KAESER M43 Service Manual

Manual is about: Screw Compressor

Summary of M43

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    Service manual screw compressor m43 no.: 9_9432 02 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/m43 1.02 en sba-mobilair-pe 20100819 162014 ramirent.

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    1 regarding this document 1.1 using the document ......................................................................................................... 1 1.2 further documents .......................................................................................................... 1 1.3 copyrigh...

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    3.4.2 defining personnel .............................................................................................. 14 3.4.3 adherence to inspection schedules and accident prevention regulations .......... 14 3.5 dangers ..............................................................................

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    8 operation 8.1 starting and stopping ....................................................................................................... 55 8.1.1 starting ............................................................................................................... 55 8.1.2 allow the machine t...

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    10.6 maintain rubber sealing strips .......................................................................................... 102 10.7 options ............................................................................................................................. 102 10.7.1 tool lubricator mai...

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    Fig. 1 location of safety signs .............................................................................................................. 20 fig. 2 overview bodywork .................................................................................................................... 24 fig. 3 si...

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    List of illustrations vi service manual screw compressor m43 no.: 9_9432 02 e ramirent.

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    Tab. 1 the levels of danger and their meaning ..................................................................................... 2 tab. 2 nameplate .................................................................................................................................. 3 tab. 3 combined ...

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    Tab. 55 maintenance tasks after commissioning .................................................................................... 68 tab. 56 maintenance intervals and regular maintenance tasks .............................................................. 68 tab. 57 regular maintenance tasks .........

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    1 regarding this document 1.1 using the document the service manual is part of the machine. It describes the machine as it was at the time of first delivery after manufacture. ➤ keep the service manual in a safe place throughout the life of the machine. ➤ pass the manual on to the next owner/user of...

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    2. Always read and comply with warning instructions. Signal word meaning consequences of non-observance danger warns of an imminent threat of danger death or serious injury may result warning warns of possible danger death or serious injury are possible caution warns of a possibly dangerous situa‐ t...

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    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 identit...

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    ➤ take a list of fitted options from the combined coupling load / options label. M43 matno serno options fitted here is given the specified coupling load. Sg sf tc tb sd se sa sb oa oe lb la ba ne ea ua bb ha tab. 3 combined label for coupling load and options fitted 2.2.1 option ea tool lubricator ...

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    2.2.4 option ba, bb low temperature equipment ➤ enter the fitted option as reference. Option option code exists? Frost protector ba engine coolant pre-heating bb tab. 7 low temperature equipment 2.2.5 option oa battery isolating switch ➤ enter the fitted option as reference. Option option code exist...

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    Option option code available? Eu chassis 03 sd eu chassis 04 se eu ≙ europe tab. 11 chassis further information for an exact description of the characteristics of the chassis and models, see chapter 4.6.8. 2.2.9 option tb, tc, te lighting ➤ enter the fitted option as a reference. Option option code ...

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    2.3 machine (without options) 2.3.1 sound emission 2.3.1.1 sound emission measurement conditions ■ free-field measurement to directive 2000/14/ec ■ measuring distance: d=1 m ■ logarithmic surface ratio: q2=16,8db(a) sound emission m43 guaranteed sound power level [db(a)] 98 emission sound pressure l...

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    2.3.4 dimensions for specifications according to the machine's operating licence, such as: ■ dimensions, ■ track width, ■ footprint, see the dimensional drawings in chapter 13.3. 2.4 chassis 2.4.1 weights maximum weights are shown. Actual weights of individual machines are dependent on equip‐ ment f...

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    2.5 compressor 2.5.1 working pressure and fad maximum working pressure [bar] 7 sigma airend 190 free air delivery [m 3 /min] 4,2 tab. 23 working pressure and fad 2.5.2 compressed air outlet discharge valve ["] no. G 3/4 2 *g 1 1 *optional tab. 24 compressed air distributor 2.5.3 pressure relief valv...

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    Characteristic sigma fluid oil grade s–460 mol classification silicone-free, synthetic oil mineral oil 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...

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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. Tab. 29 engine specification 2.6.2 oil recommendation the engine oil must meet the following classification: ■ acea, class e4, e7 ■ api, class cf, ci-4 the eng...

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    Feature value ptc testing current [a] (according to en 50342) 480 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 tool lubricator name temperature range [°c] fl...

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

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    3.4.2 defining 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 qualification...

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    ➤ oil changing according 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. This requirement may be waived if an oil analysis proves that the oil is still usable. ➤ recurring inspections according to ...

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    ➤ 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 f...

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    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...

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    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...

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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 sur...

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    3.6 safety devices safety devices ensure safe working with the machine. ➤ do not change, bypass or disable safety devices. ➤ check safety devices for correct function regularly. ➤ do not remove or obliterate labels and notices. ➤ ensure that labels and notices are clearly legible. Further informatio...

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

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    3.8 in emergency 3.8.1 correct fire fighting suitable extinguishing agents: ■ foam ■ carbon dioxide ■ sand or earth unsuitable extinguishing agents: ■ strong jet of water 1. Keep calm. 2. Give the alarm. 3. Shut down the machine from the instrument panel if possible. 4. Move to safety. ■ warn person...

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    In addition, we accept no warranty obligation for: ■ the use of unsuitable parts or operating materials, ■ unauthorised modifications, ■ incorrect maintenance, ■ incorrect repair. Correct maintenance and repair includes the use of original spare parts and operating materials. ➤ obtain confirmation f...

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    4 design and function 4.1 bodywork bodywork is understood to be the exterior of the machine mounted on the chassis. Fig. 2 overview bodywork 1 canopy 2 lower body 3 cooling air inlet 4 recessed grip for the canopy 5 snap fastener 6 canopy safety catch 7 lock 8 cover for lifting eye safe and reliable...

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    4.2 component identification fig. 3 side view (canopy removed) 1 instrument panel 2 oil separator tank 3 fuel tank 4 oil cooler 5 battery 6 canopy safety catch lock 7 coolant expansion tank 8 radiator 9 engine 10 compressor air filter 11 inlet valve 12 airend 13 compressed air outlet valve 14 pressu...

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    4.3 machine function machine function (without options) item numbers correspond to the pipe and instrument flow diagram in chapter 13.2. 4 design and function 4.3 machine function 26 service manual screw compressor m43 no.: 9_9432 02 e ramirent.

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    Fig. 4 general design 1 compressor air filter 3 inlet valve 4 airend 5 oil separator tank 7 oil separator cartridge 10 compressed air distributor 13 pressure relief valve 15 engine 17 dirt trap 19 thermostatic valve (oil temperature con‐ trol) 20 oil cooler 23 proportional controller 24 engine air f...

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    The air is then compressed in the airend 4 . The airend is driven by an internal combustion engine. Cooling oil is injected into the airend. It lubricates moving parts and forms a seal between the ro‐ tors themselves and between them and the airend casing. This direct cooling in the compression cham...

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    4.4.2 modulating control the control system regulates the volume of air generated to match the actual demand. The ma‐ chine keeps the working pressure constant by varying the volume of compressed air delivered, thereby matching the air demand. With the help of a mechanical control valve (the proport...

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    Fig. 5 tool lubricator 1 bodywork 2 instrument panel 3 location of the tool lubricator 4 tool lubricator 5 metering knob 6 oil tank 7 air line 8 shut-off valve (opened) 9 air pipe further information see chapter 8.3 for tool lubricator operation. 4.6.2 option ba, bb low temperature equipment 4.6.2.1...

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    Fig. 6 frost protector 1 shut-off valve 2 control line (frost protection) 3 frost protector 4 control line (bypass line) 5 oil separator tank cover frost protection the frost protector comes into action when the machine is stopped in ambient temperatures below freezing. The compressed air carries an...

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    Fig. 7 coolant pre-heating 1 bodywork 2 connecting socket for coolant pre-heating 3 instrument panel 4 coolant pre-heating 5 engine 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...

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    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. Fig. 8 battery isolating switch 1 «battery isolating switch» 2 lifting ...

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    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 ap...

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    Option name characteristics sd eu chassis 03 ■ single-axle ■ axle rubber-sprung ■ jockey wheel ■ fixed height towbar ■ parking brake ■ breakaway cable se eu chassis 04 ■ single-axle ■ axle rubber-sprung ■ prop stand ■ fixed height towbar ■ service brake ■ parking brake ■ breakaway cable eu ≙ europe ...

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    5 installation and operating conditions 5.1 safety ➤ strictly forbid fire, open flame and smoking. ➤ if welding is carried out on or near the machine, take adequate measures to prevent sparks or heat from igniting fuel or oil vapours or parts of the machine. ➤ the machine is not explosion-proof! Do ...

  • Page 47

    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 ...

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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. Basic safety instructions 1. Follow the instructions in chapter "safety and responsibility". 2. Installation work may only be carried out by authorized...

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    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. Height adjustment is by two serrated joints. ■ serra...

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    6. Draw out the split pin 2 . 7. Undo the locking lever 4 until the serrated joint 6 is disengaged. 8. Adjust the angle of the serrated joint 6 to bring the towing eye or coupling parallel to the ground at the height of the towing vehicle hitch. 9. Tighten the locking lever 4 making sure the serrati...

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    Fig. 11 towbar height adjustment sb 1,2 split pin 3,4 locking lever 5 serrated joint 1 6 serrated joint 2 7 towbar tube 8 towbar centre-piece 9 towing eye 10 ball coupling 11 split pin securing principle 12 overrun damper 13 parking brake 1. Caution! Danger of pinching! Severe injury to fingers is p...

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    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 lever (see 11). Check locking position 11 . ■ split pin 1 properly inserted. ■ split pin 2 properly inserted. 14. Ti...

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    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. Fig. 12 change from eye to ball coupling (height adjustable towbar) 1 towing eye 2, 3 split pin 4, 5 locking lever 6 side part 7 serrated j...

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    ➤ check that the ball coupling to be fitted is complete. ➤ proceed as illustrated. Removing the towing eye 1. Remove the split pins 2 and 3 . 2. Loosen and remove the locking lever 4 . 3. Loosen the locking lever 5 1-2 turns. 4. Shake the side part 6 to loosen the serrated joints 7 and 8 . 5. Check ...

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    Fig. 13 change from eye to ball coupling (height adjustable towbar with overrun brake) 1 towing eye 2 self-locking nut 3 screw 4 bushing overrun damper 5 overrun damper 6 tension rod 7 saddle 8 protective sleeve 9 ball coupling ➤ check that the ball coupling to be fitted is complete. ➤ proceed as il...

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    2. Remove both bolts 3 . 3. Draw off the eye 1 from the towbar 6 . Fitting the ball coupling precondition the towing eye has been removed. The assembly condition as shown in the centre graphic in 13 has been achieved. The ball coupling is complete with sleeve. 1. Push back the protective sleeve 8 if...

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    6.3.3.3 option sd changing a fixed height towbar from eye to ball coupling fig. 14 change from eye to ball coupling (fixed height towbar) 1 towing eye 2 screw 3 sleeve 4 self-locking nut 5 ball coupling 6 towbar tube ➤ check that the ball coupling to be fitted is complete. ➤ proceed as illustrated. ...

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    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. Scre...

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    ➤ check that the ball coupling to be fitted is complete. ➤ proceed in the sequence as illustrated. Removing the towing eye 1. Push back the protective sleeve 2 to the position shown 3 to expose both bolts. 2. Loosen and remove both nuts 4 . 3. Remove both bolts 5 . 4. Remove and retain the sleeve 6 ...

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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. Basic safety instructions 1. Follow the instructions in chapter "safety and responsibility". 2. Commissioning work may only be ca...

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    Function see chapter confirmed? ➤ canopy closed and all panels in place? – ➤ are the tyre pressures ok? – engine sm = engine manufacturer's service manual. Tab. 43 installation and operating conditions checklist 7.4 after storing the machine for a long period ➤ carry out the following before every r...

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    Machine operational state 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 ...

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    ➤ follow the safety rules when dealing with batteries: ■ connect batteries of the same voltage only. ■ the assisting vehicle and machine to be started must not touch. ■ do not bend over the battery when attaching jumper cables. ■ only use battery jumper cables of sufficient cross-sectional area and ...

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    Function see chapter confirmed? Close the tap on the frost protector. 8.4 tab. 45 low-temperature equipment checklist 7 initial start-up 7.5 low-temperature operation (winter) 54 service manual screw compressor m43 no.: 9_9432 02 e ramirent.

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    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. Precondition no personnel are working on the machine. Fig. 17 starting instruments 1 starting and stopping pictogram 2 instrument p...

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    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 st...

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    2. Close the «compressed air outlet valves» on the air distributor. The engine runs in idle and the turbo charger can cool down. 3. Turn the «starter switch» 12 to the “0” position after 2-3 minutes. 4. Turn the «controller on» switch 11 to the “0” position. Close and lock the canopy. 8.2 option oa ...

  • Page 68

    8.3 option ea operating the tool lubricator fig. 20 setting the tool lubricator 1 tool lubricator 2 metering knob 3 ball valve a – open b – closed adding lubricating oil 1. Open the shut-off valve 3 . 2. Set the oil flow with the adjusting knob 2 on the metering valve. Shutting off lubricating oil ➤...

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    Fig. 21 switching on the frost protector 1 shut-off valve a – open b – closed 2 control line (frost protection) 3 frost protector 4 control line (bypass line) 5 oil separator tank cover running the machine with the frost protector (winter operation) ➤ open the shut-off valve 1 (position a) in the fr...

  • Page 70

    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. 8.5.1 using the hose reel (ec version) the hose reel is on the front of the machine. Fig...

  • Page 71

    8.5.1.3 securing the hose reel for transport 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 ....

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    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. Inform kaeser service if the fault cannot be removed by the action sug...

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    Possible cause action where can i get help? Special‐ ised work‐ shop kaeser service engine service manual oil pressure switch sensing in‐ sufficient oil pressure. Check the engine oil level. – – x have the engine repaired or ex‐ changed. X – – tab. 46 alarm: engine refuses to start or comes to a sto...

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    9.3 compressor faults and alarms 9.3.1 working pressure too high possible cause remedy where can i get help? Specialised workshop kaeser ser‐ vice proportional controller maladjus‐ ted or defective. Check the diaphragm and clean the nozzle or replace the pro‐ portional controller if necessary. – x i...

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    9.3.3 pressure relief valve blowing off possible cause remedy where can i get help? Specialised workshop kaeser ser‐ vice oil separator cartridge heavily clogged. Change, see chapter 10.4.5. – – inlet valve not closing. Check the controller, the control air line and the inlet valve and replace if ne...

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    9.3.5 too much oil residue in the compressed air possible cause remedy where can i get help? Specialised workshop kaeser ser‐ vice oil separator cartridge scavenge line clogged. Clean the strainer in the separa‐ tor cartridge dirt trap or have changed if necessary. – x fractured oil separator car‐ t...

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    10 maintenance 10.1 safety follow the instructions below to ensure safe machine maintenance. Warning instructions are located before a potentially dangerous task. Basic safety instructions 1. Follow the instructions in chapter 'safety and responsibility'. 2. Maintenance work may only be carried out ...

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    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. Further information a prepared list is provided in chapter 10.8. 10.2.2 maintenance tasks after commissioning...

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    10.2.3.1 maintenance schedule ➤ carry out maintenance tasks according to the following schedule. Component function daily a250 a500 a1000 a1500 a2000 a3000 see chapter note engine check inlet air filter mainte‐ nance indicator x 10.3.2 check engine oil level. X engine sm clean the engine air filter ...

  • Page 80

    Component function daily a250 a500 a1000 a1500 a2000 a3000 see chapter note replace the fuel filter. X engine sm clean the fuel tank. X clean the tank fuel strainer. X check the fuel return line for leakage and firm fixing. X have the fuel injectors checked. X sw have the fuel injector pump checked....

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    Component function daily a250 a500 a1000 a1500 a2000 a3000 see chapter note check all screw connections, hinges, locks, catches, handles and snap fasteners for wear and secure fixing. X grease the canopy hinges. X carry out rubber sealing strip maintenance. X 10.6 have the lifting eye checked. X sw ...

  • Page 82

    Option function daily a250 a500 a1000 a1500 a2000 a3000 see chapter note option lb - engine air intake shut-off valve clean and check the engine air intake shut-off valve x 10.7.4 fuel filter with water trap, option ne x 10.3.3.1 tl-sm = tool lubricator service manual; el = refer to an electrician; ...

  • Page 83

    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. Checking coolant level check the coolant level of the engine daily bef...

  • Page 84

    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 tur...

  • Page 85

    Fig. 24 draining the coolant from the radiator 1 radiator 2 radiator drain plug 1. Have a coolant receptacle ready. 2. Unscrew the expansion tank cap (see fig. 23). 3. Loosen and remove the drain plug 2 . Result coolant flows from the expansion tank and radiator. ➤ dispose of used coolant in accorda...

  • Page 86

    Fig. 25 engine air filter maintenance 1 filter housing 2 air filter element 3 filter cap 4 spring retaining flap 5 dust evacuating valve 6 maintenance indicator 7 reset knob for the maintenance indicator 8 red zone indicator scale 9 indicating piston of the maintenance indi‐ cator 10 valve part 11 d...

  • Page 87

    5. Clean the filter element: cleaning: ■ by tapping to remove course dirt ─ some taps of the face side with the heel of the hand ■ by blowing out (as required) ─ use dry compressed air (≤ 5 bar) at an angle to blow dirt from the element from inside to outside. 6. Clean the sealing faces. 7. Insert t...

  • Page 88

    Bleeding the fuel system 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...

  • Page 89

    7. Insert the new element. 8. Replace the filter cap. 9. Connect the fuel line. 10. Tighten the hose clamp. 11. Bleed the system as described previously. Catch any escaping fuel. Dispose of escaped fuel, contaminated fuel and working materials and components contami‐ nated with fuel according to env...

  • Page 90

    Fig. 27 fuel filter with water trap 1 filter head 2 filter element 3 water trap 4 drain plug checking the water trap 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 c...

  • Page 91

    Precondition the negative cable to the battery is disconnected. 1. Raise the canopy. 2. Empty the water trap (see above). 3. Unscrew the filter element 2 from the filter head 1 anti-clockwise. 4. Unscrew the separator bowl 3 from the filter element and clean the bowl. 5. Check the separator bowl gas...

  • Page 92

    Caution danger of burns from hot components and escaping engine oil! ➤ wear long-sleeved clothing and gloves. Fig. 28 changing the engine oil 1 oil filler cap 2 oil filter 3 oil dipstick 4 engine block 5 oil pan 6 oil drain plug draining the engine oil: 1. Place the oil receptacle below the correspo...

  • Page 93

    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. Starting the machine and performing a test run: 1. Start the machine and allow it to idle fo...

  • Page 94

    2. Position the receptacle. 3. Unscrew and remove the engine sump drain plug 5 . 4. Open the shut-off valve 2 and drain the oil into the receptacle. 10.3.4.2 changing the engine oil filter material spares common tools cleaning cloths receptacle precondition the machine is shut down. The machine is f...

  • Page 95

    Dispose of old oil filters, old oil and materials contaminated with oil according to environmen‐ tal protection regulations. 10.3.5 motor belt maintenance ➤ see the engine service manual. 10.3.6 battery maintenance ➤ check the charging system if the battery discharges without reason. 10.3.6.1 safety...

  • Page 96

    10.3.6.2 battery checking and care even so-called 'maintenance-free' batteries need a degree of care to obtain their maximum opera‐ tional life. The outside of the battery and the terminals should be cleaned regularly with a soft cloth. This avoids current leaks and minimises the discharge rate. Mat...

  • Page 97

    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. 10.3.6.3 battery removal and installation precondition the machine is s...

  • Page 98

    Material wrench cleaning cloths 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 are disconnected and the air outlet valves are open. Fig. 32 checking cooling oil level 1 oil separator tank...

  • Page 99

    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 th...

  • Page 100

    Caution there is risk of burns from hot components and escaping oil. ➤ wear long-sleeved clothing and gloves. Fig. 33 changing the cooling oil 1 oil separator tank 2 oil separator tank drain plug 3 oil filler port 4 oil filler plug 5 oil cooler 6 oil cooler drain plug 7 combination valve 8 oil filte...

  • Page 101

    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. Top up if necessary. 7. Carry out a visual check for leaks. 10.4.3.1 option oe draining cooling oil via the shut-off valve material fresh cooling o...

  • Page 102

    10.4.4 changing the oil filter material spares receptacle cleaning cloths precondition the machine is shut down. The machine is fully vented, the pressure gauge reads 0 bar. Machine cooled down. All compressed air consumers are disconnected and the air outlet valves are open. The negative cable to t...

  • Page 103

    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. Top up if necessary. 7. Carry out a visual check for leaks. 10.4.5 changing the oil separator cartridge the oil separator...

  • Page 104

    Fig. 36 changing the oil separator cartridge 1 control air line union nut 2 oil scavenge pipe union nut 3 compressed air hose union nut 4 dirt trap 5 oil scavenge pipe 6 fixing screw 7 cover 8 oil separator cartridge 9 gasket 10 metal clip changing the oil separator cartridge the dirt trap must be c...

  • Page 105

    Changing the oil separator cartridge 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 cove...

  • Page 106

    1. Raise the canopy. 2. Undo the union nut 2 and bend the oil return line 1 to one side. 3. Unscrew the dirt trap 3 . 4. Remove and clean the strainer 4 and o-ring 5 . 5. Check the strainer and o-ring for function and wear. Renew if non functional. 6. Clean the housing and fitting 6 . 7. Re-insert t...

  • Page 107

    Fig. 38 compressor air filter maintenance 1 wing nut 2 washer 3 filter cap 4 air filter element 5 inlet valve 6 maintenance indicator 7 airend 8 reset knob for the maintenance indicator 9 red zone 10 indicator piston checking contamination of the air filter air filter maintenance is necessary when t...

  • Page 108

    9. Secure the cover with washer and wing nut. 10. Check that the cover is properly seated. Resetting the maintenance indicator ➤ press the maintenance indicator reset knob 8 a number of times. The yellow piston within the indicator is reset and the maintenance indicator is ready for use again. 10.4....

  • Page 109

    Fig. 39 cooler/radiator cleaning 1 rear of the machine 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...

  • Page 110

    10.5.2 towbar maintenance clean and lubricate all sliding and rotating bearings as necessary but at least every 6 months. Material lithium enriched multi-purpose grease non-corroding oil cleaning rags precondition the machine is shut down. The machine is disconnected from the towing vehicle and safe...

  • Page 111

    Checking the overrun damper 1. Loosen the transfer cable one side. 2. Press in the damper against its damping force. Have the damper 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 a...

  • Page 112

    10.6 maintain rubber sealing strips the rubber sealing strips between the lower body and the canopy serve both as a soundproofing measure and to prevent ingress of rain water. Care of the rubber sealing strips is very necessary during the winter months to prevent the strips from sticking and tearing...

  • Page 113

    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 shoul...

  • Page 114

    Fig. 42 filling the frost protector 1 shut-off valve a open b closed 2 bowl clamp ring 3 frost protector bowl 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 wit...

  • Page 115

    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 ...

  • Page 116

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

  • Page 117

    3. Check if the interior of the shut-off valve 4 is clean. Blow out any dirt with compressed air. The valve cannot be completely cleaned with a compressed air blast. ➤ remove the engine air intake shut-off valve, noting its mounted position. ➤ clean the valve with cleaning fluid or spirit and allow ...

  • Page 118

    10.8 document 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. 61 logged maintenance tasks 10 maintenance 10.8 document maintenance and service work. 108 service manual screw c...

  • Page 119

    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 120

    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 121

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  • Page 202

    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 203

    Decommissioning of the compressor for several weeks during severe frost 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 (bat...

  • Page 204

    Long-term decommissioning tasks see chapter confirmed? ➤ hang a notice on the instrument panel informing of the decommis‐ sioning measurements taken. – engine sm = engine manufacturer's service manual. Tab. 65 long-term decommissioning checklist ➤ hang the following notice on the instrument panel in...

  • Page 205

    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 perm...

  • Page 206

    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 coupl...

  • Page 207

    5. If the locking indicator is not visible: ■ press down on the coupling until the closing mechanism can be heard to lock into place. ■ press down on the release lever 7 to bring it to the horizontal position. 6. Check again that the locking indicator 6 is showing green. The coupling is locked close...

  • Page 208

    Carry out the following before starting to tow fig. 47 safety signs: secure the chocks 1. Warning! Missing chocks serious injury or death can result from an unsecured machine rolling away. ➤ secure the chocks in the transport securing device before transporting the machine. ➤ replace missing chocks ...

  • Page 209

    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 to...

  • Page 210

    2. Pull on the parking brake. 3. Detach the breakaway cable. 4. Wind down the jockey wheel. 5. Place chocks under the wheels. 6. Pull up the parking brake to the stop. 7. Uncouple the compressor from the towing vehicle. ■ pull up the coupling release lever. ■ lift the coupling off the towing hitch b...

  • Page 211

    Precondition safety chain present lock present key custody is decided 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. Result the machine is protected against theft. Releasing the anti-the...

  • Page 212

    Take care when setting down the machine 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. 12....

  • Page 213

    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 ...

  • Page 214

    ➤ parts contaminated with cooling oil or engine oil must be disposed of in accordance with local environment protection regulations. 12 decommissioning, storage and transport 12.4 disposal 204 service manual screw compressor m43 no.: 9_9432 02 e ramirent.

  • Page 215

    13 annex 13.1 marking fig. 52 marking 1 vin *) (stamped under the reflector) *vehicle identity number 2 machine nameplate with serial number 3 engine nameplate with serial number 4 combined label for coupling loading and built-in options 13.2 pipeline and instrument flow diagram (p+i diagram) 13 ann...

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  • Page 219

    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_9432 02 e service manual screw compressor m43 209 ramirent.

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    13.3.2 option sb dimensional drawing - chassis with height-adjustable tow bar 13 annex 13.3 dimensional drawings no.: 9_9432 02 e service manual screw compressor m43 211 ramirent.

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    13.3.3 option sd dimensional drawing - fixed height towbar and parking brake 13 annex 13.3 dimensional drawings no.: 9_9432 02 e service manual screw compressor m43 213 ramirent.

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    13.3.4 option se dimensional drawing - fixed height towbar and overrun brake 13 annex 13.3 dimensional drawings no.: 9_9432 02 e service manual screw compressor m43 215 ramirent.

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    13.5 option tc lighting and signalling system connection 13 annex 13.5 lighting and signalling system connection no.: 9_9432 02 e service manual screw compressor m43 227 ramirent.

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