KAESER M 64 - Page 2

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Original instructions

/KKW/M64 2.06 en SBA-MOBILAIR

20160428 104438

RAMIRENT

Main Page

Table of Contents3
Regarding this Document Using this Document13
Further Documents13
Copyright13
Symbols and Labels13
Warnings13
Tab. 1 Danger Levels and Their Definitions (Personal Injury)13
Potential Damage Warnings14
Other Alerts and Their Symbols14
Tab. 2 Danger Levels and Their Definition (Damage to Property)14
Technical Specifications Nameplate16
Options - Options Label16
Tab. 3 Nameplate16
Compressed Air Treatment Devices17
Tool Lubricator17
Compressed Air Distributor17
Tab. 4 Options Label17
Tab. 5 Compressed Air Treatment Options17
Tab. 6 Tool Lubricator Option17
Low Temperature Equipment18
Equipment for Fire Hazard Areas18
Battery Isolating Switch18
Chassis18
Tab. 7 Compressed Air Distributor Option18
Tab. 8 Low Temperature Equipment Options18
Tab. 9 Optional Equipment for Fire Hazard Areas18
Tab. 10 Optional Battery Isolating Switch18
Lighting19
Generator19
Tab. 11 Chassis Options19
Tab. 12 Options, Stationary Frame19
Tab. 13 Lighting Options19
Tab. 14 Generator Option19
Hose Reels20
Anti-Theft Device20
Pedestrian Protection20
Instrument Panel Cover20
Diesel Particulate Filter20
Tab. 15 Hose Reel Option20
Tab. 16 Optional Anti-Theft Device20
Tab. 17 Pedestrian Protection Option20
Tab. 18 Instrument Panel Cover Options20
Tab. 19 Diesel Particulate Filter Option20
Machine (Without Options)21
Noise Emission21
Tightening Torques for Screws21
Ambient Conditions21
Additional Specifications According to the Machine's Operating Licence21
Tab. 20 Guaranteed Sound Power Level21
Tab. 21 Emission Sound Pressure Level21
Tab. 22 Tightening Torques for Screws (Property Class 8.8, Coefficient of Friction Μ = 0,12)21
Tab. 23 Ambient Conditions21
Chassis22
Chassis Options22
Machines with Stationary Frame Design22
Mass of Machines with Stationary Frame Design22
Compressor22
Working Pressure and FAD22
Tab. 24 Mass of the Machine22
Tab. 25 Working Pressure and FAD22
Compressed Air Outlet23
Pressure Relief Valves23
Temperature23
Cooling Oil Recommendation23
Tab. 26 Compressed Air Distributor23
Tab. 27 Pressure Relief Valve Opening Pressure23
Tab. 28 Machine Temperatures23
Tab. 29 Airend Discharge Temperature23
Tab. 30 Cooling Oil Recommendation24
Cooling Oil Charge25
Engine25
Engine Specification25
Oil Recommendation25
Tab. 31 Cooling Oil Recommendation (Food Processing)25
Tab. 32 Cooling Oil Charge25
Tab. 33 Engine Specification25
Fuel Recommendation26
Engine Coolant Recommendation26
Tab. 34 Engine Oil Recommendation26
Tab. 35 Recommended Oil for Engines with Diesel Particulate Filters26
Fluid Volumes27
Battery27
Options27
Air Treatment Options27
Tab. 36 Fluid Volumes27
Tab. 37 Battery27
Tab. 38 Road Breaker Lubricant Recommendation27
Tab. 39 Fresh Air Filter Conditions27
Low Temperature Equipment28
Tab. 40 Interrelation between Compressed Air Treatment and Compressed Air Quality28
Tab. 41 Environmental Conditions, Low Temperature Equipment28
Tab. 42 Coolant Pre-Heater28
Diesel Particulate Filter29
Generator (50 Hz Version)29
Tab. 43 Recommended Antifreeze29
Tab. 44 Battery, Low-Temperature Equipment29
Tab. 45 Diesel Particulate Filter Data29
Tab. 46 Generator Data30
Tab. 47 Delivery in Generator Mode30
Tab. 49 Circuit Breaker31
Tab. 50 Generator Operating Limits31
Generator (60 Hz Version)32
Tab. 51 Maximum Three-Phase Mains Loading32
Tab. 52 Maximum Single-Phase Mains Loading32
Tab. 53 Power Reduction at Elevated Ambient Temperatures32
Tab. 48 Connection Sockets33
Tab. 54 Generator Data33
Tab. 55 Delivery in Generator Mode33
Tab. 56 Connection Sockets33
Tab. 57 Circuit Breaker34
Tab. 58 Generator Operating Limits34
Tab. 59 Maximum Power Supply Load34
Tab. 60 Power Reduction at Elevated Ambient Temperatures34
Safety and Responsibility Basic Instructions35
Specified Use35
Incorrect Use35
User's Responsibilities35
Observe Statutory and Universally Accepted Regulations35
Determining Personnel36
Keeping to Inspection Schedules and Accident Prevention Regulations36
Complying with Inspection Intervals for Diesel Particulate Filters37
Attachment of a "Hazardous Goods" Label37
Tab. 61 Inspection Intervals According to Ordinance on Industrial Safety and Health37
Dangers38
Safely Dealing with Sources of Danger38
Safe Machine Operation41
Organisational Measures44
Danger Areas44
Safety Devices45
Safety Signs45
Tab. 62 Danger Areas45
Fig. 1 Location of Safety Signs46
Tab. 63 Safety Signs47
Generator Operation48
Comply with the Protective Measures against Dangerous Electric Current48
Safe Generator Operation48
Connecting Extension Cables48
Do Not Exceed the Maximum Supply System Load49
Perform Regular Generator Inspections49
Emergencies49
Correct Fire Fighting49
Injury from Handling Operating Fluids/Materials50
Warranty50
Identifying the Effects of Improper Modifications51
Environment Protection52
Design and Function Bodywork53
Fig. 2 Overview Bodywork53
Machine Structure54
Fig. 3 Right-Hand Door Opened54
Fig. 4 Left-Hand Door Opened54
Machine Function55
Fig. 5 Machine Overview55
Operating Modes and Control Mode56
Operating Modes56
MODULATING Control56
Safety Devices57
Monitoring Functions with Shutdown57
Fig. 6 Stepless Regulation of FAD (Standstill)57
Further Safety Devices58
Options58
Air Treatment Options58
Fig. 7 Compressed Air Options58
Fig. 8 Tool Lubricator60
Low Temperature Equipment Options61
Fig. 9 Principle Tool Lubricator61
Fig. 10 Coolant Pre-Heating62
Fig. 11 Frost Protector62
Optional Battery Isolating Switch63
Options for Operating in Fire Hazard Areas63
Fig. 12 Battery Isolating Switch63
Generator Option64
Tab. 64 Generator / Compressor Operation64
Fig. 13 Instrument Panel - Generator Control Box, 400 V AC65
Fig. 14 Instrument Panel - Generator Control Box, 230 V AC65
Tab. 65 Generator Operating Modes65
Diesel Particulate Filter Option66
Fig. 15 Generator Instrument Panel - Control Box, 115 V, Single-Phase (50 Hz)66
Fig. 16 Generator Instrument Panel - Control Box, 230 V, Single-Phase (60 Hz)66
Hose Reel Option67
Optional Anti-Theft Device67
Pedestrian Protection Option67
Fig. 17 General Design of the Diesel Particulate Filter System67
Instrument Panel Cover Option68
Frame Design Options for Stationary Machines68
Chassis Types of Stationary Machines68
Tab. 66 Stationary Machines68
Installation and Operating Conditions69
Ensuring Safety69
Installation Conditions69
Fig. 18 Minimum Distance from Excavations/Slopes and Walls70
Installation71
Ensuring Safety71
Reporting Transport Damage71
Initial Start-Up Ensuring Safety72
Before Initial Start-Up (or Recommissioning)72
Note When Commissioning72
Special Measures for Re-Commissioning after Storage or De-Commissioning73
Checking Installation and Operating Conditions73
Tab. 67 Measures for Re-Commissioning the Compressor after a Long Period of Storage or De-Commissioning73
Tab. 68 Positioning and Operating Conditions Checklist73
Low-Temperature Operation (Winter)74
Starting Assistance74
Fig. 19 Jumper Cable Connection Diagram75
Starting up Low-Temperature Equipment76
Fig. 20 Coolant Pre-Heating77
Fig. 21 Operating the Frost Protector77
Putting the Generator into Operation78
Fig. 22 Insulation Monitoring - 400 V Three-Phase Generator78
Fig. 23 Insulation Monitoring - 230 V Three-Phase Generator78
Tab. 69 Low-Temperature Equipment Checklist78
Fig. 24 Insulation Monitoring - 115 V, Single-Phase Generator (50 Hz)79
Fig. 25 Insulation Monitoring - 230 V, Single-Phase Generator (60 Hz)79
Tab. 70 Test Instructions for a Generator with an Earth Leak Detection Device80
Putting the Generator into Operation80
Operation81
Ensuring Safety81
Starting and Stopping82
Running the Machine82
Fig. 26 Starting Instruments82
Engine Pre-Heating83
Starting the Machine83
Allow the Machine to Run up to Operating Temperature84
Switching to LOAD84
Regulating the Shut-Off Valve84
Fig. 27 Label Referring to the Warm-Up Period When Ambient Temperatures Are below -10 °C84
Shutting down the Machine85
Fig. 28 Control Line Shut-Off Valve85
Ending the Reverse Engine Run86
Using the Hose Reel86
Using the Hose Reel (EC Version)86
Fig. 29 Hose Reel (EC Design)87
Using the Hose Reel (USA Version)88
Fig. 30 Hose Reel (EC Design)88
Operating the Tool Lubricator89
Fig. 31 Setting the Tool Lubricator89
Using the Low-Temperature Equipment90
Coolant Pre-Heating90
Operating the Machine with Frost Protector90
Fig. 32 Frost Protector on and off90
Operating the Battery Isolating Switch91
Fig. 33 Battery Isolating Switch91
Start the Machine91
Generator Operation92
Note When Operating the Generator92
Switching in the Generator92
Danger92
Risk of Fatal Injury Caused by Contact with Live Components92
Switching off the Generator93
Cleaning the Machine after Operation93
Fault Recognition and Rectification95
Basic Instructions95
Evaluating Engine Faults and Alarms95
Engine Refuses to Start or Does Not Turn over95
Engine Does Not Reach Full Speed96
Indicator Lamp Remains on96
Tab. 71 Fault: Engine Refuses to Start or Comes to a Stop96
Tab. 72 Alarm: "Engine Does Not Reach Full Speed96
Tab. 73 Alarm: "Control Lamp Remains on96
Motor Running Backwards97
Analysing Compressor Faults and Alarms97
Working Pressure too High97
Working Pressure too Low97
Tab. 74 "Motor Running Backwards" Fault97
Tab. 75 Fault: Working Pressure too High97
Pressure Relief Valve Blowing off98
Machine Overheating98
Tab. 76 Fault: Working Pressure too Low98
Tab. 77 Fault: Pressure Relief Valve Blowing off98
Too Much Oil Residue in the Compressed Air99
Oil Flows from the Compressor Air Filter after Shutdown99
Tab. 78 Fault: Machine Overheating99
Tab. 79 Alarm: "Too Much Oil Residue in the Compressed Air99
Tab. 80 Alarm: "Oil Flows from the Compressor Air Filter after Shutdown99
High Moisture Content in the Compressed Air100
Evaluate Faults in the Diesel Particulate Filter100
Tab. 81 Fault: High Moisture Content in the Compressed Air100
Tab. 82 Faults in the Diesel Particulate Filter100
Tab. 83 Fault 'Blue Engine Exhaust100
Evaluate Generator Faults and Alarms101
There Is no Voltage or too Low a Voltage from the Generator101
Generator Voltage too High101
Tab. 84 Grey or Brownish Exhaust Gas101
Tab. 85 There Is no Voltage or too Low a Voltage from the Generator101
Tab. 86 Generator Voltage too High102
10.1 Maintenance103
Ensuring Safety103
Tab. 87 Advise Others that the Machine Is Being Serviced103
Following the Maintenance Plans104
Logging Maintenance Work104
Maintenance Tasks after Commissioning104
Regular Maintenance Tasks105
Tab. 88 Maintenance Tasks after Commissioning105
Tab. 89 Maintenance Intervals and Regular Maintenance Tasks105
Tab. 90 Regular Machine Maintenance Tasks108
Engine Maintenance109
Tab. 91 Regular Maintenance Task Options109
Water Cooler Maintenance110
Fig. 34 Checking Coolant Level111
Tab. 92 KAESER Coolant Mixture Table112
Fig. 35 Draining the Coolant from the Radiator114
Engine Air Filter Maintenance115
Fig. 36 Engine Air Filter Maintenance115
Fig. 37 Cleaning the Filter Element116
Fuel System Maintenance117
Fig. 38 Fuel System Maintenance117
Fig. 39 Bleeding the Fuel System118
Fig. 40 Fuel Water Separator Maintenance119
Fig. 41 Changing the Fuel Pre-Filter120
Fig. 42 Fuel Fine Filter Maintenance120
Checking the Engine Oil Level121
Engine Oil Filling and Topping up122
Fig. 43 Checking the Engine Oil Level122
Changing the Engine Oil123
Fig. 44 Draining the Engine Oil124
Fig. 45 Changing the Engine Oil125
Replace the Engine Oil Filter126
Fig. 46 Change the Oil Filter126
Drive Belt Maintenance127
Fig. 47 Belt Guard Attachment127
Fig. 48 Checking the Drive Belt Seating128
Fig. 49 Manually Checking the Belt Tension128
Fig. 50 Changing/Tensioning the Drive Belt129
Battery Maintenance130
Fig. 51 Safety Signs - Warning Stickers on the Battery130
Checking the Fastening of the Fuel Tank133
Compressor Maintenance134
Checking Cooling Oil Level134
Fig. 52 Checking Cooling Oil Level134
Cooling Oil Filling and Topping up135
Changing the Cooling Oil136
Fig. 53 Draining the Compressor Cooling Oil137
Replacing the Compressor Oil Filter138
Fig. 54 Draining the Oil from the Heat Exchanger138
Fig. 55 Change the Oil Filter139
Oil Separator Tank Dirt Trap Maintenance140
Fig. 56 Oil Separator Tank Dirt Trap Maintenance140
Changing the Oil Separator Cartridge141
Fig. 57 Changing the Oil Separator Cartridge142
Fig. 58 Changing the Oil Separator Cartridge (Option Ba)144
Compressor Air Filter Maintenance145
Fig. 59 Compressor Air Filter Maintenance146
Fig. 60 Cleaning the Filter Element147
Check Pressure Relief Valves148
Fit the Flexible Pipe Connection148
Fig. 61 Fit the Flexible Pipe Connection148
Tab. 93 Dimensions of the Flexible Pipe Connection148
Cleaning the Cooler149
Cleaning the Compressor Cooler and Engine Radiator149
Cleaning the Compressed Air Aftercooler150
Fig. 62 Cleaning the Compressor Cooler and Engine Radiator150
Maintenance of Rubber Sealing Strips151
Fig. 63 Cleaning the Compressed Air Aftercooler151
Maintenance of Optional Items152
Tool Lubricator Maintenance152
Fig. 64 Tool Lubricator Maintenance152
Cyclone Separator Maintenance153
Fig. 65 Cleaning the Dirt Trap154
Combination Filter Maintenance155
Fig. 66 Filter Combination155
Fig. 67 Combination Filter Maintenance156
Fresh Air Filter Maintenance158
Fig. 68 Fresh Air Filter Maintenance159
Frost Protector Maintenance161
Fig. 69 Filling the Frost Protector162
Spark Arrestor Cleaning163
Fig. 70 Spark Arrestor Cleaning163
Engine Air Shut-Off Valve Maintenance164
Fig. 71 Maintain the Engine Air Shut-Off Valve165
Generator Drive Belt Maintenance166
Fig. 72 Securing the Belt Guard at the Generator167
Fig. 73 Belt Tension Checking by Hand168
Tab. 94 Belt Tension Values168
Fig. 74 Generator Belt Tensioning169
Fig. 75 Generator Belt Tensioner169
Fig. 76 Checking the Pulley Alignment171
Fig. 77 Aligning the Generator172
Documenting Maintenance and Service Work173
Tab. 95 Maintenance Log173
11 Spares, Operating Materials, Service174
Note the Nameplate174
Ordering Consumable Parts and Operating Fluids/Materials174
Tab. 96 Compressor Consumables174
Kaeser Air Service175
Service Addresses175
Replacement Parts for Service and Repair175
Tab. 97 Consumable Engine Parts175
Tab. 98 Replacement Parts, Combination Filter175
Tab. 99 Replacement Parts, Fresh-Air Filter175
12 Decommissioning, Storage and Transport208
Commissioning208
Temporary De-Commissioning208
Tab. 100 "Temporarily Decommissioned" Information Notice208
Long-Term De-Commissioning and Storage209
Transport210
Tab. 101 "Long-Term Decommissioning and Storage" Checklist210
Tab. 102 Text for the "Long-Term Decommissioned and Storage" Information Notice210
Safety211
Transport with a Crane211
Transport with a Forklift Truck211
Fig. 78 Preparing for Transport Using a Forklift Truck212
Fig. 79 Lifting the Machine with a Forklift Truck213
Transporting the Machine as Load214
Fig. 80 Transport with a Forklift Truck214
Storage215
Fig. 81 Guys to Secure the Freight215
Disposal216
13 Annex217
Marking217
Pipeline and Instrument Flow Diagram (P+I Diagram)217
Fig. 82 Marking217
Dimensional Drawings222
Drawing Chassis222
Drawing Chassis224
Dimensional Drawing - Chassis226
Dimensional Drawing, Stationary Version228
Dimensional Drawing, Stationary Version230
Wiring Diagrams232
Electrical Diagram232
Connection Adapter for the Diesel Particulate Filter245
Lighting and Signalling System Connection250
Lighting and Signalling System Connection258
Generator Electrical Diagram, 400V, 3-Ph263
Generator Electrical Diagram, 230V, 3-Ph272
Generator Electrical Diagram, 115V, 2-Ph281
Generator Electrical Diagram, 230V, 2-Ph290
Fuel Circulation Diagram299
Operating Instructions for Compressed Air Filter (Combination Filter)302
Operating Instructions for Compressed Air Filter (Fresh Air Filter)330
Service Tasks on the Diesel Particulate Filter344
Service Tasks - Generator344

KAESER M 64 - Page 2

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