KAESER M26 Service Manual
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KAESER M26 Service Manual

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SERVICE MANUAL
Screw Compressor
M26
No.: 9_9446 01 USE

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Summary of Contents for KAESER M26

  • Page 1 SERVICE MANUAL Screw Compressor No.: 9_9446 01 USE...

  • Page 2: Table Of Contents

    Contents Regarding this Document Using the Document ......................Further Documents ......................Copyright .......................... Symbols and Identification ....................1.4.1 Warnings ......................1.4.2 Other instructions and symbols ................Technical Data Nameplate ........................Options ..........................2.2.1 Tool lubricator ..................... 2.2.2 Non-return function ..................... 2.2.3 Fuel filter with water trap ..................
  • Page 3 Contents 3.4.3 Adherence to inspection schedules and accident prevention regulations ..Dangers ..........................3.5.1 Safely dealing with sources of danger ..............3.5.2 Safe machine operation ..................3.5.3 Organizational Measures ..................3.5.4 Danger areas ...................... Safety Devices ......................... Safety signs ........................In Emergency ........................
  • Page 4 Contents 8.1.2 Allow the machine to run up to operating temperature ........8.1.3 Shutting down ..................... Operating the tool lubricator ..................... Using the low-temperature equipment ................8.3.1 Using the frost protector ..................8.3.2 Coolant pre-heating .................... Using the hose reel ......................8.4.1 Using the hose reel (EC version) ................
  • Page 5 Spares, Operating Materials, Service 11.1 Note the nameplate ......................108 11.2 Ordering consumable parts and operating fluids/materials ..........108 11.3 KAESER AIR SERVICE ....................109 11.4 Service Addresses ......................109 11.5 Spares for service and repair ................... 109 Decommissioning, Storage and Transport 12.1 De-commissioning ......................
  • Page 6 List of Illustrations Fig. 1 Location of safety signs ......................Fig. 2 Overview Bodywork ........................Fig. 3 Side view (canopy removed) ...................... Fig. 4 General design ........................... Fig. 5 Tool lubricator ..........................Fig. 6 Frost protector ..........................Fig. 7 Coolant pre-heating ........................Fig.
  • Page 7 List of Tables Tab. 1 The levels of danger and their meaning ..................Tab. 2 Nameplate ..........................Tab. 3 Combined label for coupling load and options fitted ..............Tab. 4 Tool lubricator ..........................Tab. 5 Non-return function ........................Tab. 6 Fuel filter with water trap ......................
  • Page 8 List of Tables Tab. 55 Fault: oil flows from the compressor air filter after shutdown ............. Tab. 56 Maintenance tasks after commissioning ..................Tab. 57 Maintenance intervals and regular maintenance tasks .............. Tab. 58 Regular maintenance tasks ......................Tab. 59 Regular maintenance task options .....................

  • Page 9: Regarding This Document Using The Document

    ➤ Make sure you give the data from the nameplate when ordering documents. Copyright This service manual is copyright protected. Queries regarding use or duplication of the documenta‐ tion should be referred to KAESER. Correct use of information will be fully supported. Symbols and Identification 1.4.1 Warnings Warning notices indicate three levels of danger signified by the signal word.

  • Page 10: Other Instructions And Symbols

    Regarding this Document Symbols and Identification 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‐...

  • Page 11: Technical Data Nameplate

    Technical Data Nameplate 2 Technical Data Nameplate The machine's nameplate provides the model designation and important technical information. The nameplate is located on the outside of the machine (see illustration in chapter 13.1). ➤ Enter here the nameplate data as a reference: Feature Value Vehicle identity no.

  • Page 12: Tool Lubricator

    Technical Data Options ➤ Take a list of fitted options from the combined coupling load / options label. MATNo SERNo Options fitted Here is given the specified coupling load. sa sb 02-M0277-PE Tab. 3 Combined label for coupling load and options fitted 2.2.1 Option ea Tool lubricator...

  • Page 13: Low Temperature Equipment

    Technical Data Options 2.2.4 Option ba Low temperature equipment ➤ Enter the fitted option as reference. Option Option code Exists? Low temperature equipment Tab. 7 Low temperature equipment 2.2.5 Option la Equipment for fire hazard areas ➤ Enter the fitted option as a reference in this overview: Option Option code Available?

  • Page 14: Lighting

    Technical Data Machine (without options) 2.2.8 Option ta, tb, tc, te Lighting ➤ Enter the fitted option as a reference in this overview: Option Option code Available? None (stationary) Reflective warning triangle EU – 12 V (7-pin connector) USA 12 V (DOT conformity) Tab.

  • Page 15: Torques

    Technical Data Machine (without options) Sound emission Emission sound pressure level* [dB(A)] 82.0 * Calculated from the guaranteed sound power level (2000/14/EG Directive, Basic Noise Emission Standard ISO 3744) to EN ISO 11203:1995 number 6.2.3.d Tab. 14 Sound emission 2.3.1.2 Sound pressure level The sound pressure level conforms to the US EPA Standard.

  • Page 16: Chassis

    Technical Data Chassis Chassis 2.4.1 Weights Maximum weights are shown. Actual weights of individual machines are dependent on equip‐ ment fitted (see machine nameplate). Feature Chassis type Stationary chassis chassis chassis chassis Height-adjustable towbar − − − Fixed height towbar −...

  • Page 17: Compressed Air Outlet

    Technical Data Compressor 2.5.2 Compressed air outlet Discharge valve ["] G 3/4 Tab. 22 Compressed air distributor 2.5.3 Pressure relief valve Further information Maximum working pressure: see nameplate Maximum working pressure [psig] Relief valve activating pressure* [psig] *The pressure relief valve is fitted to the oil separator tank. Tab.

  • Page 18: Cooling Oil Charge

    Technical Data Engine Characteristic SIGMA FLUID Oil grade S–460 Application Standard oil for all applications except in Standard oil for all applications connection with foodstuffs. except in connection with food‐ stuffs. Particularly suitable for machines with a high duty cycle. Particularly suitable for machines with a low duty cycle.

  • Page 19: Oil Recommendation

    Technical Data Engine 2.6.2 Oil recommendation The engine oil must meet the following classification: ■ ACEA, class E4, E7 ■ API, class CF, CI-4 The engine is filled initially with engine oil of viscosity class SAE 10 W / 40. Ambient temperature [°F] Viscosity class 14 –...

  • Page 20: Options

    Technical Data Options Options 2.7.1 Option ea Tool lubricator Name Temperature range [°F] Fluid volume [qt] Special road breaker lubricant −13 – 122 Tab. 32 Road breaker lubricant recommendation 2.7.2 Option ba Low temperature equipment 2.7.2.1 Ambient conditions Positioning Limit value Maximum altitude AMSL* [ft] 3000 Minimum ambient temperature [°F]...
  • Page 21 Technical Data Options Name Discharge valve Compressed air hose Length [ft] − Tab. 36 Additional discharge valve for the compressed air hose SERVICE MANUAL Screw Compressor No.: 9_9446 01 USE...

  • Page 22: Safety And Responsibility Basic Information

    Safety and Responsibility Basic Information 3 Safety and Responsibility 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, ■...

  • Page 23: Defining Personnel

    Safety and Responsibility User's Responsibilities 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.

  • Page 24: Dangers

    Inspection interval Inspecting authority Internal inspection Every 5 years after commissioning or the Competent person last inspection (e. g. KAESER Service Technician) Strength test Every 10 years after commissioning or the Competent person last inspection (e. g. KAESER Service Technician) Tab.
  • Page 25 Safety and Responsibility Dangers ➤ Never top up antifreeze (option ba) unless the machine is stopped and cooled down. ➤ Make sure that the ambient temperature at the machine's place of use is within permissible lim‐ its. Hot coolant The cooling system of a liquid-cooled engine at running temperature is under high pressure. If the filler cap is unscrewed, hot coolant can spray out under pressure and cause severe scalding.

  • Page 26: Safe Machine Operation

    ➤ Do not eat or drink while handling fuel, cooling and lubricating fluids or antifreeze. ➤ Keep suitable fire extinguishing agents ready for use. ➤ Use only KAESER approved operating materials. Unsuitable spare parts ➤ Use only spare parts approved by the manufacturer for use in this machine. Unsuitable spare parts compromise the safety of the machine.
  • Page 27 Safety and Responsibility Dangers 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. ➤...

  • Page 28: Organizational Measures

    Safety and Responsibility Dangers 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. ➤...

  • Page 29: Safety Devices

    Safety and Responsibility Safety Devices 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. ➤...
  • Page 30 Safety and Responsibility Safety signs Item Sign Meaning 283* Battery contains acid. Severe injury result from contact with battery acid. ➤ Do not allow battery acid to contact eyes, skin, clothing or painted surfa‐ ces.. ➤ Do not attempt to jump-start if battery fluid is frozen. ➤...
  • Page 31 Serious injury or death can result from loosening or opening component that is under pressure and heavily spring loaded. ➤ Never open (dismantle) valve. ➤ Contact authorized KAESER distributor. * Location within the machine ** Only machines with generator *** Only towable machines...

  • Page 32: In Emergency

    ■ lubricating oil ■ compressor cooling oil ■ tool lubricant (option e) ■ antifreeze (option ba) If necessary, request a copy of the safety data sheet for KAESER SIGMA FLUID. SERVICE MANUAL Screw Compressor No.: 9_9446 01 USE...

  • Page 33: Warranty

    ■ incorrect repair. Correct maintenance and repair includes the use of original spare parts and operating materials. ➤ Obtain confirmation from KAESER that your specific operating conditions are suitable. 3.10 Environmental Protection ➤ Store and dispose of operating materials and replaced parts in accordance with local environ‐...

  • Page 34: Design And Function Bodywork

    Design and Function Bodywork 4 Design and Function Bodywork Bodywork is understood to be the exterior of the machine mounted on the chassis. The bodywork has several functions when it is closed: ■ Weather protection ■ Sound insulation ■ Guarding against touching ■...

  • Page 35: Component Identification

    Design and Function Component identification Component identification Fig. 3 Side view (canopy removed) Water cooler Oil separator tank Drive motor Thermostatic valve Fuel tank Airend Compressor air filter Compressed air outlet valve Engine air filter Battery Lifting eye Oil cooler Coolant expansion tank Pressure relief valve SERVICE MANUAL...

  • Page 36: Machine Function

    Design and Function Machine function Machine function Machine function (without options) Item numbers correspond to the pipe and instrument flow diagram in chapter 13.2. Fig. 4 General design Compressor air filter Dirt trap Inlet valve Thermostatic valve (oil temperature con‐ Airend trol) Oil separator tank...

  • Page 37: Operating Modes And Control Modes

    This MODULATING control ensures minimum fuel consumption during times of low de‐ mand. The load and fuel consumption of the engine rises and falls with the air demand. ─ The control valve is factory set. The setting should not be changed without consultation with KAESER SERVICE. ■ IDLE ─...

  • Page 38: Modulating Control

    Design and Function Safety devices 4.4.2 MODULATING control The control system regulates the volume of air generated to match the actual demand. The ma‐ chine keeps the working pressure constant by varying the volume of compressed air delivered, thereby matching the air demand. With the help of a mechanical control valve (the proportional controller), the opening and closing of the inlet valve is continuously varied in relation to the actual air demand.

  • Page 39: Tool Lubricator

    Design and Function Options Beneath the respective drain plugs for the separator tank and oil cooler, engine oil sump, radiator and fuel tank the corresponding maintenance openings in the floor pan are closed with oil-tight stoppers. Further information See also the following chapters: ■...

  • Page 40: Low Temperature Equipment

    Design and Function Options 4.6.2.1 Option ea, ba Machine with tool lubricator and low-temperature equipment If the machine is equipped with the options Tool lubricator (ea) and low-temperature equipment (ba), the tool lubricator is positioned differently from the standard position. In this case, the tool lu‐ bricator is placed between the fuel tank and the water cooler.

  • Page 41: Option For Operating In Fire Hazard Areas

    Design and Function Options Summer operation At outside temperatures above 32 °F it is no longer necessary to inject the control lines in the ma‐ chine with antifreeze before shutting it down. Further information See chapter 8.3 for frost protector operation. 4.6.3.2 Coolant pre-heating The engine coolant can be pre-heated to improve cold-starting.

  • Page 42: Fuel Filter With Water Trap

    Design and Function Options 4.6.5 Option ne Fuel filter with water trap Diesel fuel and water have different specific gravities. Water is denser than diesel fuel. This fact is used in the water trap to separate water from the fuel. The water sinks to the bottom of the trans‐ parent trap and can be drained off.

  • Page 43: Tab. 40 Chassis - Overview

    Design and Function Options Option Name Characteristics US chassis ■ Single-axle ■ Axle rubber-sprung ■ Prop stand ■ Fixed height towbar ■ Without parking brake EU ≙ Europe, US ≙ United States of America Tab. 40 Chassis - overview Further information For adjusting the chassis, see chapter 6.3, for dimensional drawings of road-worthy machines, see chapter 13.3.

  • Page 44: Installation And Operating Conditions

    Installation and Operating Conditions Safety 5 Installation and Operating Conditions 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 vapors or parts of the machine. ➤...
  • Page 45 Installation and Operating Conditions Installation conditions 5. Ensure there is enough free space all round and above the machine. 6. Keep air inlet and outlet openings free of obstructions so that the cooling air can flow freely through the machine. 7.

  • Page 46: Installation Safety

    Installation Safety 6 Installation 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 personnel. Further information Information on authorized personnel are found in chapter 3.4.2.

  • Page 47: Adjusting The Towbar Height

    Installation Adjusting the chassis 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.

  • Page 48: Adjusting The Towbar Height

    Installation Adjusting the chassis 6. Draw out the split pin 7. Undo the locking lever until the serrated joint is disengaged. 8. Adjust the angle of the serrated joint to bring the towing eye or coupling parallel to the ground at the height of the towing vehicle hitch. 9.

  • Page 49: Fig. 10 Towbar Height Adjustment Sb

    Installation Adjusting the chassis Fig. 10 Towbar height adjustment sb Split pin Towing eye Locking lever Ball coupling Serrated joint 1 Split pin securing principle Serrated joint 2 Overrun damper Towbar tube Parking brake Towbar center-piece Danger of pinching! Severe injury to fingers is possible if they become trapped in the adjusting mechanism. ➤...

  • Page 50: Changing The Towing Eye Or Coupling

    Installation Adjusting the chassis 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 10). Check locking position ■...

  • Page 51: Fig. 11 Change From Eye To Ball Coupling (Height Adjustable Towbar)

    Installation Adjusting the chassis Fig. 11 Change from eye to ball coupling (height adjustable towbar) Towing eye Serrated joint Split pin Hex-head bolt 2, 3 Locking lever Towbar tube 4, 5 Side part Ball coupling Serrated joint ➤ Check that the ball coupling to be fitted is complete. ➤...
  • Page 52 Installation Adjusting the chassis 2. Loosen and remove the locking lever 3. Loosen the locking lever 1-2 turns. 4. Shake the side part to loosen the serrated joints 5. Check if: ■ The serrated joint has sufficient movement ■ The serrated joint has sufficient movement 6.

  • Page 53: Fig. 12 Change From Eye To Ball Coupling (Height Adjustable Towbar With Overrun Brake)

    Installation Adjusting the chassis Fig. 12 Change from eye to ball coupling (height adjustable towbar with overrun brake) Towing eye Tension rod Self-locking nut Saddle Screw Protective sleeve Bushing overrun damper Ball coupling Overrun damper ➤ Check that the ball coupling to be fitted is complete. ➤...
  • Page 54 Installation Adjusting the chassis 2. Remove both bolts 3. Draw off the eye from the towbar Fitting the ball coupling Precondition The towing eye has been removed. The assembly condition as shown in the center graphic in 12 has been achieved. The ball coupling is complete with sleeve.

  • Page 55: Fig. 13 Change From Eye To Ball Coupling (Fixed Height Towbar)

    Installation Adjusting the chassis 6.3.3.3 Option sd Changing a fixed height towbar from eye to ball coupling Fig. 13 Change from eye to ball coupling (fixed height towbar) Towing eye Self-locking nut Screw Ball coupling Sleeve Towbar tube ➤ Check that the ball coupling to be fitted is complete. ➤...
  • Page 56 Installation Adjusting the chassis 3. Push the ball coupling on to the towbar 4. Check the alignment of the holes in the towbar tube and coupling 5. Push the fixing bolts through the holes in the coupling and towbar tube 6.

  • Page 57: Initial Start-Up Safety

    Initial Start-up Safety 7 Initial Start-up 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 carried out by authorized operating and maintenance per‐ sonnel.

  • Page 58: After Storing The Machine For A Long Period

    ➤ Clean the bodywork with a grease and dirt cleansing agent. ➤ Check the tire pressures. 36 months ➤ Have the overall technical condition checked by an authorized KAESER Ser‐ vice Technician. Tab. 45 Measures for re-commissioning the compressor after a long period of storage...

  • Page 59: Starting Assistance

    Initial Start-up Low-temperature operation (winter) Machine operational state 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.

  • Page 60: Starting Up Low-Temperature Equipment

    Initial Start-up Low-temperature operation (winter) ➤ 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. ■...

  • Page 61: Tab. 46 Low-Temperature Equipment Checklist

    Initial Start-up Low-temperature operation (winter) Function See chapter Confirmed? Close the tap on the frost protector. Tab. 46 Low-temperature equipment checklist SERVICE MANUAL Screw Compressor No.: 9_9446 01 USE...

  • Page 62: Operation

    Operation Starting and stopping 8 Operation Starting and stopping Pictograms directly beneath the instrument panel illustrate the starting and stopping procedures, see also item in the following illustration. The «Control ON» switch is positioned within the machine, behind the instrument panel. See also the pictograms for Start Precondition No personnel are working on the machine.

  • Page 63: Allow The Machine To Run Up To Operating Temperature

    Operation Starting and stopping 3. Open all «compressed air outlet valves» on the air distributor. 4. Turn the «Control ON » switch to the “I” position. 5. Turn the «starter switch » to the “I” position. charging indicator lamp must light. 6.

  • Page 64: Operating The Tool Lubricator

    Operation Operating the tool lubricator Option ea Operating the tool lubricator Fig. 17 Setting the tool lubricator Tool lubricator Metering knob Shut-off valve A – open B – closed Adding lubricating oil 1. Open the shut-off valve 2. Set the oil flow with the adjusting knob on the metering valve.

  • Page 65: Coolant Pre-Heating

    Operation Using the low-temperature equipment Fig. 18 Switching on the frost protector Shut-off valve Control line (bypass line) A – open Oil separator tank cover B – closed Control line (frost protection) Frost protector Running the machine with the frost protector (winter operation) ➤...

  • Page 66: Using The Hose Reel

    Operation Using the hose reel 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. 8.4.1 Using the hose reel (EC version) The hose reel is on the front of the machine.
  • Page 67 Operation Using the hose reel 8.4.1.3 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 in the reel's side plate until it is aligned with the securing screw 3.

  • Page 68: Fault Recognition And Rectification

    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 suggested. Further information Observe the instructions in chapter "Safety"...

  • Page 69: Engine Does Not Reach Full Speed

    Fault Recognition and Rectification Engine faults and alarms Possible cause Action Where can I get help? Special‐ KAESER Engine ized Service service work‐ manual shop Oil pressure switch sensing in‐ Check the engine oil level. – – sufficient oil pressure.

  • Page 70: Compressor Faults And Alarms

    Compressor faults and alarms 9.3.1 Working pressure too high Possible cause Remedy Where can I get help? Specialized KAESER Ser‐ workshop vice Proportional controller malad‐ Check the diaphragm and clean – justed or defective. the nozzle or replace the pro‐...

  • Page 71: Pressure Relief Valve Blowing Off

    Fault Recognition and Rectification Compressor faults and alarms 9.3.3 Pressure relief valve blowing off Possible cause Remedy Where can I get help? Specialized KAESER Ser‐ workshop vice Oil separator cartridge heavily Change, see chapter 10.4.5. – – clogged. Inlet valve not closing.

  • Page 72: Too Much Oil Residue In The Compressed Air

    Compressor faults and alarms 9.3.5 Too much oil residue in the compressed air Possible cause Remedy Where can I get help? Specialized KAESER Ser‐ workshop vice Oil separator cartridge scavenge Clean the strainer in the separa‐ – line clogged. tor cartridge dirt trap or have changed if necessary.

  • Page 73: 10.1 Maintenance

    Maintenance 10.1 Safety 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 by authorized personnel. 3.

  • Page 74: Maintenance Tasks After Commissioning

    Maintenance 10.2 Maintenance schedules Wear and machine damage through unusual applications or operating condi‐ tions. ➤ Maintenance tasks must be carried out more frequently when operating conditions are un‐ favorable (e.g. dusty environment) or when the equipment is in constant use. ➤...

  • Page 75: Maintenance Schedule

    Maintenance 10.2 Maintenance schedules The table below lists regular maintenance tasks. ➤ Carry out maintenance tasks punctually taking ambient and operating conditions into consider‐ ation. 10.2.4 Maintenance schedule ➤ Carry out maintenance tasks according to the following schedule. Component Function Engine Check inlet air filter mainte‐...
  • Page 76 Maintenance 10.2 Maintenance schedules Component Function Replace the filter cartridge of the 10.3.3 Engine main fuel filter. Clean the fuel tank. Clean the tank fuel strainer. Check the fuel return line for leakage and firm fixing. Have the fuel injectors checked. Have the fuel injector pump checked.

  • Page 77: Maintenance Schedule For Options

    Option la – spark arrestor Spark arrestor cleaning 10.6.3 TL-SM = Tool lubricator service manual; EL = refer to an electrician; SW = refer to a specialized workshop; KS = call KAESER Service. SERVICE MANUAL Screw Compressor No.: 9_9446 01 USE...

  • Page 78: Engine

    Function Blow out the spark arrestor with compressed air. TL-SM = Tool lubricator service manual; EL = refer to an electrician; SW = refer to a specialized workshop; KS = call KAESER Service. Tab. 59 Regular maintenance task options 10.3 Engine ➤...

  • Page 79: Fig. 20 Checking Coolant Level

    Maintenance 10.3 Engine 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 The coolant level in the engine cooling circuit must be checked daily prior to startup.

  • Page 80: Tab. 60 Coolant Frost Protection

    Maintenance 10.3 Engine Engine casing fracture ➤ Check coolant. ➤ Protect the coolant against frost. ➤ Top up as necessary. 2. Slowly open the cap on the coolant filler by a quarter to half of a turn to allow pressure to es‐ cape.

  • Page 81: Air Filter Maintenance

    Maintenance 10.3 Engine Fig. 21 Draining the coolant from the radiator Radiator Oil-tight plug Radiator drain plug 1. Unscrew and remove the oil-tight plug 2. Unscrew the expansion tank cap (see Fig. 20). 3. Have a coolant receptacle ready. 4. Loosen and remove the drain plug Coolant flows from the expansion tank and radiator.

  • Page 82: Fig. 22 Engine Air Filter Maintenance

    Maintenance 10.3 Engine Fig. 22 Engine air filter maintenance Filter cap Reset knob for the maintenance indicator Dust evacuating valve Red zone indicator scale Spring retaining flap Indicating piston of the maintenance indi‐ Air filter element cator Filter housing Valve part Maintenance indicator Drain slit Checking contamination of the air filter:...

  • Page 83: Fuel System Maintenance

    Maintenance 10.3 Engine 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 (≤ 75 psig) at an angle to blow dirt from the element from in‐ side to outside.

  • Page 84: Fig. 23 Bleeding The Fuel System

    Maintenance 10.3 Engine Bleeding the fuel system The electric fuel pump is used to bleed the system. The negative battery terminal must be connect‐ ed for the pump to operate and bleeding to be carried out. When the starter switch is turned to the "II" position, the pump starts and bleeds the fuel system. The engine is not started! Air can find its way into the fuel system under certain conditions or maintenance tasks: ■...
  • Page 85 Maintenance 10.3 Engine 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 environmental regulations.

  • Page 86: Fig. 24 Checking The Securing Strap

    Maintenance 10.3 Engine The machine is equipped with a plastic fuel tank to save weight. The securing strap of the fuel tank is working properly as soon as the locking mechanism is proper‐ ly tightened with the correct tool Your manual force is sufficient to tighten the screw of the locking mechanism! Fig.

  • Page 87: Fig. 25 Fuel Filter With Water Trap

    Maintenance 10.3 Engine Fig. 25 Fuel filter with water trap Filter head Drain plug Fuel supply line Fuel outlet line Water trap Bleed screw Check the water trap: The water trap container is semi-transparent so the fuel level can be seen from outside. ■...

  • Page 88: Changing The Engine Oil

    Maintenance 10.3 Engine Starting the machine and carrying out a trial run 1. Start the machine and allow it to idle for about 1 minute. 2. Visually check the fuel system for leaks. 3. Shut down the machine. 4. Tighten all fittings. 10.3.4 Changing the engine oil The engine oil should be changed:...

  • Page 89: Fig. 26 Changing The Engine Oil

    Maintenance 10.3 Engine Fig. 26 Changing the engine oil Oil filler cap Oil-tight plug Oil filter Engine oil sump Oil dipstick Oil drain valve Engine block Fig. 27 Detail oil drain valve Engine oil sump Protective cap Oil drain valve Hose coupling Draining the engine oil: The engine oil sump is equipped with an oil drain valve.
  • Page 90 Maintenance 10.3 Engine 5. Unscrew and remove the oil filler cap 6. Loosen and remove the locking lever 7. Screw the hose coupling onto the valve. Engine oil drains. 8. Unscrew and remove the hose coupling. The oil drain valve is again closed. 9.

  • Page 91: Changing The Engine Oil Filter

    Maintenance 10.3 Engine 10.3.5 Changing the engine oil filter Material Spares Common tools Cleaning cloths Receptacle Precondition The machine is shut down. The machine is fully vented, the pressure gauge reads 0 psig. Engine cooled down. All compressed air consumers are disconnected and the air outlet valves are open. Danger of burns from hot components and escaping engine oil! ➤...

  • Page 92: Checking The Drive Belts

    Maintenance 10.3 Engine 10.3.6 Checking the drive belts The life of the drive belts is influenced by belt tension. ■ Slack belts can slip and become damaged. ■ Over-tight belts stretch and wear quicker. Over-tight belts also place unnecessary stress on bearings and shorten their life.

  • Page 93: Battery Maintenance

    Maintenance 10.3 Engine Fig. 29 Belt tension checking by hand Permissible deflection of the belt Direction of arrow Approximate pressure exerted: 50 lb Engine alternator screw Permissible movement: 7 – 9 mm Engine alternator Engine block mounting Checking and resetting belt tension with tension Manually check and retension the belt: measuring device: 1.

  • Page 94: Fig. 30 Warning Stickers On The Battery

    Maintenance 10.3 Engine 10.3.7.1 Safety Danger of acid burns from escaping electrolyte. ➤ Wear appropriate protective clothing including acid-proof rubber gloves. ➤ Always wear eye and face protection. ➤ Do not tip the battery. Electrolyte may run out of the vent holes. ➤...
  • Page 95 Maintenance 10.3 Engine Material Terminal grease Distilled water Cleaning rags Protective gloves Precondition The machine is shut down. The machine is standing level. The machine is fully vented, the pressure gauge reads 0 psig. Machine cooled down. 1. Clean the casing and terminals. 2.

  • Page 96: Compressor

    Maintenance 10.4 Compressor 10.3.7.3 Battery removal and installation Precondition The machine is shut down. The machine is standing level. The machine is fully vented, the pressure gauge reads 0 psig. Machine cooled down. There is danger of batteries bursting. If a battery is short circuited it will overheat and can burst. Battery electrolyte will be sprayed out in such an event.

  • Page 97: Topping Up The Cooling Oil

    Maintenance 10.4 Compressor Fig. 31 Checking cooling oil level minimum oil level Oil separator tank Mark for maximum oil level Oil filler Mark for Screw plug 1. Slowly unscrew and withdraw the plug from the oil filler port. 2. Check that oil is visible. Top up if no oil is visible.

  • Page 98: Changing The Cooling Oil

    Maintenance 10.4 Compressor 6. Replace the plug in the filler port. 7. Reconnect the negative battery terminal. Starting the machine and carrying out a trial run 1. Start the machine and run in idle up to operating temperature. 2. Close the outlet valves. 3.

  • Page 99: Fig. 32 Changing The Cooling Oil

    Maintenance 10.4 Compressor Fig. 32 Changing the cooling oil Oil separator tank Oil cooler Oil-tight plug Oil-tight plug Oil separator tank drain plug Oil cooler drain plug Oil filler Combination valve Oil filler plug Oil filter Changing the cooling oil To catch any operating fluid leaks within the machine, the floor pan is equipped with additional oil- tight plugs at the outlet openings of the oil separator tank and oil cooler.

  • Page 100: Changing The Oil Filter

    Maintenance 10.4 Compressor Starting the machine and carrying out a trial run 1. Start the machine and run in idle up to operating temperature. 2. Close the outlet valves. 3. Shut down the machine. 4. Wait until the machine has automatically vented. Pressure gauge reads 0 psig.

  • Page 101: Changing The Oil Separator Cartridge

    Maintenance 10.4 Compressor 4. Lightly oil the new filter's gasket. 5. Turn the oil filter clockwise by hand to tighten. 6. Check the oil level in the oil separator tank. Top up if necessary. 7. Reconnect the negative battery terminal. Dispose of old cooling oil and any materials or parts contaminated with oil according to envi‐...

  • Page 102: Fig. 34 Changing The Oil Separator Cartridge

    Maintenance 10.4 Compressor Fig. 34 Changing the oil separator cartridge Control air line union nut Fixing screw Oil scavenge pipe union nut Cover Compressed air hose union nut Oil separator cartridge Dirt trap Gasket or O-ring Oil scavenge pipe Changing the oil separator cartridge The dirt trap must be cleaned/changed when the oil separator cartridge is changed.

  • Page 103: Fig. 35 Oil Separator Tank Dirt Trap Maintenance

    Maintenance 10.4 Compressor Option ba 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 cover. 1.

  • Page 104: Air Filter Maintenance

    Maintenance 10.4 Compressor 1. Raise the canopy. 2. Undo the union nut and bend the oil return line to one side. 3. Unscrew the dirt trap 4. Remove and clean the strainer and O-ring 5. Check the strainer and O-ring for function and wear. Renew if non functional.

  • Page 105: Pressure Relief Valve Checking

    The indicating piston of the maintenance indicator is reset and the maintenance indicator is again ready for use. 10.4.7 Pressure relief valve checking ➤ Have pressure relief valves checked by KAESER Service in accordance with the maintenance schedule. 10.4.8 Clean cooler/radiator The frequency is mainly dependent on local operating conditions.

  • Page 106: Fig. 37 Clean Cooler/Radiator

    Maintenance 10.4 Compressor Material Compressed Air Water or steam jet blaster Precondition Machine is placed over a washing station equipped with an oil separator. The machine is shut down. Machine is cooled down. The machine is fully vented, the pressure gauge reads 0 psig. All compressed air consumers are disconnected and the air outlet valves are open.

  • Page 107: Chassis

    Maintenance 10.5 Chassis 10.5 Chassis ➤ Note the instructions in the separate documents: ■ "Chassis maintenance" ■ Chassis manufacturer's operating instructions 10.5.1 Wheel checks Check the wheels and tires after the first 30 miles and after every wheel change, but at least every six months for tightness, visible damage and tire pressures.

  • Page 108: Greasing The Brake Rods

    Maintenance 10.5 Chassis Overrun device greasing Lubricating points Option Illustration Tab. 62 Overrun brake mechanism lubricating point Item is omitted in the fixed height towbar version. 1. Use a grease gun on all nipples until grease flows from the bearing points. 2.

  • Page 109: Greasing The Canopy Hinges

    Maintenance 10.5 Chassis Material Screwdriver Torch Precondition The machine is shut down. The machine is disconnected from the towing vehicle and safely parked. Fig. 38 Checking the brake lining thickness Inspection hole Brake linings 1. Remove the plug from the inspection hole. 2.

  • Page 110: Maintain Rubber Sealing Strips

    Maintenance 10.6 Options The two grease nipples of the canopy hinges are accessible only when the canopy is opened. 1. Loosen the snap fasteners securing the cover. 2. Open the canopy 3. Find the two grease nipples. 4. Grease the nipples with the grease injector until new grease emerges.

  • Page 111: Frost Protector Maintenance

    Maintenance 10.6 Options Fig. 40 Tool lubricator maintenance Metering knob Oil tank Filler plug with dipstick and integrated riser Compressed air inlet tube Tool oil outlet Oil filler port Checking the tool lubricator oil level Check the oil level daily. 1.

  • Page 112: Fig. 41 Filling The Frost Protector

    Maintenance 10.6 Options Material Antifreeze (Wabcothyl) Cleaning cloths Precondition The machine is shut down. The machine is fully vented, the pressure gauge reads 0 psig. Machine cooled down. All compressed air consumers are disconnected and the air outlet valves are open. Danger of fire or explosion caused by the spontaneous ignition of antifreeze.

  • Page 113: Spark Arrestor Cleaning

    Maintenance 10.6 Options 10.6.3 Option la Spark arrestor cleaning The spark arrestor must be cleaned of any soot residue every two months to prevent the emission of glowing particles from the exhaust silencer. Material Suitable rubber hose Soot receptacle Cleaning cloths Protective gloves Eye protection Precondition...
  • Page 114 Maintenance 10.6 Options Result Soot will drain through the hose into the receptacle. 1. Shut down the engine. 2. Remove the hose and replace the plug It is recommended to blow out the spark arrestor with compressed air once a year. Dispose of soot according to environmental protection regulations.

  • Page 115: Document Maintenance And Service Work

    Maintenance 10.7 Document maintenance and service work. 10.7 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. 63 Logged maintenance tasks SERVICE MANUAL Screw Compressor No.: 9_9446 01 USE...

  • Page 116: 11 Spares, Operating Materials, Service

    11.2 Ordering consumable parts and operating fluids/materials KAESER consumable parts and operating fluids/materials are all genuine KAESER parts. They are selected for use in KAESER machines. There is risk of personal injury or damage to the machine resulting from the use of unsuita‐...

  • Page 117: Kaeser Air Service

    Lower costs and higher compressed air availability. 11.4 Service Addresses Addresses of KAESER representatives are given at the end of this manual. 11.5 Spares for service and repair Use this parts list to plan your material requirement according to operating conditions and to order the required spare parts.
  • Page 118 Spares, Operating Materials, Service 11.5 Spares for service and repair SERVICE MANUAL Screw Compressor No.: 9_9446 01 USE...
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  • Page 173: Decommissioning, Storage And Transport 12.1 De-Commissioning

    Decommissioning, Storage and Transport 12.1 De-commissioning 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. ■...

  • Page 174: Long-Term Decommissioning

    Decommissioning, Storage and Transport 12.1 De-commissioning 2. Remove the battery (batteries) and store in a frost-free room. 3. Make sure batteries are fully charged. 12.1.2 Long-term decommissioning Decommissioning the machine for 5 months or longer. Material Receptacle Preserving oil Preservative Desiccant Plastic foil Moisture-resistant adhesive tape...

  • Page 175: Transporting

    Decommissioning, Storage and Transport 12.2 Transporting ➤ Hang the following notice on the instrument panel informing of the decommissioning measure‐ ments taken. Attention! 1. The machine is decommissioned. 2. It is filled with preserving oil. 3. For recommissioning - ■ take measures for recommissioning after a long period of storage.

  • Page 176: Fig. 43 Towing Alignment

    Decommissioning, Storage and Transport 12.2 Transporting Additional precautions for conditions of snow and ice Considerable snow or ice may build up on the machine under low temperature conditions. There is danger of accidents caused by snow or ice falling off the machine. Snow or ice falling from the towed machine can endanger following vehicles.

  • Page 177: Fig. 44 Ball Coupling Function

    Decommissioning, Storage and Transport 12.2 Transporting Fig. 44 Ball coupling function Ball coupling (open) Coupling closed Locking indicator (showing coupling open) Locking indicator (showing coupling Coupling release lever (open) closed) Ball hitch (towing vehicle) Coupling release lever (closed) There is considerable danger of injury caused by trapped fingers. They can be trapped in the spring-loaded closing mechanism.

  • Page 178: Fig. 45 Safety Sign - Secure The Chocks

    Decommissioning, Storage and Transport 12.2 Transporting 6. Connect the cable for the lighting and indicator systems and carry out a function check. 7. Remove the chocks. Option sb Carry out the following before starting to tow 1. Check that the coupling is properly latched onto the towing hitch. 2.

  • Page 179: Parking The Compressor

    Decommissioning, Storage and Transport 12.2 Transporting Replacement chocks can be obtained from KAESER. A list is given at the end of this manual. The part number of the chock is 5.1325.0. Option sb, sd, se Emergency braking in the case of breakaway from the towing vehicle If the compressor breaks away from the towing vehicle, the cable tightens and pulls on the emer‐...

  • Page 180: Fig. 47 Injury Can Occur If The Towbar Is Unsupported And Allowed To Fall

    Decommissioning, Storage and Transport 12.2 Transporting Injury can occur if the towbar is unsupported and allowed to fall. A falling towbar can cause injury, especially by crushing the feet. If the jockey wheel is would completely out, the spindle can disengage and allow the towbar to fall to the ground.
  • Page 181 Decommissioning, Storage and Transport 12.2 Transporting Serious injury or death can result from an unchocked machine rolling away. ➤ Securely chock the machine before uncoupling. ➤ As a general rule, the machine should always be chocked when it is not being moved. ➤...

  • Page 182: Transporting With A Crane

    Decommissioning, Storage and Transport 12.2 Transporting 12.2.3 Transporting with a crane Additional precautions for conditions of snow and ice Considerable snow or ice may build up on the machine under low temperature conditions. This may adversely effect the machine's centre of gravity. It is possible that the permissible loading on the crane or lifting eye is exceeded.

  • Page 183: Transporting As A Load

    The means of transporting will determine the type of packing and load securing. Packing and securing methods must be such that, assuming proper handling, the goods arrive in perfect condition at the destination. Consult KAESER Service for advice concerning sea or air transport. Material Chocks...

  • Page 184: Storage

    2. Always observe valid accident and safety regulations when transporting. 3. The loads must be secured against rolling, tipping, slipping and falling. If you have any questions relating to transport and load securing, please contact KAESER Service. KAESER accepts no liability and provides no guarantee for any damage arising from unpro‐...
  • Page 185 Decommissioning, Storage and Transport 12.4 Disposal 1. Completely drain the fuel from the machine. 2. Completely drain the cooling oil and engine oil from the machine. 3. Remove used filters and the oil separator cartridge. 4. Drain the coolant from water-cooled engines and systems. 5.

  • Page 186: Annex 13.1 Marking

    Annex 13.1 Marking 13 Annex 13.1 Marking Fig. 51 Marking VIN *) (stamped under the reflector) Engine nameplate with serial number *Vehicle identity number Combined label for coupling loading and Machine nameplate with serial number built-in options 13.2 Pipeline and instrument flow diagram (P+I diagram) SERVICE MANUAL Screw Compressor No.: 9_9446 01 USE...
  • Page 187 Annex 13.2 Pipeline and instrument flow diagram (P+I diagram) SERVICE MANUAL Screw Compressor No.: 9_9446 01 USE...
  • Page 188 Annex 13.2 Pipeline and instrument flow diagram (P+I diagram) SERVICE MANUAL Screw Compressor No.: 9_9446 01 USE...
  • Page 189 Annex 13.2 Pipeline and instrument flow diagram (P+I diagram) SERVICE MANUAL Screw Compressor No.: 9_9446 01 USE...

  • Page 190: Dimensional Drawing

    Annex 13.3 Dimensional drawing 13.3 Dimensional drawing 13.3.1 Option sh Dimensional drawing - fixed height towbar without parking brake SERVICE MANUAL Screw Compressor No.: 9_9446 01 USE...
  • Page 191 Annex 13.3 Dimensional drawing SERVICE MANUAL Screw Compressor No.: 9_9446 01 USE...

  • Page 192: Dimensional Drawing - Stationary Machine With Skids

    Annex 13.3 Dimensional drawing 13.3.2 Option sc Dimensional drawing - stationary machine with skids SERVICE MANUAL Screw Compressor No.: 9_9446 01 USE...
  • Page 193 Annex 13.3 Dimensional drawing SERVICE MANUAL Screw Compressor No.: 9_9446 01 USE...

  • Page 194: Electrical Diagram

    Annex 13.4 Electrical Diagram SERVICE MANUAL Screw Compressor No.: 9_9446 01 USE...
  • Page 195 Annex 13.4 Electrical Diagram SERVICE MANUAL Screw Compressor No.: 9_9446 01 USE...
  • Page 196 Annex 13.4 Electrical Diagram SERVICE MANUAL Screw Compressor No.: 9_9446 01 USE...
  • Page 197 Annex 13.4 Electrical Diagram SERVICE MANUAL Screw Compressor No.: 9_9446 01 USE...
  • Page 198 Annex 13.4 Electrical Diagram SERVICE MANUAL Screw Compressor No.: 9_9446 01 USE...
  • Page 199 Annex 13.4 Electrical Diagram SERVICE MANUAL Screw Compressor No.: 9_9446 01 USE...
  • Page 200 Annex 13.4 Electrical Diagram SERVICE MANUAL Screw Compressor No.: 9_9446 01 USE...
  • Page 201 Annex 13.4 Electrical Diagram SERVICE MANUAL Screw Compressor No.: 9_9446 01 USE...
  • Page 202 Annex 13.5 Lighting and signaling system connection 13.5 Option tc Lighting and signaling system connection SERVICE MANUAL Screw Compressor No.: 9_9446 01 USE...

  • Page 203: Lighting And Signaling System Connection

    Annex 13.5 Lighting and signaling system connection SERVICE MANUAL Screw Compressor No.: 9_9446 01 USE...
  • Page 204 Annex 13.5 Lighting and signaling system connection SERVICE MANUAL Screw Compressor No.: 9_9446 01 USE...
  • Page 205 Annex 13.5 Lighting and signaling system connection SERVICE MANUAL Screw Compressor No.: 9_9446 01 USE...
  • Page 206 Annex 13.5 Lighting and signaling system connection SERVICE MANUAL Screw Compressor No.: 9_9446 01 USE...
  • Page 207 Annex 13.6 Fuel circulation diagram SERVICE MANUAL Screw Compressor No.: 9_9446 01 USE...

  • Page 208: Fuel Circulation Diagram

    Annex 13.6 Fuel circulation diagram SERVICE MANUAL Screw Compressor No.: 9_9446 01 USE...

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