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6 Installation

6.1 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 warnings

Disregard of safety warnings can cause unforeseeable dangers!
➤ Follow the instructions in chapter 3 “Safety and Responsibility”.
➤ Installation work may only be carried out by authorized personnel.
➤ Replace self-locking nuts that have been removed, do not reuse old ones. The nut is no longer

self-locking once it has been unscrewed.

Further information Details of authorized personnel are found in chapter 3.4.2.

Details of dangers and their avoidance are found in chapter 3.5.

6.2 Reporting Transport Damage

1. Check the machine for visible and hidden transport damage.
2. Inform the carrier and the manufacturer in writing of any damage found.

6.3 Fitting the towbar

If the machine is shipped on a transport frame, it is necessary to dismantle the towbar to save

space. The towbar must be re-assembled before removing the transport frame.

Material Protective gloves

Wrench
Hard rubber hammer

Precondition The machine is standing firm and level.

The machine is switched off.

Danger of pinching!

Severe pinching injury to fingers is possible.
➤ Always wear protective gloves.
➤ Work carefully.

6

Installation

6.1

Ensuring safety

No.: 9_6999 23 USE

Operator Manual Screw Compressor
M100

63

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Summary of Contents for M100

Page 1: ...Operator Manual Screw Compressor M100 No 9_6999 23 USE Manufacturer KAESER KOMPRESSOREN SE 96410 Coburg PO Box 2143 GERMANY Tel 49 0 9561 6400 Fax 49 0 9561 640130 http www kaeser com...

Page 2: ...Original instructions KKW M100 2 03 en Z1 SBA MOBILAIR 20150112 161243...

Page 3: ...15 Instrument panel cover 9 2 3 Machine without options 9 2 3 1 Sound pressure level 9 2 3 2 Tightening torques for screws 9 2 3 3 Ambient conditions 9 2 3 4 Additional specifications 9 2 4 Chassis 1...

Page 4: ...ar generator inspections 38 3 10 Emergencies 39 3 10 1 Correct fire fighting 39 3 10 2 Injury from handling operating fluids materials 39 3 11 Warranty 40 3 11 1 Noise emissions warranty 40 3 12 Ident...

Page 5: ...the machine 83 8 2 2 Engine pre heating 83 8 2 3 Starting the machine 83 8 2 4 Allow the machine to run up to operating temperature 83 8 2 5 Switching to LOAD 84 8 2 6 Manually setting the discharge...

Page 6: ...nance 130 10 4 1 Checking cooling oil level 131 10 4 2 Cooling oil filling and topping up 132 10 4 3 Changing the cooling oil 133 10 4 4 Replace the compressor oil filter 137 10 4 5 Oil separator tank...

Page 7: ...nal drawing chassis options 253 13 3 3 Dimensional drawing chassis options 255 13 3 4 Dimensional drawing chassis options 257 13 3 5 Dimensional drawing stationary version 259 13 3 6 Dimensional drawi...

Page 8: ...Contents vi Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 9: ...ht adjustment 68 Fig 28 Changing the towing eye height adjustable drawbar 69 Fig 29 Changing the towing eye ball hitch fixed height towbar 70 Fig 30 Changing the towing eye fixed height towbar USA cha...

Page 10: ...Checking the brake lining thickness 153 Fig 80 Brake system adjustment 153 Fig 81 Brake rod adjustment 154 Fig 82 Tool lubricator maintenance 156 Fig 83 Cleaning the dirt trap 157 Fig 84 Filter combin...

Page 11: ...king pressure and FAD 11 Tab 29 Compressed air distributor 11 Tab 30 Safety relief valve activating pressure 12 Tab 31 Machine temperatures 12 Tab 32 Airend discharge temperature 12 Tab 33 Cooling oil...

Page 12: ...high 94 Tab 76 Fault Working pressure too low 94 Tab 77 Fault Pressure relief valve blowing off 95 Tab 78 Fault Machine overheating 95 Tab 79 Fault Too much oil residue in the compressed air 96 Tab 80...

Page 13: ...ns contained in them Make sure you provide the data from the nameplate when ordering documents 1 3 Copyright This operator manual is copyright protected Queries regarding use or duplication of the doc...

Page 14: ...r damages are identified by their signal term Signal term Meaning Consequences of ignoring the warning NOTE Warns of a potentially dangerous situation Damage to property is possible Tab 2 Danger level...

Page 15: ...r Option codes used in this service manual are explained in chap ter 2 2 Information referring to potential problems are identified by a question mark The cause is named in the help text and a remedy...

Page 16: ...re Total weight Lifting point load capacity Rated engine power Engine speed Maximum working pressure Tab 3 Nameplate 2 2 Options A list of the options fitted to your machine helps to relate the inform...

Page 17: ...mpressed air treatment devices Option Option code Available Aftercooler and cyclone separator da Heat exchanger db Fresh air filter dc Filter combination dd Tab 5 Compressed air treatment options 2 2...

Page 18: ...l adjustment 100 psi ca With manual adjustment 145 psi cb Tab 9 Proportional controller option 2 2 6 Option ba Low temperature equipment Option Option code Available Low temperature equipment ba Engin...

Page 19: ...ssis with low axle load with height adjustable tow bar and overrun brake Chassis Chassis Option code Available Model rb rc rd EU chassis rb GB chassis rc US chassis rd Axle load rk rl low axle load rk...

Page 20: ...AD limitation gb Tab 16 Generator options 2 2 12 Option oe Sealed floor pan Option Option code Available Sealed floor pan oe Tab 17 Sealed floor pan option 2 2 13 Option sf Anti theft device Option Op...

Page 21: ...18 M20 Torque lbf in 26 6 52 2 88 5 216 8 424 8 743 5 1177 1823 2611 3673 Tab 22 Tightening torques for screws property class 8 8 coefficient of friction 0 12 2 3 3 Ambient conditions Positioning Limi...

Page 22: ...eference the actual total weight taken from the machine nameplate Tab 24 Weight of the machine 2 4 2 Tires The tire s dimensions are shown on the side wall see also Fig 1 Fig 1 Example for Tire inform...

Page 23: ...Thread Strength category Torque lbf in Ball coupling M16 8 8 1858 Towing eye M16 8 8 1858 Towbar M16 8 8 1858 M20 10 9 4778 4957 M24 8 8 5930 6107 Tab 27 Towbar tightening torque 2 5 Compressor 2 5 1...

Page 24: ...d discharge temperature during opera tion F 167 212 Maximum airend discharge temperature automatic safety shut down F 239 Tab 31 Machine temperatures Temperature at the airend discharge port Ambient t...

Page 25: ...t Density at 59 F 864 kg m3 ISO 12185 0 869 kg l D 1298 ASTM test Pour point 27 F ISO 3016 51 F D 97 ASTM test 65 F D 97 ASTM test Demulsibility at 129 F 40 40 0 10 min D 1401 ASTM test 15 min D 1401...

Page 26: ...charge 2 6 Engine 2 6 1 Engine specification Feature Specification Make Model Kubota V 3800 DI T Engine control Mechanical Fuel injection Mechanical Rated engine power hp 97 6 Speed at LOAD mode rpm...

Page 27: ...the fuel and thus cause damages within the fuel system The use of other fuels as well as the mixing with additives is only permitted after consultation with the engine manufacturer The engine service...

Page 28: ...F 34 7 Maximum ambient temperature F 86 Tab 41 Fresh air filter conditions 2 7 1 3 Air quality at the compressed air outlets Interrelation between compressed air treatment and compressed air quality A...

Page 29: ...temperature F 122 Higher altitudes are permissible only after consultation with the manufacturer Tab 43 Environmental conditions low temperature equipment 2 7 2 2 Option bb Engine coolant pre heating...

Page 30: ...uit 0 3 s 170 V 300 0 260 0 330 0 330 0 420 0 Power factor cos j 0 8 1 Frequency Hz 50 Speed rpm 3000 Distortion factor 5 Type Synchronous internal pole electronically controlled Protection rating IP...

Page 31: ...2 phase Power sockets Quantity 16 A 230 V 1 N PE 3 16 A 400 V 3 N PE 1 16 A 230 V 2 PE 2 32 A 230 V 3 PE 1 16 A 230 V 3 PE 1 32 A 115 V 2 PE 1 16 A 115 V 2 PE 2 Tab 50 Connection sockets Overload prot...

Page 32: ...VA 13 0 8 5 12 7 8 5 Inductive consumers kW Rated power 7 5 5 0 12 7 8 5 Tab 53 Maximum three phase mains loading AC power Generator 400V 3 ph 230V 3 ph 115V 2 ph Rated power kVA 13 0 8 5 13 0 8 5 7 0...

Page 33: ...wer factor cos j 0 8 1 Frequency Hz 50 Speed rpm 3600 Distortion factor 5 Type Synchronous internal pole electronically controlled Protection rating IP 54 Tab 56 Generator data Reduced compressed air...

Page 34: ...h Type Generator 250V 2 phase Generator 125V 1 phase Miniature circuit break er A Quantity 16 1 1 Tab 60 Circuit breaker Operating limits to EN 60034 22 page 10 table Features Value Design category G3...

Page 35: ...0 Inductive consumers kW Rated power 5 0 5 0 Tab 62 Maximum power supply load Power reduction at elevated ambient temperatures Ambient temperature F Generator power 86 Full power available 86 Reductio...

Page 36: ...Keep to the specifications listed in this service manual Operate the machine only within its performance limits and under the permitted ambient condi tions Do not use compressed air for breathing purp...

Page 37: ...his machine Authorized transport personnel possess the following qualifications are of legal age are familiar with and adhere to the safety instructions and sections of the service manual rele vant to...

Page 38: ...re a potentially dangerous task 3 5 1 Safely dealing with sources of danger The following describes the various forms of danger that can occur during machine operation Exhaust fumes Exhaust gases from...

Page 39: ...following information concerns work on components that could be under pressure Wait until the compressor has automatically vented check the pressure gauge it must read 0 psig Then open an outlet valv...

Page 40: ...rried out on or near the machine take adequate measures to prevent sparks or heat from igniting oil vapors or parts of the machine Noise The enclosure absorbs the machine noise to a tolerable level Th...

Page 41: ...with severe adverse health effects Wear protective clothing as necessary Suitable protective clothing examples Safety work wear Protective gloves Safety boots Eye protection Ear protection 3 5 2 1 Tra...

Page 42: ...lifting point should be used to attach lifting gear and under no circumstan ces are handles tow bar or other components to be used Use only hooks and shackles that comply with local safety regulations...

Page 43: ...owing vehicle Secure the parked machine Lower the prop stand wind down the jockey wheel Chock the wheels to prevent unwanted movement Place chocks under the wheels Pull on the parking brake Unauthoris...

Page 44: ...aged worn or of reduced quality they have couplings and connections of the right type and size Wear protective gloves when connecting or disconnecting compressed air hoses Make sure compressed air hos...

Page 45: ...in a 3 ft radius of the machine Operating personnel Maintenance Within the machine Within a 3 ft radius of the machine Maintenance personnel Tab 64 Danger areas 3 6 Safety devices Safety devices ensur...

Page 46: ...ed surfa ces Do not attempt to jump start if battery fluid is frozen Bring temperature of battery up to at least 60 F before attempting to jump start or it may explode 303 Fire or explosion caused by...

Page 47: ...o not lift towbar by hand if weight is more than you can safely handle See safety section of service manual 430 Connect air hoses only in full compliance with OSHA standard 29 CFR 1926 302 bX7 The req...

Page 48: ...proper storage Always replace missing chock immediately 600 Pressure and spring force Serious injury or death can result from loosening or opening component that is under pressure and heavily spring...

Page 49: ...00 551 The protective measure concerning isolation insulation monitoring and shut down is applied The generator is equipped with an automatic mains cut out with overcurrent release and insulation moni...

Page 50: ...ot exceed the maximum supply system load When operating the generator do not exceed the maximum supply system load due to con nected consumers Bear in mind The power consumption values of simultaneous...

Page 51: ...jury from handling operating fluids materials The following operating fluids materials are in the machine Fuel Lubricating oil Compressor cooling oil Engine coolant Battery electrolyte Tool lubricant...

Page 52: ...materials Obtain confirmation from KAESER that your specific operating conditions are suitable 3 11 1 Noise emissions warranty The manufacturer warrants to the ultimate purchaser and each subsequent p...

Page 53: ...not be met The prerequisites for approval are no longer given Remodeling or modifications restrict the service work that can be performed for you For example Warranty if directly and originally affec...

Page 54: ...ling air flow The bodywork is not suitable for the following uses Walking on standing or sitting on Use as resting place or storage of any kind of load Danger of pinching Severe injuries of the finger...

Page 55: ...filter 11 Proportional controller 12 Minimum pressure check valve Fig 5 Left hand door opened 13 Fan 14 Tool box 15 Airend 16 Inlet valve 17 Pressure relief valve 18 Lifting eye cover 19 Lifting eye 4...

Page 56: ...end casing This direct cooling in the compression chamber ensures a very low airend discharge temperature Cooling oil recovered from the compressed air in the oil separator tank 5 gives up its heat in...

Page 57: ...the oil separator tank and the control valve The pressure in the oil separator tank remains constant The engine runs at minimum speed RUN ON PERIOD STOPPED The inlet valve closes The venting valve ope...

Page 58: ...oportional controller optionally adjusta ble 27 Venting valve 62 Combined auxiliary valve directional con trol valve 4 5 Safety devices 4 5 1 Monitoring functions with shutdown The following functions...

Page 59: ...fuel level in the fuel tank falls below the rec ommended level Fig 8 Fuel level monitoring 1 Instrument panel 2 Indicator lamp LED yellow Fuel level monitoring 3 Group alarm lamp red When the fuel lev...

Page 60: ...Option da Compressed air aftercooler The aftercooler lowers the compressed air temperature to only 9 F to 18 F above ambient Most of the moisture carried in the air is removed this way in the aftercoo...

Page 61: ...ine in enclosed spaces only in the open Clean inlet air without hazardous contaminants Engine exhaust must not be drawn into the compressor The treated air does not meet the local standards for Compre...

Page 62: ...b Fig 11 Principle tool lubricator 1 Compressed air inlet 2 Oil tank 3 Tool oil outlet 4 Tool lubricator upper part with oil filling port 5 Filler plug with dipstick and integrated riser tube 6 Meteri...

Page 63: ...exi ble power cable supplied connects the machine s power plug to the user s power socket The coolant pre heater works according to the principle of self circulation Fig 12 Coolant pre heating 1 Opera...

Page 64: ...teracts a potential freezing of individual components Machine operation in summer Antifreeze is not required for the regulating air at ambient temperatures of more than 32 F 4 7 3 Option oa Optional b...

Page 65: ...ressor can be destroyed Explosion or fire are also possible When flammable gas is drawn into the engine shutting off the fuel supply will not stop the engine right away In order to shut down the engin...

Page 66: ...nerator operating mode and the power taken 4 7 5 1 Operating modes The compressor works with the normal air delivery regulation and generates electrical power at the same time The generator can work i...

Page 67: ...ockets 3 Single phase power sockets 4 Generator control box 5 Generator main switch 6 Safety cut out with overcurrent release Fig 16 Instrument panel generator control box 230 V AC 1 Mode selector swi...

Page 68: ...e 60 Hz 1 Mode selector switch 2 Power socket 250 V 3 Power socket 125 V 4 Generator control box 5 Generator main switch 6 Safety cut out with overcurrent release 4 7 6 Option rb rk rm rs rc ro rs rd...

Page 69: ...e brake May be operated on public roads 4 7 6 3 Option rd ro rs Chassis Option rd chassis USA version Option ro chassis with fixed height tow bar Option rs chassis with overrun brake The chassis has t...

Page 70: ...m 4 7 7 Option oe Sealed floor pan option The machine is fitted with a sealed floor pan catching liquids in the event of leaks Thus direct con tamination of the floor is prevented The sealed floor pan...

Page 71: ...ts for oil and coolant from engine and compressor Fig 20 Drain points for oil and coolant from engine and compressor 1 Engine oil drain 2 Coolant drain oil cooler compressor 3 Coolant drain water cool...

Page 72: ...uthorized use and as protection during transport the machine is fitted with instru ment panel cover s Instrument panel cover option pa Generator control box cover option ga 4 Design and Function 4 7 O...

Page 73: ...t explosion proof Do not operate in areas in which specific requirements with regard to explosion protection are applied Keep suitable fire extinguishing agents on hand and ready for use Ensure that r...

Page 74: ...Ensure there is enough free space all round and above the machine 7 Keep air inlet and outlet openings free of obstructions so that the cooling air can flow freely through the machine 8 Install the ma...

Page 75: ...uthorized personnel are found in chapter 3 4 2 Details of dangers and their avoidance are found in chapter 3 5 6 2 Reporting Transport Damage 1 Check the machine for visible and hidden transport damag...

Page 76: ...ign the fix ing holes 5 Push in the securing bolt using light hammer blows if necessary 6 Secure the bolt with the self locking nut see chapter 2 4 4 for tightening torque 7 Release the parking brake...

Page 77: ...rake rod 4 Tow bar 5 Jockey wheel 6 Breakaway cable 7 Parking brake not for USA type chassis 1 Open the doors 2 Remove the bag with the brake transfer cable and fastenings unpack and lay out ready 3 C...

Page 78: ...ush in the securing bolts using light hammer blows if necessary and push on U washers 3 Secure the bolts with the self locking nuts see chapter 2 4 4 for tightening torque 4 Screw in the front screw f...

Page 79: ...s of the jockey wheel mounting plate and the overrun braking mechanism coincide 3 Push through the securing screws and push on the U washers 4 Secure the bolts with self locking nuts 6 4 Adjusting the...

Page 80: ...together Manually tighten the locking lever Use a hammer to hit the locking lever to further tighten the lower serrated joint until the bore and the groove for the splint pin are aligned 4 Insert the...

Page 81: ...hanging the towing eye height adjustable drawbar 1 Self locking hexagon nut 2 Hex head screw 3 Towbar 4 Protective sleeve 5 Ball coupling 6 Towing eye Remove the ball coupling Removing the towing eye...

Page 82: ...4 Draw the protective sleeve 4 over the fix ings 6 4 2 2 Option rc ro rs rd ro rs Changing the towing eye ball hitch on a fixed height towbar The shock absorber is secured in the rear fixing screw The...

Page 83: ...oupling 9 or towing eye 10 from the towbar tube 6 6 Push the new ball coupling 9 or towing eye 10 onto the towbar 6 until the fixating holes match 7 Use the screw 4 at the rear fixating hole of the to...

Page 84: ...are found in chapter 3 4 2 Details of dangers and their avoidance are found in chapter 3 5 7 2 Before initial start up or recommissioning Incorrect or improper commissioning can cause injury to perso...

Page 85: ...missioning the compressor after a long period of storage 7 3 Checking installation and operating conditions Check and confirm all the items in the checklist before starting the machine Check See chapt...

Page 86: ...an airend discharge tem perature of 86 F is reached The airend discharge temperature is shown at the remote ther mometer contact on the instrument panel 7 4 1 Starting assistance If the machine s star...

Page 87: ...nsulated terminal clamps Observe the instructions provided with the battery jumper cables Keep jumper cables away from rotating parts Avoid short circuits due to incorrect poling and or bridging with...

Page 88: ...is important in particular for fully discharged battery The battery will pick up only little current in the beginning and has a high internal resistance Any voltage peaks occurring in the engine gener...

Page 89: ...d Have the coolant pre heating and associated wiring checked according to the maintenance schedule 2 Connect the coolant pre heater to the user s power socket with the power cable supplied Operating t...

Page 90: ...nerator Fig 34 Insulation monitoring 400 V AC 3 phase generator Fig 35 Insulation monitoring 230 V AC 3 phase generator 1 Main switch 2 Mode selection switch 3 Test button Insulation monitor with indi...

Page 91: ...d short 4 Main circuit breaker Circuit breaker designed as automatic circuit breaker with shunt trip 5 6 AC power sockets 1 Activate the machine 2 Danger of fatal injury caused by contact with live co...

Page 92: ...d if the main circuit breaker is functioning correctly Checking the safety cut out Turn on main circuit breaker 4 for the generator Press and hold the test button 3 for 3 seconds The main circuit brea...

Page 93: ...s can result in electric shocks burns or death Work on electrical equipment may only be carried out by authorized electricians Safe working with compressed air tools and hoses Open pressurized compres...

Page 94: ...the machine All doors and siding panels are closed Serious damage to engine from cold starting sprays Cold start assists such as ether or other sprays can cause severe engine damage Do not use cold s...

Page 95: ...3 Starting the machine 1 Destruction of the starter Improper operation could destroy the starter As long as the engine is running do not actuate the starter switch Do not turn and hold the starter swi...

Page 96: ...t pressure Danger from malfunctioning or not functioning compressed air tools when the machine s dis charge pressure is set incorrectly Use connected compressed air tools only with the pressure approp...

Page 97: ...nstrument panel gauge If the indicated pressure is not the discharge pressure required the machine should be shut down and the setting procedure repeated 8 2 7 Shutting down the machine Operating the...

Page 98: ...lamp fuel level Indicator lights Fill the fuel tank immediately Further information Further information on the fuel tank monitoring can be found in chapter 4 6 8 4 Option ea ec Operating the tool lubr...

Page 99: ...adjustmen increases the oil flow 1 Set the required oil flow 2 Close the access door Further information Fill the tool lubricator with suitable oil see chapter 10 8 1 Shutting off lubricating oil 1 C...

Page 100: ...r filled with antifreeze 1 Keep the frost protector shut off valve permanently closed position 0 2 Close the door Result The machine is ready for winter operation Further information See chapter 10 8...

Page 101: ...e battery is disconnected from the machine s electrical system 2 Close the access door 8 7 Option ga gb Generator operation The generator may be operated immediately after the activation of the machin...

Page 102: ...e Make sure that electric consumers are switched off 2 Before connecting electrical consumers carry out the following Determine the consumption values of the electric consumers Do not exceed the maxim...

Page 103: ...et valves are open Maintain the following minimum distances to the object to be cleaned in order to prevent damages to the machine when cleaning with the high pressure cleaner Circular section jets ap...

Page 104: ...vice manual Defective starter Have replaced X The fuel cut off device has not opened Check the coil and electrics and have replaced if necessary X Fuel tank empty Fill up the fuel tank Airlock in the...

Page 105: ...en fuel tank and injector pump Bleed the fuel line see chap ter 10 3 3 X Fuel filter clogged Clean or replace see chap ter 10 3 3 X Fuel line broken Have replaced X X Speed adjustment cylinder mal adj...

Page 106: ...laced if necessary X Venting valve does not blow off Check the connections and function and have repaired or replaced as necessary X Tab 75 Fault Working pressure too high 9 3 2 Working pressure too l...

Page 107: ...ed if nec essary X Tab 77 Fault Pressure relief valve blowing off 9 3 4 Machine overheating Possible cause Remedy Where can I get help Specialized workshop KAESER Service Defective cooling fan Have th...

Page 108: ...or replace the strainer and nozzle if necessary See chapter 10 4 5 X Fractured oil separator car tridge See chapter 10 4 6 for chang ing Oil level in the oil separator tank too high Reduce to maximum...

Page 109: ...eck the power requirement of the connected consumers and reduce if necessary check the consumers for short circuits X Check the overload protection switch and have replaced if nec essary X X Engine sp...

Page 110: ...cialized workshop KAESER Service Engine speed too high Have reset to rated speed X X Tab 83 Generator voltage too high 9 Fault Recognition and Rectification 9 4 Generator faults and alarms 98 Operator...

Page 111: ...is being serviced Tab 84 Advise others that the machine is being serviced Before switching on make sure that no personnel is working on the machine all protective guards and cover panels are attached...

Page 112: ...adverse conditions perform maintenance work e g oil and filter changes at shorter intervals Adverse conditions are e g poor fuel quality high low temperatures much dust frequent use Adjust the mainte...

Page 113: ...intervals Maintenance interval Short description Daily Every 250 h at least annually A250 Every 500 h at least annually A500 Every 1000 h at least annually A1000 Every 1500 h at least annually A1500 E...

Page 114: ...Change engine air filter X 10 3 2 Have the valve clearance adjus ted X SW Engine SM Have the turbocharger checked X SW Check the engine coolant level X 10 3 1 Engine SM Clean the cooler X 10 5 Check...

Page 115: ...level X 10 4 1 Clean the compressor air filter X 10 4 7 Clean the oil cooler X 10 5 Have the pressure relief valve s checked X 10 4 8 Check clean the oil separator tank dirt trap X 10 4 5 Change comp...

Page 116: ...replaced X SW Check that all electrical connec tions are tight X Engine SM engine manufacturer s service manual SW specialized workshop Tab 87 Regular machine maintenance tasks 10 2 3 2 Maintenance sc...

Page 117: ...or X 10 8 6 Blow out the spark arrester with compressed air X Option lb engine air intake shut off valve Clean check the engine air in take shut off valve X 10 8 7 Option ga gb generator Check adjust...

Page 118: ...cal burns from coolant containing antifreeze Avoid eye and skin contact with coolant If the eyes are affected rinse immediately with running water Wear protective glasses and gloves Insufficient coola...

Page 119: ...meters 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 float...

Page 120: ...system throughout the year The maximum permissible coolant life is 2 years Follow coolant recommendations in chapter 2 6 4 Preparing coolant Precondition Coolant must meet the specification of ASTM D...

Page 121: ...nish the coolant 10 Visually inspect for leaks 11 Close the door If the coolant has been changed check the level of the new coolant frequently at first as it can decrease due to the escape of air lock...

Page 122: ...ptacle and secure 5 Open the shut off valve 7 and catch the draining coolant 6 Close the shut off valve and remove the drain hose 7 Screw on the filler cap 8 Close the door Draining the coolant closed...

Page 123: ...ccordance with environmental protection regulations Further information The operating manual supplied by the motor manufacturer provides further information on coolant change and cleaning the cooling...

Page 124: ...r filter element Wear in the engine from intake of contaminated air Do not try to clean the filter element by striking or knocking it Do not wash the filter element Fig 47 Engine air filter maintenanc...

Page 125: ...st from the element from inside to outside until no further dust develops The blast pipe must be long enough to reach the bottom of the element The tip of the blast pipe must not touch the element Cle...

Page 126: ...he negative cable to the battery is disconnected 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...

Page 127: ...of the fuel system 5 After approx 10 to 15 minutes switch the starter switch to the STOP Off position 6 Open the right hand access door 7 Tighten the bleed screw again 8 Remove the receptacle 9 Close...

Page 128: ...ing the water trap immediately Emptying the fuel water trap Precondition Water and or contamination are visible in the water trap 1 Place a receptacle beneath the fuel micro filter housing 2 Loosen th...

Page 129: ...se clamps taking care the flow is in the right direction 4 Remove the receptacle Replacing the fuel microfilter Fig 53 Fuel micro filter maintenance 1 Turn in this direction to unscrew the filter cart...

Page 130: ...wn the machine 3 Open the right hand access door 4 Visually check the fuel system for leaks 5 Tighten all fittings 6 Close the door Further information The engine service manual provides further infor...

Page 131: ...haft If this occurs it could create oil bubbles that would reduce the oil s lubricating capability and impair engine performance 10 3 5 Engine oil filling and topping up Material Engine oil Cleaning c...

Page 132: ...gine oil The engine oil should be changed according to the maintenance schedule according to the degree of contamination of the intake air at least once a year Check the operating manual of the motor...

Page 133: ...e in the floor pan 4 Unscrew the drain plug and allow the engine oil to drain into the receptacle 5 Clean the drain plug and screw in with a new gasket 6 Replace the plug in the filler port 7 Close th...

Page 134: ...hut off valve 4 at the engine s oil pan and catch the engine oil 6 Close the shut off valve and replace the screwed sealing cap 7 Replace the plug in the filler port 8 Close the door Dispose of old oi...

Page 135: ...3 Engine block 1 Open the right hand access door 2 Prepare a receptacle 3 Use a filter wrench to loosen and unscrew the filter Catch any escaping oil 4 Carefully clean sealing surfaces using lint free...

Page 136: ...g The machine has cooled down All compressed air consumers are disconnected and the air outlet valves are open The negative cable to the battery is disconnected Beware of rotating pulleys and moving b...

Page 137: ...t immediately 1 Replace the belt guard 2 Reconnect the negative battery terminal 3 Close the doors 10 3 8 2 Checking belt tension Check belt tension when they are warm not hot to avoid length variatio...

Page 138: ...ernator and engine block 3 Gently push the alternator in the direction of the arrow outwards using the lever until the drive belt is tensioned 4 Re tighten the securing screw and clamping screw 5 Remo...

Page 139: ...ngine manufacturer provides further information on removing chang ing and tensioning drive belts 10 3 9 Battery maintenance Check the charging system if the battery discharges without reason 10 3 9 1...

Page 140: ...maintenance free batteries need a degree of care to obtain their maximum opera tional life The outside of the battery and the terminals should be cleaned regularly with a soft cloth This avoids curren...

Page 141: ...e in a frost proof room In extreme cases the use of a heavy duty cold start battery and or an additional booster bat tery is recommended 10 3 9 3 Battery removal and installation Precondition The mach...

Page 142: ...d by excessive tightening of the lashing strips The fuel tank may burst and spill Do not overtighten the lashing strips Slightly hand tighten the lashing strips Carry out visual check 1 Check the lash...

Page 143: ...All compressed air consumers are disconnected and the air outlet valves are open Fig 63 Checking cooling oil level 1 Oil separator tank 2 Oil filler port 3 Filler plug A Minimum level B Maximum level...

Page 144: ...3 Slowly unscrew and withdraw the plug from the oil filler port 4 Top up the cooling oil to the maximum level B with the help of a funnel 5 Check the oil level 6 Check the filler plug gasket for damag...

Page 145: ...lly vented the pressure gauge reads 0 psig The machine is at operating temperature All compressed air consumers are disconnected and the air outlet valves are open The negative cable to the battery is...

Page 146: ...ining the oil from the oil cooler This is done from a drain valve with the aid of a separate drain hose 1 Position a receptacle beneath the oil cooler drain point accessible through a hole in the floo...

Page 147: ...place the plug in the oil separator tank filling port 5 Close the door Dispose of used oil and oil contaminated working materials according to environmental pro tection regulations 10 4 3 2 Option oe...

Page 148: ...ng oil 4 Close the shut off valve and replace the screwed sealing cap Draining the oil from the oil cooler 1 Position a receptacle beneath the oil drainage point for the oil cooler s cooling oil 7 2 U...

Page 149: ...r 3 Combination valve 4 Ambient temperature sensor not with Op tion db Changing the oil filter 1 Open the left hand door 2 Prepare a receptacle 3 Loosen the filter by turning counter clockwise and cat...

Page 150: ...maintenance Material Cleaning cloth Wrench Small screwdriver Maintenance kit control valve Petroleum ether or spirit Precondition The machine is shut down The machine is fully vented the pressure gau...

Page 151: ...se the access door Dispose of old parts and contaminated materials according to environmental regulations Starting the machine and performing a test run 1 Switch the machine on and run it in IDLE mode...

Page 152: ...scavenge pipe screwed to the cover 3 Oil scavenge pipe union nut screwed to the dirt trap 5 Air pipe 6 Pipe fitting 7 Cover 8 Fixing screw 9 Control valve 10 Solenoid valve plug 11 Gasket 12 Metal cli...

Page 153: ...oil level in the oil separator tank Top up if necessary Maintenance of the control valve dirt trap must be carried out whenever the oil separator car tridge is changed Further information Information...

Page 154: ...ons carefully to one side 2 Pull out the plug to the solenoid valve 10 and withdraw the cable 3 Unscrew the fitting 6 and turn the air pipe 5 to one side 4 Loosen the frost protector clamp ring 14 and...

Page 155: ...tion on control valve dirt trap maintenance is given in chapter 10 4 5 Making operational 1 Reconnect the negative battery terminal 2 Close the access door Dispose of old parts and contaminated materi...

Page 156: ...ge reads 0 psig Machine is cooled down All compressed air consumers are disconnected and the air outlet valves are open Damaged air filter element Machine damage due to contaminated intake air Do not...

Page 157: ...from the element from inside to outside until no further dust develops The blast pipe must be long enough to reach the bottom of the element The tip of the blast pipe must not touch the element Clean...

Page 158: ...d down The machine is fully vented the pressure gauge reads 0 psig All compressed air consumers are disconnected and the air outlet valves are open The negative cable to the battery is disconnected Da...

Page 159: ...ide 4 Replace the sound damping louver 5 Remove the protective coverings from the air filters 6 Reconnect the battery 7 Close the doors 8 Start the machine and run up to operating temperature so that...

Page 160: ...sealing strips between the body panels and the access doors serve both as a sound proofing measure and to prevent ingress of rain water Care of the rubber sealing strips is especially necessary in win...

Page 161: ...cal roadworthy regulations at least 63 mil in most countries Profile depth too low change tires 4 Check the tire pressures Result tire pressure too low pump tires Further information See chapter 2 4 3...

Page 162: ...eight adjustment function The locking teeth on the towbar height adjustment joint are corroded and jammed and the towbar height cannot be adjusted If necessary free the teeth by jerking the towbar hor...

Page 163: ...height Option rc ro rs see illustration 76 Checking the shock absorber 1 Loosen the transfer cable one side 2 Press in the shock absorber against its damping force Have the shock absorber replaced by...

Page 164: ...only Material Screwdriver Wrench Inspection lamp or torch Cleaning cloths Lithium enriched multi purpose grease Precondition The machine is switched off 1 Jack up the machine and lower it onto support...

Page 165: ...direction of the arrow Adjust the brake Turn against the direction of the arrow Loosen the brake Fig 80 Brake system adjustment 1 Brake rod 2 Equaliser 3 Brake support 4 Screwdriver as adjusting tool...

Page 166: ...e inspection hole A light rubbing sound when the wheels turn is permissible if it does not affect free turning Brake rod adjustment Fig 81 Brake rod adjustment 1 Brake rod 2 Equaliser 3 Brake cable Bo...

Page 167: ...ase Cleaning cloths Precondition The machine is shut down The machine is disconnected from the towing vehicle and safely parked Clean and grease the brake rod s sliding and adjustment joints 10 8 Main...

Page 168: ...f the dipstick with a lint free cloth or rag and screw the plug fully in again 3 Unscrew and withdraw the plug once more and read off the oil level on the dipstick Oil level at the upper third of the...

Page 169: ...eads 0 psig All compressed air consumers are disconnected and the air outlet valves are open The negative cable to the battery is disconnected Fig 83 Cleaning the dirt trap 1 Cyclone separator 2 Dirt...

Page 170: ...nted Pressure gauge reads 0 psig 4 Open the outlet valves 5 Open the left hand door 6 Check the cyclone separator housing and hose line for leaks 7 Close the access door 10 8 3 Option dd Combination f...

Page 171: ...separator 3 Condensate drain hose fittings 4 Shut off ball valve for condensate drain age 5 Pressure differential gauge check fittings for Service personnel 6 Filter head 7 Casing gasket 8 Filter ele...

Page 172: ...is not permitted Handle new filter elements only with clean fabric gloves Do not touch the new filter elements with bare fingers Contamination risk Material Spare parts Filter wrench Wrench Cleaning c...

Page 173: ...e the condensate drain shut off valves 3 Tighten the filter combination fittings 4 Reconnect the negative cable to the batteries 5 Close the door Dispose of old parts and contaminated materials accord...

Page 174: ...ing 3 Upper element adsorption element 4 Body 5 Lower filter element high capacity ele ment 6 Lower housing 7 Condensate drain tap for manual draining 0 closed I open 8 Oil indicator Open both doors 1...

Page 175: ...arts The fresh air filter contains two different element and both must be changed as a pair Note loca tion Using the fresh air filter without an element installed is not permitted Handle new filter el...

Page 176: ...rational 1 Close the drain valve 2 Reconnect the negative battery terminal 3 Close the doors Dispose of old parts and contaminated materials according to environmental regulations Further information...

Page 177: ...of fire and explosion caused by spontaneous ignition can cause severe injury Never top up antifreeze unless the machine is stopped and cooled down Danger of injury from compressed air The frost prote...

Page 178: ...outlet valves are open Danger of suffocation from toxic exhaust fumes Exhaust fumes from internal combustion engines contain carbon monoxide which is odor less and deadly Never use the machine in encl...

Page 179: ...the appropriate plug Fig 89 Cleaning the spark arrestor sealed floor pan 1 Exhaust silencer end pipe 2 Soot drain port with plug 3 Exhaust silencer with integrated spark ar restor 4 Service opening c...

Page 180: ...ut off valve The engine air intake shut off valve does not close when flammable gas is drawn into the engine The machine does not shut down Destruction of the engine and explosion and or fire are poss...

Page 181: ...unctions in any way 1 Reposition the air intake hose and tighten the clamp 2 Close the doors 3 Start the machine and switch to LOAD If the engine stops on switching to LOAD have the valve adjusted by...

Page 182: ...rd 5 Generator belt 6 Support for belt tensioner Unscrew the securing screws of the belt guard and remove the belt guard 10 8 8 1 Visual check 1 Check the drive belt for cracks frays or stretching Cha...

Page 183: ...t tensioning 1 Support for belt tensioner 2 Hexagon nut 3 Spherical seat washer 4 Conical seat washer 5 Hexagon nut locknut 6 Drive belt 7 Generator drive pulley 8 Generator swing frame 9 Belt adjustm...

Page 184: ...The so called closed floor pan contributes to the protection of the environment by preventing a contamination of the soil in the event of leaking operating fluids Liquid accumulations within the mach...

Page 185: ...the cleaning cloth remove any dirt within the machine Dispose of collected liquid and contaminated working materials according to environmental protection regulations 10 Maintenance 10 8 Maintenance...

Page 186: ...mber Enter maintenance and service work carried out in this list Date Maintenance task carried out Operating hours Signature Tab 90 Maintenance log 10 Maintenance 10 9 Documenting maintenance and serv...

Page 187: ...from machine damage There is risk of personal injury or damage to the machine resulting from the use of unsuita ble spares or operating fluids materials Use only original KAESER parts and operating f...

Page 188: ...nal reliability ensured by preventive maintenance Energy savings achieved by avoidance of pressure losses The security of genuine KAESER spare parts Increased legal certainty as all regulations are ke...

Page 189: ...from damage Inspections preventive maintenance or repair tasks not described in this manual must not be carried out by unqualified personnel Have further tasks not described in this service manual car...

Page 190: ...11 Spares Operating Materials Service 11 5 Replacement parts for service and repair 178 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 191: ...11 Spares Operating Materials Service 11 5 Replacement parts for service and repair No 9_6999 23 USE Operator Manual Screw Compressor M100 179...

Page 192: ...11 Spares Operating Materials Service 11 5 Replacement parts for service and repair 180 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 193: ...11 Spares Operating Materials Service 11 5 Replacement parts for service and repair No 9_6999 23 USE Operator Manual Screw Compressor M100 181...

Page 194: ...11 Spares Operating Materials Service 11 5 Replacement parts for service and repair 182 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 195: ...11 Spares Operating Materials Service 11 5 Replacement parts for service and repair No 9_6999 23 USE Operator Manual Screw Compressor M100 183...

Page 196: ...11 Spares Operating Materials Service 11 5 Replacement parts for service and repair 184 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 197: ...11 Spares Operating Materials Service 11 5 Replacement parts for service and repair No 9_6999 23 USE Operator Manual Screw Compressor M100 185...

Page 198: ...11 Spares Operating Materials Service 11 5 Replacement parts for service and repair 186 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 199: ...11 Spares Operating Materials Service 11 5 Replacement parts for service and repair No 9_6999 23 USE Operator Manual Screw Compressor M100 187...

Page 200: ...11 Spares Operating Materials Service 11 5 Replacement parts for service and repair 188 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 201: ...11 Spares Operating Materials Service 11 5 Replacement parts for service and repair No 9_6999 23 USE Operator Manual Screw Compressor M100 189...

Page 202: ...11 Spares Operating Materials Service 11 5 Replacement parts for service and repair 190 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 203: ...11 Spares Operating Materials Service 11 5 Replacement parts for service and repair No 9_6999 23 USE Operator Manual Screw Compressor M100 191...

Page 204: ...11 Spares Operating Materials Service 11 5 Replacement parts for service and repair 192 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 205: ...11 Spares Operating Materials Service 11 5 Replacement parts for service and repair No 9_6999 23 USE Operator Manual Screw Compressor M100 193...

Page 206: ...11 Spares Operating Materials Service 11 5 Replacement parts for service and repair 194 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 207: ...11 Spares Operating Materials Service 11 5 Replacement parts for service and repair No 9_6999 23 USE Operator Manual Screw Compressor M100 195...

Page 208: ...11 Spares Operating Materials Service 11 5 Replacement parts for service and repair 196 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 209: ...11 Spares Operating Materials Service 11 5 Replacement parts for service and repair No 9_6999 23 USE Operator Manual Screw Compressor M100 197...

Page 210: ...11 Spares Operating Materials Service 11 5 Replacement parts for service and repair 198 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 211: ...11 Spares Operating Materials Service 11 5 Replacement parts for service and repair No 9_6999 23 USE Operator Manual Screw Compressor M100 199...

Page 212: ...11 Spares Operating Materials Service 11 5 Replacement parts for service and repair 200 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 213: ...11 Spares Operating Materials Service 11 5 Replacement parts for service and repair No 9_6999 23 USE Operator Manual Screw Compressor M100 201...

Page 214: ...11 Spares Operating Materials Service 11 5 Replacement parts for service and repair 202 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 215: ...11 Spares Operating Materials Service 11 5 Replacement parts for service and repair No 9_6999 23 USE Operator Manual Screw Compressor M100 203...

Page 216: ...11 Spares Operating Materials Service 11 5 Replacement parts for service and repair 204 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 217: ...11 Spares Operating Materials Service 11 5 Replacement parts for service and repair No 9_6999 23 USE Operator Manual Screw Compressor M100 205...

Page 218: ...11 Spares Operating Materials Service 11 5 Replacement parts for service and repair 206 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 219: ...11 Spares Operating Materials Service 11 5 Replacement parts for service and repair No 9_6999 23 USE Operator Manual Screw Compressor M100 207...

Page 220: ...11 Spares Operating Materials Service 11 5 Replacement parts for service and repair 208 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 221: ...11 Spares Operating Materials Service 11 5 Replacement parts for service and repair No 9_6999 23 USE Operator Manual Screw Compressor M100 209...

Page 222: ...11 Spares Operating Materials Service 11 5 Replacement parts for service and repair 210 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 223: ...11 Spares Operating Materials Service 11 5 Replacement parts for service and repair No 9_6999 23 USE Operator Manual Screw Compressor M100 211...

Page 224: ...11 Spares Operating Materials Service 11 5 Replacement parts for service and repair 212 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 225: ...11 Spares Operating Materials Service 11 5 Replacement parts for service and repair No 9_6999 23 USE Operator Manual Screw Compressor M100 213...

Page 226: ...11 Spares Operating Materials Service 11 5 Replacement parts for service and repair 214 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 227: ...11 Spares Operating Materials Service 11 5 Replacement parts for service and repair No 9_6999 23 USE Operator Manual Screw Compressor M100 215...

Page 228: ...11 Spares Operating Materials Service 11 5 Replacement parts for service and repair 216 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 229: ...11 Spares Operating Materials Service 11 5 Replacement parts for service and repair No 9_6999 23 USE Operator Manual Screw Compressor M100 217...

Page 230: ...11 Spares Operating Materials Service 11 5 Replacement parts for service and repair 218 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 231: ...11 Spares Operating Materials Service 11 5 Replacement parts for service and repair No 9_6999 23 USE Operator Manual Screw Compressor M100 219...

Page 232: ...11 Spares Operating Materials Service 11 5 Replacement parts for service and repair 220 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 233: ...11 Spares Operating Materials Service 11 5 Replacement parts for service and repair No 9_6999 23 USE Operator Manual Screw Compressor M100 221...

Page 234: ...11 Spares Operating Materials Service 11 5 Replacement parts for service and repair 222 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 235: ...11 Spares Operating Materials Service 11 5 Replacement parts for service and repair No 9_6999 23 USE Operator Manual Screw Compressor M100 223...

Page 236: ...11 Spares Operating Materials Service 11 5 Replacement parts for service and repair 224 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 237: ...11 Spares Operating Materials Service 11 5 Replacement parts for service and repair No 9_6999 23 USE Operator Manual Screw Compressor M100 225...

Page 238: ...11 Spares Operating Materials Service 11 5 Replacement parts for service and repair 226 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 239: ...e off the following openings with plastic foil and moisture resistant adhesive tape Engine air inlet Compressor air inlet Exhaust silencer 3 Attach the following notice on the instrument panel showing...

Page 240: ...about 10 minutes to coat all parts with a protec tive oil film Disconnect the battery the minus terminal first and then the plus ter minal and store in a frost free room Check the battery fluid level...

Page 241: ...cured 12 2 1 Safety Allow transportation only by personnel trained in safely dealing with motor vehicles and the transporting of goods 1 There is danger of being run over or crushed by an overturning...

Page 242: ...and signaling equipment 2 Check the function of wheels brakes lights and signaling equipment Correct any defects before towing Additional precautions for conditions of snow and ice Considerable snow...

Page 243: ...e Coupling a machine with towing eye 1 Open the towing coupling of the towing vehicle 2 Slowly and carefully approach the machine with the towing vehicle until the trailer coupling au dibly latches 3...

Page 244: ...cle ball hitch The weight on the coupling will cause it to audibly close The coupling locks automatically Closing and locking is automatic 5 Push the handle down to be certain of locking The coupling...

Page 245: ...en zone showing Coupling in new condition Towing vehicle ball hitch wear within acceptable limits No action necessary Red zone showing Ball hitch wear at acceptable limit ball coupling unworn Ball hit...

Page 246: ...om the towing vehi cle and cause an accident Check correct coupling Check correct location of the security pin 5 Place the open coupling over the towing vehicle ball hitch The weight on the coupling w...

Page 247: ...e a Pull the brake lever a little further on and press the release button Hold the release button in and push the lever down past the dead point zone 7 Remove the chocks Preparing the machine for tran...

Page 248: ...he 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...

Page 249: ...g bar 3 Loop the end of the cable round the towing vehicle hitch and secure with the spring clip Attach safety chains Always use safety chains Chains hold the towed machine if connections fails Fig 10...

Page 250: ...ther the bead pushes against the cam of the retaining pin see Ill 103 figure b The retaining pin 3 unlocks the wheel suspension 4 which will abruptly fold see Ill 103 figure c and drop the towing mech...

Page 251: ...rovided upward past the dead point zone see Ill 104 fig ure a The gas spring holds the brake under tension 4 Remove the cap nut if fitted 5 Lower the jockey wheel until the towing mechanism is stress...

Page 252: ...ontal the brake is under spring loading If the lever is not horizontal the brake is not fully applied and the machine may roll away 4 Detach the breakaway cable 5 Lower the jockey wheel until the towi...

Page 253: ...machine before lifting by a crane Make sure the lifting eye cover plate is freely accessible and can be opened Perform the following tasks prior to moving the machine by crane A lifting eye is provide...

Page 254: ...ng and securing methods must be such that assuming proper handling the goods arrive in perfect condition at the destination Additional measures must be taken for the transport of machines by sea or ai...

Page 255: ...is designated as dangerous goods for air freight purposes any disregard can result in a heavy fine 1 Danger of fire or explosion from operating fluids materials The machine incorporates an internal co...

Page 256: ...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 Remove the battery...

Page 257: ...ith serial number 2 VIN stamped in the bodywork Vehicle Identification Number 3 Options label 4 Engine nameplate with serial number 13 2 Pipeline and instrument flow diagram P I diagram 13 Annex 13 1...

Page 258: ...13 Annex 13 2 Pipeline and instrument flow diagram P I diagram 246 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 259: ...13 Annex 13 2 Pipeline and instrument flow diagram P I diagram No 9_6999 23 USE Operator Manual Screw Compressor M100 247...

Page 260: ...13 Annex 13 2 Pipeline and instrument flow diagram P I diagram 248 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 261: ...13 Annex 13 2 Pipeline and instrument flow diagram P I diagram No 9_6999 23 USE Operator Manual Screw Compressor M100 249...

Page 262: ...13 Annex 13 2 Pipeline and instrument flow diagram P I diagram 250 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 263: ...rs Dimensional drawing chassis options Option rb Chassis EU version Option rm Chassis with height adjustable towbar Option rs Chassis with overrun brake 13 Annex 13 3 Dimensional drawings No 9_6999 23...

Page 264: ...in sonstiger Weise zug nglich gemacht werden Entwicklungsbedingte nderungen vorbehalten Zeichnung darf nur ber CAD ge ndert werden USE Projektion 02 02 2012 F R E I G E G E B E N Status 10227568 USE...

Page 265: ...nal drawing chassis options Option rc Chassis GB version Option ro Chassis with fixed height towbar Option rs Chassis with overrun brake 13 Annex 13 3 Dimensional drawings No 9_6999 23 USE Operator Ma...

Page 266: ...Dritten ausgeh ndigt oder in sonstiger Weise zug nglich gemacht werden Entwicklungsbedingte nderungen vorbehalten Zeichnung darf nur ber CAD ge ndert werden USE Projektion 02 02 2012 F R E I G E G E...

Page 267: ...nal drawing chassis options Option rd Chassis USA version Option ro Chassis with fixed height towbar Option rs Chassis with overrun brake 13 Annex 13 3 Dimensional drawings No 9_6999 23 USE Operator M...

Page 268: ...Dritten ausgeh ndigt oder in sonstiger Weise zug nglich gemacht werden Entwicklungsbedingte nderungen vorbehalten Zeichnung darf nur ber CAD ge ndert werden USE Projektion 02 02 2012 F R E I G E G E...

Page 269: ...ptions Option rb Chassis EU version Option rl Chassis with higher axle load Option rm Chassis with height adjustable towbar Option rs Chassis with overrun brake 13 Annex 13 3 Dimensional drawings No 9...

Page 270: ...n sonstiger Weise zug nglich gemacht werden Entwicklungsbedingte nderungen vorbehalten Zeichnung darf nur ber CAD ge ndert werden USE Projektion 02 02 2012 F R E I G E G E B E N Status 10227569 USE 00...

Page 271: ...13 3 5 Option rw Dimensional drawing stationary version Option rw Skid frame on runners 13 Annex 13 3 Dimensional drawings No 9_6999 23 USE Operator Manual Screw Compressor M100 259...

Page 272: ...er in sonstiger Weise zug nglich gemacht werden Entwicklungsbedingte nderungen vorbehalten Zeichnung darf nur ber CAD ge ndert werden 02 02 2012 Projektion A3 10227572 USE 00 nderungs Nr Ma stab Origi...

Page 273: ...13 3 6 Option rx Dimensional drawing stationary version Option rx On frame 13 Annex 13 3 Dimensional drawings No 9_6999 23 USE Operator Manual Screw Compressor M100 261...

Page 274: ...en ausgeh ndigt oder in sonstiger Weise zug nglich gemacht werden Entwicklungsbedingte nderungen vorbehalten Zeichnung darf nur ber CAD ge ndert werden 02 02 2012 Projektion A3 10227573 USE 00 nderung...

Page 275: ...13 4 Wiring diagrams 13 4 1 Electrical Diagram 13 Annex 13 4 Wiring diagrams No 9_6999 23 USE Operator Manual Screw Compressor M100 263...

Page 276: ...13 Annex 13 4 Wiring diagrams 264 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 277: ...13 Annex 13 4 Wiring diagrams No 9_6999 23 USE Operator Manual Screw Compressor M100 265...

Page 278: ...13 Annex 13 4 Wiring diagrams 266 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 279: ...13 Annex 13 4 Wiring diagrams No 9_6999 23 USE Operator Manual Screw Compressor M100 267...

Page 280: ...13 Annex 13 4 Wiring diagrams 268 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 281: ...13 Annex 13 4 Wiring diagrams No 9_6999 23 USE Operator Manual Screw Compressor M100 269...

Page 282: ...13 Annex 13 4 Wiring diagrams 270 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 283: ...13 Annex 13 4 Wiring diagrams No 9_6999 23 USE Operator Manual Screw Compressor M100 271...

Page 284: ...13 Annex 13 4 Wiring diagrams 272 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 285: ...13 Annex 13 4 Wiring diagrams No 9_6999 23 USE Operator Manual Screw Compressor M100 273...

Page 286: ...13 Annex 13 4 Wiring diagrams 274 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 287: ...13 Annex 13 4 Wiring diagrams No 9_6999 23 USE Operator Manual Screw Compressor M100 275...

Page 288: ...13 Annex 13 4 Wiring diagrams 276 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 289: ...13 4 2 Option tc Lighting and signaling system connection 13 Annex 13 4 Wiring diagrams No 9_6999 23 USE Operator Manual Screw Compressor M100 277...

Page 290: ...13 Annex 13 4 Wiring diagrams 278 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 291: ...13 Annex 13 4 Wiring diagrams No 9_6999 23 USE Operator Manual Screw Compressor M100 279...

Page 292: ...13 Annex 13 4 Wiring diagrams 280 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 293: ...13 Annex 13 4 Wiring diagrams No 9_6999 23 USE Operator Manual Screw Compressor M100 281...

Page 294: ...13 Annex 13 4 Wiring diagrams 282 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 295: ...13 Annex 13 4 Wiring diagrams No 9_6999 23 USE Operator Manual Screw Compressor M100 283...

Page 296: ...13 Annex 13 4 Wiring diagrams 284 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 297: ...13 4 3 Option te Lighting and signaling system connection 13 Annex 13 4 Wiring diagrams No 9_6999 23 USE Operator Manual Screw Compressor M100 285...

Page 298: ...13 Annex 13 4 Wiring diagrams 286 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 299: ...13 Annex 13 4 Wiring diagrams No 9_6999 23 USE Operator Manual Screw Compressor M100 287...

Page 300: ...13 Annex 13 4 Wiring diagrams 288 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 301: ...13 Annex 13 4 Wiring diagrams No 9_6999 23 USE Operator Manual Screw Compressor M100 289...

Page 302: ...13 4 4 Option ga Generator electrical diagram 400V 3 ph 13 Annex 13 4 Wiring diagrams 290 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 303: ...13 Annex 13 4 Wiring diagrams No 9_6999 23 USE Operator Manual Screw Compressor M100 291...

Page 304: ...13 Annex 13 4 Wiring diagrams 292 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 305: ...13 Annex 13 4 Wiring diagrams No 9_6999 23 USE Operator Manual Screw Compressor M100 293...

Page 306: ...13 Annex 13 4 Wiring diagrams 294 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 307: ...13 Annex 13 4 Wiring diagrams No 9_6999 23 USE Operator Manual Screw Compressor M100 295...

Page 308: ...13 Annex 13 4 Wiring diagrams 296 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 309: ...13 Annex 13 4 Wiring diagrams No 9_6999 23 USE Operator Manual Screw Compressor M100 297...

Page 310: ...13 Annex 13 4 Wiring diagrams 298 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 311: ...13 4 5 Option ga Generator electrical diagram 230V 3 ph 13 Annex 13 4 Wiring diagrams No 9_6999 23 USE Operator Manual Screw Compressor M100 299...

Page 312: ...13 Annex 13 4 Wiring diagrams 300 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 313: ...13 Annex 13 4 Wiring diagrams No 9_6999 23 USE Operator Manual Screw Compressor M100 301...

Page 314: ...13 Annex 13 4 Wiring diagrams 302 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 315: ...13 Annex 13 4 Wiring diagrams No 9_6999 23 USE Operator Manual Screw Compressor M100 303...

Page 316: ...13 Annex 13 4 Wiring diagrams 304 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 317: ...13 Annex 13 4 Wiring diagrams No 9_6999 23 USE Operator Manual Screw Compressor M100 305...

Page 318: ...13 Annex 13 4 Wiring diagrams 306 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 319: ...13 Annex 13 4 Wiring diagrams No 9_6999 23 USE Operator Manual Screw Compressor M100 307...

Page 320: ...13 4 6 Option ga Generator electrical diagram 115 V 2 ph 13 Annex 13 4 Wiring diagrams 308 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 321: ...13 Annex 13 4 Wiring diagrams No 9_6999 23 USE Operator Manual Screw Compressor M100 309...

Page 322: ...13 Annex 13 4 Wiring diagrams 310 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 323: ...13 Annex 13 4 Wiring diagrams No 9_6999 23 USE Operator Manual Screw Compressor M100 311...

Page 324: ...13 Annex 13 4 Wiring diagrams 312 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 325: ...13 Annex 13 4 Wiring diagrams No 9_6999 23 USE Operator Manual Screw Compressor M100 313...

Page 326: ...13 Annex 13 4 Wiring diagrams 314 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 327: ...13 Annex 13 4 Wiring diagrams No 9_6999 23 USE Operator Manual Screw Compressor M100 315...

Page 328: ...13 Annex 13 4 Wiring diagrams 316 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 329: ...13 4 7 Option ga Generator electrical diagram 230 V 2 ph 13 Annex 13 4 Wiring diagrams No 9_6999 23 USE Operator Manual Screw Compressor M100 317...

Page 330: ...13 Annex 13 4 Wiring diagrams 318 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 331: ...13 Annex 13 4 Wiring diagrams No 9_6999 23 USE Operator Manual Screw Compressor M100 319...

Page 332: ...13 Annex 13 4 Wiring diagrams 320 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 333: ...13 Annex 13 4 Wiring diagrams No 9_6999 23 USE Operator Manual Screw Compressor M100 321...

Page 334: ...13 Annex 13 4 Wiring diagrams 322 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 335: ...13 Annex 13 4 Wiring diagrams No 9_6999 23 USE Operator Manual Screw Compressor M100 323...

Page 336: ...13 Annex 13 4 Wiring diagrams 324 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 337: ...13 Annex 13 4 Wiring diagrams No 9_6999 23 USE Operator Manual Screw Compressor M100 325...

Page 338: ...13 5 Fuel circulation diagram 13 Annex 13 5 Fuel circulation diagram 326 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 339: ...13 Annex 13 5 Fuel circulation diagram No 9_6999 23 USE Operator Manual Screw Compressor M100 327...

Page 340: ...13 Annex 13 5 Fuel circulation diagram 328 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 341: ...13 6 Assembly diagrams chassis 13 6 1 Assembly diagrams chassis EU version 13 Annex 13 6 Assembly diagrams chassis No 9_6999 23 USE Operator Manual Screw Compressor M100 329...

Page 342: ...13 Annex 13 6 Assembly diagrams chassis 330 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 343: ...13 6 2 Assembly diagrams chassis GB US version 13 Annex 13 6 Assembly diagrams chassis No 9_6999 23 USE Operator Manual Screw Compressor M100 331...

Page 344: ...13 Annex 13 6 Assembly diagrams chassis 332 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 345: ...Verschraubung K26 Bowdenzug Gest nge 13 Annex 13 6 Assembly diagrams chassis No 9_6999 23 USE Operator Manual Screw Compressor M100 333...

Page 346: ...13 6 3 Assembly diagram brake rod 13 Annex 13 6 Assembly diagrams chassis 334 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

Page 347: ...oment 20 25Nm 4 Srew the long nut M10 4 and fix it until no tolerance is available Counter with hex nut M10 6 torque to 20 25Nm 5 Gest ngehalter 9 wahlweise 5 Brake rod rear 9 optional 694917 Mittwoch...

Page 348: ...dd Operating instructions for compressed air filter combination filter 13 Annex 13 7 Operating instructions for compressed air filter combination filter 336 Operator Manual Screw Compressor M100 No 9_...

Page 349: ...FE D E FF D E FG Kaeser Kompressoren GmbH Postfach 2143 96410 Coburg Tel 09561 640 0 Fax 09561 640130 http www kaeser com STANDARD D Pack D PACK E PACK Basic OPTION OPTION OPTION g ltig ab 01 04 2007...

Page 350: ...50 D 9 4617 00010 E A 185 9 4810 0 FA 2480 9 4618 0 FA 2480 D 9 4618 00010 E A 185 9 4810 0 Filter Standard Filter D Pack Filter Element Cartrigde Filter E Pack Typ Type Nr No Typ Type Nr No Typ Type...

Page 351: ...9 00110 FC 221 D 9 4649 00120 FC 221 E E C 221 9 4833 0 FC 185 9 4650 0 FC 185 D 9 4650 00120 FC 185 E E C 185 9 4834 0 FC 283 9 4651 0 FC 283 D 9 4651 00120 FC 283 E E C 283 9 4835 0 FC 354 9 4652 0...

Page 352: ...D 9 4712 00120 FE 354 E E E 185 9 4870 0 FE 526 9 4713 0 FE 526 D 9 4713 00120 FE 526 E E E 185 9 4870 0 FE 708 9 4714 0 FE 708 D 9 4714 00120 FE 708 E E E 185 9 4870 0 FE 885 9 4715 0 FE 885 D 9 471...

Page 353: ...0 E G 185 9 4894 0 FG 2480 9 4758 0 E G 185 9 4894 0 Filter Standard Filter Element Cartrigde Filter E Pack Typ Type Nr No Typ Type Nr No Typ Type Nr No Typ Type FFG 6 9 4760 0 FFG 6 B 9 4760 00110 F...

Page 354: ...timmung keine Gew hr ber nehmen Technische nderungen vorbehalten Contents 1 Introduction 2 Safety rules warnings 3 Technical data 4 Description of functions 5 Condensate discharger 6 Transportation ch...

Page 355: ...en Warnung vor Gefahren Elektrisches Gefahrensymbol Ausf hrende T tigkeit Vom Bediener auszuf hrende Bedienschritte 1 3 Erkl rung der Symbole am Ger t 1 Introduction 1 1 General remarks The compressed...

Page 356: ...ung bezogenen Inhalt dieser Dokumen tation kennt Es besitzt als solches eine zur Inbetriebnahme und War tung derartiger Einrichtungen bef higendeAusbildung bzw Berechtigung 2 Safety rules warnings 2 1...

Page 357: ...von Atemluft d rfen nur nach Genehmigung des Herstellers der Filter systeme eingesetzt und betrieben werden 2 Safety rules warnings 2 3 Security warnings Warning The filter system contains components...

Page 358: ...auf 20 C und 1 bar absol ut bei Betriebs berdruck 7 bar Air flow m h based on 20 C and 1 bar absolute at working pressure 7 bar Gr ere Betriebsdr cke auf Anfrage Contact factory for dryers with a high...

Page 359: ...h dem Prinzip der Tiefenfiltration sowie des Coalescings ausgefiltert Die Luft tritt durch den perforierten u e ren St tzmantel aus 4 Description of operation 4 3 Series FC 1 MICRON COALESCING FILTER...

Page 360: ...durch Schwerkraft in den unteren Teil des Filters und tropfen dann in den Filterbeh lter ab 4 Description of operation 4 5 Series FE 0 01 MICRON COALESCING FILTER at 0 01 ppm w w max oil content DUO...

Page 361: ...schriften Bei den Filtern FD FG entf llt der Kondensatableitungsanschlu 7 Mounting 7 1 Location of mounting The filter system should be installed in a dry and frost proof room indoors Ample free space...

Page 362: ...ustrittsleitung unter Druck Schlie en Sie das Absperrorgan im Bypass falls vorhanden Das Filter system ist nun in BETRIEB 8 Start up operation 8 1 Preconditions for starting the dryer The filter syste...

Page 363: ...Wartungs intervalle gewechselt werden Siehe Kapitel 9 Das Filter FG ben tigt keine Differenzdruckanzeige 8 Start up operation 8 3 Differential pressure indicator standard and D Pack OPTION The differe...

Page 364: ...er high pressure All pressure must be let off before servicing Close the shut off device in the compressed air inlet outlet Loosen condensate drain hose at 1 only on FB FC FE FF models Slowly turn the...

Page 365: ...r Filterelemente siehe Kapitel 3 Technische Daten WARNUNG Das die Filter beinhaltet n unter erh htem Druck ste hende Systeme Vor Servicearbeiten sind sie drucklos zu machen 9 Servicing filter cartridg...

Page 366: ...Reihenfolge schlie en Filter durch langsames ffnen der Absperrvorrichtungen wieder mit Druck beaufschlagen 9 Servicing filter cartridge replacement Close shut off device in compressed air inlet outlet...

Page 367: ...e set The condensate drains service packages must be changed according to the table below For more details please see annexe ECO DRAIN l i e t s g n u t r a W e c n a n e t n i a m f o t r a P l l a v...

Page 368: ...r andere Personen unsachgem ge ffnet oder repariert wurde und oder mechanische Besch digungen irgendwelcher Art aufweist 10 Guarantee conditions 10 1 General The guarantee covers the delivered device...

Page 369: ...n dc Operating instructions for compressed air filter fresh air filter 13 Annex 13 8 Operating instructions for compressed air filter fresh air filter No 9_6999 23 USE Operator Manual Screw Compressor...

Page 370: ...LTROS DE REMO O DOS CHEIROS IT FILTRI PER L ELIMINAZIONE DEGLI ODORI E DEI VAPORI D OLIO PL FILTRY DO USUWANIA OPAR W I ZAPACHU OLEJU SK FILTRE NA ODSTRA OVANIE OLEJOV CH V PAROV A Z PACHU CS OLEJOV A...

Page 371: ...13 Annex 13 8 Operating instructions for compressed air filter fresh air filter No 9_6999 23 USE Operator Manual Screw Compressor M100 359...

Page 372: ...o Real a as ac es ou procedimentos que se n o forem executados correctamente poder o danificar este produto Segnala azioni o procedure che se non eseguite correttamente comportano il rischio di danneg...

Page 373: ...de absor o Carv o granular Filtro a cartuccia ad adsorbimento granuli di carbone Adsorpcyjny wk ad filtruj cy z w gla ziarnistego Adsorp n filtra n kazeta Granulovan uhl k Adsorp n filtra n prvek gran...

Page 374: ...rning Produkten f r endast installeras och underh llas av utbildad och beh rig personal som f ljer denna bruksanvisning och eventuella till mpliga normer och lagf reskrifter noga i f rekommande fall B...

Page 375: ...ktar l isfel mill valvs li jift u malajr u g andu jkun protett minn possibilit ta fluss b lura jew kundizzjonijiet o ra stressanti Naddaf il pajps kollha li jwasslu g at tag mir ta purifikazzjoni qabe...

Page 376: ...C030 1 4 1 2 010 FI 030 FI 010 MI 030 MI 6 FILTER DH OIL XEVOLUTION 01 13 Annex 13 8 Operating instructions for compressed air filter fresh air filter 364 Operator Manual Screw Compressor M100 No 9_69...

Page 377: ...re Parts Service Kits Reserve onderdelen servicekits Ersatzteile Service Kits Pi ces de rechange n cessaires d entretien Varaosat Huoltopakkaukset Reservdelar servicesatser Reservedeler service sett R...

Page 378: ...en indikerar inte filterelementets livsl ngd Modell AC010 I AC030 I er montert med bulkvolum oljeindikator B de filterelementer og indikator skal skiftes n r indikatoren er bl Merk Dette er en bulkvol...

Page 379: ...2 2 3 4 5 6 1 2 1 2 1 0 bar 0 psi 0 bar 0 psi 9 FILTER DH OIL XEVOLUTION 01 13 Annex 13 8 Operating instructions for compressed air filter fresh air filter No 9_6999 23 USE Operator Manual Screw Comp...

Page 380: ...2 1 2 1 1 2 0 bar 0 psi 0 bar 0 psi 0 bar 0 psi 0 bar 0 psi 10 FILTER DH OIL XEVOLUTION 01 13 Annex 13 8 Operating instructions for compressed air filter fresh air filter 368 Operator Manual Screw Com...

Page 381: ...1 AC010 AC030 13 14 2 1 15 1 2 11 FILTER DH OIL XEVOLUTION 01 13 Annex 13 8 Operating instructions for compressed air filter fresh air filter No 9_6999 23 USE Operator Manual Screw Compressor M100 369...

Page 382: ...oben genannten Richtlinien Unterschrift Datum 28 09 05 Nummer der Erkl rung 0001 280905 F rs kran om verensst mmelse SV domnick hunter Dukesway TVTE Gateshead Tyne Wear NE11 0PZ Storbritannien AC010 0...

Page 383: ...f the protective conductor Measurement of the dielectric resistance Measurement of the substitute leakage current Inspection of generator functionality Inspection of the proper functioning of the gene...

Page 384: ...13 Annex 13 9 Service tasks Generator 372 Operator Manual Screw Compressor M100 No 9_6999 23 USE...

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