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KAESER M122 Service Manual

Manual is about: Portable compressor

Summary of M122

  • Page 1

    Service manual portable compressor m122 no.: 9_6974 20 e manufacturer: kaeser kompressoren gmbh 96410 coburg • po box 2143 • germany • tel. +49-(0)9561-6400 • fax +49-(0)9561-640130 http://www.Kaeser.Com ramirent.

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    Original instructions /kkw/m122 2.00 en sba-mobilair 20110303 105803 ramirent.

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    1 regarding this document 1.1 using this document ......................................................................................................... 1 1.2 further documents .......................................................................................................... 1 1.3 copyrig...

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    3 safety and responsibility 3.1 basic instructions ............................................................................................................. 17 3.2 specified use .................................................................................................................... 1...

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    6.4 adjusting the chassis ....................................................................................................... 52 6.4.1 adjusting the towbar height ................................................................................ 53 6.4.2 changing the towing eye ......................

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    10.3.3 fuel system maintenance ................................................................................... 93 10.3.4 checking the engine oil level .............................................................................. 97 10.3.5 engine oil filling and topping up .........................

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    13 annex 13.1 identification ..................................................................................................................... 240 13.2 pipeline and instrument flow diagram (p+i diagram) ....................................................... 240 13.3 dimensional drawings ..........

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    Contents vi service manual portable compressor m122 no.: 9_6974 20 e ramirent.

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    Fig. 1 location of safety signs .............................................................................................................. 26 fig. 2 bodywork .................................................................................................................................... 31 fi...

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    Fig. 55 draining cooling oil ..................................................................................................................... 113 fig. 56 draining the cooling oil (closed floor pan - stationary machine) ................................................. 114 fig. 57 changing the o...

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    Tab. 1 danger levels and their definitions (personal injury) .................................................................. 1 tab. 2 danger levels and their definition (damage to property) ............................................................ 2 tab. 3 nameplate ..............................

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    Tab. 55 indicator lamp remains on .......................................................................................................... 73 tab. 56 fault: working pressure too high ................................................................................................ 74 tab. 57 fault: ...

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    1 regarding this document 1.1 using this document the operating manual is a component of the product. It describes the machine as it was at the time of first delivery after manufacture. ➤ keep the operating manual in a safe place throughout the life of the machine. ➤ supply any successive owner or u...

  • Page 14

    Danger these show the kind of danger and its source. The possible consequences of ignoring a warning are shown here. If you ignore the warning notice, the "danger" signal word indicates a lethal or severe in‐ jury will occur. ➤ the measures required to protect yourself from danger are shown here. Wa...

  • Page 15

    Result shows the expected conclusion of the previous action. ➤ information relating to one option only are marked with an option code (e.G., "option da" means that this section is only valid for machines with the air treatment components "aftercooler and cyclone separator"). Option codes used in thi...

  • Page 16

    2 technical specifications 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 identit...

  • Page 17

    M122 part number serial number: options fitted here is given the specified coupling load. 02-m0277 pa sg sf tc tb ta sc sd sa sh si oa oe lb lc la ba bb fa ec te dd dc db da ea fc hd hc cb ca tab. 4 combined label for coupling load and options fitted. ➤ take a list of fitted options from the combine...

  • Page 18

    Option option code available? Separated compressed air lines downstream of the option fc tab. 7 compressed air distributor option 2.2.4 option hc, hd check valve function option option code available? Pressure/check valve (without option dd) hc pressure/check valve (with option dd) hd tab. 8 non-ret...

  • Page 19

    Option option code available? Spark arrestor and engine air intake shut-off valve (automatic) lb tab. 12 optional equipment for fire hazard areas 2.2.9 option oa battery isolating switch option option code available? Battery isolating switch oa tab. 13 optional battery isolating switch 2.2.10 option...

  • Page 20

    2.2.13 option sf anti-theft device option option code available? Anti-theft device sf tab. 17 optional anti-theft device 2.2.14 option sg pedestrian protection option option code available? Pedestrian protection sg tab. 18 pedestrian protection option 2.2.15 option pa instrument panel cover option o...

  • Page 21

    Sound pressure level m122 guaranties sound pressure level [db (a)] 76 tab. 22 sound pressure level [db(a)] 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 tab. 23 torques for hex-head ...

  • Page 22

    Feature chassis stationary height adjustment with without – actual total weight [kg]* permissible axle load [kg] 1900 1900 – * enter here for reference, the actual total weight taken from the nameplate. Tab. 25 mass of the machine 2.4.2 tyres characteristic/marking value dekkdimensjon 195 r 14c maxi...

  • Page 23

    2.5.2 compressed air outlet outlet valve ["] number g 3/4 3 g 1 1/2 1 tab. 30 compressed air distributor 2.5.3 pressure relief valves maximum working pressure: see machine nameplate maximum working pres‐ sure [bar] activating pressure [bar] pressure relief valve * pressure relief valve ** 7 9.5 – 8....

  • Page 24

    Characteristic sigma fluid oil grade s–460 mol application standard oil for all applications except in connection with foodstuffs. Particularly suitable for machines with a high duty cycle. Standard oil for all applications except in connection with food‐ stuffs. Particularly suitable for machines w...

  • Page 25

    Feature specification type of fuel diesel * fuel consumption under load mode [l/h] 20.5 oil consumption related to fuel consumption [%] approx. 0.5 * use only diesel fuel to en 590 or astm d975. Consult the engine manufacturer on the use of other fuels if necessary. Tab. 35 engine data 2.6.2 oil rec...

  • Page 26

    Do not use a standard coolant / antifreeze that only meets the requirements of astm d3306. Such coolants are intended only for light use in vehicles and could shorten the useful life of the engine. The engine service manual gives further information on coolant application. 2.6.4 fluid volumes descri...

  • Page 27

    2.7.3 option ba low temperature equipment 2.7.3.1 ambient conditions positioning limit value maximum altitude amsl* [m] 1000 minimum ambient temperature [°c] −25 maximum ambient temperature [°c] +50 * higher altitudes are permissible only after consultation with the manufacturer. Tab. 42 environment...

  • Page 28

    Feature data degree of particle separation [%] (by mass) ≥99 (elementary carbon) ambient temperature [°c] −20 ..... +50 protection rating ip 65 * use only diesel fuel to en 590 or astm d975. Consult the engine manufacturer on the use of additives. Tab. 46 diesel particulate filter data 2 technical s...

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    3 safety and responsibility 3.1 basic instructions the machine is manufactured to the latest engineering standards and acknowledged safety regula‐ tions. Nevertheless, dangers can arise through its operation: ■ danger to life and limb of the operator or third parties, ■ impairments to the machine an...

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    3.4.2 determining personnel suitable personnel are experts who, by virtue of their training, knowledge and experience as well as their knowledge of relevant regulations can assess the work to be done and recognize the pos‐ sible dangers involved. Authorised operators possess the following qualificat...

  • Page 31

    ➤ carry out oil changes to bgr 500, chapter 2.11. The user must ensure that the cooling oil is changed as required or at least annually and the oil change must be documented. Intervals may be varied if an analysis proves that the oil is still usable. ➤ keep to inspection intervals in accordance with...

  • Page 32

    ➤ do not inhale exhaust fumes. ➤ never use the machine in enclosed spaces, only in the open. ➤ direct the exhaust fumes to the open air with a pipe of at least 100 mm diameter. Fire and explosion spontaneous ignition and combustion of fuel can result in serious injury or death. ➤ do not allow open f...

  • Page 33

    ➤ use appropriate systems for air treatment before using the compressed air from this machine as breathing air (fresh air reinforcement) and/or for the processing of foodstuffs. ➤ use foodstuff-compatible cooling oil whenever compressed air is to come into contact with foodstuffs. Spring force sprin...

  • Page 34

    ➤ follow safety regulations when dealing with fuel, lubricants, antifreeze and chemical substan‐ ces. ➤ avoid contact with skin and eyes. ➤ do not inhale fumes or vapours from fuel or oil. ➤ do not eat or drink while handling fuel, cooling and lubricating fluids or antifreeze. ➤ suitable fire exting...

  • Page 35

    Transport as trailer non-compliance with the basic rules for a safe trailer operation may cause severe accidents during machine transport. ➤ the maximum permissible load for the towing vehicle coupling and the maximum coupling load given for the machine must not be exceeded. ➤ avoid causing a shift ...

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    ➤ ensure accessibility so that all work on the machine can be carried out without danger or hin‐ drance. ➤ do not operate in areas in which specific requirements with regard to explosion protection are applied. For instance, the requirements of atex directive 94/9/ec "equipment and protective system...

  • Page 37

    ➤ components removed from the machine can still be dangerous: do not attempt to open or destroy any components taken from the machine. ➤ use only suitable compressed air hoses. Compressed air hoses must meet the following requirements: ■ that are of the right type and size for the highest permissibl...

  • Page 38

    ➤ do not change, bypass or disable safety devices. ➤ regularly check safety devices for their correct function. ➤ do not remove or obliterate labels and notices. ➤ ensure that labels and notices are clearly legible. Further information more information on safety devices is contained in chapter 4.5. ...

  • Page 39

    Item sign meaning 330 331 hot surface! Risk of burns caused by contact with hot components! ➤ do not touch the surface. ➤ wear long-sleeved garments (not synthetics such as polyest‐ er) and protective gloves. 332 hot surfaces and dangerous gasses! Burns from contact with hot components or gasses. ➤ ...

  • Page 40

    Item sign meaning 1222*** danger! Mortal danger from co, co₂ or toxic gas. ➤ draw in only surrounding air of breathing quality. Danger! Danger to health from discharge of oily compressed air. ➤ maintain surrounding air temperature between +1.5 °c and 30 °c. ➤ check the oil indicator at least once a ...

  • Page 41

    ■ tool lubricant (option e) ■ antifreeze (option ba) eye contact fuel, oil and other fluids/materials can cause irritation. ➤ rinse open eyes thoroughly for a few minutes. ➤ seek medical advice for persistent irritation. Skin contact fuel, oil and other fluids/materials may irritate after prolonged ...

  • Page 42

    ➤ do not allow operating materials to escape to the environment or into the sewage system. ➤ store and dispose of operating materials and replaced parts in accordance with local environ‐ ment protection regulations. ➤ observe national regulations. This applies particularly to parts contaminated with...

  • Page 43

    4 design and function 4.1 bodywork bodywork is understood to be the exterior of the machine mounted on the chassis. Fig. 2 bodywork 1 right-hand wing door 2 sound damping louvre for cooler 3 snap fastener 4 handle 5 lower body 6 left-hand wing door 7 cover for lifting eye the bodywork has several fu...

  • Page 44

    4.2 machine installation fig. 3 right-hand door opened 1 instrument panel 2 oil separator tank 3 engine speed control cylinder 4 fuel tank 5 drive motor 6 fuel filter. 7 fuel filter with water trap 8 engine air filter 9 control valve with proportional controller 10 minimum pressure/check valve fig. ...

  • Page 45

    Fig. 5 machine layout 1 compressor air filter 3 inlet valve 4 airend 5 oil separator tank 7 oil separator cartridge 10 compressed air distributor 12 temperature gauge switch 13 pressure relief valve 14 pressure gauge 15 drive motor 16 oil return line 19 combination valve (thermostatic valve) 20 oil ...

  • Page 46

    4.4 operating modes and control modes 4.4.1 operating modes the machine operates in the following modes: ■ load ─ the inlet valve is open. ─ the engine runs at maximum speed. ─ the compressor block delivers compressed air. ■ modulating ─ with the help of a control valve (the proportional controller)...

  • Page 47

    Fig. 6 stepless regulation of fad (standstill) 3 inlet valve 4 airend 5 oil separator tank 26 engine speed control cylinder 46 nozzle 63 directional valve (proportional valve) 52 control valve comprising the following components: 23 proportional controller (optionally adjusta‐ ble) 27 venting valve ...

  • Page 48

    The fuel stop device is activated when an alarm occurs. The engine comes to a stop and the venting valve vents pressure from the machine. 4.5.2 further safety devices the following safety devices are provided and may not be modified in any way. ■ pressure relief valves pressure relief valves protect...

  • Page 49

    You can restart the machine only after deactivating and refilling the machine. 4.6.2 fuel pre-filter level monitoring when the fuel level in the pre-filter (water trap) drops to a certain point, the combined indicating lamp fuel level monitoring on the instrument panel lights. It indicates that the ...

  • Page 50

    4.7.1.2 option da cyclone separator condensate accumulating during the air cooling process is separated, fed to the exhaust gas si‐ lencer and evaporated there. 4.7.1.3 option db heat exchanger the oil/air heat exchanger is fed with hot compressor cooling oil that warms the outgoing moisture- reduce...

  • Page 51

    A metering valve on the lubricator regulates the amount of oil in the compressed air: ■ minimum oil to lubricate the tools and prevent corrosion, ■ more oil for cleaning and to prevent wear in the tools. The oil flow can be stopped by a shut-off valve. The oil flow adjusts automatically to changes i...

  • Page 52

    Fig. 10 frost protector 1 control line (bypass line) 2 shut-off ball valve 3 control line (defrosting) 4 frost protector operating the machine in cold temperatures: the frost protector is activated when the machine is started or stopped in ambient temperatures below freezing. Due to the anti-freeze ...

  • Page 53

    Fig. 11 coolant pre-heating 1 instrument panel 2 connection for the coolant pre-heater 3 engine block 4 coolant pre-heating the ideal coolant pre-heating period is 2-3 hours before the machine is started. A pre-heating peri‐ od of more than 3 hours is not necessary, as the maximum effect has already...

  • Page 54

    4.7.4 option la, lb options for operating in fire hazard areas 4.7.4.1 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‐ bl...

  • Page 55

    4.7.5 option lc diesel particulate filter option the exhaust from a diesel engine contains invisible particles that are dangerous to health. The die‐ sel particulate filter reduces the amount of particles (mostly soot), protecting human health and the environment. The diesel particulate filter is in...

  • Page 56

    ■ rubber-spring axle ■ height-adjustable towbar 4.7.6.2 option sd chassis the chassis has the following features: ■ single-axle ■ rubber-spring axle ■ fixed height towbar 4.7.6.3 option sh chassis the chassis has the following features: ■ single-axle ■ rubber-spring axle ■ fixed height towbar ■ with...

  • Page 57

    Position of service openings in the closed floor pan: fig. 15 position of service openings in the closed floor pan 1 central drain for oil/coolant 2 cleaning opening closed with bung 3 access to the storage box of the anti-theft chain 4 spark arrestor in the service opening, closed with bung the dra...

  • Page 58

    5 installation and operating conditions 5.1 ensuring safety the conditions in which the machine is installed and operated have a decisive effect on safety. Warning instructions are located before a potentially dangerous task. Disregard of warning instructions can cause serious injuries! Complying wi...

  • Page 59

    2. Ensure that the machine is as level as possible. The machine can be temporarily operated on a slope of not more than 15°. 3. Ensure accessibility so that all work on the machine can be carried out without danger or hin‐ drance. 4. Notice! Fire hazard from build-up of heat and hot exhaust system! ...

  • Page 60

    6 installation 6.1 ensuring safety follow the instructions below for safe installation. Warning instructions are located before a potentially dangerous task. Disregard of warning instructions can cause serious injuries! Complying with safety notes disregard of safety notes can cause unforeseeable da...

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    6.3.1 option sa fitting the height adjustable towbar fig. 18 height adjustable towbar, fitted 1 overrun braking mechanism 2 handle 3 tie bar 4 locking lever with split pin 5 hand brake lever, parking brake 6 securing bolt with self-locking nut fig. 19 fitting the height adjustable towbar 1. Remove a...

  • Page 62

    6.3.2 option sd, sh fitting a non-adjustable towbar fig. 20 non-adjustable towbar fitted 1 overrun braking mechanism 2 brake transfer cable 3 brake rod 4 towbar 5 jockey wheel 6 sikringstau 7 parking brake * not for usa type chassis 1. Open the doors. 2. Remove the bag with the brake transfer cable ...

  • Page 63

    Fitting the overrun braking mechanism of the non-adjustable towbar: fig. 21 fitting the overrun braking mechanism of the non-adjustable towbar 1 overrun braking mechanism 2 lever with securing sleeve 3 brake transfer cable 4 brake rod 5 towbar 6 securing bolts 7 washer 8 hexagon nut (self-locking) 9...

  • Page 64

    Fitting the jockey wheel of the non-adjustable towbar: fig. 22 fitting the jockey wheel of the non-adjustable towbar 1 overrun braking mechanism 2 jockey wheel 3 fixing screw 4 washer 5 hexagon nut (self-locking) 1. Place a u-washer on each securing screw and insert each of these into the top four s...

  • Page 65

    6.4.1 option sa adjusting the towbar height fig. 23 towbar height adjustment 1 locking lever 2 split pin 3 split pin properly inserted 4 handle 1. Pull out the split pin and unscrew the locking lever to the stop. 2. Adjust the towbar with the handle until it is horizontal with the coupling on the to...

  • Page 66

    Material protective gloves wrench hammer installation pin (thin metal rod ø 8–10 mm) precondition the machine is shut down. The machine is disconnected from the towing vehicle and safely parked. ➤ ascertain which towbar is fitted to the machine. 6.4.2.1 option sa changing the towing eye on a height-...

  • Page 67

    Fitting the ball coupling fitting the towing eye 1. Fit the new ball coupling 5 to the towbar. 2. Position the various parts so that the bolts can be freely inserted. 3. Insert the bolts 2 through the correspond‐ ing fixing holes of both screw connections and secure with self-locking nuts 1 . 1. Sli...

  • Page 68

    Fig. 26 changing the towing eye (fixed height towbar, usa chassis version) 1 self-locking hexagon nut 2 hex-head screw 3 damper fixing eye 4 hex-head screw 5 protective sleeve 6 tension rod 7 damper 8 installation pin 9 ball coupling 10 towing eye 1. Push back the protective sleeve 5 . 2. Unscrew an...

  • Page 69

    7 initial start-up 7.1 ensuring safety here you will find instructions for a safe commissioning of the machine. Warning instructions are located before a potentially dangerous task. Disregard of warning instructions can cause serious injuries! Complying with safety notes disregard of safety notes ca...

  • Page 70

    7.2.2 special measures for re-commissioning after storage ➤ carry out the following before every start-up after long period of storage: storage period longer than: remedy 5 months ➤ remove the desiccant from the openings in the air intake filters of the engine and compressor. ➤ check the air and oil...

  • Page 71

    7.4 low-temperature operation (winter) the machine's electrical equipment is designed for starting at ambient temperatures as low as −10 °c. ➤ in temperatures below 0°c, use the following operating materials/components: ■ winter-grade engine oil, ■ low viscosity cooling oil for the compressor, ■ win...

  • Page 72

    Fig. 27 jumper cable connection diagram a engine battery (receiving battery) b assisting vehicle battery (external donor battery) 1 negative pole clamp (black/blue) on bat‐ tery of assisting vehicle 2 positive pole clamp (red) on battery of as‐ sisting vehicle 3 positive pole clamp (red) on engine b...

  • Page 73

    Connecting the battery jumper cables 1. Clamp the first terminal clamp 3 of the red jumper cable to the positive pole of the engine's battery. 2. Clamp the second terminal clamp 2 of the red jumper cable to the positive pole of the assist‐ ing vehicle's battery. 3. Danger! Explosion hazard! A spark ...

  • Page 74

    Operating the frost protector ➤ use the checklist when initially starting the frost protector. Check see chapter confirmed? Check the level of antifreeze in the frost protector. 10.8.5 close the tap on the frost protector. 8.5 tab. 52 low-temperature equipment checklist operating the coolant pre-hea...

  • Page 75

    8 operation 8.1 ensuring safety here you will find instructions for a safe commissioning of the machine. Warning instructions are located before a potentially dangerous task. Disregard of warning instructions can cause serious injuries! Complying with safety notes disregard of safety notes can cause...

  • Page 76

    Fig. 29 starting instruments 1 «controller on » switch 2 «starter switch » – stop/off – on – start 3 – «full load mode on» pushbutton with integrated full load mode control lamp. 4 – back-pressure indicator 5 charging indicating light, group alarm lamp 6 compressed air outlet pressure gauge 7 temper...

  • Page 77

    8.2.2 starting the machine 1. Notice! 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 ...

  • Page 78

    8.2.4 switching to load precondition the airend discharge temperature must be at least +30 ℃ 1. Warning! Compressed air can cause serious injury! ➤ never direct compressed air at a person or animal! ➤ no personnel may work on the machine. ➤ all body panels must be secured in place. ➤ all access door...

  • Page 79

    7. Open the «compressed air outlet valve» on the air distributor slightly. 8. Check pressure on the instrument panel gauge. If the indicated pressure is not the discharge pressure required, the machine should be shut down and the setting procedure repeated. 8.2.6 shutting down the machine operating ...

  • Page 80

    Indicator lights. ➤ machine must be re-fuelled immediately and/or ➤ water trap must be emptied immediately further information further information on the fuel system monitoring can be found in chapter4.6. See chapter 10.3.3 for the maintenance of the fuel pre-filter (water trap). 8.4 option ea, ec o...

  • Page 81

    1. Set the required oil flow. 2. Close the access door. Further information fill the tool lubricator with suitable oil (see chapter 10.8.1) shutting off lubricating oil 1. Close the shut-off valve. 2. Close the access door. 8.5 option ba, bb using the low-temperature equipment ➤ ascertain which low ...

  • Page 82

    1. Keep the frost protector shut-off valve permanently closed (position 0). 2. Close the access door. Result the machine is ready for winter operation. Further information see chapter 10.8.5 for filling the frost protector with antifreeze. Machine operation without activated frost protector: operati...

  • Page 83

    8.7 option lb shut down the machine if any dangerous situation arises if there is a danger of the engine drawing in flammable gas the air intake shut-off valve can be manually closed to bring it to an immediate stop. A handle is provided to close the air intake valve. A wire pulls the valve closed p...

  • Page 84

    9 fault recognition and rectification 9.1 basic instructions the following tables are intended to assist in fault finding and rectification. 1. Do not attempt fault rectification measures other than those given in this manual! 2. In all other cases: have the fault rectified by an authorized kaeser s...

  • Page 85

    Possible cause remedy where can i get help? Special‐ ised work‐ shop kaeser -service engine service manual defective alternator. Have repaired or replaced if necessary. X x – defective alternator regulator. Have repaired or replaced if necessary. X x – oil pressure switch indicating in‐ sufficient o...

  • Page 86

    Possible cause remedy where can i get help? Special‐ ised work‐ shop kaeser -service engine service manual defective alternator regulator. Have repaired or replaced if necessary. X x – engine oil pressure too low. Check engine oil level, see chapter 10.3.4. – – x check the engine and have re‐ paired...

  • Page 87

    Possible cause remedy where can i get help? Specialised workshop kaeser-ser‐ vice venting valve does not close. Check the connections and function and have repaired or replaced as necessary. – x the engine runs at maximum speed (load). See chapter 9.2. X x engine air filter and/or compres‐ sor air f...

  • Page 88

    Possible cause remedy where can i get help? Specialised workshop kaeser-ser‐ vice compressor oil filter clogged. Change, see chapter 10.4.4. – – compressor cooling oil level too low. Topping up, see chapter 10.4.2. – – oil pipes leaking. Seal leaks or have pipes changed. X x engine cooling system or...

  • Page 89

    9.3.7 option da, db, dc, dd high moisture content in the compressed air possible cause remedy where can i get help? Specialised workshop kaeser-ser‐ vice blocked condensate drain on the cyclone separator. Clean the cyclone separator dirt trap or replace the strainer and nozzle if necessary. See chap...

  • Page 90

    Grey or brownish exhaust gas meaning remedy where can i get help? Special‐ ised work‐ shop kaeser -service engine service manual the exhaust contains residues of hydrocarbons or sulphate. Have the fuel injection system checked. Use an engine oil that produces low white ash. X x x tab. 65 grey or bro...

  • Page 91

    10 maintenance 10.1 ensuring safety follow the instructions below for safe installation. Warning instructions are located before a potentially dangerous task. Disregard of warning instructions can cause serious injuries! Complying with safety notes disregard of safety notes can cause unforeseeable d...

  • Page 92

    Work on the diesel particulate filter notice damage of the diesel particulate filter! ➤ the machine must be shut down immediately if any damage or functional defect in the diesel particulate filter is noticed. ➤ only authorised specialists, such as kaeser service technicians may carry out main‐ tena...

  • Page 93

    Component: task after the first 50 h see chapter note re-tighten the wheel nuts/bolts. X t = driftstimer; motor-ba = se motorprodusentens bruksanvisning. Tab. 66 maintenance tasks after commissioning 10.2.3 regular maintenance tasks the following table lists the various maintenance intervals. Mainte...

  • Page 94

    Component: function daily a250 a500 a1000 a1500 a2000 a3000 a36000 see chapter note replace the engine oil filter. X 10.3.7 engine sm check/adjust the drive belt ten‐ sion. X 10.3.8 engine sm change engine air filter. X 10.3.2 have intercooler maintained. X sw have the turbocharger checked. X sw hav...

  • Page 95

    Component: function daily a250 a500 a1000 a1500 a2000 a3000 a36000 see chapter note check fuel lines and hose clamping bands, have replaced if necessary. X sw change the fuel pre-filter. X 10.3.3 engine sm replace the fuel micro-filter. X 10.3.3 engine sm check the fuel return line for leakage and f...

  • Page 96

    Component: function daily a250 a500 a1000 a1500 a2000 a3000 a36000 see chapter note check wear on the brake lin‐ ings. X 10.7.3.2 have the wheel brakes adjus‐ ted. X sw check all screw connections, hinges, locks, handles and snap fasteners of the doors for wear and secure fixing. X grease the door h...

  • Page 97

    Option function daily a250 a500 a1500 see chapter note option dd – filter combination: drain condensate. X 10.8.3 change the filter elements x 10.8.3 option dc – fresh air filter: drain condensate. X 10.8.4 check the oil indicator. X 10.8.4 change the filter elements x 10.8.4 option ba – frost prote...

  • Page 98

    10.3.1 water cooler maintenance material coolant coolant tester receptacle drain hose with hose coupling is disconnectedly laying at the machine funnel cleaning cloth precondition the machine is shut down. The machine is standing level. The machine is fully vented, the pressure gauge reads 0 bar. Ma...

  • Page 99

    Fig. 36 checking coolant level 1 filler port with cap 2 overflow 3 coolant expansion tank 4 radiator connection hose 5 coolant level a maximum markings (full) b minimum-markings (low) 1. Check the level of coolant in the expansion tank. Top up when the coolant level falls below the minimum marking b...

  • Page 100

    1. Notice! The engine can be damaged if the antifreeze concentration is insufficient. Corrosion damages in the cooling system. Engine casing fracture ➤ check coolant. ➤ protect the coolant against frost. ➤ top up as necessary. 2. Use the coolant tester as instructed by the manufacturer to test the c...

  • Page 101

    Precondition negative cable to the batteries disconnected. 1. Twist and remove the expansion tank filler cap. 2. Mix a quantity of coolant according to the table and top up to the mark. Top up until the coolant level is just below the maximum mark a . 3. Screw on the filler cap. 4. Reconnect the neg...

  • Page 102

    1. Unscrew and remove the expansion tank filler cap 1 . 2. Position a receptacle beneath the water cooler drain point (accessible through a hole in the floor panel). 3. Connect a suitable drain hose 7 to the radiator quick-release coupling 6 . 4. Lead the hose through the hole in the floor panel and...

  • Page 103

    10.3.2 engine air filter maintenance clean the filter according to the maintenance schedule or if the maintenance indicator shows this to be necessary. Renew the air filter element after 2 years at the latest or after it has been cleaned 5 times. ■ using the engine without an air filter element is n...

  • Page 104

    Fig. 40 cleaning the filter element 1 compressed air gun with blast pipe bent to 90° at the end 2 filter element ➤ open both doors. Checking contamination of the air filter: air filter maintenance is necessary when the yellow piston inside the maintenance indicator rea‐ ches the red zone. ➤ check th...

  • Page 105

    10.3.3 fuel system maintenance make sure no dirt enters the fuel system during maintenance. Clean components and their sur‐ roundings before dismounting. Material spare parts receptacle cleaning cloth precondition the machine is shut down. The machine is standing level. The machine is fully vented, ...

  • Page 106

    10.3.3.1 bleeding the fuel system air can enter the fuel system if the fuel tank is empty, after a fuel filter change or when carrying out work on the fuel lines. If the engine refuses to start despite a full tank, bleed the fuel system. Fig. 42 bleeding the fuel system 1 bleed screw 2 manual fuel p...

  • Page 107

    Fig. 43 emptying the fuel pre-filter water trap 1 fuel pre-filter 2 filter cartridge with integrated water re‐ ceptacle. 3 water draining stopper with integrated lev‐ el sensor i - open 0 - close 4 level sensor connecting plug (fuel filter maintenance) 1. Place a receptacle beneath the fuel pre-filt...

  • Page 108

    Changing the filter cartridge fig. 44 changing the fuel pre-filter cartridge 1 filter head 2 filter cartridge with integrated water re‐ ceptacle. 3 draining stopper seal 4 draining stopper with integrated level sen‐ sor 5 water level sensor connecting plug (fuel fil‐ ter maintenance) 6 direction of ...

  • Page 109

    10.3.3.3 fuel filter maintenance fig. 45 fuel filter maintenance 1 filter holder 2 filter cartridge 3 turn in this direction to unscrew the filter cartridge. 1. Place a container beneath the fuel filter. 2. Use a filter wrench to loosen then unscrew the micro-filter cartridge. Collect any escaping f...

  • Page 110

    Material cleaning cloth precondition the machine is shut down. The machine is standing level. 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. Fig. 46 checking the engine oil level 1 oil...

  • Page 111

    Filling with engine oil see chapter 2.6.4 for engine oil filling volume. The oil dipstick is marked with the «maximum oil level». 1. Open the right-hand access door. 2. Remove the filler cap and fill with fresh oil. 3. Wait 5 minutes then check the oil level. It takes a few minutes for oil to reach ...

  • Page 112

    Material engine oil receptacle wrench cleaning cloth precondition the machine is shut down. The machine is standing level. The machine is fully vented, the pressure gauge reads 0 bar. Engine at operating temperature. All compressed air consumers are disconnected and the air outlet valves are open. N...

  • Page 113

    Draining the engine oil (closed floor pan - stationary machine): compressor cooling oil and engine coolant drain lines are led to a central point outside the ma‐ chine on stationary machines and machines with closed floor pan. The engine oil is drained via a pipe which is screwed into the drain open...

  • Page 114

    10.3.7 replace the engine oil filter material spares chain pipe wrench (part no. 8.8095.0) cleaning cloth receptacle precondition the machine is shut down. The machine is fully vented, the pressure gauge reads 0 bar. Engine cooled down. All compressed air consumers are disconnected and the air outle...

  • Page 115

    Dispose of old oil filters, old oil and materials contaminated with oil according to environmen‐ tal protection regulations. 10.3.8 drive belt maintenance the life of the drive belts is influenced by belt tension. ■ slack belts can slip and become damaged and may result in engine overheating. ■ over...

  • Page 116

    Removing the belt guard: fig. 50 belt guard attachment 1 engine 2 hexagon screws (belt guard attachment) 3 belt guard ➤ unscrew the securing screws of the belt guard and remove the belt guard. 10.3.8.1 visual check 1. Check the belts thoroughly for cracks, fraying or stretching. Replace the belt imm...

  • Page 117

    Fig. 51 belt tension checking by hand a permissible deflection of the belt * approximate pressure exerted: 10 kg permissible movement: 10 – 15 mm checking belt tension with tension measuring device. Belt tension checking by hand 1. Check belt tension with the tension measur‐ ing device. 2. Increase ...

  • Page 118

    Fig. 52 changing/tensioning the drive belt 1 drive belt 2 jockey wheel 3 locking pin 4 ratchet tensioning the drive belt: 1. Insert the ratchet square in the corresponding hole in the jockey wheel. 2. Using the ratchet, press the jockey wheel opposite the arrow direction. Ensure that the drive belt ...

  • Page 119

    Making operational: 1. Replace the belt guard. 2. Reconnect the negative cable to the batteries. 3. Close the doors. Further information the operating manual of the engine manufacturer provides further information on removing, chang‐ ing and tensioning drive belts. 10.3.9 battery maintenance ➤ check...

  • Page 120

    ➤ do not place tools on the battery. This can lead to short-circuiting, overheating and bursting of the battery! ➤ take particular care when the battery has been in service for a long time or has just been charged as highly explosive gas is emitted! Ensure adequate ventilation! 10.3.9.2 battery chec...

  • Page 121

    Winter operation: batteries are particularly stressed in winter. Only a fraction of the normal starting energy is availa‐ ble at low temperatures. 1. Notice! Danger of batteries freezing! Discharged batteries are subject to frost damage and can freeze at −10 °c. ➤ check battery charge with a specifi...

  • Page 122

    Old batteries are hazardous waste and must be disposed of correctly in accordance with local environment protection regulations. 10.4 compressor maintenance ➤ perform maintenance tasks according to the schedule in chapter 10.2.3.1. 10.4.1 checking cooling oil level the oil level is checked at the oi...

  • Page 123

    10.4.2 cooling oil filling and topping up material cooling oil funnel cleaning cloth wrench precondition the machine is shut down. The machine is standing level. The machine is fully vented, the pressure gauge reads 0 bar. Machine is cooled down. All compressed air consumers are disconnected and the...

  • Page 124

    10.4.3 changing the cooling oil drain the oil completely from the following components: ■ oil separator tank ■ oil cooler ■ oil pipes ➤ always change the oil filter when changing the oil. Material cooling oil receptacle drain hose with hose coupling is disconnectedly laying at the machine new gasket...

  • Page 125

    Fig. 55 draining cooling oil 1 oil separator tank 2 oil separator tank drain plug 3 oil filler plug 4 oil cooler 5 shut-off ball valve i – open 0 – closed 6 quick-release coupling 7 drain hose with male coupling ➤ remove the plug 3 from the oil separator tank filling port. Draining the cooling oil f...

  • Page 126

    10.4.3.2 option oe, sc, si draining the cooling oil (closed floor pan - stationary machine): compressor cooling oil and engine coolant drain lines are led to a central point outside the ma‐ chine on stationary machines and machines with closed floor pan. The cooling oil is drained via pipes which ar...

  • Page 127

    Finish off the work steps: 1. Replace the plug 2 in the oil separator tank filling port. 2. Close the access door. Dispose of used oil and oil-contaminated working materials according to environmental pro‐ tection regulations. Further information see chapter 10.4.2 for oil filling. 10.4.4 replace th...

  • Page 128

    5. Lightly oil the new filter's gasket. 6. Turn the oil filter clockwise by hand to tighten. 7. Check the oil level in the oil separator tank. Top up if necessary. 8. Reconnect the negative terminals to the batteries. 9. Close the access door. Dispose of old cooling oil and any materials or parts co...

  • Page 129

    Fig. 58 oil separator tank dirt trap maintenance 1 oil separator tank cover 2 control valve 3 union nut 4 oil return line 5 strainer 6 gasket 7 screw-in connector 8 nozzle ➤ open the right-hand access door. Dirt trap maintenance: 1. Undo the union nut and bend the oil return line to one side. 2. Uns...

  • Page 130

    10.4.6 changing the oil separator cartridge the oil separator cartridge cannot be cleaned. The life of the oil separator cartridge is influenced by: ■ contamination in the air drawn into the compressor, ■ and adherence to the changing intervals for: ─ cooling oil ─ oil filter ─ air filter material s...

  • Page 131

    10.4.6.1 changing the oil separator cartridge fig. 59 changing the oil separator cartridge 1 control air line union nut 2 oil scavenge pipe (screwed to the cover) 3 oil scavenge pipe union nut (screwed to the dirt trap) 5 air pipe 6 pipe fitting 7 cover 8 fixing screw 9 control valve 10 solenoid val...

  • Page 132

    11. Reconnect cables. 12. Check the oil level in the oil separator tank. Top up if necessary. Maintenance of the control valve dirt trap must be carried out whenever the oil separator car‐ tridge is changed. Further information information on control valve dirt trap maintenance is given in chapter 1...

  • Page 133

    10.4.6.2 option ba changing the oil separator (machine with low-temperature equipment) fig. 60 changing the oil separator cartridge (option ba) 1 control air line union nut 2 oil scavenge pipe (screwed to the cover) 3 oil scavenge pipe union nut (screwed to the dirt trap) 5 air pipe 6 pipe fitting 7...

  • Page 134

    8. Clean all sealing surfaces, taking care that no foreign bodies (dirt particles) fall into the oil sep‐ arator tank. Do not remove the metal clips! The metal parts of the oil separator cartridge are electrically interconnected. The gaskets 11 are fitted with metal clips 12 that fulfil this require...

  • Page 135

    ■ using the machine without an air filter element is not permitted! ■ do not use an air filter element with damaged folds or gasket. ■ the use of an unsuitable air filter can permit dirt to ingress the pressure system and cause premature wear and damage to the machine. Material compressed air for bl...

  • Page 136

    Fig. 62 cleaning the filter element 1 compressed air gun with blast pipe bent to 90° at the end 2 filter element ➤ open both doors. Checking contamination of the air filter: air filter maintenance is necessary when the yellow piston inside the maintenance indicator rea‐ ches the red zone. ➤ check th...

  • Page 137

    10.4.8 checking pressure relief valves ➤ have pressure relief valves checked by kaeser service in accordance with the maintenance schedule. 10.5 clean cooler/radiator the frequency of cleaning is mainly dependent on local operating conditions. Heavy clogging of the cooler/radiator can cause oil over...

  • Page 138

    Fig. 63 cleaning the cooler/ radiator. 1 front end of machine, sound insulation (radiator grill) removed 2 direction of impacting water or steam jet (from outside to inside). 3 compressor oil cooler 4 turbo air cooler (engine) 5 radiator (engine) cooler cleaning 1. Seal off the air intakes of the en...

  • Page 139

    Fig. 64 cleaning the compressed air aftercooler 1 compressed air aftercooler 2 direction of impacting water or steam jet (from inside to outside). 1. Seal off the air intakes of the engine and compressor air filters before starting cleaning. 2. Clean the aftercooler with compressed air, water or ste...

  • Page 140

    10.7 chassis maintenance ➤ perform maintenance tasks according to the schedule in chapter 10.2.3.1. 10.7.1 wheel checks check the wheels for tightness, visible damage and tyre pressures: ■ after the first 50 km ■ after every wheel change ■ at least every six months material torque wrench tyre pressu...

  • Page 141

    Fig. 65 towbar maintenance 1 handle 2 transfer cable 3 lubricating points 4 lubricating points 10.7.2.1 check the towbar 1. Check the towbar for correct function and movement. 2. Clean and oil all sliding and rotating bearings. Check the height setting of the towbar ➤ check the towbar height adjustm...

  • Page 142

    2. Press in the shock absorber against its damping force. Have the shock absorber replaced by a specialist workshop if: ■ there is little resistance to pushing in, ■ air has entered the device, ■ there is little resistance to pulling out the shock absorber. ■ oil leaks out. 10.7.2.3 ball coupling ma...

  • Page 143

    The following points must be observed: ■ carry out the adjustment procedure on all wheel brakes, one after the other. ■ during adjustment, turn the wheel in the 'forward' direction only. Material screwdriver wrench torch cleaning cloth lithium-enriched multi-purpose grease precondition the machine i...

  • Page 144

    Fig. 69 brake system adjustment 1 brake rod 2 equaliser 3 brake support 4 screwdriver as adjusting tool 5 adjusting wheel 1. Remove the plug from the inspection hole. 2. Use a screwdriver to turn the adjusting wheel 5 until the wheels no longer turn in the forward direction. 3. Apply the parking bra...

  • Page 145

    Brake rod adjustment: fig. 70 brake rod adjustment 1 brake rod 2 equaliser 6 ball nut 7 sekskantmutter 8 brake cable (bowden) 9 axle (cross-section) 1. To free the brake rod, remove the hexagon nut 7 at the equaliser 2 and loosen the ball nut 6 . 2. Clean and grease the brake rod threads. 3. Tighten...

  • Page 146

    10.8.1 option ea, ec tool lubricator maintenance material tool oil (special lubricant for road breakers), funnel cleaning cloth precondition the machine is shut down. The machine is standing level. The machine is fully vented, the pressure gauge reads 0 bar. Machine is cooled down. All compressed ai...

  • Page 147

    3. Unscrew and withdraw the plug once more and read off the oil level on the dipstick. Oil level at the upper third of the dip stick: ok. Top up if the oil does not reach this level. 4. Close the access door. Filling and topping up with tool lubricator oil 1. Slowly unscrew and withdraw the oil fill...

  • Page 148

    Fig. 72 cleaning the dirt trap 1 cyclone separator 2 dirt trap 3 condensate drain hose 4 filler plug 5 o-ring 6 strainer 7 condensate drain hose union nut 8 nozzle 9 dirt trap housing ➤ open the left-hand door. Cleaning the dirt trap: 1. Unscrew the plug 4 and remove the strainer. 2. Loosen the unio...

  • Page 149

    6. Check the cyclone separator housing and hose line for leaks. 7. Close the access door. 10.8.3 option dd combination filter maintenance precondition the machine is shut down. The machine is standing level. The machine is fully vented, the pressure gauge reads 0 bar. All compressed air consumers ar...

  • Page 150

    10.8.3.1 draining condensate material receptacle cleaning cloth 1. Place the receptacle under the combination filter hose lines. 2. Open the pre-filter and micro-filter condensate drain shut off valves. 3. Close the access door. 4. Start up the machine and run in idle. The condensate collecting in t...

  • Page 151

    6. Insert the new filter element. Wear gloves! 7. Screw on the filter housing clockwise. 8. Screw on the condensate drain hose. Changing the micro-filter element: 1. Unscrew and remove the drain hose from the filter housing. 2. Unscrew the filter housing counter-clockwise. 3. Draw the filter element...

  • Page 152

    10.8.4 option dc fresh air filter maintenance before commencing work on the fresh air filter, read and understand the operating instructions for pressurised air filters (fresh air filters) provided in chapter 13.7. Precondition the machine is shut down. The machine is standing level. The machine is ...

  • Page 153

    5. Shut down the machine. 6. Open both doors. 7. Close the drain valve. 8. Carefully remove the receptacle. 9. Close the doors. Condensate must be stored in suitable containers and disposed of in accordance with local environmental regulations. 10.8.4.2 check the oil indicator the fresh air filter i...

  • Page 154

    5. Insert a new lower filter element. Wear gloves! 6. Screw on the lower housing clockwise. Change the upper filter element (adsorption insert). 1. Unscrew the upper housing counter-clockwise. 2. Draw the filter element up and out. 3. Clean the lower housing and sealing surface with a lint-free clot...

  • Page 155

    10.8.5 option ba frost protector maintenance at temperatures below 5°c, the level of antifreeze in the protector must be checked daily before starting the compressor. Material antifreeze (wabcothyl) cleaning cloth precondition the machine is shut down. The machine is fully vented, the pressure gauge...

  • Page 156

    10.8.6 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. Material suitable rubber hose soot receptacle cleaning cloth protective gloves eye protection precondition the mach...

  • Page 157

    4. In order to increase the pressure in the exhaust system, partially cover the exhaust discharge pipe with a fire-proof object. Soot will drain through the hose into the receptacle. 5. Shut down the engine. 6. Remove the hose and replace the plug . It is recommended to blow out the spark arrestor w...

  • Page 158

    10.8.7 option lb engine air intake shut-off valve maintenance material compressed air for blowing out petroleum ether or spirit cleaning cloth precondition the machine is shut down. The machine is fully vented, the pressure gauge reads 0 bar. Machine is cooled down. All compressed air consumers are ...

  • Page 159

    3. Check if the interior of the shut-off valve is clean. Blow out any dirt with compressed air. If necessary, clean the valve with petroleum ether or spirit and allow to dry. Refer to a specialised workshop or kaeser service if dirt cannot be removed. Checking the engine air intake shut-off valve fo...

  • Page 160

    10.9 documenting maintenance and service work machine number: ➤ enter maintenance and service work carried out in the list. Date maintenance task carried out operating hours signature tab. 71 maintenance log 10 maintenance 10.9 documenting maintenance and service work 148 service manual portable com...

  • Page 161

    11 spares, operating materials, service 11.1 note the nameplate the nameplate contains all information to identify your machine. This information is essential to us in order to provide you with optimal service. ➤ please give the information from the nameplate with every enquiry and order for spares....

  • Page 162

    11.3 kaeser air service kaeser air service offers: ■ authorized service technicians with kaeser factory training. ■ increased operational reliability ensured by preventive maintenance. ■ energy savings achieved by avoidance of pressure losses. ■ the security of genuine kaeser spare parts. ■ increase...

  • Page 163

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  • Page 236

    12 decommissioning, storage and transport 12.1 de-commissioning de-commissioning is necessary, for example, under the following circumstances: ■ the machine is temporarily not needed ■ the machine will not be needed for a considerable time. ■ the machine is to be scrapped. Precondition the machine i...

  • Page 237

    Decommissioning of the compressor for several weeks during severe frost 1. Notice! 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 (batt...

  • Page 238

    Long-term decommissioning and storage tasks see chapter confirmed? ➤ feste et skilt på betjeningspanelet med angivelse av utførte tiltak fordi maskinen satt ut av drift. – tab. 75 "long-term decommissioning and storage" checklist ➤ attach the following notice on the instrument panel showing the deco...

  • Page 239

    1. Warning! Risk of accident when towing the unilluminated machine on public roads. Death or severe injury possible due to accidents with unilluminated trailer. ➤ do not tow machines without illumination on public roads. 2. Observe the safety instructions in chapter 3.5.2 "safe machine operation". 1...

  • Page 240

    Fig. 80 towing alignment 1. Warning! Danger from problematic driving dynamics! The permissible loading range may be exceeded or undercut. Personal injury may result from towing. Damage to the machine and/or towing vehicle is possible. ➤ do not couple up the machine at an angle to the towing vehicle....

  • Page 241

    3. Warning! Risk of accident due to unhitching of the ball coupling during transport! If the coupling is not fully closed the compressor can become uncoupled from the towing vehi‐ cle and cause an accident. ➤ check correct coupling. 4. Place the open coupling over the towing vehicle ball hitch. The ...

  • Page 242

    2. Couple-up the machine and tow slowly and carefully for about 500 m. The action of towing sets the coupling mechanism to maximum closure and gives a true read‐ ing on the wear indicator. 3. Interpret the wear indicator as follows: wear indicator meaning green zone showing ■ coupling in new conditi...

  • Page 243

    4. Warning! Risk of accident due to unhitching of the ball coupling during transport! If the coupling is not fully closed the compressor can become uncoupled from the towing vehi‐ cle and cause an accident. ➤ check correct coupling. ➤ check correct location of the security pin. 5. Place the open cou...

  • Page 244

    Prepare the machine with fixed chassis with parking brake) for transport: 1. Wind the jockey wheel to its uppermost position. 2. Check that the wheels are securely fitted and the tyres are in good condition. 3. Check the tyre pressures. 4. Connect the cable for the lighting and indicator systems and...

  • Page 245

    Fig. 86 breakaway cable attachment 1 breakaway cable 2 breakaway cable guide (eye) 3 connection (spring clip) 1. Notice! 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...

  • Page 246

    Fig. 87 warning "risk of injury due to falling towbar" fig. 88 actuating the parking brake a parking brake with gas spring assistance 1 parking brake lever 2 gas spring 3 dead point zone b parking brake with ratchet and spring load‐ ing 4 ratchet 5 spring loading device parking the machine with heig...

  • Page 247

    2. Pull on the parking brake to the last ratchet tooth (see fig. 88/b). When the hand brake lever is horizontal, the brake is under spring loading. If the lever is not horizontal, the brake is not fully applied and the machine may roll away. 3. Detach the breakaway cable. 4. Wind down the jockey whe...

  • Page 248

    ➤ perform the following tasks in snow and ice conditions: ■ remove any snow and ice from the machine before lifting by a crane. ■ make sure the lifting eye cover plate is freely accessible and can be opened. Perform the following tasks prior to moving the machine by crane: a lifting eye is provided ...

  • Page 249

    1. Close and lock the access doors or canopy. 2. Position the fork truck to the side of the machine with the forks lined up with the lifting lugs. 3. Drive the forks fully through the lifting lugs as far as possible. The forks are fully under the machine. 4. Lift the machine carefully. 12.2.6 transp...

  • Page 250

    Contact kaeser service with any questions regarding transporting or load securing. Kaeser accepts no liability and provides no guarantee for damage arising from incorrect transport or insufficient or incorrect load securing provisions. For hire, rental and trade fair plant, any transport safety devi...

  • Page 251

    4. Drain the coolant from water-cooled engines and systems. 5. The battery has been removed. 6. Hand the machine over to an authorised disposal expert. ➤ operating materials and components contaminated with fuel, cooling oil or engine oil must be disposed of in accordance with local environment prot...

  • Page 252

    13 annex 13.1 identification fig. 92 identification 1 machine nameplate with serial number 2 vin *) (stamped in the bodywork) *vehicle identity number 3 combined label for coupling loading and built-in options 4 engine nameplate with serial number (on the cylinder head cover or crankcase). 5 option ...

  • Page 253

    13 annex 13.2 pipeline and instrument flow diagram (p+i diagram) no.: 9_6974 20 e service manual portable compressor m122 241 ramirent.

  • Page 254

    13 annex 13.2 pipeline and instrument flow diagram (p+i diagram) 242 service manual portable compressor m122 no.: 9_6974 20 e ramirent.

  • Page 255

    13 annex 13.2 pipeline and instrument flow diagram (p+i diagram) no.: 9_6974 20 e service manual portable compressor m122 243 ramirent.

  • Page 256

    13 annex 13.2 pipeline and instrument flow diagram (p+i diagram) 244 service manual portable compressor m122 no.: 9_6974 20 e ramirent.

  • Page 257

    13.3 dimensional drawings 13.3.1 option sa dimensional drawing - chassis with height-adjustable tow bar 13 annex 13.3 dimensional drawings no.: 9_6974 20 e service manual portable compressor m122 245 ramirent.

  • Page 258

    13 annex 13.3 dimensional drawings 246 service manual portable compressor m122 no.: 9_6974 20 e ramirent.

  • Page 259

    13.3.2 option sd dimensional drawing, chassis with fixed height tow bar 13 annex 13.3 dimensional drawings no.: 9_6974 20 e service manual portable compressor m122 247 ramirent.

  • Page 260

    13 annex 13.3 dimensional drawings 248 service manual portable compressor m122 no.: 9_6974 20 e ramirent.

  • Page 261

    13.3.3 option sh dimensional drawing, chassis without parking brake 13 annex 13.3 dimensional drawings no.: 9_6974 20 e service manual portable compressor m122 249 ramirent.

  • Page 262

    13 annex 13.3 dimensional drawings 250 service manual portable compressor m122 no.: 9_6974 20 e ramirent.

  • Page 263

    13.3.4 option sc dimensional drawings of stationary machine (skids) 13 annex 13.3 dimensional drawings no.: 9_6974 20 e service manual portable compressor m122 251 ramirent.

  • Page 264

    13 annex 13.3 dimensional drawings 252 service manual portable compressor m122 no.: 9_6974 20 e ramirent.

  • Page 265

    13.3.5 option si dimensional drawings of stationary machine (base frame) 13 annex 13.3 dimensional drawings no.: 9_6974 20 e service manual portable compressor m122 253 ramirent.

  • Page 266

    13 annex 13.3 dimensional drawings 254 service manual portable compressor m122 no.: 9_6974 20 e ramirent.

  • Page 267

    13.4 wiring diagrams 13.4.1 electrical diagram 13 annex 13.4 wiring diagrams no.: 9_6974 20 e service manual portable compressor m122 255 ramirent.

  • Page 268

    13 annex 13.4 wiring diagrams 256 service manual portable compressor m122 no.: 9_6974 20 e ramirent.

  • Page 269

    13 annex 13.4 wiring diagrams no.: 9_6974 20 e service manual portable compressor m122 257 ramirent.

  • Page 270

    13 annex 13.4 wiring diagrams 258 service manual portable compressor m122 no.: 9_6974 20 e ramirent.

  • Page 271

    13 annex 13.4 wiring diagrams no.: 9_6974 20 e service manual portable compressor m122 259 ramirent.

  • Page 272

    13 annex 13.4 wiring diagrams 260 service manual portable compressor m122 no.: 9_6974 20 e ramirent.

  • Page 273

    13 annex 13.4 wiring diagrams no.: 9_6974 20 e service manual portable compressor m122 261 ramirent.

  • Page 274

    13 annex 13.4 wiring diagrams 262 service manual portable compressor m122 no.: 9_6974 20 e ramirent.

  • Page 275

    13 annex 13.4 wiring diagrams no.: 9_6974 20 e service manual portable compressor m122 263 ramirent.

  • Page 276

    13 annex 13.4 wiring diagrams 264 service manual portable compressor m122 no.: 9_6974 20 e ramirent.

  • Page 277

    13 annex 13.4 wiring diagrams no.: 9_6974 20 e service manual portable compressor m122 265 ramirent.

  • Page 278

    13 annex 13.4 wiring diagrams 266 service manual portable compressor m122 no.: 9_6974 20 e ramirent.

  • Page 279

    13 annex 13.4 wiring diagrams no.: 9_6974 20 e service manual portable compressor m122 267 ramirent.

  • Page 280

    13 annex 13.4 wiring diagrams 268 service manual portable compressor m122 no.: 9_6974 20 e ramirent.

  • Page 281

    13 annex 13.4 wiring diagrams no.: 9_6974 20 e service manual portable compressor m122 269 ramirent.

  • Page 282

    13 annex 13.4 wiring diagrams 270 service manual portable compressor m122 no.: 9_6974 20 e ramirent.

  • Page 283

    13 annex 13.4 wiring diagrams no.: 9_6974 20 e service manual portable compressor m122 271 ramirent.

  • Page 284

    13 annex 13.4 wiring diagrams 272 service manual portable compressor m122 no.: 9_6974 20 e ramirent.

  • Page 285

    13 annex 13.4 wiring diagrams no.: 9_6974 20 e service manual portable compressor m122 273 ramirent.

  • Page 286

    13 annex 13.4 wiring diagrams 274 service manual portable compressor m122 no.: 9_6974 20 e ramirent.

  • Page 287

    13 annex 13.4 wiring diagrams no.: 9_6974 20 e service manual portable compressor m122 275 ramirent.

  • Page 288

    13 annex 13.4 wiring diagrams 276 service manual portable compressor m122 no.: 9_6974 20 e ramirent.

  • Page 289

    13 annex 13.4 wiring diagrams no.: 9_6974 20 e service manual portable compressor m122 277 ramirent.

  • Page 290

    13 annex 13.4 wiring diagrams 278 service manual portable compressor m122 no.: 9_6974 20 e ramirent.

  • Page 291

    13 annex 13.4 wiring diagrams no.: 9_6974 20 e service manual portable compressor m122 279 ramirent.

  • Page 292

    13.4.2 option lc connection adapter for the diesel particulate filter 13 annex 13.4 wiring diagrams 280 service manual portable compressor m122 no.: 9_6974 20 e ramirent.

  • Page 293

    13 annex 13.4 wiring diagrams no.: 9_6974 20 e service manual portable compressor m122 281 ramirent.

  • Page 294

    13 annex 13.4 wiring diagrams 282 service manual portable compressor m122 no.: 9_6974 20 e ramirent.

  • Page 295

    13 annex 13.4 wiring diagrams no.: 9_6974 20 e service manual portable compressor m122 283 ramirent.

  • Page 296

    13 annex 13.4 wiring diagrams 284 service manual portable compressor m122 no.: 9_6974 20 e ramirent.

  • Page 297

    13.4.3 option tc lighting and signalling system connection 13 annex 13.4 wiring diagrams no.: 9_6974 20 e service manual portable compressor m122 285 ramirent.

  • Page 298

    13 annex 13.4 wiring diagrams 286 service manual portable compressor m122 no.: 9_6974 20 e ramirent.

  • Page 299

    13 annex 13.4 wiring diagrams no.: 9_6974 20 e service manual portable compressor m122 287 ramirent.

  • Page 300

    13 annex 13.4 wiring diagrams 288 service manual portable compressor m122 no.: 9_6974 20 e ramirent.

  • Page 301

    13 annex 13.4 wiring diagrams no.: 9_6974 20 e service manual portable compressor m122 289 ramirent.

  • Page 302

    13 annex 13.4 wiring diagrams 290 service manual portable compressor m122 no.: 9_6974 20 e ramirent.

  • Page 303

    13 annex 13.4 wiring diagrams no.: 9_6974 20 e service manual portable compressor m122 291 ramirent.

  • Page 304

    13 annex 13.4 wiring diagrams 292 service manual portable compressor m122 no.: 9_6974 20 e ramirent.

  • Page 305

    13.4.4 option te lighting and signalling system connection 13 annex 13.4 wiring diagrams no.: 9_6974 20 e service manual portable compressor m122 293 ramirent.

  • Page 306

    13 annex 13.4 wiring diagrams 294 service manual portable compressor m122 no.: 9_6974 20 e ramirent.

  • Page 307

    13 annex 13.4 wiring diagrams no.: 9_6974 20 e service manual portable compressor m122 295 ramirent.

  • Page 308

    13 annex 13.4 wiring diagrams 296 service manual portable compressor m122 no.: 9_6974 20 e ramirent.

  • Page 309

    13 annex 13.4 wiring diagrams no.: 9_6974 20 e service manual portable compressor m122 297 ramirent.

  • Page 310

    13.5 fuel circulation diagram 13 annex 13.5 fuel circulation diagram 298 service manual portable compressor m122 no.: 9_6974 20 e ramirent.

  • Page 311

    13 annex 13.5 fuel circulation diagram no.: 9_6974 20 e service manual portable compressor m122 299 ramirent.

  • Page 312

    13.6 option dd operating instructions for compressed air filter (combination filter) 13 annex 13.6 operating instructions for compressed air filter (combination filter) 300 service manual portable compressor m122 no.: 9_6974 20 e ramirent.

  • Page 313: Bedienungsanleitung

    - 1 - 7 0 5 0 f 7 0 . 3 0 . 5 0 c k 7 0 . 3 0 . 5 0 c k 2 1 4 0 f e m a n - d t ll e t s r e e m a n . R p e g e m a n . F t z t e s r e . D t z t e s r e bedienungsanleitung instruction manual hochleistungs - druckluftfilter compressed-air filters serie / series fa (d), fb (d&e), fc (d&e), fd (e), ...

  • Page 314

    - 2 - 7 0 5 0 f 7 0 . 3 0 . 5 0 c k 7 0 . 3 0 . 5 0 c k 2 1 4 0 f e m a n - d t ll e t s r e e m a n . R p e g e m a n . F t z t e s r e . D t z t e s r e sign of material d-pack: filter with eco-drain d-pack: filter with differential pressure gauge and eco-drain d-pack-basic: filter with differenti...

  • Page 315

    - 3 - 7 0 5 0 f 7 0 . 3 0 . 5 0 c k 7 0 . 3 0 . 5 0 c k 2 1 4 0 f e m a n - d t ll e t s r e e m a n . R p e g e m a n . F t z t e s r e . D t z t e s r e sign of material d-pack: filter with differential pressure gauge and eco-drain d-pack-basic: filter with differential pressure gauge and eco-drai...

  • Page 316

    - 4 - 7 0 5 0 f 7 0 . 3 0 . 5 0 c k 7 0 . 3 0 . 5 0 c k 2 1 4 0 f e m a n - d t ll e t s r e e m a n . R p e g e m a n . F t z t e s r e . D t z t e s r e materialkennzeichnung d-pack: filter mit differenzdruckmanometer und eco-drain d-pack-basic: filter mit differenzdruckmanometer und eco-drain 30 ...

  • Page 317

    - 5 - 7 0 5 0 f 7 0 . 3 0 . 5 0 c k 7 0 . 3 0 . 5 0 c k 2 1 4 0 f e m a n - d t ll e t s r e e m a n . R p e g e m a n . F t z t e s r e . D t z t e s r e materialkennzeichnung filterkombination bestehend aus serie ff & fg d-pack: filter mit differenzdruckmanometer und eco-drain d-pack-basic: filter...

  • Page 318

    - 6 - 7 0 5 0 f 7 0 . 3 0 . 5 0 c k 7 0 . 3 0 . 5 0 c k 2 1 4 0 f e m a n - d t ll e t s r e e m a n . R p e g e m a n . F t z t e s r e . D t z t e s r e inhaltsverzeichnis 1. Einleitung 2. Sicherheitsregeln, warnhinweise 3. Technische daten 4. Funktionsbeschreibung 5. Kondensatableiter 6. Transpor...

  • Page 319

    - 7 - 7 0 5 0 f 7 0 . 3 0 . 5 0 c k 7 0 . 3 0 . 5 0 c k 2 1 4 0 f e m a n - d t ll e t s r e e m a n . R p e g e m a n . F t z t e s r e . D t z t e s r e 1. Einleitung 1.1 allgemeines die in dieser betriebsanleitung dokumentierten druckluftfilter erfül- len alle anforderungen, die an moderne filter...

  • Page 320

    - 8 - 7 0 5 0 f 7 0 . 3 0 . 5 0 c k 7 0 . 3 0 . 5 0 c k 2 1 4 0 f e m a n - d t ll e t s r e e m a n . R p e g e m a n . F t z t e s r e . D t z t e s r e 2. Sicherheitsregeln, warnhinweise 2.1 bestimmungsgemäßer gebrauch achtung! • die filter dürfen nur für die in dieser bedienungsanleitung vorgese...

  • Page 321

    - 9 - 7 0 5 0 f 7 0 . 3 0 . 5 0 c k 7 0 . 3 0 . 5 0 c k 2 1 4 0 f e m a n - d t ll e t s r e e m a n . R p e g e m a n . F t z t e s r e . D t z t e s r e 2. Sicherheitsregeln, warnhinweise 2.3 warnhinweise warnung! Das (die) filter beinhalten unter erhöhtem druck stehende systeme. Vor servicearbeit...

  • Page 322

    - 10 - 7 0 5 0 f 7 0 . 3 0 . 5 0 c k 7 0 . 3 0 . 5 0 c k 2 1 4 0 f e m a n - d t ll e t s r e e m a n . R p e g e m a n . F t z t e s r e . D t z t e s r e 3. Technische daten 3. Technical data m o d e l l b e z e ic h n u n g / m o d e l d e s ig n a t io n v o lu m e n s tr o m c a p a c it y a n ...

  • Page 323

    - 13 - 7 0 5 0 f 7 0 . 3 0 . 5 0 c k 7 0 . 3 0 . 5 0 c k 2 1 4 0 f e m a n - d t ll e t s r e e m a n . R p e g e m a n . F t z t e s r e . D t z t e s r e 4. Funktionsbeschreibung 4.3 serie fc 1-mikron-coalescing-filter • zweistufige tiefenfiltration bewirkt hervorragende leistung und höhere standz...

  • Page 324

    - 15 - 7 0 5 0 f 7 0 . 3 0 . 5 0 c k 7 0 . 3 0 . 5 0 c k 2 1 4 0 f e m a n - d t ll e t s r e e m a n . R p e g e m a n . F t z t e s r e . D t z t e s r e 4. Funktionsbeschreibung 4.5 serie fe 0,01-mikron-coalescing-filter (bei 0,01 ppm w/w max. Ölgehalt) duo-system abscheidung 1. Stufe: flüssige b...

  • Page 325

    - 21 - 7 0 5 0 f 7 0 . 3 0 . 5 0 c k 7 0 . 3 0 . 5 0 c k 2 1 4 0 f e m a n - d t ll e t s r e e m a n . R p e g e m a n . F t z t e s r e . D t z t e s r e 7. Montage 7.1 montageort das filter/ -system sollte in einem trockenen, frostfreien innenraum installiert werden. Zur wartung ist genügend frei...

  • Page 326

    - 24 - 7 0 5 0 f 7 0 . 3 0 . 5 0 c k 7 0 . 3 0 . 5 0 c k 2 1 4 0 f e m a n - d t ll e t s r e e m a n . R p e g e m a n . F t z t e s r e . D t z t e s r e 8. Inbetriebnahme, betrieb 8.1 bereitschaft zur inbetriebnahme druckluftfilter/ -systeme sind bereit zur inbetriebnahme, wenn: • der auf dem typ...

  • Page 327

    - 25 - 7 0 5 0 f 7 0 . 3 0 . 5 0 c k 7 0 . 3 0 . 5 0 c k 2 1 4 0 f e m a n - d t ll e t s r e e m a n . R p e g e m a n . F t z t e s r e . D t z t e s r e 8. Inbetriebnahme, betrieb 8.3 differenzdruckanzeige-standard und d-pack (option) die differenzdruckanzeige informiert als störanzeige über eine...

  • Page 328

    - 32 - 7 0 5 0 f 7 0 . 3 0 . 5 0 c k 7 0 . 3 0 . 5 0 c k 2 1 4 0 f e m a n - d t ll e t s r e e m a n . R p e g e m a n . F t z t e s r e . D t z t e s r e 9. Wartung austausch der filterelemente 9.1 standzeit der filterelemente die standzeit der filterelemente ist abhängig von der beladung. Mit ste...

  • Page 329

    - 33 - 7 0 5 0 f 7 0 . 3 0 . 5 0 c k 7 0 . 3 0 . 5 0 c k 2 1 4 0 f e m a n - d t ll e t s r e e m a n . R p e g e m a n . F t z t e s r e . D t z t e s r e 9. Wartung austausch der filterelemente filtergehäuse entfernen. • filtergehäuse -6 bis -48 (bajonett-verschluß) ∗ das filtergehäuse nach oben, ...

  • Page 330

    - 34 - 7 0 5 0 f 7 0 . 3 0 . 5 0 c k 7 0 . 3 0 . 5 0 c k 2 1 4 0 f e m a n - d t ll e t s r e e m a n . R p e g e m a n . F t z t e s r e . D t z t e s r e 9. Wartung austausch der filterelemente absperrvorrichtung im druckluftein- und -austritt schließen. Kondensatableitungsschlauch an (1) lösen. (...

  • Page 331

    - 35 - 7 0 5 0 f 7 0 . 3 0 . 5 0 c k 7 0 . 3 0 . 5 0 c k 2 1 4 0 f e m a n - d t ll e t s r e e m a n . R p e g e m a n . F t z t e s r e . D t z t e s r e 9. Wartung austausch der filterelemente 9.3 austausch der schwimmerableiter / eco-drain service-unit / eco-drain membransätze die kondensatablei...

  • Page 332

    - 36 - 7 0 5 0 f 7 0 . 3 0 . 5 0 c k 7 0 . 3 0 . 5 0 c k 2 1 4 0 f e m a n - d t ll e t s r e e m a n . R p e g e m a n . F t z t e s r e . D t z t e s r e 10. Garantiebedingungen 10.1 allgemeines die garantie erstreckt sich, im rahmen unserer allgemeinen liefer- bedingungen, auf das gelieferte filt...

  • Page 333

    13.7 option dc operating instructions for compressed air filter (fresh air filter) 13 annex 13.7 operating instructions for compressed air filter (fresh air filter) no.: 9_6974 20 e service manual portable compressor m122 321 ramirent.

  • Page 334: Domnick Hunter

    Ac010 - ac030 domnick hunter dh en original language oil vapour & odour removal filters nl oliedamp & geur verwijderingsfilters de filter zum entfernen von Ölnebel und gerÜchen fr filtres d'Élimination des odeurs et des vapeurs d'huile fi ÖljyhÖyryn ja hajun poistosuodattimet sv filter fÖr avlÄgsnin...

  • Page 335

    13 annex 13.7 operating instructions for compressed air filter (fresh air filter) no.: 9_6974 20 e service manual portable compressor m122 323 ramirent.

  • Page 336

    1 ac010 - ac030 warning caution • highlights actions or procedures, which if not performed correctly, may lead to personal injury or death. • benadrukt de acties of procedures die, indien niet juist uitgevoerd, lichamelijk letsel of de dood kunnen veroorzaken. • weist auf aktionen oder verfahren hin...

  • Page 337

    2 ac010 - ac030 • pressure. • druk • druck. • pression. • paine. • tryck • trykk • tryk • Πίεση • presión. • pressão. • pressione. • ciśnienie • tlak. . • tlak. • surve . • nyomás alatt. • spiediens. • slėgis. • Давление • tlak • basınç • pressjoni • release pressure. • druk aflaten. • druck ablasse...

  • Page 338

    3 ac010 - ac030 warning! This product must be installed and maintained by competent and authorised personnel only, under strict observance of these operating instructions, any relevant standards and legal requirements where appropriate. Retain this user guide for future reference waarschuwing! Dit p...

  • Page 339

    20 ac010 - ac030 rakkomandazzjonijiet g[all-installazzjoni nirrakkomandaw li l-arja kompressata ti;i trattata qabel ma tid[ol fis-sistema ta’ distribuzzjoni kif ukoll fil-punti / l-applikazzjonijiet kriti/i ta’ l-u]u. L-installazzjoni ta’ tag[mir li jnixxef l-arja kumpressata fuq sistema li kienet i...

  • Page 340

    21 ac010 - ac030 1/4” 1/2” 010 fi - 030 fi 010 mi - 030 mi 6 filter-dh-oil-xevolution 01 13 annex 13.7 operating instructions for compressed air filter (fresh air filter) 328 service manual portable compressor m122 no.: 9_6974 20 e ramirent.

  • Page 341

    26 ac010 - ac030 • automatic drain • automatischer ablauf • vidange automatique • automischaftappen • drenaje automatico • scario automatico • automatisk aflØb • dreno automÁtico • aytomath aΠoΣtpaΓΓiΣh • automatdrÄnering • automaattinen • tyhjennyskappale • dren automatyczny • automatickÉ vysuŠenie...

  • Page 342

    27 ac010 - ac030 + 20 (68) 30 (86) 40 (104) 50 (122) 1,000 10,000 ˚c ˚f ¡ hrs 1000 50 models ac010 i - ac030 i are fitted with a bulk oil indicator. Both filter elements and indicator should be changed if indicator is blue in colour. Please note - this is a bulk oil indicator, it does not indicate f...

  • Page 343

    29 ac010 - ac030 1 2 2 3 4 5 6 1 2 1 2 1 0 bar 0 psi 0 bar 0 psi 9 filter-dh-oil-xevolution 01 13 annex 13.7 operating instructions for compressed air filter (fresh air filter) no.: 9_6974 20 e service manual portable compressor m122 331 ramirent.

  • Page 344

    30 ac010 - ac030 7 8 9 10 11 12 2 1 2 1 1 2 0 bar 0 psi 0 bar 0 psi 0 bar 0 psi 0 bar 0 psi 10 filter-dh-oil-xevolution 01 13 annex 13.7 operating instructions for compressed air filter (fresh air filter) 332 service manual portable compressor m122 no.: 9_6974 20 e ramirent.

  • Page 345

    31 ac010 - ac030 13 14 2 1 15 1 2 11 filter-dh-oil-xevolution 01 13 annex 13.7 operating instructions for compressed air filter (fresh air filter) no.: 9_6974 20 e service manual portable compressor m122 333 ramirent.

  • Page 346

    Ac010 - ac030 de clar atio n of con for m it y en domni c k h unt er duk e s w a y, tvte , gat es head, tyne & w e a r, ne11 0pz. Uk a c 01 0, 015, 020 02 5 , 030 di re ct iv e s 97/ 2 3 /e c, st andar ds used ge ner al ly i n ac c o rdan c e wi th asm evii i d iv 1 : 20 04. Ped a sse sm ent rout e ...

  • Page 347

    13.8 option lc service tasks on the diesel particulate filter to ensure the proper functioning of the diesel particulate filter, an authorised service technician must perform annual maintenance. Have the following tasks performed by a specialist shop or the kaeser service: ■ pressure lines: ─ check ...

  • Page 348

    13 annex 13.8 service tasks on the diesel particulate filter 336 service manual portable compressor m122 no.: 9_6974 20 e ramirent.