KAESER M100 - Page 8

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Contents

Operator Manual Screw Compressor

M100

No.: 9_6999 23 USE

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 Data Nameplate16
Options16
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
Check Valve Function18
Proportional Controller18
Low Temperature Equipment18
Equipment for Fire Hazard Areas18
Tab. 7 Compressed Air Distributor Option18
Tab. 8 Check Valve Option18
Tab. 9 Proportional Controller Option18
Tab. 10 Low Temperature Equipment Options18
Tab. 11 Optional Equipment for Fire Hazard Areas18
Battery Isolating Switch19
Chassis19
Tab. 12 Battery Isolating Switch Option19
Tab. 13 Chassis Options19
Tab. 14 Options, Stationary Frame19
Lighting20
Generator20
Sealed Floor Pan20
Anti-Theft Device20
Pedestrian Protection20
Tab. 15 Lighting Options20
Tab. 16 Generator Options20
Tab. 17 Sealed Floor Pan Option20
Tab. 18 Anti-Theft Device Option20
Tab. 19 Pedestrian Protection Option20
Instrument Panel Cover21
Machine (Without Options)21
Sound Pressure Level21
Tightening Torques for Screws21
Ambient Conditions21
Additional Specifications21
Tab. 20 Instrument Panel Cover Options21
Tab. 21 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
Weight22
Tires22
Fig. 1 Example for Tire Information on the Side Wall22
Tab. 24 Weight of the Machine22
Wheel Nut/Bolt Tightening Torque23
Towbar Tightening Torque23
Compressor23
Working Pressure and FAD23
Compressed Air Outlet23
Tab. 25 Tires23
Tab. 26 Wheel Nut/Bolt Tightening Torque23
Tab. 27 Towbar Tightening Torque23
Tab. 28 Working Pressure and FAD23
Tab. 29 Compressed Air Distributor23
Safety Relief Valves24
Temperature24
Cooling Oil Recommendation24
Tab. 30 Safety Relief Valve Activating Pressure24
Tab. 31 Machine Temperatures24
Tab. 32 Airend Discharge Temperature24
Tab. 33 Cooling Oil Recommendations25
Cooling Oil Charge26
Engine26
Engine Specification26
Oil Recommendation26
Tab. 34 Cooling Oil Recommendation (Food Processing)26
Tab. 35 Cooling Oil Charge26
Tab. 36 Engine Specification26
Fuel Recommendation27
Recommended Cooling Fluid27
Fluid Volumes27
Battery27
Tab. 37 Engine Oil Recommendation27
Tab. 38 Fluid Volumes27
Tab. 39 Battery27
Options28
Air Treatment Options28
Tab. 40 Road Breaker Lubricant Recommendation28
Tab. 41 Fresh Air Filter Conditions28
Low Temperature Equipment29
Tab. 42 Interrelation between Compressed Air Treatment and Compressed Air Quality29
Tab. 43 Environmental Conditions, Low Temperature Equipment29
Tab. 44 Coolant Pre-Heater29
Tab. 45 Recommended Antifreeze29
Tab. 46 Battery, Low-Temperature Equipment29
Generator (50 Hz Version)30
Tab. 47 Generator Data30
Tab. 48 Compressed Air Delivery with Generator in Operation (Generator Without FAD Limitation)30
Tab. 49 Compressed Air Delivery with Generator in Operation (Generator with FAD Limitation)31
Tab. 50 Connection Sockets31
Tab. 51 Circuit Breaker31
Tab. 52 Generator Operating Limits32
Tab. 53 Maximum Three-Phase Mains Loading32
Tab. 54 Maximum Single-Phase Mains Loading32
Tab. 55 Power Reduction at Elevated Ambient Temperatures32
Generator (60 Hz Version)33
Tab. 56 Generator Data33
Tab. 57 Compressed Air Delivery with Generator in Operation (Generator Without FAD Limitation)33
Tab. 58 Compressed Air Delivery with Generator in Operation (Generator with FAD Limitation)34
Tab. 59 Connection Sockets34
Tab. 60 Circuit Breaker34
Tab. 61 Generator Operating Limits34
Tab. 62 Maximum Power Supply Load35
Tab. 63 Power Reduction at Elevated Ambient Temperatures35
Safety and Responsibility Basic Instructions36
Specified Use36
Incorrect Use36
User's Responsibilities36
Observe Statutory and Universally Accepted Regulations36
Determining Personnel37
Adherence to Inspection Schedules and Accident Prevention Regulations37
Attachment of a "Hazardous Goods" Label37
Dangers38
Safely Dealing with Sources of Danger38
Safe Machine Operation41
Organizational Measures44
Danger Areas45
Safety Devices45
Safety Signs45
Tab. 64 Danger Areas45
Fig. 2 Location of Safety Signs46
Tab. 65 Safety Signs48
Noise Control Requirements49
Generator Operation49
Comply with the Protective Measures against Dangerous Electric Current49
Safe Generator Operation49
Connecting Extension Cables50
Do Not Exceed the Maximum Supply System Load50
Perform Regular Generator Inspections50
Emergencies51
Correct Fire Fighting51
Injury from Handling Operating Fluids/Materials51
Warranty52
Noise Emissions Warranty52
Identifying the Effects of Improper Modifications52
Environmental Protection53
Design and Function Bodywork54
Fig. 3 Overview Bodywork54
Component Identification55
Machine Function55
Fig. 4 Right-Hand Door Opened55
Fig. 5 Left-Hand Door Opened55
Fig. 6 Machine Layout56
Operating Modes and Control Mode57
Operating Modes57
MODULATING Control57
Safety Devices58
Monitoring Functions with Shutdown58
Fig. 7 Stepless Regulation of FAD (Standstill)58
Further Safety Devices59
Fuel Level Monitoring59
Options59
Fig. 8 Fuel Level Monitoring59
Compressed Air Treatment Options60
Fig. 9 Compressed Air Options60
Fig. 10 Tool Lubricator62
Fig. 11 Principle Tool Lubricator62
Low Temperature Equipment Options63
Fig. 12 Coolant Pre-Heating63
Optional Battery Isolating Switch64
Fig. 13 Frost Protector64
Options for Operating in Fire Hazard Areas65
Fig. 14 Battery Isolating Switch65
Generator Option66
Tab. 66 Generator / Compressor Operation66
Tab. 67 Generator Operating Modes66
Fig. 15 Instrument Panel - Generator Control Box, 400 V AC67
Fig. 16 Instrument Panel - Generator Control Box, 230 V AC67
Transport Options68
Fig. 17 Generator Instrument Panel - Control Box, 115 V, Single-Phase (50 Hz)68
Fig. 18 Generator Instrument Panel - Control Box, 230 V, Single-Phase (60 Hz)68
Sealed Floor Pan Option70
Optional Anti-Theft Device71
Pedestrian Protection Option71
Fig. 19 Position of Service Openings in the Sealed Floor Pan71
Fig. 20 Drain Points for Oil and Coolant from Engine and Compressor71
Instrument Panel Cover Option72
Installation and Operating Conditions73
Ensuring Safety73
Installation Conditions73
Fig. 21 Minimum Distance from Excavations/Slopes and Walls73
Installation75
Ensuring Safety75
Reporting Transport Damage75
Fitting the Towbar75
Fitting the Height Adjustable Towbar76
Fig. 22 Height Adjustable Towbar, Fitted76
Fig. 23 Fitting the Height Adjustable Towbar76
Fitting a Non-Adjustable Tow Bar77
Fig. 24 Non-Adjustable Tow Bar Fitted77
Fig. 25 Fitting the Overrun Braking Mechanism of the Non-Adjustable Tow Bar78
Adjusting the Chassis79
Fig. 26 Fitting the Jockey Wheel of the Non-Adjustable Tow Bar79
Adjusting the Towbar Height80
Changing the Towing Eye/Ball Hitch80
Fig. 27 Towbar Height Adjustment80
Fig. 28 Changing the Towing Eye (Height-Adjustable Drawbar)81
Fig. 29 Changing the Towing Eye/Ball Hitch (Fixed Height Towbar)82
Fig. 30 Changing the Towing Eye (Fixed Height Towbar, USA Chassis Version)83
Initial Start-Up Ensuring Safety84
Before Initial Start-Up (or Recommissioning)84
Instructions to be Observed before Commissioning or Recommissioning84
Special Measures for Re-Commissioning after Storage85
Checking Installation and Operating Conditions85
Tab. 68 Measures for Re-Commissioning the Compressor after a Long Period of Storage85
Tab. 69 Positioning and Operating Conditions Checklist85
Low-Temperature Operation (Winter)86
Starting Assistance86
Fig. 31 Jumper Cable Connection Diagram87
Starting up Low-Temperature Equipment88
Fig. 32 Engine Coolant Pre-Heating89
Fig. 33 Operating the Frost Protector89
Activating the Generator90
Fig. 34 Insulation Monitoring - 400 V AC, 3-Phase Generator90
Fig. 35 Insulation Monitoring - 230 V AC, 3-Phase Generator90
Tab. 70 Low-Temperature Equipment Checklist90
Fig. 36 Insulation Monitoring - 115 V, Single-Phase Generator91
Fig. 37 Insulation Monitoring - 230 V, Single-Phase Generator91
Tab. 71 Test Instructions for a Generator with an Ground Short Detection Device92
Operation93
Ensuring Safety93
Starting and Stopping94
Fig. 38 Starting Instruments94
Starting the Machine95
Engine Pre-Heating95
Allow the Machine to Run up to Operating Temperature95
Switching to LOAD96
Manually Setting the Discharge Pressure96
Fig. 39 Label Referring to the Warm-Up Period When Ambient Temperatures Are below -50 °F96
Shutting down the Machine97
Fig. 40 Proportional Controller97
Monitoring Fuel Level in the Fuel Tank98
Operating the Tool Lubricator98
Fig. 41 Setting the Tool Lubricator98
Using the Low-Temperature Equipment99
Pre-Warms the Engine Cooling Water99
Operating the Machine with Frost Protector100
Fig. 42 Frost Protector on and off100
Operating the Battery Isolating Switch101
Generator Operation101
Fig. 43 Battery Isolating Switch101
Note When Operating the Generator102
Switching in the Generator102
Switching off the Generator102
Cleaning the Machine after Operation103
Fault Recognition and Rectification104
Basic Instructions104
Engine Faults and Alarms104
Engine Refuses to Start or Comes to a Stop104
Engine Does Not Reach Full Speed105
Indicator Lamp Remains on105
Tab. 72 Alarm: Engine Refuses to Start or Comes to a Stop105
Tab. 73 Alarm: Engine Does Not Reach Full Speed105
Compressor Faults and Alarms106
Working Pressure too High106
Working Pressure too Low106
Tab. 74 Indicator Lamp Remains on106
Tab. 75 Fault: Working Pressure too High106
Pressure Relief Valve Blowing off107
Machine Overheating107
Tab. 76 Fault: Working Pressure too Low107
Tab. 77 Fault: Pressure Relief Valve Blowing off107
Too Much Oil Residue in the Compressed Air108
Oil Flows from the Compressor Air Filter after Shutdown108
Tab. 78 Fault: Machine Overheating108
Tab. 79 Fault: too Much Oil Residue in the Compressed Air108
Tab. 80 Fault: Oil Flows from the Compressor Air Filter after Shutdown108
High Moisture Content in the Compressed Air109
Generator Faults and Alarms109
There Is no Voltage or too Low a Voltage from the Generator109
Generator Voltage too High109
Tab. 81 Fault: High Moisture Content in the Compressed Air109
Tab. 82 There Is no Voltage or too Low a Voltage from the Generator109
Tab. 83 Generator Voltage too High109
10.1 Maintenance111
Ensuring Safety111
Tab. 84 Advise Others that the Machine Is Being Serviced111
Maintenance Schedules112
Logging Maintenance Work112
Maintenance Tasks after Commissioning112
Regular Maintenance Tasks113
Tab. 85 Maintenance Tasks after Commissioning113
Tab. 86 Maintenance Intervals and Regular Maintenance Tasks113
Tab. 87 Regular Machine Maintenance Tasks116
Tab. 88 Regular Maintenance Task Options117
Engine Maintenance118
Water Cooler Maintenance118
Fig. 44 Checking Coolant Level119
Tab. 89 KAESER Coolant Mixture Table120
Fig. 45 Draining the Coolant from the Radiator122
Engine Air Filter Maintenance123
Fig. 46 Draining the Coolant from the Radiator (Closed Floor Pan - Stationary Machine)123
Fig. 47 Engine Air Filter Maintenance124
Fig. 48 Cleaning the Filter Element125
Fuel System Maintenance126
Fig. 49 Fuel System Maintenance126
Fig. 50 Bleeding the Fuel System127
Fig. 51 Fuel Filter with Water Trap Maintenance128
Fig. 52 Changing the Fuel Pre-Filter129
Fig. 53 Fuel Micro-Filter Maintenance129
Checking the Engine Oil Level130
Engine Oil Filling and Topping up131
Fig. 54 Checking the Engine Oil Level131
Changing the Engine Oil132
Fig. 55 Draining the Engine Oil133
Fig. 56 Draining the Engine Oil (Closed Floor Pan - Stationary Machine)134
Replace the Engine Oil Filter135
Fig. 57 Changing the Oil Filter135
Drive Belt Maintenance136
Fig. 58 Belt Guard Attachment136
Fig. 59 Checking the Drive Belt Seating137
Fig. 60 Manually Checking the Belt Tension137
Fig. 61 Changing/Tensioning the Drive Belt138
Battery Maintenance139
Fig. 62 Safety Signs - Warning Stickers on the Battery139
Checking the Fastening of the Fuel Tank142
Compressor Maintenance142
Checking Cooling Oil Level143
Fig. 63 Checking Cooling Oil Level143
Cooling Oil Filling and Topping up144
Changing the Cooling Oil145
Fig. 64 Draining the Compressor Cooling Oil146
Fig. 65 Draining the Oil from the Heat Exchanger147
Fig. 66 Draining the Cooling Oil (Closed Floor Pan - Stationary Machine)148
Replace the Compressor Oil Filter149
Fig. 67 Changing the Oil Filter149
Oil Separator Tank Dirt Trap Maintenance150
Fig. 68 Oil Separator Tank Dirt Trap Maintenance150
Changing the Oil Separator Cartridge151
Fig. 69 Changing the Oil Separator Cartridge152
Fig. 70 Changing the Oil Separator Cartridge (Option Ba)154
Compressor Air Filter Maintenance155
Fig. 71 Compressor Air Filter Maintenance156
Fig. 72 Cleaning the Filter Element157
Checking Safety Relief Valves158
Cleaning the Cooler158
Cleaning the Compressor Cooler and Engine Radiator158
Cleaning the Compressed Air Aftercooler159
Fig. 73 Cleaning the Compressor Cooler and Engine Radiator159
Maintenance of Rubber Sealing Strips160
Fig. 74 Cleaning the Compressed Air Aftercooler160
Chassis Maintenance161
Wheel Checks161
Towbar Maintenance161
Fig. 75 Towbar Maintenance162
Fig. 76 Maintaining the Fixed Height Towbar162
Fig. 77 Ball Coupling (EC Version)163
Brake Maintenance164
Fig. 78 Ball Coupling (USA Version)164
Fig. 79 Checking the Brake Lining Thickness165
Fig. 80 Brake System Adjustment165
Fig. 81 Brake Rod Adjustment166
Maintenance for Optional Items167
Tool Lubricator Maintenance167
Fig. 82 Tool Lubricator Maintenance168
Cyclone Separator Maintenance169
Fig. 83 Cleaning the Dirt Trap169
Combination Filter Maintenance170
Fig. 84 Filter Combination171
Fig. 85 Combination Filter Maintenance171
Fresh Air Filter Maintenance174
Fig. 86 Fresh Air Filter Maintenance174
Frost Protector Maintenance177
Fig. 87 Filling the Frost Protector177
Spark Arrestor Maintenance178
Fig. 88 Cleaning the Spark Arrestor (Floor Pan with Service Openings)178
Fig. 89 Cleaning the Spark Arrestor (Sealed Floor Pan)179
Engine Air Intake Shut-Off Valve Maintenance180
Fig. 90 Engine Air Intake Shut-Off Valve Maintenance180
Generator Drive Belt Maintenance181
Fig. 91 Securing the Belt Guard at the Generator182
Fig. 92 Generator Belt Tensioning183
Draining Liquid Accumulation Within the Machine184
Documenting Maintenance and Service Work186
Tab. 90 Maintenance Log186
11 Spares, Operating Materials, Service187
Note the Nameplate187
Ordering Consumable Parts and Operating Fluids/Materials187
Tab. 91 Compressor Consumables187
Kaeser Air Service188
Service Addresses188
Replacement Parts for Service and Repair188
Tab. 92 Consumable Engine Parts188
Tab. 93 Replacement Parts, Combination Filter188
Tab. 94 Replacement Parts, Fresh-Air Filter188
12 Decommissioning, Storage and Transport239
Commissioning239
Temporary De-Commissioning239
Tab. 95 "Temporarily Decommissioned" Information Notice239
Long-Term Decommissioning and Storage240
Tab. 96 Long-Term Decommissioning and Storage Checklist240
Transport241
Safety241
Towing the Compressor on the Road241
Tab. 97 Text for the Long-Term Decommissioned and Storage Information Notice241
Fig. 93 Towing Position243
Fig. 94 Ball Coupling (ALKO-EU)244
Fig. 95 Wear Alert, Ball Coupling (ALKO-EU)245
Tab. 98 Ball Coupling Wear Indicator245
Fig. 96 Ball Coupling (ALKO-USA)246
Fig. 97 Release the Parking Brake246
Fig. 98 Automatic Jockey Wheel in Transport Position247
Fig. 99 Safety Sign - Secure the Chocks248
Fig. 100 Breakaway Cable Attachment249
Fig. 101249
Parking the Machine250
Fig. 102 Warning "Injury Can Occur if the Towbar Is Allowed to Fall250
Fig. 103 Towbar with Automatic Jockey Wheel251
Fig. 104 Actuating the Parking Brake251
Fig. 105 Safety Sign - Secure the Chocks252
Transport with a Crane253
Transport with a Forklift Truck253
Transporting the Machine as Load254
Fig. 106 Transporting Using a Forklift Truck254
Storage255
Fig. 107 Guys to Secure the Freight255
Disposal256
13 Annex257
Identification257
Pipeline and Instrument Flow Diagram (P+I Diagram)257
Fig. 108 Identification257
Dimensional Drawings263
Dimensional Drawing, Chassis Options263
Dimensional Drawing, Chassis Options265
Dimensional Drawing, Chassis Options267
Dimensional Drawing, Chassis Options269
Dimensional Drawing, Stationary Version271
Dimensional Drawing, Stationary Version273
Wiring Diagrams275
Electrical Diagram275
Lighting and Signaling System Connection289
Lighting and Signaling System Connection297
Generator Electrical Diagram, 400V, 3-Ph302
Generator Electrical Diagram, 230V, 3-Ph311
Generator Electrical Diagram, 115 V, 2-Ph320
Generator Electrical Diagram, 230 V, 2-Ph329
Fuel Circulation Diagram338
Assembly Diagrams - Chassis341
Assembly Diagrams - Chassis EU Version341
Assembly Diagrams - Chassis GB/US Version343
Assembly Diagram Brake Rod346
Operating Instructions for Compressed Air Filter (Combination Filter)348
Operating Instructions for Compressed Air Filter (Fresh Air Filter)369
Service Tasks - Generator383

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