Name: KAESER KOMPRESSOREN M43
Brand: KAESER KOMPRESSOREN
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Service Manual

Screw Compressor

M43

No.: 9_9432 02 E

Manufacturer:

KAESER KOMPRESSOREN GmbH

96410 Coburg • PO Box 2143 • GERMANY • Tel. +49-(0)9561-6400 • Fax +49-(0)9561-640130

http://www.kaeser.com

RAMIRENT

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Table of Contents3
Regarding this Document11
Using the Document11
Further Documents11
Copyright11
Symbols and Identification11
Warnings11
Other Instructions and Symbols12
Tab. 1 the Levels of Danger and Their Meaning12
Technical Specification13
Nameplate13
Options13
Tab. 2 Nameplate13
Tool Lubricator14
Non-Return Function14
Fuel Filter with Water Trap14
Tab. 3 Combined Label for Coupling Load and Options Fitted14
Tab. 4 Tool Lubricator14
Tab. 5 Non-Return Function14
Tab. 6 Fuel Filter with Water Trap14
Low Temperature Equipment15
Battery Isolating Switch15
Sealed Floor Pan15
Equipment for Fire Hazard Areas15
Chassis15
Tab. 7 Low Temperature Equipment15
Tab. 8 Battery Isolating Switch15
Tab. 9 Sealed Floor Pan15
Tab. 10 Equipment for Fire Hazard Areas15
Lighting16
Pedestrian Protection16
Hose Reel16
Anti-Theft Device16
Tab. 11 Chassis16
Tab. 12 Lighting16
Tab. 13 Pedestrian Protection16
Tab. 14 Hose Reel16
Tab. 15 Anti-Theft Device16
Machine (Without Options)17
Sound Emission17
Torques17
Ambient Conditions17
Tab. 16 Sound Emission17
Tab. 17 Sound Pressure Level17
Tab. 18 Torques for Hex-Head Screws17
Tab. 19 Ambient Conditions17
Dimensions18
Chassis18
Weights18
Tyres18
Wheel Fixing Tightening Torque18
Tab. 20 Machine Weights18
Tab. 21 Tyres18
Tab. 22 Wheel Fixing Tightening Torque18
Compressor19
Working Pressure and FAD19
Compressed Air Outlet19
Pressure Relief Valve19
Temperature19
Cooling Oil Recommendation19
Tab. 23 Working Pressure and FAD19
Tab. 24 Compressed Air Distributor19
Tab. 25 Relief Valve Activating Pressure19
Tab. 26 Machine Temperatures19
Cooling Oil Charge20
Engine20
Engine Data20
Tab. 27 Cooling Oil Recommendation20
Tab. 28 Cooling Oil Charge20
Oil Recommendation21
Engine Coolant Recommendation21
Fluid Volumes21
Battery21
Tab. 29 Engine Specification21
Tab. 30 Engine Oil Recommendation21
Tab. 31 Engine Fluid Volumes21
Options22
Tool Lubricator22
Low Temperature Equipment22
Tab. 32 Battery22
Tab. 33 Road Breaker Lubricant Recommendation22
Tab. 34 Ambient Conditions22
Tab. 35 Antifreeze Recommendation22
Tab. 36 Coolant Pre-Heater22
Safety and Responsibility23
Basic Information23
Specified Use23
Improper Use23
User's Responsibilities23
Observe Statutory and Universally Accepted Regulations23
Defining Personnel24
Adherence to Inspection Schedules and Accident Prevention Regulations24
Dangers25
Safely Dealing with Sources of Danger25
Tab. 37 Inspection Intervals According to Ordinance on Industrial Safety and Health25
Safe Machine Operation27
Organisational Measures29
Danger Areas29
Tab. 38 Danger Areas29
Safety Devices30
Safety Signs30
Fig. 1 Location of Safety Signs30
Tab. 39 Safety Signs31
In Emergency32
Correct Fire Fighting32
Contact with Operating Materials32
Warranty32
Environmental Protection33
Design and Function Bodywork34
Fig. 2 Overview Bodywork34
Component Identification35
Fig. 3 Side View (Canopy Removed)35
Machine Function36
Fig. 4 General Design37
Operating Modes and Control Modes38
Operating Modes38
MODULATING Control39
Safety Devices39
Monitoring Functions with Shutdown39
Further Safety Devices39
Options39
Tool Lubricator39
Low Temperature Equipment40
Fig. 5 Tool Lubricator40
Fig. 6 Frost Protector41
Fig. 7 Coolant Pre-Heating41
Sealed Floor Pan42
Battery Isolating Switch42
Fuel Filter with Water Trap43
Option for Operating in Fire Hazard Areas43
Fig. 8 Battery Isolating Switch43
Optional Anti-Theft Device44
Transportation Option44
Tab. 40 Chassis - Overview45
Installation and Operating Conditions Safety46
Installation Conditions46
Fig. 9 Minimum Distance from Excavations/Slopes and Walls46
Installation48
Safety48
Reporting Transport Damage48
Adjusting the Chassis48
Tab. 41 Height Adjustable Towbar48
Adjusting the Towbar Height49
Fig. 10 Height Adjustable Towbar Sa49
Adjusting the Towbar Height50
Fig. 11 Towbar Height Adjustment Sb51
Changing the Towing Eye or Coupling52
Tab. 42 Choice of Ball Couplings52
Fig. 12 Change from Eye to Ball Coupling (Height Adjustable Towbar)53
Fig. 13 Change from Eye to Ball Coupling (Height Adjustable Towbar with Overrun Brake)55
Fig. 14 Change from Eye to Ball Coupling (Fixed Height Towbar)57
Fig. 15 Changing from Eye to Ball Coupling (Fixed Height Towbar with Overrun Brake)58
Initial Start-Up60
Safety60
Instructions to be Observed before Commissioning or Recommissioning60
Checking Installation and Operating Conditions60
After Storing the Machine for a Long Period61
Low-Temperature Operation (Winter)61
Tab. 43 Installation and Operating Conditions Checklist61
Tab. 44 Measures for Re-Commissioning the Compressor after a Long Period of Storage61
Starting Assistance62
Fig. 16 Jumper Cable Connection Diagram62
Starting up Low-Temperature Equipment63
Tab. 45 Low-Temperature Equipment Checklist64
Operation65
Starting and Stopping65
Starting65
Fig. 17 Starting Instruments65
Allow the Machine to Run up to Operating Temperature66
Shutting down66
Fig. 18 Warm-Up Period When Ambient Temperatures Are below -10 °C66
Operating the Battery Isolating Switch67
Fig. 19 Battery Isolating Switch67
Operating the Tool Lubricator68
Using the Low-Temperature Equipment68
Using the Frost Protector68
Fig. 20 Setting the Tool Lubricator68
Coolant Pre-Heating69
Fig. 21 Switching on the Frost Protector69
Using the Hose Reel70
Using the Hose Reel (EC Version)70
Fig. 22 Hose Reel (EC Design)70
Fault Recognition and Rectification72
Basic Instructions72
Engine Faults and Alarms72
Engine Refuses to Start or Comes to a Stop72
Engine Does Not Reach Full Speed73
Indicator Lamp Remains on73
Tab. 46 Alarm: Engine Refuses to Start or Comes to a Stop73
Tab. 47 Alarm: Engine Does Not Reach Full Speed73
Tab. 48 Indicator Lamp Remains on73
Compressor Faults and Alarms74
Working Pressure too High74
Working Pressure too Low74
Tab. 49 Fault: Working Pressure too High74
Tab. 50 Fault: Working Pressure too Low74
Pressure Relief Valve Blowing off75
Machine Overheating75
Tab. 51 Fault: Pressure Relief Valve Blowing off75
Tab. 52 Fault: Machine Overheating75
Too Much Oil Residue in the Compressed Air76
Oil Flows from the Compressor Air Filter after Shutdown76
Tab. 53 Fault: too Much Oil Residue in the Compressed Air76
Tab. 54 Fault: Oil Flows from the Compressor Air Filter after Shutdown76
10 Maintenance77
Safety77
Maintenance Schedules77
Logging Maintenance Work77
Maintenance Tasks after Commissioning78
Regular Maintenance Tasks78
Tab. 55 Maintenance Tasks after Commissioning78
Tab. 56 Maintenance Intervals and Regular Maintenance Tasks78
Tab. 57 Regular Maintenance Tasks81
Engine82
Cooler Maintenance82
Tab. 58 Regular Maintenance Tasks for Options82
Fig. 23 Checking Coolant Level83
Tab. 59 Coolant Frost Protection84
Air Filter Maintenance85
Fig. 24 Draining the Coolant from the Radiator85
Fig. 25 Engine Air Filter Maintenance86
Fuel System Maintenance87
Fig. 26 Bleeding the Fuel System88
Fig. 27 Fuel Filter with Water Trap90
Changing the Engine Oil91
Fig. 28 Changing the Engine Oil92
Fig. 29 Engine Sump Drain Valve93
Fig. 30 Changing the Engine Oil Filter94
Motor Belt Maintenance95
Battery Maintenance95
Fig. 31 Warning Stickers on the Battery95
Compressor97
Checking Cooling Oil Level97
Topping up the Cooling Oil98
Fig. 32 Checking Cooling Oil Level98
Changing the Cooling Oil99
Fig. 33 Changing the Cooling Oil100
Fig. 34 Shut-Off Valves for Oil Cooler and Separator Tank101
Changing the Oil Filter102
Fig. 35 Changing the Oil Filter102
Changing the Oil Separator Cartridge103
Fig. 36 Changing the Oil Separator Cartridge104
Fig. 37 Oil Separator Tank Dirt Trap Maintenance105
Air Filter Maintenance106
Fig. 38 Compressor Air Filter Maintenance107
Pressure Relief Valve Checking108
Cooler/Radiator Cleaning108
Chassis109
Wheel Checks109
Fig. 39 Cooler/Radiator Cleaning109
Towbar Maintenance110
Overrun Braking Mechanism Maintenance110
Tab. 60 Overrun Brake Mechanism Lubricating Point110
Greasing the Brake Rods111
Checking Brake Linings111
Fig. 40 Checking the Brake Lining Thickness111
Maintain Rubber Sealing Strips112
Options112
Tool Lubricator Maintenance112
Fig. 41 Tool Lubricator Maintenance112
Frost Protector Maintenance113
Spark Arrestor Cleaning114
Fig. 42 Filling the Frost Protector114
Fig. 43 Spark Arrestor Cleaning115
Engine Air Intake Shut-Off Valve Maintenance116
Fig. 44 Engine Air Intake Shut-Off Valve Maintenance116
Document Maintenance and Service Work118
Tab. 61 Logged Maintenance Tasks118
11 Spares, Operating Materials, Service119
Note the Nameplate119
Ordering Consumable Parts and Operating Fluids/Materials119
Tab. 62 Compressor Consumables119
Tab. 63 Consumable Engine Parts119
Kaeser Air Service120
Service Addresses120
Spares for Service and Repair120
Decommissioning, Storage and Transport 12.1 De-Commissioning202
Temporary Decommissioning202
Tab. 64 "Temporarily Decommissioned" Information Notice202
Long-Term Decommissioning203
Transporting204
Towing the Compressor on the Road204
Tab. 65 Long-Term Decommissioning Checklist204
Tab. 66 "Long-Term Decommissioned" Information Notice204
Fig. 45 Towing Alignment205
Fig. 46 Ball Coupling Function206
Fig. 47 Safety Signs: Secure the Chocks208
Fig. 48 Breakaway Cable Attachment208
Parking the Compressor209
Fig. 49 Injury Can Occur if the Towbar Is Unsupported and Allowed to Fall209
Fig. 50 Safety Sign - Secure the Chocks210
Transporting with a Crane211
Transporting as a Load212
Fig. 51 Load Secured by Straps212
Storage213
Disposal213
Annex 13.1 Marking215
Pipeline and Instrument Flow Diagram (P+I Diagram)215
Fig. 52 Marking215
Dimensional Drawings219
Dimensional Drawing - Chassis with Height-Adjustable Tow Bar219
Dimensional Drawing - Chassis with Height-Adjustable Tow Bar221
Dimensional Drawing - Fixed Height Towbar and Parking Brake223
Dimensional Drawing - Fixed Height Towbar and Overrun Brake225
Electrical Diagram227
Lighting and Signalling System Connection237
Fuel Circulation Diagram243

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KAESER KOMPRESSOREN M43 Specifications

General

Brand	KAESER KOMPRESSOREN
Model	M43
Category	Compressor
Language	English

KAESER KOMPRESSOREN M43 User Manual

Table of Contents

Questions and Answers:

KAESER KOMPRESSOREN M43 Specifications