Contents Regarding this document Using this document ......................Further documents ......................Copyright .......................... Symbols and labels ......................1.4.1 Warnings ......................1.4.2 Potential damage warnings ................1.4.3 Other alerts and their symbols ................Technical Specifications Nameplate ........................Options – options label ..................... 2.2.1 Tool lubricator .....................
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Contents Incorrect Use ........................User's responsibilities ....................... 3.4.1 Observe statutory and universally accepted regulations ........3.4.2 Determining personnel ..................3.4.3 Adherence to inspection schedules and accident prevention regulations ..3.4.4 Attachment of a "Hazardous goods" label ............Dangers ..........................3.5.1 Safely dealing with sources of danger ..............
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Contents 6.5.3 Installing the brake rod ..................Adjusting the chassis ....................... 6.6.1 Adjusting the towbar height ................6.6.2 Adjusting the towbar height ................6.6.3 Replacing the ball coupling with a towing eye ............ Initial Start-up Ensuring safety ........................ Before Initial Start-up (or Recommissioning) ..............7.2.1 Note when commissioning ..................
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Spares, Operating Materials, Service 11.1 Note the nameplate ......................150 11.2 Ordering consumable parts and operating fluids/materials ..........150 11.3 KAESER AIR SERVICE ....................151 11.4 Service Addresses ......................151 11.5 Replacement parts for service and repair ................ 151 Decommissioning, Storage and Transport 12.1 De-commissioning ......................
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List of Illustrations Fig. 1 Example for tyre information on the side wall ................Fig. 2 Location of safety signs ......................Fig. 3 Bodywork ............................ Fig. 4 Side view (canopy removed) ...................... Fig. 5 Machine overview ........................Fig. 6 Tool lubricator ..........................Fig.
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List of Illustrations Fig. 55 Maintenance indicator ........................ 128 Fig. 56 Compressor air filter maintenance ..................... Fig. 57 Cleaning the filter element ......................129 Fig. 58 Supporting the machine ......................Fig. 59 Cleaning the compressor cooler and engine radiator ..............133 Fig.
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List of Tables Tab. 1 Danger levels and their definitions (personal injury) ..............Tab. 2 Danger levels and their definition (damage to property) ............Tab. 3 Nameplate ..........................Tab. 4 Options label ..........................Tab. 5 Tool lubricator option ........................Tab. 6 Compressed air distributor option ....................
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Maintenance intervals and regular maintenance tasks .............. Tab. 64 Regular machine maintenance tasks ..................Tab. 65 Regular maintenance task for options ..................Tab. 66 KAESER coolant mixture table ....................Tab. 67 Connecting elements ........................132 Tab. 68 Lubricating points of the towbar ....................Tab. 69 Maintenance log .........................
➤ Make sure you provide the data from the nameplate when ordering documents. Copyright This operating manual is protected by copyright. Any queries regarding the use or duplication of this documentation should be referred to KAESER. Correct use of information will be fully suppor‐ ted. Symbols and labels ➤...
Regarding this document Symbols and labels For example, DANGER These show the kind of danger and its source. The possible consequences of ignoring a warning are shown here. If you ignore the warning notice, the "DANGER" signal word indicates a lethal or severe in‐ jury will occur.
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Regarding this document Symbols and labels 1. In process instructions with several steps ... 2..the sequence of action steps is numbered. Result Shows the expected conclusion of the previous action. Option da ➤ Information relating to one option only are marked with an option code (e.g., "option da" means that this section is only valid for machines with the air treatment components "aftercooler and cyclone separator").
Technical Specifications Nameplate 2 Technical Specifications Nameplate The model designation and important technical information are given on the machine's nameplate. 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.
Technical Specifications Options – options label Chassis Option code Available? Height adjustment (rm, rn, ro): With height adjustment Adjustable coupling height Without height adjustment Anti-twist protection, tow bar tube (rp) Adapter, mounted rotatable Service brake (rr, rs): Without service brake With overrun brake EU ≙...
Technical Specifications Chassis 2.3.3 Ambient conditions Positioning Limit value Maximum altitude amsl* [m] 1000 Minimum ambient temperature [°C] −10 Maximum ambient temperature [°C] * Higher altitudes are permissible only after consultation with the manufacturer. Tab. 21 Ambient conditions 2.3.4 Additional specifications according to the machine's operating licence For specifications according to the machine's operating licence, such as: ■...
Technical Specifications Chassis Option rb/rm/rr rb/rm/rs rc/ro/rr rg/rp/rr rc/ro/rs rd/ro/rr rd/rn/rr Chassis type chassis chassis chassis chassis chassis chassis chassis Permissible axle load [kg] x ≙ fitted, − ≙ not fitted EU ≙ Europe, GB ≙ Great Britain, US ≙ United States of America Tab.
Technical Specifications Compressor Maximum working overpressure [bar] − − − Relief valve activating pressure* [bar] − − − *The pressure relief valve is fitted to the oil separator tank. Tab. 29 Relief valve activating pressure 2.5.5 Temperature An automatic combination valve regulates the compressor temperature depending on the ambient temperature.
Technical Specifications Engine Characteristic SIGMA FLUID Oil grade S–460 Density at 15 °C – 864 kg/m (ISO 12185) Pour point -46 °C -33 °C (D 97; ASTM test) (ISO 3016) Demulsibility at 54 °C 40/40/0/10 min – (D 1401; ASTM test) Tab.
Technical Specifications Options Feature Value PTC testing current [A] (according to EN 50342) Tab. 37 Batteries Further information Depending on machine equipment, a higher capacity battery may be required. See chapter 2.7.2. Options 2.7.1 Option ea, ec Tool lubricator Name Temperature range [°C] Fluid volume [l] Special road breaker lubricant...
Safety and Responsibility Basic instructions 3 Safety and Responsibility Basic instructions The machine is manufactured to the latest engineering standards and acknowledged safety regula‐ tions. Nevertheless, dangers can arise through its operation: ■ danger to life and limb of the operator or third parties, ■...
Safety and Responsibility User's responsibilities 3.4.2 Determining personnel Suitable personnel are experts who, by virtue of their training, knowledge and experience as well as their knowledge of relevant regulations can assess the work to be done and recognize the pos‐ sible dangers involved.
Approved supervisory body tion Internal inspection Every 5 years after commissioning or Competent person the last inspection (e. g. KAESER Service Technician) Strength test Every 10 years after commissioning or Competent person the last inspection (e. g. KAESER Service Technician) Tab.
Safety and Responsibility Dangers Dangers Basic instructions The following describes the various forms of danger that can occur during machine operation. Basic safety instructions are found in this service manual at the beginning of each chapter in the section entitled 'Safety'. Warning instructions are found before a potentially dangerous task.
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Safety and Responsibility Dangers ➤ Check regularly that all electrical connections are tight and in proper condition. ➤ Switch off any external power sources. For example, the connections to the electrical engine cooling water pre-heater. Forces of compression Compressed air is contained energy. Uncontrolled release of this energy can cause serious injury or death.
➤ Do not eat or drink while handling fuel, cooling and lubricating fluids or antifreeze. ➤ Keep suitable fire extinguishing agents ready for use. ➤ Use only KAESER approved operating materials. Unsuitable spare parts Unsuitable spare parts compromise the safety of the machine.
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Safety and Responsibility Dangers Personal protective equipment When working on the machine you may be exposed to dangers that can result in accidents with severe adverse health effects. ➤ Wear protective clothing as necessary. Suitable protective clothing (examples): ■ Safety workwear ■...
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Safety and Responsibility Dangers ➤ Do not exceed the lifting capacity on the machine's lifting point (lifting eye). ➤ Only the designated lifting point should be used to attach lifting gear and under no circumstan‐ ces are handles, towbar or other components to be used. ➤...
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➤ Allow the machine to cool down. ➤ Do not open the bodywork while the machine is switched on. ➤ Do not open or dismantle any valves. ➤ Use only spare parts approved by KAESER for use in this machine. ➤ Carry out regular inspections: ■...
Safety and Responsibility Safety devices ➤ Remove the towing vehicle from the machine. ➤ Nobody must enter the parked machine and its chassis, in particular. ➤ Nobody must sit on the parked machine and in particular its towing mechanism. 3.5.2.5 Decommissioning, storage, disposal Improper handling of old operating fluids and components represent a danger for the environment.
Safety and Responsibility Safety signs Safety signs The figure shows the position of the safety signs on the machine. The table lists the various safety signs used and their meanings. Fig. 2 Location of safety signs Item Sign Meaning Hazardous good! Identifies machines filled with fuel during transport as a hazardous good.
Safety and Responsibility Safety signs Item Sign Meaning Hot surface! Risk of burns caused by contact with hot components! ➤ Do not touch the surface. ➤ Wear long-sleeved garments (no synthetics such as polyester) and protective gloves. Toxic gases into areas of work! ➤...
Safety and Responsibility Emergencies Emergencies 3.8.1 Correct fire fighting Suitable measures Calm and prudent action can safe lives in the event of a fire. ➤ Keep calm. ➤ Give the alarm. ➤ Shut down the machine from the instrument panel if possible. ➤...
■ incorrect maintenance, ■ incorrect repair. Correct maintenance and repair includes the use of genuine KAESER spare parts and operating materials. ➤ Obtain confirmation from KAESER that your specific operating conditions are suitable. 3.10 Environment protection The operation of this machine may cause dangers for the environment.
Design and Function Bodywork 4 Design and Function Bodywork Bodywork is understood to be the exterior of the machine mounted on the chassis. Fig. 3 Bodywork Canopy Snap fastener Lower body Canopy safety catch Cooling air inlet Lock Recessed grip for the canopy Cover for lifting eye The bodywork has several functions when it is closed: ■...
Design and Function Machine function Machine function Machine function (without options) Item numbers correspond to the pipe and instrument flow diagram (P&ID) in chapter 13.2. Operator manual Portable compressor No.: 9_9432_24 E...
Design and Function Machine function Fig. 5 Machine overview Compressor air filter Engine Inlet valve Combination valve (thermostatic valve) Airend Oil cooler Oil separator tank Engine air filter Oil separator cartridge Engine speed control cylinder Air distributor Pressure relief valve Control valve Ambient air is cleaned as it is drawn in through the filter The air is then compressed in the airend...
Design and Function Operating modes and control mode 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 chamber ensures a very low airend discharge temperature.
Design and Function Setting full load operation With the help of a mechanical control valve (the proportional controller), the opening and closing of the inlet valve is continuously varied in relation to the actual air demand. The airend provides com‐ pressed air for connected consumers.
Design and Function Options Options The options available for your machine are described below. 4.7.1 Option ea Tool lubricator Compressed air containing lubricating oil is needed for the lubrication of certain air tools. The tool lubricator introduces a fine oil mist into the compressed air for this purpose. A metering valve on the lubricator regulates the amount of oil in the compressed air: ■...
Design and Function Options ■ Wetting valves and control lines with anti-freeze prevent the freezing of the control and regulat‐ ing devices. ■ The electrical system starts the engine without problem at ambient temperatures to -10 °C. 4.7.2.1 Option bb Coolant pre-heating The engine coolant can be pre-heated to improve starting under cold conditions.
Design and Function Options Fig. 8 Frost protector Shut-off valve Control line (bypass line) Control line (frost protection) Oil separator tank cover Frost protector Frost protection The frost protector comes into action when the machine is stopped in ambient temperatures below 0 °C.
Design and Function Options 4.7.4.2 Option lb Engine air 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 motor speed that can result in serious mechanical damage.
Design and Function Options Fig. 9 Battery isolating switch «Battery isolating switch» 4.7.8 Option ua Hose reel option The machine is provided with an extension hose to allow connection and operation of remote air tools. A hose reel is provided for safe storage of this hose. 4.7.9 Option sf Optional anti-theft device...
Design and Function Options 4.7.10 Options for roadworthy machines 4.7.10.1 Option rb/rm/rr, rb/rm/rs, rc/ro/rr, rg/rp/rr, rc/ro/rs, rd/ro/rr Chassis of roadworthy machines Option rg/rp/rr Anti-twist protection, tow bar tube Chassis with the rg/rp/rr option are fitted with a rotatably mounted adapter for seating the towing eye or ball coupling.
Installation and Operating Conditions Ensuring safety 5 Installation and Operating Conditions Ensuring safety The conditions in which the machine is installed and operated have a decisive effect on safety. Warning instructions are located before a potentially dangerous task. Disregard of warning instructions can cause serious injuries! Complying with safety notes Disregard of safety notes can cause unforeseeable dangers! ➤...
Installation and Operating Conditions Installation conditions Fig. 11 Minimum distance from excavations/slopes and walls 1. Keep sufficient distance (at least 1.5 m) from the edges of excavations and slopes. 2. Ensure that the machine is as level as possible. The machine can be temporarily operated on a slope of not more than 15° . 3.
Installation Ensuring safety 6 Installation Ensuring safety Follow the instructions below for safe installation. Warning instructions are located before a potentially dangerous task. Disregard of warning instructions can cause serious injuries! Complying with safety notes Disregard of safety notes can cause unforeseeable dangers! ➤...
Installation Fitting the tow bar 1. Loosen the transport safety means. 2. Remove the securing strap and the foam from the towing device. 6.3.1 Fitting the height adjustable tow bar Option rb/rm/rr, rb/rm/rs Fig. 12 Fitting the height adjustable tow bar Delivery state, towing device rb/rm/rr Tow bar tube Delivery state, towing device rb/rm/rs...
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Installation Fitting the tow bar Option rb/rm/rr Option rb/rm/rs 1. Use a suitable base to jack up the towing 1. Crank the jockey wheel downward until the device until the machine is in horizontal po‐ machine is standing horizontally. sition. 2.
Installation Installing the fixed towing device (US towing device) Installing the fixed towing device (US towing device) Option rd/ro/rr Fig. 14 Fixed height towbar Supplied state of tow bar rd/ro/rr Base Transport frame Support (turned) Support (delivery state) 1. Use a suitable base to jack up the towing device. 2.
Installation Installing and adjusting the brake rod Fig. 15 Screw in the con-rod. Pivot mount Con-rod Option rb/rm/rs , rc/ro/rs Option rc/ro/rr , rg/rp/rr 1. Fully release the parking brake. 1. Fully release the parking brake. 2. Fully extend the draw pipe of the overrun 2.
Installation Installing and adjusting the brake rod Option rb/rm/rs , rc/ro/rs Fig. 17 M10 brake rod Equaliser Bowden cable Axle abutment Draw bar Connecting sleeve Bowden cable nipple Spacer 1. Insert both Bowden cables in the axle abutment. 2. Use nuts to fasten both Bowden cables.
Installation Installing and adjusting the brake rod 6.5.3 Option rc/ro/rr , rg/rp/rr Installing the brake rod Aligning the equaliser at right angles to the brake rod The axle abutment is a mechanism to accept and fixate the exterior sleeve of the Bowden cables.
Installation Adjusting the chassis Brake rod adjustment 1. Manually tighten the nut 2. Check whether the equaliser is aligned at right angles to the brake rod. 3. Forcefully pull and release the hand brake three times. 4. Turn the wheel in forward direction and simultaneously tighten the nut up to a clearly experi‐ enced braking resistance.
Installation Adjusting the chassis CAUTION Danger of pinching! Severe injury to fingers is possible if they become trapped in the adjusting mechanism. ➤ Always wear protective gloves. ➤ Work carefully. ➤ Comply with the safety instructions in chapter 3.5. 6.6.1 Option rb/rm/rr Adjusting the towbar height The purpose of height adjustment is to bring the towing eye, or coupling, to the correct height for...
Installation Adjusting the chassis 3. Make the angle adjustment to the serrated joint 4. Tighten the locking lever making sure the serrations engage. 5. Draw out the split pin 6. Undo the locking lever until the serrated joint is disengaged. 7.
Installation Adjusting the chassis 12. 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 21). Check locking position ■...
Installation Adjusting the chassis Option rb/rm/rr Fig. 22 Replacing the ball coupling with a towing eye Ball coupling Serrated joint Adapter for ball coupling Screw Split pin Side part Locking lever Towing eye Locking lever Operator manual Portable compressor No.: 9_9432_24 E...
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Installation Adjusting the chassis Remove the ball coupling Removing the towing eye 1. Remove both split pins 1. Remove both split pins. 2. Loosen and remove the locking lever 2. Loosen and remove the locking lever 3. Loosen the locking lever 1-2 turns.
Installation Adjusting the chassis Option rb/rm/rs Fig. 23 Replacing the ball coupling with a towing eye Top part, towing device Distance bow for ball coupling Ball coupling Tow bar tube Self-locking nut Distance bush for towing eye Washer Fastening eye of the shock absorber Mounting pin Towing eye Retaining screw, shock absorber...
Installation Adjusting the chassis Use the proper distance elements for the tow bar Depending on the use of either ball coupling or towing eye, different distance elements must be installed to equalise the size difference between tow bar and towing adapter: Towing adapter Type (example) Distance element...
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Installation Adjusting the chassis Remove the ball coupling Removing the towing eye 1. Push back the protective sleeve, if necessa‐ 1. Push back the protective sleeve, if necessa‐ 2. Remove the self-locking nuts of both screw 2. Remove the self-locking nuts of both screw connections.
Installation Adjusting the chassis If you don't feel a resistance: The fastening eye of the shock absorber is not hung correctly. ➤ Repeat the assembly steps. 6.6.3.3 Option rc/ro/rr Replacing the ball coupling with a towing eye The following alternative tasks must be carried out to change the towing eye or the ball coupling. Option rc/ro/rr Fig.
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Installation Adjusting the chassis Removing the ball coupling Removing the towing eye 1. Unscrew and remove the nuts of the ver‐ 1. Unscrew and remove the nuts of the vertical tical screw connections. screw connections. 2. Immediately dispose of the used self-locking 2.
Installation Adjusting the chassis Option rg/rp/rr Fig. 26 Replacing the towing eye with a ball coupling Self-locking nut Tow bar (mounted rotatable) Screw Tow bar tube Towing eye Ball coupling Distance bush New self-locking nut Operator manual Portable compressor No.: 9_9432_24 E...
Installation Adjusting the chassis Fig. 27 Distance bush Tow bar Distance bush External diameter, tow bar External diameter, distance bush Depending on whether a towing eye or a ball coupling is used, you must install a distance bush as additional element, in order to offset the size difference between tow bar and towing eye or ball coupling: ➤...
Installation Adjusting the chassis Option rd/ro/rr Fig. 28 Changing the towing eye (towbar - US-version) Self-locking nut Prop stand Screw (horenzontally screw connection) Towbar tube Adapter Ball coupling Self-locking nut Towing eye Screw (vertikally screw connection) Remove the ball coupling Removing the towing eye 1.
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Installation Adjusting the chassis Fitting the ball coupling Fitting the towing eye 1. Align the adapter according to the corre‐ 1. Fit the new towing eye in the towbar. sponding bores in the tow bar tube. 2. Position the towing eye so that the bolts can 2.
Initial Start-up Ensuring safety 7 Initial Start-up Ensuring safety Here you will find instructions for a safe commissioning of the machine. Warning instructions are located before a potentially dangerous task. Disregard of warning instructions can cause serious injuries! Complying with safety notes Disregard of safety notes can cause unforeseeable dangers! ➤...
➤ Clean the bodywork with a grease and dirt dissolving agent. ➤ Check the tyre pressures. 36 months ➤ Have the overall technical condition checked by an authorised KAESER Serv‐ ice Technician. Tab. 49 Measures for re-commissioning the compressor after a long period of storage Checking installation and operating conditions ➤...
Initial Start-up Low-temperature operation (winter) Low-temperature operation (winter) The machine's electrical equipment is designed for starting at ambient temperatures as low as −10 °C. ➤ In temperatures below 0°C, use the following operating materials/components: ■ Winter-grade engine oil, ■ Low viscosity cooling oil for the compressor ■...
Initial Start-up Low-temperature operation (winter) 2. DANGER! Explosion hazard! A spark may ignite an explosive gas mixture. ➤ Do not, under any circumstances, connect the negative pole of the assisting machine to the negative pole of the battery in the machine to be started. This can cause sparks when connecting and disconnecting.
Initial Start-up Low-temperature operation (winter) Fig. 30 Coolant pre-heating Bodywork Engine Connection for the coolant pre-heater Coolant pre-heating Power cable 1. DANGER! Danger of fatal injury from electric shock! Serious injury or death can result from a short-circuit in the electric coolant pre-heater. ➤...
Operation Ensuring safety 8 Operation Ensuring safety Here you will find instructions for a safe operation of the machine. Warning instructions are located before a potentially dangerous task. Disregard of warning instructions can cause serious injuries! Complying with safety notes Disregard of safety notes can cause unforeseeable dangers! ➤...
Operation Starting, setting the full load mode and shutting down Starting, setting the full load mode and shutting down instrument pane l illustrate the starting and stopping procedures; see also Pictograms above the item in the following illustration. Precondition No personnel are working on the machine. Fig.
Operation Starting, setting the full load mode and shutting down 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. ➤...
Operation Operating the tool lubricator 2. Close all «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» to the “0” position after 2-3 minutes. 4.
Operation Using the low-temperature equipment 1. Set the required oil flow. 2. Close the canopy. Further information Fill the tool lubricator with lubricant (see chapter 10.8.1). Shutting off lubricating oil 1. Close the shut-off valve 2. Close the canopy. Option ba Using the low-temperature equipment ➤...
Operation Operating the battery isolating switch Operating the machine with frost protector Operation at temperatures below 0 °C (winter operation). Subsequently to the daily operation of the machine, the compressed air conduits and valves must be moistened with anti-freeze. For this purpose, the defroster must be activated for a short time. Anti-freeze is added to the compressed air.
Operation Using the hose reel Fig. 34 Battery isolating switch «Battery isolating switch» I – on 0 – off ➤ Raise the cover. Start the machine 1. Switch on the «battery isolating switch». The battery is now connected to the machine's electrical system. The machine can now be started.
Operation Using the hose reel Fig. 35 Hose reel Front side, machine Connecting bore Winding handle (fold out) Clamping screw Hose reel Transport securing bolt Compressed air extension hose Bracket Hose end in safety position Claw coupling Connecting hose Compressed air outlet valve Claw coupling Side wall with safety bores Adapter...
Operation Cleaning the machine after operation 8.6.2 Operating the machine without an extension air hose 1. Close the shut-off valve for the compressed air extension hose. 2. Disconnect the air consumer. 3. Unfold the crank. 4. Coil the hose evenly and tightly. 5.
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Operation Cleaning the machine after operation Water has accumulated in the sealed floor pan. ➤ Drain the water. Catch the liquid and dispose in accordance with applicable environmental regulations. Further information See chapter 10.8.5 for information to the draining of liquids within the machine. Operator manual Portable compressor No.: 9_9432_24 E...
1. Do not attempt fault rectification measures other than those given in this manual! 2. In all other cases: Have the fault rectified by an authorized KAESER service representative. Further information Observe the instructions in chapter 3 "Safety and Responsibility" and prevailing local safety regula‐...
Fault Recognition and Rectification Evaluate engine faults and alarms Possible cause Remedy Where can I get help? Special‐ KAESER Engine ised Service service work‐ manual shop Defective alternator. Have repaired or replaced if – necessary. Defective alternator regulator. Have repaired or replaced if –...
Indicator lamp remains on Evaluate compressor faults and alarms 9.3.1 Working pressure too high Possible cause Remedy Where can I get help? Specialised KAESER Serv workshop Proportional controller maladjus‐ Have repaired or replaced if – ted or defective. necessary. Inlet valve not closing.
Fault Recognition and Rectification Evaluate compressor faults and alarms Possible cause Remedy Where can I get help? Specialised KAESER Serv workshop The engine runs at maximum See chapter 9.2. speed (LOAD). Engine air filter and/or compres‐ Clean or change, see chap‐...
Fault Recognition and Rectification Evaluate compressor faults and alarms Possible cause Remedy Where can I get help? Specialised KAESER Serv workshop Oil pipes leaking. Seal leaks or have pipes changed. Engine cooling system or cool‐ Have repaired. ing fan defective.
Maintenance 10.1 Ensuring safety 10 Maintenance 10.1 Ensuring safety Follow the instructions below to ensure safe machine maintenance. Warning instructions are located before a potentially dangerous task. Disregard of warning instructions can cause serious injuries! Complying with safety notes Disregard of safety notes can cause unforeseeable dangers! ➤...
Details of dangers and their avoidance are found in chapter 3.5. 10.2 Following the maintenance plans 10.2.1 Logging maintenance work The maintenance intervals given are those recommended for KAESER original components with average operating conditions. ➤ In adverse conditions, perform maintenance work at shorter intervals. Adverse conditions are, e.g.: ■...
Maintenance 10.2 Following the maintenance plans Component: Task Wheels/chassis: Tighten the wheel nuts. Have brake system inspected and adjusted, if necessary. h ≙ operating hours; Engine SM ≙ engine manufacturer's service manual Tab. 62 Maintenance tasks after commissioning 10.2.3 Regular maintenance tasks The following table lists the various maintenance intervals.
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Maintenance 10.2 Following the maintenance plans Component: Task Clean the engine air filter 10.3.2 Change the engine oil 10.3.4 Replace the engine oil filter. 10.3.5 Engine Check/adjust the drive belt ten‐ 10.3.6 Engine sion. Change the engine air filter. 10.3.2 Have the engine mounts checked.
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Maintenance 10.2 Following the maintenance plans Component: Task Have the fuel injector pump checked. Check the battery electrolyte 10.3.7 level and connections. Compressor: Check inlet air filter mainte‐ 10.4.7 nance indicator. Check the cooling oil level. 10.4.1 Clean the compressor air filter. 10.4.7 Clean the oil cooler.
Blow out the spark arrestor with compressed air. Option lb - engine air intake shut-off valve Clean/check the engine air in‐ 10.8.4 take shut-off valve. SW = refer to a specialised workshop; KS = call KAESER Service Operator manual Portable compressor No.: 9_9432_24 E...
10.3.3.3 Option oe – sealed floor pan: Checking the machine interior 10.8.5 for liquid accumulations SW = refer to a specialised workshop; KS = call KAESER Service Tab. 65 Regular maintenance task for options 10.3 Engine maintenance ➤ Perform maintenance tasks according to the schedule in chapter 10.2.3.1.
Maintenance 10.3 Engine maintenance NOTICE 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. ➤...
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Maintenance 10.3 Engine maintenance Coolant quality can be determined by the following parameters: ■ Visual check ■ Antifreeze concentration measurement ➤ Unscrew and remove the expansion tank filler cap Visual check The coolant should be checked for its colour and any particles or sediments floating in it. ➤...
Maintenance 10.3 Engine maintenance ➤ The coolant should be mixed in the proportions given by the manufacturer. KAESER coolant mixture table Antifreeze Water Frost protection to [°C] 1 part 2 parts 1 part 1.5 parts 1 part 1 part Tab. 66 KAESER coolant mixture table The concentration of antifreeze should not be less than 33% for ensured corrosion protection.
Maintenance 10.3 Engine maintenance Fig. 37 Draining the coolant from the radiator Water cooler Screw plug Bung (Option oe) 1. Unscrew and remove the expansion tank filler cap. 2. In Option oe (sealed floor pan), the bung must be removed from the floor panel. 3.
Maintenance 10.3 Engine maintenance Material Compressed air for blowing out Spare parts (as required) Cleaning cloth Precondition The machine is shut down. The machine is fully vented, the pressure gauge reads 0 bar. The machine is cooled down. All compressed air consumers are disconnected and the air outlet valves are open. NOTICE Damaged filter element.
Maintenance 10.3 Engine maintenance Cleaning the air filter Fig. 39 Engine air filter maintenance Filter housing Dust evacuating valve Filter element Valve part Filter cap Drain slit Spring retaining flap Maintenance indicator Fig. 40 Cleaning the filter element Compressed air gun with blast pipe bent to 90° at the end Filter element 1.
Maintenance 10.3 Engine maintenance 5. To empty the dust evacuator valve: ■ Pinch the valve part above the drain slit (drain slit opens). ■ Remove any dust clumps. ■ Clean the slit. 6. Insert the cleaned or new filter element into the filter housing. Make sure it is properly in place and sealed by its gasket.
Maintenance 10.3 Engine maintenance DANGER Danger of fire from spontaneous ignition of fuel! Serious injury or death could result from the ignition and combustion of fuel. ➤ Allow no open flames or sparks at the place of use. ➤ Stop the engine. ➤...
Maintenance 10.3 Engine maintenance 3. Turn the «starter switch» to the “0” position. The venting process is completed. 4. Disconnect the negative terminal on the battery. 10.3.3.2 Filter maintenance Changing the fuel prefilter element The filter element should be changed according to the maintenance schedule. Precondition The negative cable to the battery is disconnected! Fig.
Maintenance 10.3 Engine maintenance 2. Unscrew and remove the cartridge 3. Take a new filter cartridge. 4. Smear fuel on the gasket. 5. Spin on the new oil filter by hand until the gasket is firmly seated. 6. Bleed the system as described previously. Catch any escaping fuel.
Maintenance 10.3 Engine maintenance 1. Raise the canopy. 2. Check the fuel in the water trap. The water trap should be emptied when dirty. 3. Close the canopy. Emptying the water trap: 1. Place a receptacle under the drain plug of the water trap.
Maintenance 10.3 Engine maintenance Material New engine oil, see chapter 2.6.5 for engine oil filling quantity. Receptacle Wrench Cleaning cloth Precondition The machine is shut down. The machine is standing level. The machine is fully vented, the pressure gauge reads 0 bar. Engine at operating temperature.
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Maintenance 10.3 Engine maintenance 6. Replace the plug in the filler port. 7. Close the canopy. Dispose of old oil and oil-soaked working materials according to environmental protection regulations. Filling with engine oil Precondition Screw plug with the sealing ring screwed into the oil pan. Filler plug tightened.
Maintenance 10.3 Engine maintenance Material New engine oil, see chapter 2.6.5 for engine oil filling quantity. Receptacle Hose coupling Cleaning cloth Funnel Precondition The machine is shut down. The machine is standing level. The machine is fully vented, the pressure gauge reads 0 bar. Engine at operating temperature.
Maintenance 10.3 Engine maintenance 10.3.5 Changing the engine oil filter Material Spares Common tools Cleaning cloth Receptacle Precondition The machine is shut down. The machine is fully vented, the pressure gauge reads 0 bar. Engine cooled down. All compressed air consumers are disconnected and the air outlet valves are open. CAUTION Danger of burns from hot components and escaping engine oil! ➤...
Maintenance 10.3 Engine maintenance 10.3.6 Drive belt maintenance The life of the drive belts is influenced by belt tension. ■ Slack belts can slip and become damaged and may result in engine overheating. ■ Over-tight belts stretch and fatigue quicker. Over-tight belts also place unnecessary stress on bearings and shorten their life.
Maintenance 10.3 Engine maintenance Fig. 47 Belt tension checking by hand Permissible deflection of the belt Direction of arrow Compressive load approximately: 10 kg Engine alternator screw permissible intrusion depth: 7 – 9 mm Engine-generator Engine block mounting Checking and resetting belt tension with tension Manually check and retension the belt: measuring device: 1.
Maintenance 10.3 Engine maintenance A belt that has been replaced may not be used again. Check the belt tension after running for approximately 15 minutes. Old belts should be disposed of in accordance with the latest environmental regulations. Putting in operation: 1.
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Maintenance 10.3 Engine maintenance ➤ Take heed of any safety signs on the battery warning labels. The individual safety signs have the following meaning: ■ – Fire, sparks, open flame and smoking are forbidden! ■ – Eye and face protection must be worn because of the danger of acid burns. ■...
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Maintenance 10.3 Engine maintenance NOTICE! Battery destruction! Topping up with pure acid will increase the electrolyte concentration and can destroy the bat‐ tery. ➤ Top up only with distilled water. 2. Check the electrolyte level. If the level does not reach the mark - ➤...
Maintenance 10.4 Compressor Maintenance 5. Unscrew the battery fixing clamp. 6. Replace in the reverse order. 7. Make sure the battery is properly secured. 8. Close the canopy. Battery replacement If the battery is to be replaced, the new battery should have the same capacity, current rating and shape as the original battery.
Maintenance 10.4 Compressor Maintenance 10.4.1 Checking cooling oil level The oil level is checked at the oil separator tank filling port. Oil must be visible in the port when the filler plug is removed. Material Wrench Cleaning cloth Precondition The machine is shut down. The machine is standing level.
Maintenance 10.4 Compressor Maintenance 10.4.2 Cooling oil filling and topping up Material Cooling oil Funnel Cleaning cloth Wrench Precondition The machine is shut down. The machine is standing level. The machine is fully vented, the pressure gauge reads 0 bar. Machine is cooled down.
Maintenance 10.4 Compressor Maintenance 10.4.3 Changing the cooling oil Drain the oil completely from the following components: ■ Airend ■ Oil separator tank ■ Oil cooler ■ Oil pipes ➤ Always change the oil filter when changing the oil. Material See chapter 2.5.7 for oil filling volume.
Maintenance 10.4 Compressor Maintenance Option oe Draining cooling oil via the shut-off valve Material Fresh cooling oil Receptacle New gasket for the filler caps Funnel Cleaning cloth Precondition Machine shut down The machine is standing level. The machine is at operating temperature. The machine is fully vented, the pressure gauge reads 0 bar.
Maintenance 10.4 Compressor Maintenance 10.4.4 Replace the compressor oil filter Material Spares Tool Receptacle Cleaning cloth Precondition The machine is shut down. The machine is fully vented, the pressure gauge reads 0 bar. The machine is cooled down. All compressed air consumers are disconnected and the air outlet valves are open. Negative cable to the batteries disconnected.
Maintenance 10.4 Compressor Maintenance Starting the machine and performing a test run: 1. Start the machine and run in IDLE until the operating temperature is reached. 2. Close the outlet valves. 3. Shut down the machine. 4. Wait until the machine has automatically vented. Pressure gauge reads 0 bar! 5.
Maintenance 10.4 Compressor Maintenance 5. Use a screwdriver to unscrew the nozzle from the screw-in connector. 6. Clean the housing, strainer and sealing ring with cleaning solvent or spirit. 7. Check the nozzle, strainer and sealing ring for wear. When clearly worn: Replace 8.
Maintenance 10.4 Compressor Maintenance Fig. 54 Changing the oil separator cartridge Control air line union nut Fastening screw Oil scavenge pipe union nut Oil scavenge pipe Compressed air hose union nut Cover Solenoid valve Oil separator cartridge Solenoid valve plug Gasket Control valve Metal clip...
Maintenance 10.4 Compressor Maintenance Dispose of the old separator cartridge and gaskets, along with any working materials conta‐ minated with cooling oil, in accordance with environment protection regulations. Option ba Changing the oil separator cartridge Changing the oil separator cartridge with the frost protector option is carried out as described above.
Maintenance 10.4 Compressor Maintenance ➤ Open the canopy. Checking contamination of the air filter Air filter maintenance is necessary when the yellow piston inside the maintenance indicator rea‐ ches the red zone. Fig. 55 Maintenance indicator Maintenance indicator Red zone indicator scale Indicator piston Reset knob for the maintenance indicator ➤...
Maintenance 10.4 Compressor Maintenance Cleaning the filter element: Fig. 56 Compressor air filter maintenance Wing nut Inlet valve Washer Maintenance indicator Filter cap Airend Filter element Fig. 57 Cleaning the filter element Compressed air gun with blast pipe bent to 90° at the end Filter element 1.
➤ Close the canopy. Dispose of old parts and contaminated materials according to environmental regulations. 10.4.8 Checking pressure relief valves ➤ Have pressure relief valves checked by KAESER Service in accordance with the maintenance schedule. 10.5 Cleaning the cooler The frequency of cleaning is mainly dependent on local operating conditions.
Maintenance 10.5 Cleaning the cooler NOTICE Damage to the machine can be caused by water or steam jets. Direct water or steam jets can damage or destroy electrical components and indicating in‐ struments. ➤ Cover up electrical components such as the control cabinet, alternator, starter and in‐ struments.
Maintenance 10.5 Cleaning the cooler 2. Secure the wheels with chocks. 3. If available, engage the machine's parking brake. 4. Place chocks or squared timbers beneath the machine's rear. Result Machine is supported. 10.5.2 Cleaning the compressor cooler and engine radiator Connection elements, po‐...
Maintenance 10.5 Cleaning the cooler Cooler cleaning Fig. 59 Cleaning the compressor cooler and engine radiator Machine rear view, cover removed 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.
10.6 Maintainance of rubber sealing strips Is a cooler leaking? ➤ Have the defective cooler repaired or replaced immediately by KAESER Service. ➤ Close the canopy. Clean the cooler blades only in a washing area equipped with an oil separator.
Maintenance 10.7 Chassis maintenance 3. Check the tyre treads for sufficient depth. According to local roadworthy regulations, at least 1.6 mm in most countries. Profile depth too low: change tyres. 4. Check the tyre pressures. Result Tyre pressure too low: pump tyres. Further information See chapter 2.4.3 for wheel fixing torques.
Maintenance 10.7 Chassis maintenance Greasing points Option Representation rg/rp/rr 10-M2005 Tab. 68 Lubricating points of the towbar 1. Check the towbar for correct function and movement. 2. Clean all teeth , sliding and bearing components of the height adjustment and lubricate with acid-free oil 3.
Maintenance 10.7 Chassis maintenance 10.7.2.3 Maintenance of towing system with rotatable adapter Grease the bearing: ➤ Pump fresh grease into the nipple until fresh grease is squeezed out. Further information See table 68 for lubricating points (Option rg/rp/rr). 10.7.2.4 Ball coupling maintenance Option rb/rm/rr, rb/rm/rs, rc/ro/rr, rc/ro/rs Fig.
Maintenance 10.7 Chassis maintenance The following points must be observed: ■ Carry out the adjustment procedure on all wheel brakes, one after the other. ■ During adjustment, turn the wheel in the 'forward' direction only. Material Screwdriver Wrench Inspection lamp or torch Lithium-enriched multi-purpose grease Acid-free oil Cleaning cloths...
Maintenance 10.7 Chassis maintenance 2. Check the brake lining thickness. The brake lining thickness is less than 2 mm. ➤ Have the brake shoes replaced in a specialist workshop. 3. Replace the plug in the inspection hole. 10.7.3.3 Option rb/rm/rs , rc/ro/rs Brake system adjustment There is an arrow pressed into the brake back plate near the adjustment hole.
Maintenance 10.7 Chassis maintenance Securing the screw joint against loosening ➤ Secure the connecting sleeve with the lock nut Further information If tow bar, equaliser or Bowden cables require replacement, note the instructions for initial installa‐ tion in chapter 6.5. 10.7.3.5 Servicing and adjusting the brake rod Option rc/ro/rr , rg/rp/rr...
Maintenance 10.8 Maintenance of Optional Items 1. Forcefully pull and release the hand brake three times. 2. Turn the wheel in forward direction and simultaneously tighten the nut up to a clearly experi‐ enced braking resistance. You must be able to manually turn the wheel in forward driving direction. You are unable to manually turn the wheel in forward driving direction.
Maintenance 10.8 Maintenance of Optional Items Fig. 66 Tool lubricator maintenance Metering knob Oil tank Filler plug with dipstick and integrated riser Compressed air inlet tube Tool oil outlet Tool lubricator upper part with oil filling port ➤ Open the canopy. Checking the tool lubricator oil level Check the oil level daily.
Maintenance 10.8 Maintenance of Optional Items 10.8.2 Option bc Frost protector maintenance At temperatures below 5°C, the level of antifreeze in the protector must be checked daily before starting the compressor. Fill the bowl of the frost protector to a maximum of Material New antifreeze (Wabcothyl) - see chapter 2.7.2 for the filling volume.
Maintenance 10.8 Maintenance of Optional Items 2. Fill the bowl with antifreeze – ensure the maximum level 3. Screw the bowl carefully back into place. 10.8.3 Spark arrester cleaning The spark arrester must be cleaned of any soot residue every two months to prevent the emission of glowing particles from the exhaust silencer.
Maintenance 10.8 Maintenance of Optional Items Fig. 68 Spark arrester cleaning Exhaust silencer end pipe Soot drain port with plug Opening in floor panel to access drain port Exhaust silencer with integrated spark ar‐ rester 1. If availabe, remove th plugs. 2.
The machine does not shut down? Destruction of the engine and explosion and/or fire are possible. ➤ Do not move the valve adjusting screw. ➤ Have the valve set by a specialist workshop or KAESER Service. Fig. 69 Engine air intake shut-off valve maintenance...
4. Close the canopy. 5. Start the machine and switch to LOAD operation. The engine stops in LOAD operation: Have the engine air intake valve checked by a specialist workshop or KAESER Service. 10.8.5 Option oe Draining liquid accumulation within the machine The so-called "closed floor pan"...
Maintenance 10.9 Documenting maintenance and service work 10.9 Documenting maintenance and service work Machine number: ➤ Enter maintenance and service work carried out in the list. Date Maintenance task carried out Operating hours Signature Tab. 69 Maintenance log Operator manual Portable compressor No.: 9_9432_24 E...
11.2 Ordering consumable parts and operating fluids/materials KAESER consumable parts and operating materials are original Kaeser products. They are match‐ ed to application in our machines and ensure trouble-free operation. Unsuitable or poor quality consumable parts and operating fluids/materials may damage the ma‐...
Lower costs and higher compressed air availability. 11.4 Service Addresses Addresses of KAESER agents are given at the end of this manual. 11.5 Replacement parts for service and repair Use these parts lists to plan your material requirement according to operating conditions and to or‐...
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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. ■...
Decommissioning, Storage and Transport 12.1 De-commissioning Decommissioning of the compressor for several weeks during severe frost NOTICE! Danger of batteries freezing! Discharged batteries are subject to frost damage and can freeze at −10 °C. ➤ Store batteries in a frost-free place. ➤...
Decommissioning, Storage and Transport 12.2 Transport Long-term decommissioning and storage tasks Complied? chapter ➤ Hang a notice on the instrument panel informing of the decommis‐ – sioning measurements taken. Tab. 73 "Long-term decommissioning and storage" checklist ➤ Hang the following notice on the instrument panel informing of the decommissioning measure‐ ments taken.
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Decommissioning, Storage and Transport 12.2 Transport 1. WARNING! Risk of accident when towing the unilluminated machine on public roads. Death or severe injury possible due to accidents with unilluminated trailer. ➤ Do not tow machines without illumination on public roads. 2.
Decommissioning, Storage and Transport 12.2 Transport Fig. 70 Transport position 1. WARNING! Danger from problematic driving dynamics! The permissible loading range may be exceeded or undercut. Personal injury may result from towing. Damage to the machine and/or towing vehicle is possible. ➤...
Decommissioning, Storage and Transport 12.2 Transport 3. WARNING! Risk of accident due to unhitching of the ball coupling during transport. If the coupling is not fully closed the compressor can become uncoupled from the towing vehi‐ cle and cause an accident. ➤...
Decommissioning, Storage and Transport 12.2 Transport 2. Couple-up the machine and tow slowly and carefully for about 500 m. The action of towing sets the coupling mechanism to maximum closure and gives a true read‐ ing on the wear indicator. 3.
Decommissioning, Storage and Transport 12.2 Transport 4. WARNING! Risk of accident due to unhitching of the ball coupling during transport. If the coupling is not fully closed the compressor can become uncoupled from the towing vehi‐ cle and cause an accident. ➤...
Decommissioning, Storage and Transport 12.2 Transport 2. Push the support upward or crank the automatic jockey wheel to the op (end stop). The relieved automatic jockey wheel of the coupled machine swivels into transport position, see illustration 75. 3. Check that the wheels are securely fitted and the tyres are in good condition. 4.
5. Attach the lighting and indicator systems and carry out a function check. 6. Remove the chocks and secure them in the transport securing device. Replacement chocks can be purchased from KAESER representatives. A list is given at the end of this manual. The part number of the chock is 5.1325.0.
Decommissioning, Storage and Transport 12.2 Transport Fig. 78 Breakaway cable attachment Breakaway cable Breakaway cable guide (eye) Connection (spring clip) NOTICE! Unintentional brake application. If the breakaway cable is too short it can apply the brakes when rounding a curve. This impo‐ ses high wear on the braking system.
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Decommissioning, Storage and Transport 12.2 Transport 12.2.3.1 Option rb/rm/rr Parking the machine with adjustable height chassis When parking on a slope, securely chock the machine before uncoupling. WARNING Machine without parking brake. Serious injury or death can result from an unsecured machine rolling away. ➤...
Decommissioning, Storage and Transport 12.2 Transport Fig. 80 Warning "Risk of injury due to falling towing device" Bead Retaining pin Wheel suspension 1. Use a coupled towing vehicle to move the machine into position. 2. Place chocks under the wheels. 3.
Decommissioning, Storage and Transport 12.2 Transport 9. If necessary, lower the jockey wheel further. 10. Slowly remove the towing vehicle from the machine. 12.2.3.4 Option rd/ro/rr Parking the machine with fixed chassis without parking brake: When parking on a slope, securely chock the machine before uncoupling. WARNING Machine without parking brake.
Decommissioning, Storage and Transport 12.2 Transport Fig. 82 Container for safety chain Machine Position of the container for the safety chain Safety chain 1. From below, insert your hand into the opining in the floor panel. 2. Press the rubber cover upward. 3.
Packing and securing methods must be such that, assuming proper handling, the goods arrive in perfect condition at the destination. Other measures must be taken for the transport of machines by sea or air. Please contact KAESER Service for more information. Material Chocks...
Moisture can lead to corrosion, particularly in the engine, airend and oil separator tank. Frozen moisture can damage components, valve diaphragms and gaskets. The following measures also apply to machines not yet commissioned. Please consult with KAESER if you have questions to the appropriate storage and commis‐ sioning. NOTICE Moisture and frost can damage the machine! ➤...
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Decommissioning, Storage and Transport 12.4 Disposal 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. The battery has been removed. 6.
Annex 13.6 Lighting and signalling system connection 13.6 Option te Lighting and signalling system connection Operator manual Portable compressor No.: 9_9432_24 E...
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Annex 13.6 Lighting and signalling system connection Operator manual Portable compressor No.: 9_9432_24 E...
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