Ramirent: Service Manual
Ramirent: Service Manual
Ramirent: Service Manual
Screw Compressor
M43
No.: 9_9432 02 E
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EN
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AM
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Manufacturer:
Original instructions
/KKW/M43 1.02 en SBA-MOBILAIR-PE
20100819 162014
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2.2.4 Low temperature equipment ............................................................................... 5
2.2.5 Battery isolating switch ....................................................................................... 5
2.2.6 Sealed floor pan .................................................................................................. 5
2.2.7 Equipment for fire hazard areas ......................................................................... 5
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2.2.8 Chassis ............................................................................................................... 5
2.2.9 Lighting ............................................................................................................... 6
2.2.10 Pedestrian protection .......................................................................................... 6
2.2.11 Hose reel ............................................................................................................ 6
2.2.12 Anti-theft device .................................................................................................. 6
2.3 Machine (without options) ................................................................................................ 7
2.3.1 Sound emission ................................................................................................. 7
2.3.2 Torques ............................................................................................................... 7
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2.3.3 Ambient conditions ............................................................................................. 7
2.3.4 Dimensions ......................................................................................................... 8
2.4 Chassis ........................................................................................................................... 8
2.4.1 Weights ............................................................................................................... 8
2.4.2 Tyres ................................................................................................................... 8
2.4.3 Wheel fixing tightening torque ............................................................................ 8
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3.10 Environmental Protection ................................................................................................. 23
4 Design and Function
4.1 Bodywork ......................................................................................................................... 24
4.2 Component identification .................................................................................................. 25
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4.3 Machine function .............................................................................................................. 26
4.4 Operating modes and control modes ............................................................................... 28
4.4.1 Operating modes ................................................................................................ 28
4.4.2 MODULATING control ........................................................................................ 29
4.5 Safety devices .................................................................................................................. 29
4.5.1 Monitoring functions with shutdown .................................................................... 29
4.5.2 Further safety devices ........................................................................................ 29
4.6 Options ............................................................................................................................. 29
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4.6.1 Tool lubricator ..................................................................................................... 29
4.6.2 Low temperature equipment ............................................................................... 30
4.6.3 Sealed floor pan .................................................................................................. 32
4.6.4 Battery isolating switch ....................................................................................... 32
4.6.5 Fuel filter with water trap ..................................................................................... 33
4.6.6 Option for operating in fire hazard areas ............................................................ 33
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8 Operation
8.1 Starting and stopping ....................................................................................................... 55
8.1.1 Starting ............................................................................................................... 55
8.1.2 Allow the machine to run up to operating temperature ....................................... 56
8.1.3 Shutting down ..................................................................................................... 56
8.2 Operating the battery isolating switch .............................................................................. 57
8.3 Operating the tool lubricator ............................................................................................. 58
8.4 Using the low-temperature equipment ............................................................................. 58
8.4.1 Using the frost protector ..................................................................................... 58
8.4.2 Coolant pre-heating ............................................................................................ 59
8.5 Using the hose reel .......................................................................................................... 60
8.5.1 Using the hose reel (EC version) ........................................................................ 60
9 Fault Recognition and Rectification
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9.1 Basic instructions ............................................................................................................. 62
9.2 Engine faults and alarms .................................................................................................. 62
9.2.1 Engine refuses to start or comes to a stop ......................................................... 62
9.2.2 Engine does not reach full speed. ...................................................................... 63
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9.2.3 Indicator lamp remains on .................................................................................. 63
9.3 Compressor faults and alarms ......................................................................................... 64
9.3.1 Working pressure too high .................................................................................. 64
9.3.2 Working pressure too low ................................................................................... 64
9.3.3 Pressure relief valve blowing off ......................................................................... 65
9.3.4 Machine overheating .......................................................................................... 65
9.3.5 Too much oil residue in the compressed air ....................................................... 66
9.3.6 Oil flows from the compressor air filter after shutdown ....................................... 66
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10 Maintenance
10.1 Safety ............................................................................................................................... 67
10.2 Maintenance schedules ................................................................................................... 67
10.2.1 Logging maintenance work ................................................................................. 67
10.2.2 Maintenance tasks after commissioning ............................................................. 68
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12 Decommissioning, Storage and Transport
12.1 De-commissioning ............................................................................................................ 192
12.1.1 Temporary decommissioning .............................................................................. 192
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12.1.2 Long-term decommissioning ............................................................................... 193
12.2 Transporting ..................................................................................................................... 194
12.2.1 Towing the compressor on the road ................................................................... 194
12.2.2 Parking the compressor ...................................................................................... 199
12.2.3 Transporting with a crane ................................................................................... 201
12.2.4 Transporting as a load ........................................................................................ 202
12.3 Storage ............................................................................................................................. 203
12.4 Disposal ........................................................................................................................... 203
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13 Annex
13.1 Marking ............................................................................................................................ 205
13.2 Pipeline and instrument flow diagram (P+I diagram) ....................................................... 205
13.3 Dimensional drawings ...................................................................................................... 209
13.3.1 Dimensional drawing - chassis with height-adjustable tow bar .......................... 209
13.3.2 Dimensional drawing - chassis with height-adjustable tow bar .......................... 211
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13.3.3 Dimensional drawing - fixed height towbar and parking brake ........................... 213
13.3.4 Dimensional drawing - fixed height towbar and overrun brake ........................... 215
13.4 Electrical Diagram ............................................................................................................ 217
13.5 Lighting and signalling system connection ....................................................................... 227
13.6 Fuel circulation diagram ................................................................................................... 233
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Fig. 14 Change from eye to ball coupling (fixed height towbar) ............................................................. 47
Fig. 15 Changing from eye to ball coupling (fixed height towbar with overrun brake) ............................ 48
Fig. 16 Jumper cable connection diagram ............................................................................................. 52
Fig. 17 Starting instruments ................................................................................................................... 55
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Fig. 18 Warm-up period when ambient temperatures are below -10 °C ................................................ 56
Fig. 19 Battery isolating switch ............................................................................................................... 57
Fig. 20 Setting the tool lubricator ............................................................................................................ 58
Fig. 21 Switching on the frost protector .................................................................................................. 59
Fig. 22 Hose reel (EC design) ................................................................................................................ 60
Fig. 23 Checking coolant level ............................................................................................................... 73
Fig. 24 Draining the coolant from the radiator ........................................................................................ 75
Fig. 25 Engine air filter maintenance ...................................................................................................... 76
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Fig. 26 Bleeding the fuel system ............................................................................................................ 78
Fig. 27 Fuel filter with water trap ............................................................................................................ 80
Fig. 28 Changing the engine oil .............................................................................................................. 82
Fig. 29 Engine sump drain valve ............................................................................................................ 83
Fig. 30 Changing the engine oil filter ...................................................................................................... 84
Fig. 31 Warning stickers on the battery .................................................................................................. 85
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Tab. 14 Hose reel .................................................................................................................................... 6
Tab. 15 Anti-theft device .......................................................................................................................... 6
Tab. 16 Sound emission .......................................................................................................................... 7
Tab. 17 Sound pressure level .................................................................................................................. 7
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Tab. 18 Torques for hex-head screws ..................................................................................................... 7
Tab. 19 Ambient conditions ..................................................................................................................... 7
Tab. 20 Machine weights ......................................................................................................................... 8
Tab. 21 Tyres .......................................................................................................................................... 8
Tab. 22 Wheel fixing tightening torque .................................................................................................... 8
Tab. 23 Working pressure and FAD ........................................................................................................ 9
Tab. 24 Compressed air distributor ......................................................................................................... 9
Tab. 25 Relief valve activating pressure .................................................................................................. 9
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Tab. 26 Machine temperatures ................................................................................................................ 9
Tab. 27 Cooling oil recommendation ....................................................................................................... 10
Tab. 28 Cooling oil charge ....................................................................................................................... 10
Tab. 29 Engine specification .................................................................................................................. 10
Tab. 30 Engine oil recommendation ........................................................................................................ 11
Tab. 31 Engine fluid volumes .................................................................................................................. 11
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1.2 Further Documents
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Included with this service manual are additional documents intended to assist in the safe operation
of the machine:
■ Certificate of acceptance / operating instructions for the pressure vessel
■ Manufacturer's declaration / declaration of conformity in accordance with applicable directives
■ Chassis maintenance instructions
■ Operating instructions from the chassis manufacturer
■ Engine documentation (not electric-motor-driven machines)
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Missing documents can be requested from KAESER.
➤ Make sure all documents are complete and observe the instructions contained in them.
➤ Make sure you give the data from the nameplate when ordering documents.
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1.3 Copyright
This service manual is copyright protected. Queries regarding use or duplication of the documenta‐
tion should be referred to KAESER. Correct use of information will be fully supported.
1.4.1 Warnings
Warning notices indicate three levels of danger signified by the signal word.
■ DANGER
■ WARNING
■ CAUTION
1. DANGER!
These show the kind of danger and its source!
The possible consequences of ignoring a warning are shown here.
The word "Danger" indicates that death or severe injury can result from ignoring the instruc‐
tion.
➤ The measures required to protect yourself from danger are shown here.
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This symbol refers to particularly important information.
Material Here you will find details on special tools, operating materials or spare parts.
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Precondition Here you will find conditional requirements necessary to carry out the task.
Here conditions relevant to safety are named that will help you to avoid dangerous situations.
Option H1 ➤ This bullet is is placed by lists of actions comprising one stage of a task.
In lists of actions with several stages the sequence of actions is numbered.
Information that refers to only one option is marked with an indicator (e.g.: H1 means that this
section is only valid for machines with adjustable machine mountings). Option indicators used
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in this service manual are explained in chapter 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‐
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tion.
2 Technical Specification
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 here the nameplate data as a reference:
Feature Value
Vehicle identity no.
Permissible total weight
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Permissible axle load
Permissible coupling load
Portable compressor
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Material number
Serial number
Year of manufacture
Total weight
Lifting point load capacity
Rated motor power
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Engine speed
Maximum working pressure
Tab. 2 Nameplate
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2.2 Options
A list of the options fitted to your machine helps to relate the information in this service manual.
A list of options fitted is given as code letters on the right side of the coupling load / options label.
➤ Take a list of fitted options from the combined coupling load / options label.
ha
ba bb
la lb
oa oe
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ne
sa sb sd se
tb tc
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sf sg ua
2.2.1 Option ea
Tool lubricator
➤ Enter the fitted option as reference.
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Option Option code Exists?
Tool lubricator ea
2.2.2 Option ha
Non-return function
➤ Enter the fitted option as reference.
2.2.3 Option ne
Fuel filter with water trap
➤ Enter the fitted option as reference.
2.2.5 Option oa
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Battery isolating switch
➤ Enter the fitted option as reference.
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Option Option code Exists?
Battery isolating switch oa
2.2.6 Option oe
Sealed floor pan
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➤ Enter the fitted option as reference.
Tab. 11 Chassis
Further information For an exact description of the characteristics of the chassis and models, see chapter 4.6.8.
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➤ Enter the fitted option as a reference.
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Reflective warning triangle tb
EC 12 V (13-pin connector) tc
USA 12 V (DOT conformity) te
Tab. 12 Lighting
2.2.10 Option sg
Pedestrian protection
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➤ Enter the fitted option as reference.
2.2.11 Option ua
Hose reel
➤ Enter the fitted option as reference.
Hose reel ua
2.2.12 Option sf
Anti-theft device
➤ Enter the fitted option as reference.
Measurement conditions
■ Free-field measurement to directive 2000/14/EC
■ Measuring distance: d=1 m
■ Logarithmic surface ratio: Q2=16,8dB(A)
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Guaranteed sound power level [dB(A)] 98
Emission sound pressure level* [dB(A)] 81,0
* Calculated from the guaranteed sound power level (2000/14/EG Directive, Basic Noise Emission
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Standard ISO 3744) to EN ISO 11203:1995 number 6.2.3.d
2.3.2 Torques
Recommended values for hexagonal bolts of strength category 8.8
Hex-head screws
Thread M6 M8 M10 M12 M14 M16 M18
Torque [Nm] 9,5 23 46 80 127 195 280
2.3.4 Dimensions
For specifications according to the machine's operating licence, such as:
■ dimensions,
■ track width,
■ footprint,
2.4 Chassis
2.4.1 Weights
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Maximum weights are shown. Actual weights of individual machines are dependent on equip‐
ment fitted (see machine nameplate).
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Feature 01 02 03 04
Chassis type EU EU EU EU
chassis chassis chassis chassis
Height-adjustable towbar x x − −
Fixed height towbar − − x x
Parking brake
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− x x x
Service brake − x − x
Actual total weight [kg]*
Permissible axle load [kg] 750 850 750 850
x ≙ available, − ≙ not available
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EU ≙ Europe
* Enter here the actual overall weight from the nameplate as reference,
2.4.2 Tyres
Characteristic/marking
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Tab. 21 Tyres
2.5 Compressor
2.5.1 Working pressure and FAD
Maximum working pressure [bar] 7
SIGMA airend 190
Free air delivery [m /min]
3 4,2
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Discharge valve ["] No.
G 3/4 2
*G 1 1
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*Optional
2.5.4 Temperature
Machine temperatures Values
Recommended airend discharge temperature for 30
switching to load [°C]
Typical airend discharge temperature during opera‐ 75 – 100
tion [°C]
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(D 445; ASTM test) (DIN 51562–1)
Viscosity at 7.2 mm2/s 6.8 mm2/s
100 °C (D 445; ASTM test) (DIN 51562–1)
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Flash point 238 °C 220 °C
(D 92; ASTM test) (ISO 2592)
Density at 15 °C 864 kg/m3 –
(ISO 12185)
Pour point -46 °C -33 °C
(D 97; ASTM test) (ISO 3016)
Demulsibility at 54 °C 40/40/0/10 min –
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(D 1401; ASTM test)
2.6 Engine
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Feature Specification
* Use only diesel fuel to EN 590 or ASTM D975. Consult the engine manufacturer on the use of
other fuels if necessary.
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The engine is filled initially with engine oil of viscosity class SAE 10 W / 40.
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−10 – 50 SAE 15 W / 40
−20 – 30 SAE 5 W / 30
−20 – 50 SAE 10 W / 40
2.6.5 Battery
Feature Value
Voltage [V] 12
Capacity [Ah] 60
Feature Value
PTC testing current [A] 480
(according to EN 50342)
Tab. 32 Battery
Further information Depending on machine equipment, a higher capacity battery may be required. See chapter 2.7.2
for low temperature equipment.
2.7 Options
2.7.1 Option ea
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Tool lubricator
Name Temperature range [°C] Fluid volume [l]
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Special road breaker lubricant −25 – 50 2,5
* Higher altitudes are permissible only after consultation with the manufacturer.
2.7.2.2 Option ba
Air lines frost protection
Wabcothyl 0,3
2.7.2.3 Option bb
Coolant pre-heating
DANGER
Disregard of these instructions can result in serious injury.
➤ Read the service manual carefully and take note of the contents for safe machine opera‐
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tion.
➤ Use this machine only if it is in a technically perfect condition and only for the purpose for
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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.
➤ Do not use compressed air for breathing purposes unless it is specifically treated.
➤ Do not use compressed for any application that will bring it into direct contact with foodstuffs
unless it is specifically treated.
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Authorised maintenance personnel possess the following qualifications:
■ are of legal age,
■ have read, are conversant with and adhere to the safety instructions and sections of the ser‐
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vice manual applicable to installation and maintenance,
■ are fully conversant with the safety concepts and regulations of motor vehicle, electrical and
compressed air engineering,
■ are able to recognise 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.
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Authorised transport personnel possess the following qualifications:
■ are of legal age,
■ are conversant with and adhere to the safety instructions and sections of the service manual
relevant to transporting,
■ are trained and authorised in safe vehicle transporting,
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■ are conversant with the safety regulations relating to handling motor vehicles and transport
goods,
■ are able to recognise the possible dangers of motor vehicles and take appropriate measures to
safeguard persons and property.
1. DANGER!
There is danger of fatal injury caused by contact with live components.
➤ Only qualified electricians may work on the installation, maintenance and repair of the ma‐
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Strength test Every 10 years after commissioning or the Competent person
last inspection (e. g. KAESER Service Technician)
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Tab. 37 Inspection intervals according to Ordinance on Industrial Safety and Health
3.5 Dangers
Basic Information
Information concerning the various forms of danger that can arise during machine operation are
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found here.
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.
Information is found here concerning how to counter the various forms of danger that can arise dur‐
ing machine operation.
Exhaust fumes
Exhaust fumes from combustion engines contain carbon monoxide; this gas is odourless and can
cause death.
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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 refuelling.
➤ Never refuel the machine when it is running.
➤ Do not allow fuel to overflow.
➤ Wipe up spilled fuel immediately.
➤ Keep fuel away from hot machine parts.
➤ Never top up antifreeze (option ba) unless the machine is stopped and cooled down.
➤ Make sure that the ambient temperature at the machine's place of use is within permissible lim‐
its.
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. When pressure has escaped,
remove the filler cap completely.
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Forces of compression
Escaping compressed air can cause serious injury. The following information concerns work on
components that could be under pressure.
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➤ Wait until the machine has automatically vented (check that the pressure gauge indicates 0
bar).
➤ 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.
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Spring force
foodstuffs.
Rotating components
Touching the fan wheel, the coupling or the belt drive while the machine is running can result in
serious injury.
➤ Operate the machine only with closed safety guards, access doors and panels.
➤ Shut down the machine before opening a door or canopy.
➤ Wear close-fitting clothes and a hair net if necessary.
➤ Fit all safety devices and panels before starting the engine.
Electricity
➤ 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.
➤ Check regularly that all electrical connections are tight and in order.
➤ Only qualified and authorised electricians may carry out work on the generator or generator
control box.
➤ Never carry out work on the generator or generator control box unless the machine is shut
down.
High temperature
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➤ Avoid contact with hot components. These include, for example, engine, compressor airend, oil
and compressed air lines, coolers and oil separator tank.
➤ Wear protective clothing.
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➤ If welding is carried out on or near the machine, take adequate measures to prevent sparks or
heat from igniting fuel or oil vapours or parts of the machine.
Noise
Operating materials
➤ 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.
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➤ Use only spare parts approved by the manufacturer for use in this machine. Unsuitable spare
parts compromise the safety of the machine.
➤ Use only genuine KAESER pressure components.
➤ Do not permit conversion or modification of the machine as this can compromise function and
safe working.
Transport
➤ Shut down and fully disconnect the machine before transporting it.
➤ 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.
➤ If the machine is towed on public roads, the local regulations regarding safe road transport
must be observed.
➤ The maximum permissible load for the towing vehicle coupling and the maximum coupling load
given for the machine must not be exceeded.
➤ If the towbar is not horizontal, towing instability can develop and damage to the machine occur.
➤ When the machine is lifted by a crane, the safety regulations relating to the crane and lifting
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slings must be observed.
■ Do not enter the danger zone while the machine is being lifted.
■ Never lift the machine over people or residential buildings.
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■ Secondary or attached loads may not:
─ cause excessive loading on the machine's lifting point (lifting eye),
─ adversely influence the machine's centre of gravity so that it hangs out of square.
■ Use lifting slings that are suitable for the loads to which they will be subjected.
■ 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 tamper with the fixing points of the lifting eye.
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■ 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.
■ Transporting by slinging beneath a helicopter is forbidden.
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Positioning
➤ Do not position the compressor directly against a wall. A build up of heat from the exhaust can
damage the machine.
➤ Do not operate in areas in which specific requirements regarding 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".
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Operation
➤ Keep the access doors closed for safety and to ensure correct cooling function.
➤ Carry out regular inspections:
■ for visible damage and leakage,
■ of safety devices,
■ of components needing to be monitored.
➤ Never operate machines without an air filter when drawing in air from the surroundings.
Maintenance
➤ Make sure the machine is shut down, cooled down and pressure-free before commencing any
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maintenance work.
➤ Wear close-fitting, flame-resistant clothing. Wear protective clothing as necessary.
➤ Do not leave any loose components, tools or cleaning rags on or in the machine.
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➤ Components removed from the machine can still be dangerous.
Do not open or destroy removed components as some (inlet valves, for instance) are powerful‐
ly spring-loaded.
Transport Within a 3 m radius of the machine. Operating personnel to prepare for transport.
No personnel during transport.
Beneath the lifted machine. No personnel!
Commissioning Within the machine. Maintenance personnel
Within a 1 m radius of the machine.
Operation Within a 1 m radius of the machine. Operating personnel
Maintenance Within the machine. Maintenance personnel
Within a 1 m radius of the machine.
Further information More information on safety devices is contained in chapter 4, section 4.5.
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The diagram shows the positions of safety signs on the machine. The table lists the various safety
signs used and their meanings.
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gloves.
620 Risk of serious lacerations or even severing of extremities (fingers) from rotating
621 components.
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➤ Operate the machine only with closed safety guards, access doors and pan‐
els.
➤ Shut down the machine before opening a door or canopy.
600* Risk of fatal injury caused by dismantling valves (spring-loaded or under pres‐
sure)
➤ Do not open or dismantle valves.
➤ Call an authorized Service Technician if a fault occurs.
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160* Incorrect oil levels can cause damage to the machine or excessive oil content in
the compressed air.
➤ Check the oil level regularly and correct as necessary.
320* Loud noise and oil mist!
Hearing damage and burning by relief valve blowoff.
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3.8 In Emergency
3.8.1 Correct fire fighting
Suitable extinguishing agents:
■ Foam
■ Carbon dioxide
■ Sand or earth
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1. Keep calm.
2. Give the alarm.
3. Shut down the machine from the instrument panel if possible.
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4. Move to safety.
■ Warn persons in danger.
■ Help incapacitated persons.
■ close the doors.
5. Try to extinguish the fire if you have the skill to do so.
■ lubricating oil
■ compressor cooling oil
■ Tool lubricant (option e)
■ Antifreeze (option ba)
If necessary, request a copy of the safety data sheet for KAESER SIGMA FLUID.
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➤ Eye contact:
rinse thoroughly with lukewarm water and seek medical assistance.
➤ Skin contact:
wash off immediately.
3.9 Warranty
This service manual contains no independent warranty commitment. Our general terms and condi‐
tions 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.
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.
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➤ Store and dispose of operating materials and replaced parts in accordance with local environ‐
mental protection regulations.
➤ Observe relevant national regulations.
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This applies particularly to parts contaminated with fuel, oil, coolants and acids.
➤ Do not allow operating materials to escape to the environment or into the sewage sys‐
tem.
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Fig. 2 Overview Bodywork
1 Canopy 5 Snap fastener
2 Lower body 6 Canopy safety catch
3 Cooling air inlet 7 Lock
4 Recessed grip for the canopy 8 Cover for lifting eye
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Safe and reliable operation is only ensured when the bodywork is closed.
The canopy 1 can be opened when the snap fastener 5 and the canopy safety latch 6 are re‐
leased.
The safety latch is inside the canopy on the right side, next to the handle.
The safety latch can be seen when the snap fastener is released.
When the safety latch is released (pressed in the direction of the arrow) the canopy should open on
its own.
Two spring struts hold the canopy open.
For closing the canopy, 1 a recessed grip 4 is incorporated within the canopy.
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The cooling fan 28 ensures optimum cooling of all components within the enclosure.
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Item numbers correspond to the pipe and instrument flow diagram (P&ID) in chapter 13.2.
below the set minimum. The minimum pressure ensures continuous circulation of cooling oil
through the machine.
■ 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.
─ Engine speed is also varied accordingly by the control cylinder.
─ The airend provides compressed air for connected consumers.
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─ This MODULATING control ensures minimum fuel consumption during times of low de‐
mand. The load and fuel consumption of the engine rises and falls with the air demand.
─ The control valve is factory set. The setting should not be changed without consultation with
KAESER SERVICE.
■ IDLE
─ The engine speed control cylinder is at minimum speed.
─ The inlet valve is closed.
─ The minimum pressure nozzle maintains minimum internal pressure.
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4.5.1 Monitoring functions with shutdown
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The following functions are monitored automatically.
■ Engine oil pressure
■ Coolant temperature
■ Airend discharge temperature
■ Engine alternator
The fuel stop device is activated when an alarm occurs. The engine comes to a stop and the
venting valve releases pressure from the machine.
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4.5.2 Further safety devices
The following safety devices are provided and may not be modified in any way.
■ Pressure relief valve:
AM
This valve protects the system from excessive pressure. It is factory set.
■ Enclosures and covers over moving parts and electrical connections:
These protect against accidental contact.
4.6 Options
4.6.1 Option ea
R
Tool lubricator
Compressed air containing lubricating oil is needed for the lubrication of certain air tools. A tool lu‐
bricator serves this purpose.
WARNING
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.
The amount of oil in the compressed air is controlled by a metering valve on the lubricator.
The oil can be cut off completely by a shut-off valve.
The shut-off valve is in the air pipe.
T
Fig. 5 Tool lubricator
1 Bodywork 6 Oil tank
EN
2 Instrument panel 7 Air line
3 Location of the tool lubricator 8 Shut-off valve (opened)
4 Tool lubricator 9 Air pipe
5 Metering knob
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Fig. 6 Frost protector
1
2
3
Shut-off valve
EN
Control line (frost protection)
Frost protector
4
5
Control line (bypass line)
Oil separator tank cover
IR
Frost protection
The frost protector comes into action when the machine is stopped in ambient temperatures below
freezing. The compressed air carries antifreeze to coat and protect airlines and valves. This pre‐
vents freezing up of control and regulating components.
The heat of the machine prevents individual control components freezing up during operation.
AM
Summer operation
At outside temperatures above 0 °C it is no longer necessary to inject the control lines in the ma‐
chine with antifreeze before shutting it down.
4.6.2.2 Option bb
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Coolant pre-heating
The engine coolant can be pre-heated to improve starting under cold conditions.
A separate mains power connection provides power to the coolant pre-heater. A flexible power ca‐
ble joins the machine's power plug to the user's power socket.
The coolant pre-heater works according to the principle of self-circulation.
T
1 Bodywork 4 Coolant pre-heating
2 Connecting socket for coolant pre-heating 5 Engine
3 Instrument panel
EN
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).
4.6.3 Option oe
IR
Sealed floor pan
The sealed floor pan catches any spilt or leaking operating fluids.
■ engine oil
■ engine coolant
■ fuel
■ battery electrolyte
The drains from the oil separator tank, oil cooler and engine sump are fitted with hoses that lead to
shut-off valves. The shut-off valves are next to each other at a conveniently accessible location.
This greatly simplifies oil changing. The shut-off valves are within the machine enclosure on the
R
4.6.4 Option oa
Battery isolating switch
The «battery isolating switch» disconnects the battery completely from the machine's electrical sys‐
tem (fire protection, battery discharge protection).
The «battery isolating switch» is within the bodywork on the lifting frame on the right side of the
machine.
CAUTION
Danger of short circuit
Damage to the machine electrics is possible.
➤ Use the «battery isolating switch» only when the machine is at standstill.
➤ Do not use the «battery isolating switch» as a main or emergency switch.
T
Fig. 8 Battery isolating switch
1
2
EN
«Battery isolating switch»
Lifting eye
IR
Further information See 8.2 for operating the battery isolating switch.
4.6.5 Option ne
Fuel filter with water trap
AM
Diesel fuel and water have different specific gravities. Water is denser than diesel fuel. This fact is
used in the water trap to separate water from the fuel. The water sinks to the bottom of the trans‐
parent trap and can be drained off.
Further information See 10.3.3.1 for draining off water and dirt particles.
4.6.6.1 Option la
Spark arrestor
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.
4.6.6.2 Option lb
Engine air intake shut-off valve
Any flammable gas drawn into the diesel engine's air intake alters and enriches the controlled fuel/
air mixture fed to the engine. This causes a sudden and uncontrolled increase in engine speed that
can lead to serious mechanical damage. Without appropriate preventive measures, 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. Only by shutting off the air intake can the engine be brought to an immediate stop.
The self-closing valve (Chalwyn valve) shuts off the engine air intake as soon as flammable gas is
drawn in. This brings the engine to an immediate stop.
Further information See 10.7.4 for engine air intake shut-off valve maintenance.
T
4.6.7 Option sf
Optional anti-theft device
EN
The machine is fitted with a security chain as theft protection.
The chassis fitted with options sb and se are equipped with a service brake.
If the towing vehicle brakes during the towing event, the trailer presses the overrun device together
IR
to a point where the trailer is actively braked.
Function:
■ The overrun device activates the relay lever.
■ The relay lever pulls the brake actuating rod with the brake cable.
AM
■ The brake joint lock is twisted and spreads the brake shoes in the drum brake.
■ The trailer brakes.
■ Height-adjustable towbar
sb EU chassis 02 ■ Single-axle
■ Axle rubber-sprung
■ Jockey wheel
■ Height-adjustable towbar
■ Service brake
■ Parking brake
■ Breakaway cable
T
■ Service brake
■ Parking brake
EN
■ Breakaway cable
EU ≙ Europe
T
➤ Ensure that required ambient conditions are maintained with regard to:
■ ambient temperature,
■ clean inlet air with no damaging contaminants,
EN
■ inlet air free of explosive or chemically unstable gases or vapours,
■ inlet air free of acid/alkaline forming substances, particularly ammonia, chlorine or hydro‐
gen sulphide.
➤ Keep suitable fire extinguishing agents ready for use.
1. Keep sufficient distance (at least 1.5 m) from the edges of excavations and slopes.
R
3. Ensure accessibility so that all work on the machine can be carried out without danger or hin‐
drance.
4. CAUTION!
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 under a low roof or covering.
➤ Ensure always sufficient ventilation space around the machine.
5. Ensure there is enough free space all round and above the machine.
6. Keep air inlet and outlet openings free of obstructions so that the cooling air can flow freely
through the machine.
7. Do not allow wind to blow into the cooling air outlet.
8. Do not allow exhaust gases and heated cooling air to be drawn into the compressor.
9. Ensure accessibility so that all work on the machine can be carried out without danger or hin‐
drance.
10. CAUTION!
Ambient temperature too low!
Frozen condensate and highly viscous engine or compressor oil can cause damage when
starting the machine.
➤ Use winter grade engine oil.
➤ Use low viscosity compressor oil.
T
11. At ambient temperatures below 0 °C, follow instructions in chapter 7.5.
EN
IR
AM
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6 Installation
6.1 Safety
Follow the instructions below for safe installation.
Warning instructions are located before a potentially dangerous task.
T
Further information Information on authorized personnel are found in chapter 3.4.2.
Information on dangers and their avoidance are found in chapter 3.5.
EN
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.
06-M0553
sb braked 06-M0554
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Material Pliers
Hard rubber hammer
6.3.1 Option sa
Adjusting the towbar height
The purpose of height adjustment is to bring the towing eye, or coupling, to the correct height for
the towing vehicle.
At the correct height, the towing eye or coupling should be parallel to the ground.
T
EN
IR
AM
1. CAUTION!
Danger of pinching!
Severe injury to fingers is possible if they become trapped in the adjusting mechanism.
➤ Always wear protective gloves.
➤ Work with caution.
2. Draw out the split pin 1 .
3. Undo the locking lever 3 until the serrated joint 5 is disengaged.
4. Make the angle adjustment to the serrated joint 5 .
5. Tighten the locking lever 3 making sure the serrations engage.
T
12. Insert the split pins 1 and 2 .
13. Check the correct position of the split pin.
The split pin must be fully inserted so that it is trapped by its bow over the axis of the locking
EN
lever (see 10.).
6.3.2 Option sb
Adjusting the towbar height
AM
The purpose of height adjustment is to bring the towing eye, or coupling, to the correct height for
the towing vehicle.
At the correct height, the towing eye or coupling should be parallel to the ground.
T
Fig. 11 Towbar height adjustment sb
1,2
3,4
Split pin
Locking lever
EN 9
10
Towing eye
Ball coupling
IR
5 Serrated joint 1 11 Split pin securing principle
6 Serrated joint 2 12 Overrun damper
7 Towbar tube 13 Parking brake
8 Towbar centre-piece
1. CAUTION!
AM
Danger of pinching!
Severe injury to fingers is possible if they become trapped in the adjusting mechanism.
➤ Always wear protective gloves.
➤ Work with caution.
2. Draw out the split pin 1 .
3. Undo the locking lever 3 until the serrated joint 5 is disengaged.
4. Make the angle adjustment to the serrated joint 5 .
R
T
➤ Free the serrations by jerking the towbar horizontally and vertically.
EN
The towbar can be fitted with various towing eyes or couplings.
sd unbraked
AM
06-M0571
se braked
06-M0556
CAUTION
Danger of pinching!
Severe injury to fingers is possible if they become trapped in the adjusting mechanism.
➤ Always wear protective gloves.
➤ Work carefully.
6.3.3.1 Option sa
Changing a height adjustable towbar from eye to ball coupling
The eye coupling on the height adjustable towbar is replaced by a ball coupling.
T
EN
IR
AM
R
T
6. Secure the towing eye and withdraw the hex-head bolt 9 from the side part.
7. Remove the towing eye 1 .
EN
Fitting the ball coupling
Precondition The towing eye has been removed.
The assembly condition as shown in the centre graphic in 12 has been achieved.
The complete ball coupling is to hand.
1. Position the ball coupling 11 between the two serrated joints 7 of the side parts 6 .
2. Pass the hex-head bolt 9 through the side parts 6 .
IR
3. Screw the locking lever 4 onto the bolt 9 .
4. Check if:
■ The serrated joints 7 and 8 engage correctly.
■ That the ball coupling 11 is horizontal.
5. Tighten the locking lever 5 .
AM
6.3.3.2 Option sb
Changing a height adjustable towbar with overrun brake from eye to ball coupling
The eye coupling on the height adjustable towbar is replaced by a ball coupling.
T
EN
IR
AM
R
Fig. 13 Change from eye to ball coupling (height adjustable towbar with overrun brake)
1 Towing eye 6 Tension rod
2 Self-locking nut 7 Saddle
3 Screw 8 Protective sleeve
4 Bushing overrun damper 9 Ball coupling
5 Overrun damper
T
3. Press the saddle 7 down over the towbar 6 .
4. Push the ball coupling 9 on to the towbar 6 .
5. Align the holes for the fixing bolts 3 .
EN
6. Use a metal rod if necessary to align the holes.
7. Push the fixing bolts 3 through the holes in the coupling 9 , the saddle 7 , and the towbar 6 .
8. Screw on and tighten the self-locking nuts 2 .
IR
AM
R
6.3.3.3 Option sd
Changing a fixed height towbar from eye to ball coupling
T
EN
IR
AM
2. If necessary, use a metal rod to adjust until the hole is flush with the sleeve 3 .
3. Push the ball coupling 5 on to the towbar 6 .
4. Check the alignment of the holes in the towbar tube 6 and coupling 5 .
5. Push the fixing bolts 2 through the holes in the coupling 5 and towbar tube 6 .
6. Screw on and tighten the self-locking nuts 4 .
6.3.3.4 Option se
Changing a fixed height towbar with overrun brake from eye to ball coupling
T
EN
IR
AM
R
Fig. 15 Changing from eye to ball coupling (fixed height towbar with overrun brake)
1 Towing eye 7 Towbar tube
2 Protective sleeve 8 Bushing overrun damper
3 Direction of arrow: to expose the bolts 9 Overrun damper
4 Self-locking nut 10 Direction of arrow: to cover the bolts
5 Screw 11 Ball coupling
6 Sleeve
T
Precondition The towing eye has been removed.
The assembly condition as shown in the third graphic in 15 has been achieved.
The complete ball coupling is to hand (sleeve).
EN
1. Push back the protective sleeve 2 if necessary.
2. Bring the bush 8 of the overrun damper 9 to the fixing position so holes align.
■ Push a metal rod through the towbar tube 7 and bush 8 to align the holes.
■ Withdraw the rod.
3. Push the ball coupling 11 on to the towbar tube..
4. Align the holes for the fixing bolts 5 .
IR
5. Use a metal rod if necessary to align the holes.
6. Push the first bolt through the rear hole in the damper bush 8 .
7. Push the sleeve 6 for the front bolt into the towbar tube 7 from below and hold in position.
8. Push the second bolt 5 through the front hole and bush 6 .
9. Screw on and tighten the self-locking nuts 4 .
AM
10. Pull the protective sleeve 2 in the direction shown 10 to cover the bolts.
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7 Initial Start-up
7.1 Safety
Here you will find instructions for safe commissioning of the machine.
Warning instructions are located before a potentially dangerous task.
T
Further information Information on authorized personnel are found in chapter 3.4.2.
Information on dangers and their avoidance are found in chapter 3.5.
EN
7.2 Instructions to be observed before commissioning or recommis‐
sioning
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.
Incorrect or improper commissioning can cause injury to persons and damage to the machine.
IR
➤ Commissioning may only be carried out by authorized installation and service personnel who
have been trained on this machine.
➤ Remove all packing materials and tools on and in the machine.
➤ Observe the machine during the first few hours of operation to ensure that it is operating cor‐
rectly.
AM
T
Storage Action
period longer
than
5 months ➤ Remove the desiccant from the openings in the air intake filters of the engine
EN
and compressor.
➤ Check the air and oil filters.
➤ Drain the preserving oil from the separator tank.
➤ Fill with compressor oil.
➤ Drain the preserving oil from the engine.
➤ Fill up with engine oil.
IR
➤ Check the engine coolant
➤ Check the battery charge.
➤ Re-connect the battery.
➤ Check all fuel lines, engine oil lines and compressor oil lines for leaks, loose
connections, wear and damage.
AM
Tab. 44 Measures for re-commissioning the compressor after a long period of storage
The machine's electrical equipment is designed for starting at ambient temperatures as low as
−10 °C.
➤ At temperatures below 0 °C use:
■ winter-grade engine oil,
■ low viscosity compressor oil
■ winter-grade diesel fuel
Use air hoses that are as short as possible under extremely cold conditions.
1. CAUTION!
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 +30 °C is reached. The airend discharge temperature is shown by the temperature
gauge switch on the instrument panel.
T
If the machine's starter battery is discharged, the engine can be started with the battery of another
vehicle or engine-driven machine.
EN
Material Jumper cables
Precondition The machine is disconnected from the towing vehicle and safely parked.
DANGER
Fire and explosion hazard.
High currents caused by short-circuited battery. Shorted batteries can catch fire or explode.
Battery casing may crack and allow acidic fluid to spray out.
➤ Observe the instructions provided with the battery jumper cables.
IR
➤ 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.
AM
T
Connecting the battery jumper cables
EN
3. Connect positive terminals 2 and 1 .
4. DANGER!
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.
IR
➤ Work with caution.
5. Connect the minus terminal of the assisting battery 4 to a bare metal point on the compressor
engine to be started 3 as far away from the battery as possible.
1. Start the engine of the assisting vehicle and run at high speed.
2. Start the compressor engine.
Let the two engines run for approximately 3 minutes.
7.5.2 Option ba
Starting up low-temperature equipment
➤ Use the checklist when initially starting the low-temperature equipment.
T
EN
IR
AM
R
8 Operation
8.1 Starting and stopping
Pictograms on the instrument panel illustrate the starting and stopping procedures, see also item 1
in the following illustration.
T
EN
IR
Fig. 17 Starting instruments
1 Starting and stopping pictogram 9 Location of the «controller ON» switch
AM
8.1.1 Starting
1. CAUTION!
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.
2. CAUTION!
Destruction of the starter.
Improper operation could destroy the starter.
➤ The starter must not operate while the engine is running.
➤ Do not hold the start switch in the start position 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).
3. Turn the «Controller ON» switch 11 to the “I” position.
4. Turn the «starter switch» 12 to the “I” position.
The charging indicator lamp 4 must light.
T
5. Turn the «starter switch» to “II” and hold (max. 5-10 seconds).
The engine's glow plugs are energised and the engine pre-heated.
6. Turn the «starter switch» to "III" and release it as soon as the engine starts.
EN
The charging indicator lamp 4 extinguishes as soon as the engine is running.
There is a fault if the charging indicator lamp does not extinguish, see chapter 9.2.
The electric fuel pump starts when the starter switch is in the "II" position. This vents the fuel
line before each start.
Maximum preheating time should be 5-10 seconds.
Option ba
R
8.2 Option oa
Operating the battery isolating switch
T
Fig. 19 Battery isolating switch EN
IR
1 «Battery isolating switch»
I – on
0 – off
8.3 Option ea
Operating the tool lubricator
T
Fig. 20 Setting the tool lubricator
1 Tool lubricator
2 Metering knob
EN
3 Ball valve
A – open
B – closed
Further information See separate tool lubricator operating instructions for operation and maintenance of the tool lubri‐
AM
cator.
For suitable tool oil see chapter 2.7.1.
8.4.1 Option ba
Using the frost protector
Air flow through the frost protector is switched on just before shutting down the compressor.
T
Fig. 21
1
2
Shut-off valve
A – open
B – closed EN
Switching on the frost protector
➤ Open the shut-off valve 1 (position A) in the frost protector control line 2 before shutting down
the compressor.
AM
Further information Fill the frost protector with antifreeze (see chapter 10.7.2).
➤ Keep the shut-off valve in the frost protector control line permanently closed (position B).
8.4.2 Option bb
Coolant pre-heating
R
8.5 Option ua
Using the hose reel
The machine is fitted with an additional compressed air extension hose.
A hose reel is provided for safe storage of this hose.
➤ Check which hose reel is fitted to your machine.
T
EN
IR
Fig. 22 Hose reel (EC design)
1 Winding handle (fold out) 5 Securing holes
2 Hose reel 6 Hose reel side plate
3 Hose 7 Clamping screw
4 Hose coupling 8 Transport securing screw
AM
1. Check that the hose is firmly and evenly reeled in. Reel again, if necessary.
2. Locate the securing hole 5 in the reel's side plate 2 until it is aligned with the securing screw
8.
3. Engage the securing screw fully.
4. Tighten the clamping screw 7 .
T
EN
IR
AM
R
Further information Observe the instructions in chapter "Safety" and prevailing local safety regulations when rectifying
faults and malfunctions.
T
Further information See also the engine service manual.
EN
9.2.1 Engine refuses to start or comes to a stop
Possible cause Action Where can I get help?
Special‐ KAESER Engine
ised Service service
work‐ manual
shop
IR
Defective starter. Have changed. X – –
The fuel cut-off device has not Check the coil and electrics and X – –
opened. have changed if necessary.
Fuel tank empty. Fill up the fuel tank – – –
Airlock in the fuel line between Bleed the fuel line. – – X
AM
too high.
Defective temperature gauge Repair or have replaced if nec‐ – X –
switch giving no enable signal. essary.
Starter switch defective. Repair or have replaced if nec‐ – X –
essary.
Electrical connections and/or ca‐ Tighten connection or replace X – –
bles loose or broken. cable.
Defective battery or low charge. Maintain battery, see chapter – – –
10.6.
Defective alternator. Have changed. X – –
Defective alternator regulator. Change. X – –
T
Possible cause Action Where can I get help?
Special‐ KAESER Engine
EN
ised Service service
work‐ manual
shop
Airlock in the fuel line between Bleed the fuel line. – – X
fuel tank and injector pump.
Fuel filter clogged. Clean or replace, see chapter – – X
10.3.3.
IR
Fuel line broken. Have changed. X – –
Speed adjustment cylinder mal‐ Repair or have replaced if nec‐ X X –
adjusted or defective. essary.
T
replace if necessary.
Pressure gauge giving false Have repaired or replaced if – X
reading. necessary.
EN
Venting valve does not blow off. Check the connections and – X
function and have repaired or
replaced as necessary.
T
Tab. 51 Fault: pressure relief valve blowing off
EN
Possible cause Remedy Where can I get help?
Specialised KAESER Ser‐
workshop vice
Defective cooling fan. Have the blades or the complete – X
fan wheel replaced.
IR
Oil cooler clogged. Clean surface, see chap‐ – –
ter 10.4.8.
Defective working element in the Have repaired or replaced if – X
combination valve. necessary.
Working pressure too high (pro‐ Reset to the permissible value – X
portional controller maladjus‐ or have replaced.
AM
ted).
Oil separator cartridge heavily Measure the pressure differen‐ – X
clogged. tial and change the cartridge if
greater than 1 bar (see chap‐
ter 10.4.5).
Compressor oil filter clogged. Change, see chapter 10.4.4. – –
Compressor oil level too low. Top up (see chapter 10.4.2). – –
R
T
Tab. 53 Fault: too much oil residue in the compressed air
9.3.6 Oil flows from the compressor air filter after shutdown
EN
Possible cause Remedy Where can I get help?
Specialised KAESER Ser‐
workshop vice
Defective non-return function of Repair or have replaced if nec‐ – X
the inlet valve. essary.
IR
Tab. 54 Fault: oil flows from the compressor air filter after shutdown
AM
R
10 Maintenance
10.1 Safety
Follow the instructions below to ensure safe machine maintenance.
Warning instructions are located before a potentially dangerous task.
T
■ no personnel are working on the machine,
■ all protective guards and cover panels are screwed back on,
■ all tools have been removed from the machine.
EN
Working on pressure systems
1. WARNING!
Wear and machine damage through unusual applications or operating conditions.
➤ Maintenance tasks must be carried out more frequently when operating conditions are un‐
favourable (e.g. dusty atmosphere) or when the equipment is in constant use.
➤ Adjust the maintenance intervals with regard to local installation and operating conditions.
2. Keep a log of all properly carried out maintenance and service work.
This enables the frequency of individual maintenance tasks and deviations from our recom‐
mendations to be determined.
See chapter
T
Component
Note
50 h
Task
Engine:
EN
Change oil. X 10.3.4 Engine
SM
Change the oil filter. X Engine
SM
Wheels/chassis:
Tighten the wheel nuts. X
IR
h ≙ operating hours; Engine SM ≙ engine manufacturer's service manual
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 Engine
T
SM
Clean the engine air filter X 10.3.2 Engine
SM
EN
Change the engine oil X 10.3.4
Change the engine oil filter. X Engine
SM
Check the engine air intake line. X Engine
SM
Replace the engine air filter ele‐ X 10.3.2
ment.
IR
Adjust the valve clearance. X Engine
SM
SW
Have the turbocharger checked. X SW
AM
SM
Fill up the fuel tank. X
Check the fuel lines and clamps. X Engine
SM
Replace fuel lines and clamps. X Engine
SM
Clean the fuel filter. X Engine
SM
Change the fuel prefilter. X 10.3.3
Engine-SM ≙ engine manufacturer's service manual; SW ≙ specialized workshop; CM-SM ≙ chas‐
sis maintenance tasks.
chapter
Component
A1000
A1500
A2000
A3000
A250
A500
Daily
Note
See
Function
Replace the fuel filter. X Engine
SM
Clean the fuel tank. X
Clean the tank fuel strainer. X
Check the fuel return line for X
leakage and firm fixing.
Have the fuel injectors checked. X SW
T
Have the fuel injector pump X SW
checked.
Check the battery electrolyte X 10.3.6
EN
level and connections.
Compressor unit
Check inlet air filter mainte‐ X 10.4.6
nance indicator.
Check cooling oil level. X 10.4.1
Clean the compressor air filter. X 10.4.6
IR
Clean the oil cooler. X 10.4.8
Have the pressure relief valve X 10.4.7
checked.
Check/clean the oil separator X 10.4.5.1
tank dirt trap.
AM
chapter
Component
A1000
A1500
A2000
A3000
A250
A500
Daily
Note
See
Function
Check all screw connections, X
hinges, locks, catches, handles
and snap fasteners for wear and
secure fixing.
Grease the canopy hinges. X
Carry out rubber sealing strip X 10.6
maintenance.
T
Have the lifting eye checked. X SW
Other maintenance tasks
Check all accessible fittings, X
EN
pipes and clamps for wear and
tightness.
Check hoses for leaks and X
wear.
Check that all electrical connec‐ X
tions are tight.
Engine-SM ≙ engine manufacturer's service manual; SW ≙ specialized workshop; CM-SM ≙ chas‐
IR
sis maintenance tasks.
chapter
Option
A1000
A1500
A2000
A3000
A250
A500
Daily
Note
See
Function
Tool lubricator, option ea
Check the oil level in the tool lu‐ X 10.7.1 TL-SM
R
bricator.
Option ba – frost protector
Winter operation X 10.7.2
Check the level of antifreeze in
the frost protector.
Option la – spark arrestor
Clean the spark arrestor. X 10.7.3
Blow out the spark arrestor with X
compressed air.
TL-SM = Tool lubricator service manual; EL = refer to an electrician; SW = refer to a specialized
workshop; KS = call KAESER Service.
chapter
Option
A1000
A1500
A2000
A3000
A250
A500
Daily
Note
See
Function
Option lb - engine air intake shut-off valve
Clean and check the engine air X 10.7.4
intake shut-off valve
Fuel filter with water trap, option ne
X 10.3.3.1
TL-SM = Tool lubricator service manual; EL = refer to an electrician; SW = refer to a specialized
workshop; KS = call KAESER Service.
T
Tab. 58 Regular maintenance tasks for options
EN
10.3 Engine
➤ Carry out maintenance according to the schedule in chapter 10.2.3.1.
WARNING
R
CAUTION
There is danger of injury 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.
CAUTION
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.
T
EN
IR
AM
Top up when the coolant level falls below the minimum level B .
The coolant is a mixture of clean, fresh water and antifreeze/corrosion inhibitor. For reasons of cor‐
rosion protection and the need to raise the boiling point, the coolant must remain in the cooling sys‐
tem throughout the year. Maximum frost protection is ensured with an antifreeze concentration of
55% volume as frost protection and heat transfer properties deteriorate beyond this point.
The maximum permissible coolant life is 2 years.
1. CAUTION!
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. Slowly open the cap on the coolant filler by a quarter to half of a turn to allow pressure to es‐
cape.
3. Then remove the filler cap completely.
4. Use the coolant tester as instructed by the manufacturer to test the coolant.
T
Change the coolant when the concentration of antifreeze is too low.
5. Mix the concentration of antifreeze as shown in the table.
EN
Description Antifreeze concentra‐ Water percentage Freezing point
tion [% vol.] [°C]
[% vol.]
Minimum required anti‐ 40 60 −25
freeze concentration
Minimum required anti‐ 50 50 −37
freeze concentration for
IR
topping up
Maximum permissible an‐ 55 45 −45
tifreeze concentration
Make sure that there is sufficient room for the coolant to expand when hot without overflow‐
ing.
1. Slowly open the cap on the coolant filler by a quarter to half of a turn to allow pressure to es‐
cape.
2. Then remove the filler cap completely.
3. Mix a quantity of coolant according to the table and top up to the mark.
R
The radiator drain plug 2 can be reached through a hole in the floor pan.
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1 Radiator
2 Radiator drain plug
EN
1. Have a coolant receptacle ready.
2. Unscrew the expansion tank cap (see Fig. 23).
3. Loosen and remove the drain plug 2 .
mands.
Renew the air filter element after 2 years at the latest or after it has been cleaned 5 times.
T
Fig. 25 Engine air filter maintenance
1
2
3
4
Filter housing
Air filter element
Filter cap
Spring retaining flap
EN 7
8
9
Reset knob for the maintenance indicator
Red zone indicator scale
Indicating piston of the maintenance indi‐
cator
IR
5 Dust evacuating valve 10 Valve part
6 Maintenance indicator 11 Drain slit
Air filter maintenance is necessary when the yellow piston inside the maintenance indicator 6 rea‐
AM
The dust evacuator valve 5 must be at the bottom. The dust evacuation valve is on the filter
cap 3 .
R
1. Press both spring retaining flaps 4 together and remove the filter cap 3 .
2. Withdraw the filter element 2 .
3. Clean the filter housing 1 , filter cap 3 and sealing surfaces.
4. To empty the dust evacuator valve 5 :
■ Pinch the valve part 10 above the drain slit 11 (drain slit opens).
■ Remove any dust clumps.
■ Clean the slit.
T
10. Press on the cap until the spring retaining flaps snap home.
11. Check that:
■ the filter cap is properly seated,
EN
■ both spring retaining flaps are secure,
■ the dust evacuator valve is at the bottom.
Cleaning cloth
DANGER
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.
➤ Stop the engine.
➤ Wipe up escaped fuel.
➤ Keep fuel away from hot machine parts.
➤ Ensure that the maximum ambient temperature is not exceeded at the place of use.
The electric fuel pump is used to bleed the system. The negative battery terminal must be connec‐
ted for the pump to operate and bleeding to be carried out.
When the starter switch is turned to the "II" position, the pump starts and bleeds the fuel system.
The engine is not started!
Air can find its way into the fuel system under certain conditions or maintenance tasks:
■ Fuel tank empty.
■ Replacing the filter element/cartridge of:
─ Fuel pre-filter
─ Main fuel filter
■ Replacing the fuel pump
T
■ Work on the fuel lines
EN
IR
AM
The filter cartridge of the main fuel filter should be changed according to the maintenance sched‐
T
ule.
Use a filter wrench to loosen the cartridge if necessary.
EN
1. Place a receptacle under the filter cartridge 5 .
2. Unscrew and remove the cartridge 5 .
3. Take a new filter cartridge.
4. Smear fuel on the gasket.
5. Spin on the new oil filter by hand until the gasket is firmly seated.
6. Bleed the system as described previously.
IR
Catch any escaping fuel.
Dispose of escaped fuel, contaminated fuel and working materials and components contami‐
nated with fuel according to environmental regulations.
10.3.3.1 Option ne
Maintenance of the fuel prefilter with water trap
R
A combined water trap and filter element is used to clean the fuel.
Material Spares
Wrench
Receptacle
Cleaning cloths
Option ne
T
2 Filter element 4 Drain plug
EN
The water trap is semi-transparent so the fuel level can be seen from outside.
■ Water, being denser than diesel fuel, sinks to the bottom of the water trap.
■ The presence of water can be verified by its different colour to the fuel.
A check should be made daily as to whether water and dirt has accumulated.
1. Raise the canopy.
2. Check the fuel in the water trap.
IR
The water trap should be emptied when dirty.
3. Close the canopy.
The interval between filter element changes is dependent on fuel quality and cleanliness.
The fuel tank should be nearly empty when the filter element is changed.
T
Change the gasket if defective.
9. Smear some clean fuel on the gasket.
10. Check that the drain plug 4 under the separator bowl is tight.
EN
Screw in the plug if it is loose.
11. Fill the filter element 2 with clean fuel.
12. Screw the filter element 2 carefully into the filter head 1 .
13. Reconnect the battery.
14. Close the canopy.
Material New engine oil, see chapter 2.6.4 for engine oil filling quantity.
Receptacle
New gasket for the drain plug
Cleaning cloth
Funnel
CAUTION
Danger of burns from hot components and escaping engine oil!
➤ Wear long-sleeved clothing and gloves.
T
Fig. 28 Changing the engine oil
EN
IR
1 Oil filler cap 4 Engine block
2 Oil filter 5 Oil pan
3 Oil dipstick 6 Oil drain plug
1. Place the oil receptacle below the corresponding drain hole in the floor pan.
2. Unscrew and remove the oil filler cap 1 .
3. Undo and remove the oil drain plug 6 .
All the old oil must be drained out.
4. Replace the drain plug with a new gasket and tighten.
Dispose of old oil and oil-soaked working materials according to environmental protection
regulations.
R
Further information See engine service manual for oil change under dusty conditions.
1. Pour in the specified volume of fresh oil into the oil filler.
2. Screw on the filler cap 1 .
1. Pull out the dip stick 3 , wipe it clean and reinsert it.
2. Pull out the dip stick once more and read off the oil level.
3. Top up if the level is too low.
4. Reconnect the negative cable to the battery.
T
10.3.4.1 Option oe
Draining engine oil via the shut-off valve
EN
Material See chapter 2.6.4 for engine oil filling quantity.
Receptacle
New gasket for the drain plug
Funnel
Cleaning cloths
CAUTION
Danger of burns from hot components and escaping engine oil!
➤ Wear long-sleeved clothing and gloves.
R
Material Spares
Common tools
Cleaning cloths
Receptacle
T
The machine is fully vented, the pressure gauge reads 0 bar.
Engine cooled down.
All compressed air consumers are disconnected and the air outlet valves are open.
EN
CAUTION
Danger of burns from hot components and escaping engine oil!
➤ Wear long-sleeved clothing and gloves.
IR
AM
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.
10.3.6.1 Safety
T
WARNING
Danger of acid burns from escaping electrolyte.
➤ Wear appropriate protective clothing including acid-proof rubber gloves.
EN
➤ Always wear eye and face protection.
➤ Do not tip the battery. Electrolyte may run out of the vent holes.
➤ Work with caution.
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.
T
The machine is standing level.
The machine is fully vented, the pressure gauge reads 0 bar.
Machine cooled down.
EN
1. Clean the casing and terminals.
2. Lightly grease the terminals to prevent corrosion.
3. Check that connections are tight and tighten if necessary.
The fluid is generally sufficient for the life of the battery. Nevertheless, the fluid level should be
IR
checked annually. The level should be up to the mark, 1 cm above the plates.
If a battery casing leaks fluid, the battery must be replaced immediately.
1. WARNING!
Battery destruction!
AM
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 fluid level
If the fluid level does not reach the mark -
➤ top up with distilled water.
R
Winter operation
Batteries are particularly stressed in winter. Only a fraction of the normal starting energy is availa‐
ble at low temperatures.
1. CAUTION!
Danger of batteries freezing.
Discharged batteries are subject to frost damage and can freeze at −10 °C.
➤ Check battery charge with a specific gravity tester.
➤ Recharge the battery
➤ Clean the battery terminals and wipe with 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 heavy-duty cold-start batteries (to DIN 75311) and/or additional
batteries is recommended.
T
1. WARNING!
There is danger of batteries bursting.
If a battery is short circuited it will overheat and can burst.
EN
Battery electrolyte will be sprayed out in such an event.
➤ Never short-circuit a battery (e.g. with a hand tool).
➤ Always wear protective gloves.
2. CAUTION!
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.
IR
3. Disconnect the negative cable first, then the positive cable.
4. Unscrew the battery fixing clamp.
5. Replace in the reverse order.
Battery replacement
AM
Replacement batteries must have the same capacity, current strength and form as the original bat‐
teries.
➤ Always replace a battery with one of the same type.
Old batteries are special waste and must be disposed of correctly in accordance with local
environment protection regulations.
R
10.4 Compressor
➤ Carry out maintenance according to the schedule in chapter 10.2.3.1.
Material Wrench
Cleaning cloths
T
Fig. 32 Checking cooling oil level
1 Oil separator tank
EN A Mark for minimum oil level
IR
2 Oil filler port B Mark for maximum oil level
3 Screw plug
1. Slowly unscrew and withdraw the plug 3 from the oil filler port.
2. Check that oil is visible.
Top up if no oil is visible.
AM
Cleaning cloths
A sticker on the oil separator tank specifies the type of oil used.
1. CAUTION!
The machine could be damaged by unsuitable oil.
➤ Never mix incompatible types of oil.
➤ Never top up with a different type of oil to that already used in the machine.
2. Slowly unscrew and withdraw the plug from the oil filler port.
3. Top up the cooling oil to the maximum level with the help of a funnel.
4. Check the oil level.
5. Check the filler plug gasket for damage.
Change a damaged gasket immediately.
6. Replace the plug in the filler port.
7. Reconnect the negative cable to the battery.
T
Starting the machine and carrying out a trial run
EN
1. Start the machine and run in idle up to operating temperature.
2. Close the outlet valves.
3. Shut down the machine.
4. Wait until the machine has automatically vented.
Pressure gauge reads 0 bar.
5. Open the outlet valves.
6. Check the oil level after about 5 minutes.
IR
Top up if necessary.
7. Carry out a visual check for leaks.
CAUTION
There is risk of burns from hot components and escaping oil.
➤ Wear long-sleeved clothing and gloves.
T
Fig. 33 Changing the cooling oil
1
2
3
4
Oil separator tank
The separator tank and oil cooler drain plugs are accessible through holes in the floor pan.
1. Remove the plug 4 from the oil separator tank 1 filling port.
2. Position the receptacle below the separator tank drain plug 2 .
AM
3. Unscrew the drain plug 2 on the separator tank and allow the oil to drain into the receptacle.
4. Fit a new gasket on the drain plug 2 and screw it back in again.
5. Place the receptacle beneath the oil cooler 5 .
6. Unscrew the drain plug 6 and allow the cooling oil to drain into the receptacle.
7. Fit a new gasket on the drain plug 6 and screw it back in again.
8. Fill up the cooling oil using a funnel.
9. Check the cooling oil level.
R
10.4.3.1 Option oe
Draining cooling oil via the shut-off valve
T
New gasket for the drain plug
Funnel
Cleaning cloths
EN
Precondition Machine shut down
The machine is standing level.
The machine is at operating temperature.
The machine is fully vented, the pressure gauge reads 0 bar.
All compressed air consumers are disconnected and the air outlet valves are open.
The negative cable to the battery is disconnected.
IR
CAUTION
There is risk of burns from hot components and escaping oil.
➤ Wear long-sleeved clothing and gloves.
AM
R
T
CAUTION
There is risk of burns from hot components and escaping oil.
➤ Wear long-sleeved clothing and gloves.
EN
IR
Fig. 35 Changing the oil filter
AM
1. Prepare a receptacle.
2. Loosen the filter 3 by turning anticlockwise 4 and catch any escaping oil.
3. Carefully clean sealing surfaces using lint-free cloth.
R
T
The life of the oil separator cartridge is influenced by:
EN
─ Cooling oil
─ Oil filter
─ Air filter
Material Spares
Cleaning cloths
T
Fig. 36
1
2
3
4
EN
Changing the oil separator cartridge
Control air line union nut
Oil scavenge pipe union nut
Compressed air hose union nut
Dirt trap
6
7
8
9
Fixing screw
Cover
Oil separator cartridge
Gasket
IR
5 Oil scavenge pipe 10 Metal clip
The dirt trap must be cleaned/changed when the oil separator cartridge is changed.
Maintain dirt trap, (see chapter 10.4.5.1).
AM
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 tank are electrically coupled. The gaskets 13 have metal
clips 14 to make contact with the oil separator tank and the machine frame.
8. Insert the new oil separator cartridge with gaskets and screw down the cover.
9. Replace and tighten all fittings.
10. Check the oil level in the oil separator tank.
Top up if necessary.
11. Reconnect the negative cable to the battery.
Dispose of the old separator cartridge and gaskets, along with any working materials conta‐
minated with cooling oil, in accordance with environment protection regulations.
Changing the oil separator cartridge with the frost protector option is carried out as described
above.
In addition, the frost protector must be emptied and its fittings undone.
Be careful of the frost protector control lines when removing the separator tank cover.
1. Empty the lower part of the frost protector. See chapter 10.7.2 on frost protector maintenance.
2. Remove the screws fixing the frost protector to the cover.
3. Lift the cover carefully and remove the frost protector control lines if necessary.
T
2. Close the outlet valves.
3. Shut down the machine.
4. Wait until the machine has automatically vented.
EN
Pressure gauge reads 0 bar.
5. Open the outlet valves.
6. Check the oil level after about 5 minutes.
Top up if necessary.
7. Carry out a visual check for leaks.
T
10.4.6 Air filter maintenance
EN
The air filter must be cleaned at the latest when the corresponding maintenance indicator de‐
mands.
Renew the air filter element after 2 years or after it has been cleaned 5 times.
T
Fig. 38
1
2
3
4
Washer
Filter cap
Air filter element
EN
Compressor air filter maintenance
Wing nut 6
7
8
9
Maintenance indicator
Airend
Reset knob for the maintenance indicator
Red zone
IR
5 Inlet valve 10 Indicator piston
Air filter maintenance is necessary when the yellow piston inside the maintenance indicator 6 rea‐
ches the red zone 9 .
AM
T
10.4.8 Cooler/radiator cleaning
EN
The frequency is mainly dependent on local operating conditions.
Heavy clogging of the cooler/radiator can cause oil overheating and overheating of the engine.
Check the cooler/radiator regularly for clogging.
Avoid creating dust eddies. Wear breathing protection if necessary.
Do not clean the cooler/radiator with a sharp instrument, otherwise they could be damaged.
A severely contaminated cooler/radiator should be cleaned by KAESER Service.
IR
Material Compressed air
Water or steam jet blaster
Precondition Machine placed over a washing point equipped with an oil separator.
The machine is shut down.
Machine cooled down.
AM
CAUTION
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.
R
➤ 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 the starter or instru‐
ments.
T
Fig. 39 Cooler/radiator cleaning
1 Rear of the machine
EN
2 Direction of impacting water or steam jet (from outside to inside).
1. Seal off the air intakes of the engine and compressor air filters before starting cleaning.
2. Remove the cooler/radiator trim.
3. Clean the cooler/radiator with compressed air, water or steam jet in the opposite direction to
the cooling air flow.
4. Replace the cooler/radiator trim.
IR
5. Remove the protective coverings from the air filters.
6. Reconnect the battery.
7. Start the machine and run up to operating temperature so that excess water is evaporated.
Clean the cooler/radiator only in a washing area equipped with an oil separator.
AM
10.5 Chassis
➤ Note the instructions in the separate documents:
■ "Chassis maintenance"
■ Chassis manufacturer's operating instructions
R
T
2. Clean and oil all sliding and rotating bearings.
The locking teeth on the towbar height adjustment joint are corroded and jammed and the
towbar height cannot be adjusted.
EN
➤ If necessary, free the teeth by jerking the towbar horizontally and vertically.
➤ Clean the locking teeth and smear with water-repellent grease.
Greasing points
Option Portrayal
sb 2
2 3
R
4
1
1. Use a grease gun 2 on all nipples 3 until grease flows from the bearing points.
2. Lubricate the serrated joints 1 with an acid-free oil 4 .
T
Grease the brake rods when necessary (stiff movement) but at least annually.
EN
Cleaning rags
Material Screwdriver
Torch
AM
10.7 Options
➤ Carry out maintenance tasks in accordance with the schedules in chapter 10.2.3.2 .
T
10.7.1 Option ea
Tool lubricator maintenance
EN
Material Tool oil (special lubricant for road breakers),
Funnel
Cleaning cloths
2. Slowly unscrew and withdraw the plug 2 from the oil filler port.
A dipstick is attached to the plug.
3. Wipe off the dipstick with a lint-free cloth or rag and screw the plug fully in again.
4. Unscrew and withdraw the plug once more and read off the oil level on the dipstick.
The oil level should be in the upper third of the dipstick. Top up if the oil does not reach this
level.
1. Use the funnel to top up oil to 10 - 15 mm below the top of the oil tank
(see chapter 2.7.1 for oil grade and quantity).
2. Check the oil level again.
T
3. Check the filler plug gasket for damage.
Change a damaged gasket immediately.
4. Replace the plug 2 in the filler port.
EN
10.7.2 Option ba
Frost protector maintenance
At temperatures under 5°C, the level of antifreeze in the protector must be checked daily before
starting the compressor.
All compressed air consumers are disconnected and the air outlet valves are open.
DANGER
Danger of fire or explosion caused by the spontaneous ignition of antifreeze.
➤ Never top up antifreeze unless the machine is stopped and cooled down.
WARNING
Danger of injury from compressed air!
The frost protector is under pressure when operating; serious injury can result from loosen‐
R
Option ba
T
Fig. 42 Filling the frost protector
1
A
B
Shut-off valve
Open
Closed
EN 2
3
Bowl clamp ring
Frost protector bowl
IR
1. Open the shut-off valve ( A ) and wait about 30 seconds until the frost protector is fully depres‐
surised.
2. Unscrew the clamp ring 2 and remove the bowl 3 .
3. Fill the bowl ¾ full with antifreeze.
4. Screw the bowl carefully back into place.
AM
10.7.3 Option la
Spark arrestor cleaning
The spark arrestor must be cleaned of any soot residue every two months to prevent the emission
of glowing particles from the exhaust silencer.
R
DANGER
Danger of suffocation from toxic exhaust fumes.
Exhaust fumes from internal combustion engines contain carbon monoxide, which is odour‐
less and deadly.
➤ Use the machine only outdoors!
➤ Do not inhale exhaust fumes.
CAUTION
Danger of burns from hot components and sparks.
➤ Wear long-sleeved clothing and gloves.
➤ Wear eye protection.
T
Fig. 43 Spark arrestor cleaning
EN
IR
1 Exhaust silencer with integrated spark ar‐ 3 Exhaust discharge pipe
restor 4 Exhaust inlet pipe
2 Soot drain plug
Result Soot will drain through the hose into the receptacle.
10.7.4 Option lb
Engine air intake shut-off valve maintenance
Material Compressed air for blowing out
Cleaning fluid or spirit
Cleaning cloths
T
WARNING
The engine air intake shut-off valve does not function.
The engine does not stop when taking in flammable gas.
Destruction of the engine and explosion or fire are possible.
EN
The engine stops when the compressor is switched to LOAD (high speed).
➤ Do not move the valve adjusting screw.
➤ Refer any problems with the valve setting or function to a specialist workshop or
KAESER Service.
IR
AM
1. WARNING!
Engine air intake shut-off valve sticks.
The valve does not close completely. The engine does not stop when taking in flammable gas.
Destruction of the engine and explosion or fire are possible.
➤ Do not grease the valve, as this may cause a build up of dust and valve sticking.
2. Loosen the hose clamp 3 on the filter side of the valve 4 and turn the air intake hose 2 to
one side.
Check the engine air intake shut-off valve for correct function and movement
T
Result Have the valve changed if it is heavily worn or malfunctions in any way.
EN
3. Run the machine under LOAD.
If the engine stops on switching to LOAD, have the valve adjusted by a specialist workshop or
KAESER Service.
IR
AM
R
T
EN
IR
AM
R
T
selected for use in KAESER machines.
WARNING
There is risk of personal injury or damage to the machine resulting from the use of unsuita‐
EN
ble spares or operating fluids/materials.
Unsuitable or poor quality consumable parts and operating fluids/materials may damage the
machine or impair its proper function.
Personal injury may result from machine damage.
➤ Use only original KAESER parts and operating fluids/materials.
➤ Have an authorized KAESER Service Technician carry out regular maintenance.
IR
Compressor
T
11.4 Service Addresses
EN
Addresses of KAESER agents are given at the end of this manual.
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1. Carry out the following de-commissioning procedures.
2. Place a notice on the instrument panel describing the de-commissioning procedures carried
out.
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12.1.1 Temporary decommissioning
Decommissioning for about 4 months.
1. Disconnect the battery (the minus terminal first and then the plus terminal).
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2. Close off the following openings with plastic foil and moisture-resistant adhesive tape.
■ Engine air inlet
■ Compressor air inlet
■ Exhaust
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3. Hang the following notice on the instrument panel informing of the decommissioning measure‐
ments taken.
Attention!
1. The machine is temporarily decommissioned.
2. The following machine openings have been covered:
1. CAUTION!
Danger of batteries freezing.
Discharged batteries are subject to frost damage and can freeze at −10 °C.
➤ Store batteries in a frost-free place.
➤ Store batteries preferably fully charged.
2. Remove the battery (batteries) and store in a frost-free room.
3. Make sure batteries are fully charged.
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Decommissioning the machine for 5 months or longer.
Material Receptacle
Preserving oil
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Preservative
Desiccant
Plastic foil
Moisture-resistant adhesive tape
10.4.2
➤ Run the machine for about 10 minutes to coat all parts with a pro‐ –
tective oil film.
➤ Disconnect the battery, the minus terminal first and then the plus –
terminal, 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‐ –
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➤ Hang the following notice on the instrument panel informing of the decommissioning measure‐
ments taken.
Attention!
1. The machine is decommissioned.
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2. It is filled with preserving oil.
3. For recommissioning -
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■ Recommission according to service manual.
Date / signature
Any loose or movable parts that may fall when transporting, removed or secured.
Allow transportation only by personnel trained in safely dealing with motor vehicles and the trans‐
porting of goods.
1. WARNING!
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.
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Additional loading
Do not exceed the permissible loading (overall weight, coupling load, axle load).
Observe national traffic laws. Any essential but excessive additional loads must be carried by 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 and secure carefully.
Considerable snow or ice may build up on the machine under low temperature conditions.
1. CAUTION!
There is danger of accidents caused by snow or ice falling off the machine.
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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.
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➤ Do not tow the machine if it is covered by snow or ice.
2. Remove any snow or ice before towing.
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.
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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 canopy.
Adjust the towbar to suit the height of the towing vehicle hitch.
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When the machine is coupled up, the towbar must be parallel with the ground.
See chapter 6.3 for the height adjustment.
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1. WARNING!
Unstable towing alignment.
Personal injury may result from towing.
Stability problems with the machine or towing vehicle.
Damage to the machine towbar or vehicle tow hitch.
➤ Do not couple up the machine at an angle to the towing vehicle.
➤ Ensure that the towbar is horizontal when coupled to the towing vehicle.
2. Adjust the towbar height to suit the height of the hitch on the towing vehicle.
Coupling-up
To couple up the compressor, lower the open coupling onto the ball hitch of the towing vehicle so
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that it clicks into place. The coupling mechanism closes automatically. The coupling release lever
springs back to the horizontal position. The locking indicator shows green. If the locking indicator
does not show green, try pushing the release down to the horizontal.
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1. CAUTION!
There is considerable danger of injury caused by trapped fingers.
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1. Check that the coupling is properly latched onto the towing hitch.
2. Check that the towbar is adjusted to the correct height. See also chapter 6.3.
Check that:
■ The teeth in the tow bar height adjusting joints are fully engaged
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■ The locking levers are tightened
■ The split pin is fully inserted.
3. Wind the support full up.
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4. Check that the wheels are securely fitted and the tyres are in good condition.
5. Check the tyre pressures.
6. Connect the cable for the lighting and indicator systems and carry out a function check.
7. Remove the chocks.
1. Check that the coupling is properly latched onto the towing hitch.
2. Wind the jockey wheel to its uppermost position.
3. Check that the wheels are securely fitted and the tyres are in good condition.
4. Check the tyre pressures.
5. Connect the cable for the lighting and indicator systems and carry out a function check.
6. Release the parking brake and remove the chocks from under the wheels.
Option sh
1. WARNING!
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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.
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➤ Replace missing chocks immediately.
2. Check that the coupling is properly latched onto the towing hitch.
3. Wind the support to its uppermost position.
4. Check that the wheels are securely fitted and the tyres are in good condition.
5. Check the tyre pressures.
6. Attach the lighting and indicator systems and carry out a function check.
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7. 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 sb, sd, se Emergency braking in the case of breakaway from the towing vehicle
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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.
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1. CAUTION!
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 towbar.
3. Loop the end of the cable round the towing vehicle hitch and secure with the spring clip.
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The towbar may be provided with two safety chains as additional protection against breakaway
from the towing vehicle (see 10).
If these are provided, it is essential that they be attached to the towing vehicle before towing.
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1. Pick up the ends of the chains and cross the chains.
2. Loop the ends over the hooks provided on the towing vehicle.
3. If no special hooks are provided, secure the chains to the ball hitch.
CAUTION
Injury can occur if the towbar is unsupported and allowed to fall.
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Fig. 49 Injury can occur if the towbar is unsupported and allowed to fall.
Option sb, sd, se Carry out the following when parking the compressor
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Option sa, sh Carry out the following when parking the compressor
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Fig. 50 Safety sign - secure the chocks
1. WARNING!
Machine without parking brake.
Serious injury or death can result from an unchocked machine rolling away.
➤ Securely chock the machine before uncoupling.
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➤ As a general rule, the machine should always be chocked when it is not being moved.
➤ The machine should not be manoeuvred by hand.
2. Wind down the jockey wheel.
3. Place chocks under the wheels.
4. Dismantle the lighting and signalling system.
5. Uncouple the compressor from the towing vehicle.
■ Pull up the coupling release lever.
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12.2.2.1 Option sf
Using the anti-theft device
CAUTION
Machine damage due to excessive static load on the axles
➤ Never place an excavator bucket as anti-theft protection on the machine's enclosure.
Use only the safety chain (available as option) to secure a parked machine against theft.
1. Remove the safety chain from the storage locker on the machine.
2. Loop the safety chain around a solidly anchored object.
3. Secure the chain with the lock.
CAUTION
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Components may break.
➤ Release the chained machine.
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The safety chain must be released prior to transport to prevent the destruction of machine compo‐
nents.
1. Open the lock.
2. Remove the safety chain from the solidly anchored object.
3. Place the safety chain in the storage locker on the machine.
Considerable snow or ice may build up on the machine under low temperature conditions.
This may adversely effect the machine's centre of gravity.
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It is possible that the permissible loading on the crane or lifting eye is exceeded.
➤ Additional measures should be taken under conditions of snow or ice.
■ 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.
A lifting eye is provided for transporting with a crane. The lifting eye is located beneath a lift-up cov‐
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1. CAUTION!
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.
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Packing and securing methods must be such that, assuming proper handling, the goods arrive in
perfect condition at the destination.
Consult KAESER Service for advice concerning sea or air transport.
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Material Chocks
Restraints or timber balks
Straps
1. CAUTION!
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 for damages arising through incorrect transport methods or in‐
sufficient or wrong securing of loads.
The transport restraints on rented, hired or exhibition machines should be re-used for the re‐
turn journey.
The machine is designated as dangerous goods for air freight purposes; any disregard can result in
a heavy fine.
1. DANGER!
Danger of fire or explosion from operating fluids/materials.
The machine incorporates an internal combustion engine.
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➤ Any dangerous fluids/materials contained within the machine must be removed before
transport.
2. Remove all dangerous fluids/materials.
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These include:
■ Residues of fuel or fuel vapours
■ Lubricating and cooling oils in the engine and compressor unit
■ Battery electrolyte
12.3 Storage
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Moisture can lead to corrosion, particularly in the engine, airend and oil separator tank.
Frozen moisture can damage components, valve diaphragms and gaskets.
Advice can be obtained from KAESER on storage and commissioning.
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CAUTION
Moisture and frost can damage the machine.
➤ Prevent ingress of moisture and formation of condensation.
➤ Maintain a storage temperature of >0 °C.
12.4 Disposal
When disposing of a machine, drain out all liquids and remove old filters.
➤ Parts contaminated with cooling oil or engine oil must be disposed of in accordance with
local environment protection regulations.
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13 Annex
13.1 Marking
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Fig. 52 Marking
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VIN *) (stamped under the reflector)
*Vehicle identity number
Machine nameplate with serial number
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Engine nameplate with serial number
Combined label for coupling loading and
built-in options
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13.2 Pipeline and instrument flow diagram (P+I diagram)
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13.3.2 Option sb
Dimensional drawing - chassis with height-adjustable tow bar
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13.3.3 Option sd
Dimensional drawing - fixed height towbar and parking brake
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13.3.4 Option se
Dimensional drawing - fixed height towbar and overrun brake
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13.5 Option tc
Lighting and signalling system connection
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