartuşu – Taneli karbon
• Kaxxa assorbenti tal-filtru – Karbonju mrammel
• Adsorption filter element - Wrapped carbon cloth
• Adsorptie filterelement - gewikkelde koolstofdoek
• Adsorptionsfilterelement - eingewickeltes Filtertuch aus Kohlenstoff
• Cartouche filtrante d'adsorption - Charbon entouré de tissu.
• Adsorptiosuodatinelementti – kääritty hiilikangas
• Adsorptionsfilterelement – Veckad kolfiberduk
• Adsorpsjonsfilterelement – Innpakket karbonstoff
• Adsorptionsfilterelement – Veckad kolfiberduk
• Φίλτρο προσρ(φησης - Τυλιγµένο ύφασµα άνθρακα
• Elemento filtrante de adsorción, capas de tejido de carbón.
• Elemento do filtro de absorção - Pano revestido de carvão
• Elemento filtrante ad adsorbimento - tessuto al carbone con struttura ad avvolgimento
• Wkład adsorpcyjny filtra ze zwijanej tkaniny z włókna węglowego
• Adsorpčný filtračný článok – Zabalená uhlíková tkanina
• Adsorpční filtrační prvek – zabalená uhlíková tkanina
• Adsorptsioonfiltri element – isoleeritud süsinikriie
• Adszorpciós szűrőelem – göngyölt szénszövet
• Absorbējošs filtra elements – satīta oglekļa drāniņa
• Adsorbcinis filtravimo elementas – susuktas anglies audinys
• Адсорбционный фильтрующий элемент – ткань из углеродистого волокна
• Adsorpcijski filtrirni element – navita ogljikova krpa
• Adsorpsiyon filtresi öğesi - Sarılı karbon kumaş
• Element tal-filtru li jassorbixxi - Xoqqa tal-karbonju mge]wra
• Ensure coorrect tool is used
• Zorg dat het juiste gereedschap wordt gebruik • Stellen Sie sicher, dass Sie das richtige Werkzeug
verwenden.
• Vérifier que les outils adéquats sont utilisés. • Käytettävä oikeaa työkalua
• Se till att rätt verktyg används. • Pass på at korrekt verktøy brukes
• Sørg for at benytte korrekt værktøj • Βεβαιωθείτε (τι χρησιµοποιείται το σωστ( εργαλείο
• Asegúrese de que se utiliza la herramienta adecuada • Certifique-se de que é utilizada a ferramenta correcta
• Assicurarsi di utilizzare l'utensile corretto • Należy używać odpowiedniego narzędzia.
• Uistite sa, že používate správny nástroj • Zkontrolujte použití správného nástroje
• Tagage õige tööriista kasutamine • Mindig a célnak megfelelő szerszámot használja
• Izmantojiet tikai atbilstošus darbarīkus • Įsitikinkite, kad naudojamas reikiamas įrankis
• Убедитесь, что используется правильный инструмент • Poskrbite, da boste uporabili ustrezno orodje
• Doğru alet kullanılmasını sağlayın • Kun ]gur li tintu]a l-g[odda t-tajba
2

No.: 9_6999 23 USE M100 361
13 Annex
AC010 - AC030
Warning!
This product must be installed and maintained by competent and authorised personnel only, under strict observance of these operating instructions,
any relevant standards and legal requirements where appropriate.
Retain this user guide for future reference
Waarschuwing!
Dit product mag alleen geïnstalleerd en onderhouden worden door deskundig en bevoegd personeel met strikte inachtneming van deze
bedieningsinstructies en de betreffende normen en wettelijke vereisten indien van toepassing.
Bewaar deze handleiding als naslag.
Warnung!
Das Produkt darf ausschließlich von autorisiertem Fachpersonal unter strikter Befolgung dieser Betriebsanleitung, ggf. relevanter Normen sowie
gesetzlicher Vorschriften installiert und gewartet werden.
Bewahren Sie die Bedienungsanleitung zu Referenzzwecken auf.
Attention !
Ce produit doit être installé et entretenu exclusivement par un personnel compétent et autorisé, dans le respect le plus strict de ce mode d’emploi
et des normes applicables et exigences légales éventuelles.
Conserver ce guide de l’utilisateur à titre de référence future
Varoitus!
Tämän tuotteen saa asentaa ja huoltaa vain pätevä ja valtuutettu henkilöstö, noudattaen tarkasti näitä käyttöohjeita, kaikkia asiaankuuluvia normeja
ja tarpeen vaatiessa lain asettamia vaatimuksia.
Säilytä tämä käyttöohje tulevaa tarvetta varten.
Varning!
Produkten får endast installeras och underhållas av utbildad och behörig personal, som följer denna bruksanvisning och eventuella tillämpliga
normer och lagföreskrifter noga i förekommande fall.
Behåll denna användarhandbok som referens
Advarsel!
Dette produktet må bare installeres og vedlikeholdes av kompetent og autorisert personale, i streng overholdelse av disse betjeningsanvisningene,
alle relevante standarder og rettslige krav der det passer.
Ta vare på denne brukerveiledningen for senere bruk
Advarsel!
Dette produkt må kun installeres og vedligeholdes af autoriseret personale, under nøje overholdelse af disse driftsinstruktioner, relevante standarder
og lovgivningsmæssige krav, hvor dette er aktuelt.
Gem denne vejledning til senere reference.
Προειδοποίηση!
Η εγκατάσταση και συντήρηση αυτού του προϊ(ντος πρέπει να γίνεται µ(νο απ( κατάλληλα εκπαιδευµένο και εξουσιοδοτηµένο
προσωπικ(, µε αυστηρή τήρηση των οδηγιών χειρισµού, των εφαρµοζ(µενων προτύπων και των νοµικών απαιτήσεων (που απαιτείται.
Φυλάξτε αυτ το εγχειρίδιο χρήσης για µελλοντική αναφορά
Advertencia
La instalación y mantenimiento de este producto debe ser efectuada únicamente por personal competente y autorizado, respetándose de forma
estricta estas instrucciones de funcionamiento, así como cualquier norma y requerimiento legal que sean aplicables.
Conserve esta guía del usuario para poder consultarla en el futuro.
Advertência!
A instalação e a manutenção deste produto só deve ser realizada por pessoal autorizado e competente, sob estrita observância destas instruções
de utilização e de quaisquer normas e requisitos legais relevantes, quando adequado.
Conserve este guia do utilizador para referência futura
3

362 M100 No.: 9_6999 23 USE
13 Annex
AC010 - AC030
MT
Rakkomandazzjonijiet g[all-Installazzjoni
Nirrakkomandaw li l-arja kompressata ti;i trattata qabel ma tid[ol fis-sistema ta’ distribuzzjoni kif ukoll fil-punti / l-applikazzjonijiet kriti/i ta’ l-u]u.
L-installazzjoni ta’ tag[mir li jnixxef l-arja kumpressata fuq sistema li kienet imxarrba jista’ jirri]ulta f’aktar tag[bija ta’ [mie; g[all-filtri li jintu]aw f’punt
wie[ed, g[all-perjodu sakemm is-sistema ta’ distribuzzjoni tinxef. L-elementi tal-filtri jista’ jkollhom b]onn li jinbidlu aktar spiss matul dan il-perjodu.
G[al installazzjonijiet fejn jintu]aw kumpressuri ming[ajr ]ejt, xorta jkun hemm pre]enti ajrusols u partijiet ta’ l-ilma, g[alhekk xorta g[andhom jintu]aw gradi
bi skop ;enerali u b’effi//jenza kbira.
Filtru g[al skopijiet ;enerali g[andu dejjem ji;i installat biex jipprote;i l-filtru ta’ effi/jenza kbira mill-volum kbir ta’ ajrusols likwidi u partijiet solidi.
Installa tag[mir ta’ purifikazzjoni fl-aktar temperatura baxxa possibbli imma b’mod li ma jkunx hemm iffri]ar, preferibbilment aktar ‘l isfel mill-aftercoolers u
mir-ri/evituri ta’ l-arja.
Tag[mir tal-purifikazzjoni fil-punt ta’ l-u]u g[andu ji;i installat kemm jista’ jkun qrib tal-post fejn g[andu japplika.
It-tag[mir ta’ purifikazzjoni m’g[andux ji;i installat aktar ‘l isfel mill-valvs li jift[u malajr u g[andu jkun protett minn possibilità ta’ fluss b’lura jew
kundizzjonijiet o[ra stressanti.
Naddaf il-pajps kollha li jwasslu g[at-tag[mir ta’ purifikazzjoni qabel tinstalla u l-papjs kollha wara li tinstalla t-tag[mir ta’ purifikazzjoni u qabel ma tqabbad
ma’ l-applikazzjoni finali.
Jekk tiffittja linji ta’ by-pass madwar it-tag[mir ta’ purifikazzjoni, kun ]gur li hemm bi]]ejjed filtrazzjoni ffittjata mal-linja tal-by-pass biex ma t[allix li jkun
hemm kontaminazzjoni tas-sistema aktar ‘l isfel.
Ipprovdi fa/ilità biex tiddrejnja l-likwidi li jin;abru mit-tag[mir tal-purifikazzjoni. Il-likwidi li jin;abru g[andhom ji;u trattati u mormija b’mod risponsabbli.
I]-]mien kemm idumu jservu l-elementi tal-filtru li jne[[i l-fwar ta]-]jut huwa affettwat mill-kon/entrazzjoni ta]-]ejt tad-d[ul, l-umdità relattiva u t-temperatura
tas-sistema ta’ l-arja kumpressata. L-elementi li jne[[u l-fwar ta]-]jut ikollhom b]onn jinbidlu aktar ta’ sikwit mill-element s[i[ ekwivalenti.
Mudelli AC010 I - AC030 I huma ffittjati b’indikatur tal-volum ta]-]ejt. Kemm l-elementi tal-filtru kif ukoll l-indikatur g[andhom jinbidlu jekk l-
indikatur isir ta’ kulur blu.
Jekk Jog[;bok Innota - Dan hu indikatur tal-volum ta]-]ejt u ma jindikax i]-]mien li jdum iservi l-element tal-filtru.
20

No.: 9_6999 23 USE M100 363
13 Annex
AC010 - AC030
010 FI 010 MI
- -
030 FI 030 MI
1/4” 1/2”
21

364 M100 No.: 9_6999 23 USE
13 Annex
AC010 - AC030
5. Spare Parts (Service Kits)

Reserve-onderdelen (servicekits) • Ersatzteile (Service-Kits) • Pièces de rechange (nécessaires d’entretien) • Varaosat (Huoltopakkaukset)
• Reservdelar (servicesatser) • Reservedeler (service-sett) • Reservedele (Servicekit) • Ανταλλακτικά (Πακέτα τεχνικής υποστήριξης)
• Piezas de repuesto (kits de mantenimiento) • Peças Sobressalentes (Kit de Reparação) • Ricambi (kit per l’assistenza)
• Części zamienne (zestawy serwisowe) • Náhradné diely (Servisná súprava) • Náhradní díly (Sady pro údržbu) • Varuosad (hooldekomplektid)
• Pótalkatrészek (szervizkészletek) • Rezerves daļas (apkopes komplekti) • Atsarginės dalys (priežiros detalių komplektai)
• Запасные части (ЗИП) • Nadomestni deli (servisni kompleti) • Yedek parça (Servis kitleri) • Partijiet G[at-Tibdil (Kitts tas-Servizz)
• AUTOMATIC DRAIN • MANUAL DRAIN

• AUTOMATISCHER ABLAUF • MANUELLER ABLAUF
• VIDANGE AUTOMATIQUE • VIDANGE MANUELLE
• AUTOMISCHAFTAPPEN • MANUEEL AFTAPPEN
• DRENAJE AUTOMATICO • DRENAJE MANUAL
• SCARIO AUTOMATICO • SCARIO MANUALE
• AUTOMATISK AFLØB • MANUELT AFLØB
• DRENO AUTOMÁTICO • DRENO MANUAL
• AYTOMATH AΠOΣTPAΓΓIΣH • XEIPOKINHTH AΠOΣTPAΓΓIΣH
• AUTOMATDRÄNERING • MANUELL DRÄNERING
• AUTOMAATTINEN • KÄSIKÄYTTÖINEN
• TYHJENNYSKAPPALE • TYHJENNYSKAPPALE
• DREN AUTOMATYCZNY • DREN RĘCZNY
EF1 • AUTOMATICKÉ VYSUŠENIE EM1 • RUČNÉ VYSUŠENIE
• AUTOMATICKÉ VYPOUŠTĚNÍ • RUČNÍ VYPOUŠTĚNÍ
• AUTOMAATNE VÄLJALASE • KÄSITSI VÄLJALASE
• AUTOMATIKUS LEERESZTÉS • KÉZI LEERESZTÉS
• AUTOMĀTISKA IZTECINĀŠANA • MANUĀLA IZTECINĀŠANA
• AUTOMATINIS IŠLEIDIMAS • RANKINIS IŠLEIDIMAS
• АВТОМАТИЧЕСКИЙ ДРЕНАЖ • ДРЕНАЖ ВРУЧНУЮ
• SAMODEJNI ODTOK • ROČNI ODTOK
• OTOMATİK SÜZDÜRÜCÜ • ELLE KULLANILACAK SÜZDÜRÜCÜ
• DREJN AWTOMATIKU • DREJN MANWALI
AA AC AC
010 A
010 B 010AA 010AC
010 C
015 B
015AA 015AC
015 C
020 C
020 D 020AA 020AC
020 E
025 D 025AA 025DAC
025 E 025AA 025EAC
030 E BOIE1
030 F 030AA 030AC AC010 I - AC030 I
030 G
26

No.: 9_6999 23 USE M100 365
13 Annex
AC010 - AC030
6. Maintenance
Onderhoud • Wartung • Entretien • Kunnossapito • Underhåll • Vedlikehold • Vedligeholdelse • Συντήρηση • Mantenimiento • Manutenção
• Manutenzione • Konserwacja • Údržba • Údržba • Hooldus • Karbantartás • Tehniskā apkope • Techninė priežiūra • Обслуживание
• Vzdrževanja • Bakım • Manutenzjoni
+
AA
1000
10,000
¡ 1,000 AC AC
50
hrs
20 30 40 50 ˚C
(68) (86) (104) (122) ˚F
Models AC010 I - AC030 I are fitted with a bulk oil indicator. Both filter elements and indicator should be changed if indicator is blue in
colour.
Please Note - This is a bulk oil indicator, it does not indicate filter element life.
Modellen AC010 I - AC030 I zijn uitgerust met een bulk olie indicator. Zowel de filterelementen als de indicator moeten vervangen
worden als de indicator blauw van kleur is.
N.B. - Dit is een bulk olie indicator, het is geen indicator voor de levensduur van het filterelement.
Die Modelle AC010 I - AC030 I sind mit einer Ölanzeige ausgestattet. Sowohl die Filterelemente also auch die Anzeige sollte
ausgetauscht werden, wenn sich die Anzeige blau färbt.
Bitte beachten - Es handelt sich hier um eine Ölanzeige. Diese gibt keinen Hinweis auf die Lebensdauer des Filterelements.
Les modèles AC010 I - AC030 I sont fournis avec un indicateur de présence massive d'huile. Lorsque l'indicateur est bleu, il est
nécessaire de remplacer les cartouches et l'indicateur.
Remarque : Il s'agit d'un indicateur de présence massive d'huile, et non pas de la durée de vie des cartouches.
Malleissa AC010 I – AC030 I on öljynilmaisin. Sekä suodatinelementit että ilmaisin on vaihdettava, jos ilmaisin on sininen.
Huomautus – Tämä on öljynilmaisin. Se ei ilmaise suodatinelementin ikää.
Modell AC010 I - AC030 I har en indikator för större mängder olja. Både filterelement och indikator ska bytas om indikatorn har blå
färg.
Observera –- indikatorn visar oljeförekomst, den indikerar inte filterelementets livslängd.
Modell AC010 I - AC030 I er montert med bulkvolum oljeindikator. Både filterelementer og indikator skal skiftes når indikatoren er blå.
Merk – Dette er en bulkvolum oljeindikator, den indikerer ikke filterelementets levetid.
Modell AC010 I - AC030 I har en indikator för större mängder olja. Både filterelement och indikator ska bytas om indikatorn har blå
färg.
Observera –- indikatorn visar oljeförekomst, den indikerar inte filterelementets livslängd.
Τα µοντέλα AC010 I - AC030 I διαθέτουν ένα δείκτη παρουσίας λαδιού. Dταν ο δείκτης είναι µπλε πρέπει να αλλάζονται
τ(σο τα φίλτρα (σο και οι δείκτες.
Παρακαλούµε σηµειώστε τι - Αυτς είναι ένας δείκτης παρουσίας λαδιού, δεν υποδεικνύει τη διάρκεια ζωής του φίλτρου.
Los modelos AC010 I - AC030 I disponen de un indicador de presencia de aceite. Si el indicador se vuelve azul deben cambiarse
tanto los elementos filtrantes como el indicador.
Nota importante: se trata de un indicador de presencia de aceite. No indica la vida del elemento filtrante.
Modelos AC010 I - AC030 I são instalados com um indicador do óleo em bruto. Ambos os elementos do filtro e o indicador deverão
ser mudados se o indicador estiver azul.
Nota - Este é um indicador do óleo em bruto, não indica a vida útil do elemento do filtro.
I modelli AC010 I - AC030 I sono provvisti di un indicatore degli oli misti. Sostituire gli elementi filtranti e l'indicatore quando il secondo
assume una colorazione blu.
Nota - L'indicatore segnala la presenza di oli misti, ma non la durata dell'elemento filtrante.
27

366 M100 No.: 9_6999 23 USE
13 Annex
AC010 - AC030
1 2
3 4
2
1
0 bar 0 bar
0 psi 0 psi
5 6
1 2
29

No.: 9_6999 23 USE M100 367
13 Annex
AC010 - AC030
7 8
0 bar
0 psi
9 10
0 bar 0 bar
0 psi 0 psi
11 12
1
2 0 bar
0 psi 2
30

368 M100 No.: 9_6999 23 USE
13 Annex
AC010 - AC030
13 14
1
15
31

No.: 9_6999 23 USE M100 369
370
Declaration of Conformity EN Verklaring van Conformiteit NL Konformitätserklärung DE
domnick hunter domnick hunter domnick hunter

Dukesway, TVTE, Gateshead, Tyne & Wear, NE11 0PZ. UK Dukesway, TVTE, Gateshead, Tyne & Wear, NE11 0PZ. GB Dukesway, TVTE, Gateshead, Tyne & Wear NE11 0PZ GROSSBRITANNIEN
AC010, 015, 020 025, 030 AC010, 015, 020 025, 030 AC010, 015, 020 025, 030
Directives 97/23/EC, Richtlijnen 97/23/EC, Richtlinien 97/23/EC,

AC010 - AC030
Standards used Generally in accordance with ASMEVIII Div 1 : Gehanteerde normen Gewoonlijk volgens ASMEVIII Div 1 : 2004. Angewandte Normen Allgemein in Übereinstimmung mit ASMEVIII
2004. Div 1 : 2004.
PED-beoordelingstraject: Artikel 3.3 (AC 010, 015, 020, 025)
PED Assesment Route : Article 3.3 (AC 010, 015, 020, 025) Module A (AC 030) Beurteilungsroute der Druckgeräterichtlinie: Artikel 3.3 (AC 010, 015, 020, 025)
13
Module A (AC 030) Modul A (AC030)

13.8
M100
Aangemelde instantie voor PED: N/A
Notified body for PED: N/A Benannte Stelle für die N/A
EC Type onderzoekscertificaat: N/A Druckgeräterichtlinie:
EC Type-examination Certificate: N/A
Bevoegde vertegenwoordiger Barry Wade EG-Baumusterprüfbescheinigung: N/A
Authorised Representative Barry Wade
Business Systems Improvement Manager Manager Bedrijfssysteemverbetering
domnick hunter ltd Bevollmächtigter Vertreter Barry Wade
domnick hunter ltd
Operator Manual
Business Systems Improvement Manager
Declaration Verklaring domnick hunter ltd
Annex
I declare that as the authorised representative, the above information in relation to the supply / Als bevoegde vertegenwoordiger verklaar ik dat bovenstaande informatie met betrekking tot de Erklärung
manufacture of this product, is in conformity with the standards and other related documents levering / vervaardiging van dit product overeenstemt met de normen en andere bijbehorende
following the provisions of the above Directives. documentatie volgens de bepalingen van bovengenoemde richtlijnen. Hiermit erkläre ich als bevollmächtigter Vertreter die Konformität der oben aufgeführten
Informationen in Bezug auf die Lieferung/Herstellung dieses Produkts mit den Normen und
anderen zugehörigen Dokumenten gemäß den Bestimmungen der oben genannten Richtlinien.
Signature: Date: 28 / 09 / 05 Handtekening: Datum: 28 / 09 / 05
Unterschrift: Datum: 28 / 09 / 05
Declaration Number: 0001/280905 Verklaringnummer: 0001/280905
Nummer der Erklärung: 0001/280905
Screw Compressor
Déclaration de conformité FR Vaatimustenmukaisuusvakuutus FI Försäkran om överensstämmelse SV
domnick hunter domnick hunter domnick hunter

Dukesway, TVTE, Gateshead, Tyne & Wear, NE11 0PZ GB Dukesway, TVTE, Gateshead, Tyne & Wear NE11 0PZ ISO-BRITANNIA Dukesway, TVTE, Gateshead, Tyne & Wear, NE11 0PZ, Storbritannien
AC010, 015, 020 025, 030 AC010, 015, 020 025, 030 AC010, 015, 020 025, 030
Directives 97/23/EC, Direktiivit 97/23/EC, Direktiv 97/23/EC,
Normes utilisées Généralement conforme à ASMEVIII div. 1 : Käytetyt standardit Yleensä seuraavan standardin mukaisesti: Använda standarder Generellt i enlighet med ASMEVIII Div 1:
2004. ASMEVIII Div 1: 2004. 2004.
Méthode d’évaluation de la directive Article 3.3 (AC010, 015, 020, 025, 030) PED-arviointimenettely: Artikla 3.3 (AC010, 015, 020, 025, 030) Fastställningsväg för PED: Artikel 3.3 (AC010, 015, 020, 025, 030)
d'équipements de pression : Module A (AC030) Moduuli A (AC030) Modul A (AC030)
Organisme de notification pour la directive N/A PED-säännösten ilmoitettu laitos: N/A Anmält organ för PED: N/A
d'équipement sous pression :
EY-tyyppihyväksynnän sertifikaatti: N/A EG-intyg om typprovning: N/A
Certificat d’examen de type CE : N/A
Valtuutettu edustaja Barry Wade Auktoriserad representant Barry Wade
Représentant agréé Barry Wade Yritysjärjestelmien kehityspäällikkö Business Systems Improvement Manager
Business Systems Improvement Manager domnick hunter ltd domnick hunter ltd
Operating instructions for compressed air filter (fresh air filter)
domnick hunter ltd

Vakuutus Försäkran
Déclaration Valtuutettuna edustajana vakuutan, että yllä olevat tiedot, jotka liittyvät tämän tuotteen Jag försäkrar, i egenskap av auktoriserad representant, att ovannämnda information avseende
Je déclare à titre de représentant agréé que les informations ci-dessus liées à la toimittamiseen tai valmistamiseen, ovat standardien ja muiden asiaan liittyvien asiakirjojen leverans/tillverkning av denna produkt överensstämmer med standarder och övriga relaterade
fourniture/fabrication de ce produit sont en conformité avec les normes et autres documents mukaisia ja noudattavat yllä mainittuja direktiivejä. dokument enligt villkoren i ovanstående direktiv.
liés déclarés selon les dispositions des directives susmentionnées.
Allekirjoitus: Päiväys: 28 / 09 / 05
Underskrift: Datum: 28 / 09 / 05
Signature : Date : 28 / 09 / 05
Vakuutuksen numero: 0001 /280905
Försäkran nummer: 0001/280905
N° de déclaration : 0001/280905
No.: 9_6999 23 USE

13 Annex
13.9 Service tasks - Generator
13.9 Option ga, gb

Service tasks - Generator
In order to ensure a safe operation of the machine, the generator must be inspected once every
year by a trained and authorized electrician.
Have the following tasks performed by a specialist electrician or an authorized KAESER service
representative:
■ Inspection of the generator and generator control cubicle for mechanical damages.
■ Inspection of the protective conductor.
■ Measurement of the dielectric resistance.
■ Measurement of the substitute leakage current.
■ Inspection of generator functionality.
■ Inspection of the proper functioning of the generator fan and cleaning, if required.
■ Cleaning the cooling air apertures.
■ Check all screwed connections on the generator and control box and tighten if necessary.
■ Check covers and power socket caps for damage and good sealing.
■ Check that all warning and other labels are complete and undamaged.

No.: 9_6999 23 USE M100 371
13 Annex
13.9 Service tasks - Generator

372 M100 No.: 9_6999 23 USE

Operator Manual: Screw Compressor M100

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Operator Manual

1 Regarding this Document

Operator Manual Screw Compressor

2.7.4 Generator (60 Hz version) .................................................................................. 21

Operator Manual Screw Compressor

5 Installation and Operating Conditions

Operator Manual Screw Compressor

9.3.3 Pressure relief valve blowing off ......................................................................... 95

Operator Manual Screw Compressor

11 Spares, Operating Materials, Service

Operator Manual Screw Compressor

Operator Manual Screw Compressor

Fig. 1 Example for Tire information on the side wall ............................................................................ 10

Operator Manual Screw Compressor

Fig. 55 Draining the engine oil ................................................................................................................ 121

Operator Manual Screw Compressor

Tab. 1 Danger levels and their definitions (personal injury) .................................................................. 1

Operator Manual Screw Compressor

Tab. 55 Power reduction at elevated ambient temperatures ................................................................... 20

Operator Manual Screw Compressor

1 Regarding this Document

1.2 Further Documents

Missing documents can be requested from KAESER.

1.4 Symbols and labels

Tab. 1 Danger levels and their definitions (personal injury)

Operator Manual Screw Compressor

These show the kind of danger and its source.

1.4.2 Potential damage warnings

Warning notices for damages are identified by their signal term.

Tab. 2 Danger levels and their definition (damage to property)

These show the kind of danger and its source.

➤ Carefully read and fully comply with warnings against damages.

1.4.3 Other alerts and their symbols

➤ This symbol is placed by lists of actions comprising one stage of a task.

Operator Manual Screw Compressor

Result Shows the expected conclusion of the previous action.

Further information Further topics are introduced here.

Operator Manual Screw Compressor

The nameplate can be found:

The following table lists all possible options.

Operator Manual Screw Compressor

M100 Part Number Serial no.

*r1 - r5 = place holders for chassis options

Tab. 4 Options label

2.2.1 Option da, db, dc, dd

Tab. 5 Compressed air treatment options

2.2.2 Option ea, ec

Tab. 6 Tool lubricator option

2.2.3 Option fa, fc

Operator Manual Screw Compressor

Option Option code Available?

Tab. 7 Compressed air distributor option

2.2.4 Option hc, hd

Tab. 8 Check valve option

2.2.5 Option ca, cb

Tab. 9 Proportional controller option

Tab. 10 Low temperature equipment options

2.2.7 Option la, lb

Tab. 11 Optional equipment for fire hazard areas