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: Table Of Contents
Fuel recommendation ..................2.6.4 Recommended Cooling Fluid ................2.6.5 Fluid volumes ...................... 2.6.6 Battery ........................ Options ..........................2.7.1 Air treatment options ................... 2.7.2 Low temperature equipment ................2.7.3 Generator (50 Hz version) .................. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 4 Options for operating in fire hazard areas ............4.7.5 Generator option ....................4.7.6 Transport options ....................4.7.7 Sealed floor pan option ..................4.7.8 Optional anti-theft device ................... 4.7.9 Pedestrian protection option ................4.7.10 Instrument panel cover option ................Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 5 9.2.2 Engine does not reach full speed ............... 9.2.3 Indicator lamp remains on .................. Compressor faults and alarms ..................9.3.1 Working pressure too high .................. 9.3.2 Working pressure too low................... Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 6 10.8.7 Engine air intake shut-off valve maintenance ............. 168 10.8.8 Generator drive belt maintenance ..............169 10.8.9 Draining liquid accumulation within the machine ..........172 10.9 Documenting maintenance and service work ..............Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 7 Spares, Operating Materials, Service 11.1 Note the nameplate ......................175 11.2 Ordering consumable parts and operating fluids/materials ..........175 11.3 KAESER AIR SERVICE ....................176 11.4 Service Addresses ......................176 11.5 Replacement parts for service and repair ................ 176 Decommissioning, Storage and Transport 12.1 De-commissioning ......................
Page 8 Contents Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 9 Fuel filter with water trap maintenance ..................116 Fig. 52 Changing the fuel pre-filter......................117 Fig. 53 Fuel micro-filter maintenance ..................... 117 Fig. 54 Checking the engine oil level ...................... 119 Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 10 Safety sign - secure the chocks ....................Fig. 106 Transporting using a forklift truck ....................242 Fig. 107 Guys to secure the freight ......................243 Fig. 108 Identification ..........................245 Operator Manual Screw Compressor viii M100 No.: 9_6999 23 USE...
Page 11 Compressed air delivery with generator in operation (generator with FAD limitation) ....Tab. 50 Connection sockets ........................Tab. 51 Circuit breaker ..........................Tab. 52 Generator operating limits ......................Tab. 53 Maximum three-phase mains loading ..................Tab. 54 Maximum single-phase mains loading ..................Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 12 Maintenance intervals and regular maintenance tasks .............. 101 Tab. 87 Regular machine maintenance tasks ..................102 Tab. 88 Regular maintenance task options ..................... 104 Tab. 89 KAESER coolant mixture table ....................108 Tab. 90 Maintenance log ......................... 174 Tab. 91 Compressor consumables ......................175 Tab. 92 Consumable engine parts ......................
Page 13: Regarding This Document Using This Document
Copyright This operator manual is copyright protected. Queries regarding use or duplication of the documen‐ tation should be referred to KAESER. Correct use of information will be fully supported. Symbols and labels ➤ Please note the symbols and labels used in this document.
Page 14: Potential Damage Warnings
The conditions relevant to safety shown here will help you to avoid dangerous situations. ➤ This symbol is placed by lists of actions comprising one stage of a task. 1. For instructions with several steps ... 2..the sequence of actions is numbered. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 15 The cause is named in the help text ... ➤ ... and a remedy given. This symbol refers to important information or measures concerning environmental protec‐ tion. Further information Further topics are introduced here. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 16: Technical Data Nameplate
■ On the front of the machine (see chapter 13.1) The following table lists all possible options. Only the codes for those options fitted on the machine appear on the nameplate. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 17: Compressed Air Treatment Devices
Technical Data Options M100 Part Number Serial no. Options fitted hc hd ca cb bb bc bd ga gb r1= rb; rc; rd r3= rm; ro r4= rr; rs; rt r5= rw; rx pa pb 02-M0277 *r1 - r5 = place holders for chassis options Tab.
Page 18: Check Valve Function
Option la, lb Equipment for fire hazard areas Option Option code Available? Spark arrestor Spark arrestor and engine air intake shut-off valve (automatic) Tab. 11 Optional equipment for fire hazard areas Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 19: Battery Isolating Switch
Without height adjustment Service brake (rs): With overrun brake Tab. 13 Chassis options Stationary frame Chassis Option code Available? Stationary (rw, rx): on skids on frame Tab. 14 Options, stationary frame Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 20: Lighting
Option sf Anti-theft device Option Option code Available? Anti-theft device Tab. 18 Anti-theft device option 2.2.14 Option sg Pedestrian protection Option Option code Available? Pedestrian protection Tab. 19 Pedestrian protection option Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 21: Instrument Panel Cover
Instrument panel cover options Machine (without options) 2.3.1 Sound pressure level Sound pressure levels comply with the American EPA Standard. Measurement distance: 23 ft M100 Guaranteed sound pressure level [dB(A)] Tab. 21 Sound pressure level 2.3.2 Tightening torques for screws Recommended values for screws of property class 8.8...
Page 22: Chassis
[%] Cross-section width Radial design Use the following table for detailed information regarding the tires of your machine: Characteristic/marking Value Axle load high Tire size 185 R 14C 195 R 14C Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 23: Wheel Nut/Bolt Tightening Torque
FAD as per ISO 1217:2009. Annex D Tab. 28 Working pressure and FAD 2.5.2 Compressed air outlet Outlet valve ["] Number G 3/4 G 1 1/2 Tab. 29 Compressed air distributor Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 24: Safety Relief Valves
Airend discharge temperature 2.5.5 Cooling oil recommendation A sticker showing the type of oil used is located near the oil separator tank filler. Information on ordering cooling oil is found in chapter 11. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 25: Tab. 33 Cooling Oil Recommendations
Viscosity at 50.7 mm 70.0 mm 104 °F (D 445; ASTM test) (D 445; ASTM test) Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 26: Cooling Oil Charge
Oil consumption relative to fuel consumption [%] approx. 0.5 Tab. 36 Engine specification 2.6.2 Oil recommendation The engine oil must meet the following classification: ■ ACEA, class E4, E7 ■ API, class CF, CI-4 Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 27: Fuel Recommendation
The engine service manual gives further information on coolant application. 2.6.5 Fluid volumes Description Fluid volume [gal] Engine oil Fuel 39.63 Coolant 4.23 Tab. 38 Fluid volumes 2.6.6 Battery Feature Value Voltage [V] Capacity [Ah] Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 28: Options
■ Cyclone separator ■ Filter combination da + dd + db ■ After-cooler technically oil-free and warmed ■ Cyclone separator ■ Filter combination ■ Heat exchanger Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 29: Low Temperature Equipment
Antifreeze protection for air brake systems 0.32 (e.g., Wabcothyl) Tab. 45 Recommended antifreeze 2.7.2.4 Option bd Battery Feature Value Voltage [V] Capacity [Ah] PTC testing current [A] (according to EN 50342) Tab. 46 Battery, low-temperature equipment Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 30: Generator (50 Hz Version)
13.0 [kVA] 8.5 [kVA] Maximum working pres‐ sure [psi] FAD [cfm] − generator FAD cfm] − generator ON Tab. 48 Compressed air delivery with generator in operation (generator without FAD limitation) Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 31: Tab. 49 Compressed Air Delivery With Generator In Operation (Generator With Fad Limitation)
Tab. 51 Circuit breaker Operating limits: (to EN 60034-22, page 10, table) Features Value Design category Voltage adjustment range [%] ±5 Static voltage deviation [%] Maximum dynamic voltage drop [%] –15 Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 32: Tab. 52 Generator Operating Limits
Power reduction at elevated ambient temperatures: Ambient temperature Generator power [°F] ≤86 Full power available >86 Reduction of 10 % for each temperature rise of 50 °F. Tab. 55 Power reduction at elevated ambient temperatures Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 33: Generator (60 Hz Version)
Generator 8.0 [kVA] Maximum working pres‐ sure [psig] Free air delivery [cfm] FAD with simultaneous generator operation [cfm] Tab. 57 Compressed air delivery with generator in operation (generator without FAD limitation) Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 34: Tab. 58 Compressed Air Delivery With Generator In Operation (Generator With Fad Limitation)
Maximum voltage settling time [ms] 1500 Maximum voltage asymmetry [%] Tab. 61 Generator operating limits Maximum power loading by consumers Resistive consumers include lamps and heaters, for example. Electric motors and transformers are inductive consumers. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 35: Tab. 62 Maximum Power Supply Load
Power reduction at elevated ambient temperatures: Ambient temperature Generator power [°F] ≤86 Full power available >86 Reduction of 10 % for each temperature rise of 50 °F. Tab. 63 Power reduction at elevated ambient temperatures Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 36: Safety And Responsibility Basic Instructions
➤ Do not operate the machine in areas in which specific requirements with regard to explosion protection are in effect. User's Responsibilities 3.4.1 Observe statutory and universally accepted regulations ➤ Observe relevant statutory and accepted regulations during operation, transporting and main‐ tenance of the machine. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 37: Determining Personnel
This regulation requires that machines filled with more than 0.26 gallons petrol or 1.32 gallons die‐ sel (in the fuel tank) during transport must be identified with hazardous goods labels on the ma‐ chine's exterior. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 38: Dangers
➤ Do not allow fuel to overflow. ➤ Wipe up spilled fuel immediately. ➤ Provide a fire extinguisher in the immediate vicinity. ➤ For operation in combustible environment, fit the machine with an exhaust silencer (Option la). Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 39 Springs under tension or compression store energy. Uncontrolled release of this energy can cause serious injury or death. Minimum pressure / check valves, safety relief valves, and inlet valves are powerfully spring-loa‐ ded. ➤ Do not open or dismantle any valves. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 40 ➤ Do not eat or drink while handling fuel, cooling and lubricating fluids or antifreeze. ➤ Keep suitable fire extinguishing agents ready for use. ➤ Use only KAESER approved operating materials. Unsuitable spare parts Unsuitable spare parts compromise the safety of the machine.
Page 41: Safe Machine Operation
Dangers ➤ Use only spare parts approved by the manufacturer for use in this machine. ➤ Use only genuine KAESER pressure components. Conversion or modification of the machine Modifications, additions or conversions to or of the machine can result in unpredictable hazards.
Page 42 ➤ Do not position the machine directly against a wall. A build up of heat from the exhaust can damage the machine. ➤ Ensure accessibility so that all work on the machine can be carried out without danger or hin‐ drance. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 43 ➤ De-pressurise all pressurised components and enclosures. ■ Wait until the machine has automatically vented. ■ Carefully open the compressed air outlet valve. ■ Check: The pressure gauge must read 0 psig! Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 44: Organizational Measures
➤ Do not open the body while the machine is switched on. ➤ Do not open or dismantle any valves. ➤ Use only spare parts approved by KAESER for use in this machine. ➤ Operate the machine only in technically sound condition.
Page 45: Danger Areas
More information on safety devices is contained in chapter 4.5. Safety signs The diagram shows the positions of safety signs on the machine. The table lists the various safety signs used and their meanings. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 46: Fig. 2 Location Of Safety Signs
➤ Always wipe up fuel spills which may occur inside the compressor enclo‐ sure and allow the machine to ventilate. * Location within the machine ** Only towable machines *** Only machines with option dc **** only machines with option ga, gb Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 47 ➤ Food grade coolant must be used for food processing. * Location within the machine ** Only towable machines *** Only machines with option dc **** only machines with option ga, gb Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 48: Tab. 65 Safety Signs
Serious injury or death can result from loosening or opening component that is under pressure and heavily spring loaded. ➤ Never open (dismantle) valve. ➤ Contact an authorized KAESER service representative. 830**** There is danger of fatal injury touching electrically live components! ➤...
Page 49: Noise Control Requirements
➤ Only a qualified electrician is allowed to carry out work on the generator or generator control box. The electrician is responsible for the effectiveness of the protective measures provided. ➤ Do not use the generator for feeding the construction current distribution. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 50: Connecting Extension Cables
➤ Check and tighten the screw connections at the generator and the generator control cubicle. ➤ Check covers and power socket caps for damage and good sealing. ➤ Check the completeness of labeling and warning labels. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 51: Emergencies
Skin contact Fuel, oil and other fluids/materials may irritate after prolonged contact. ➤ Wash thoroughly with skin cleaner, then with soap and water. ➤ Contaminated clothing should be intensively cleaned before reuse. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 52: Warranty
■ incorrect repair. Correct maintenance and repair includes the use of original spare parts and operating 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 purchaser that this air compressor was designed, built, and equipped to conform, at the time of sale to the first retail pur‐...
Page 53: Environmental Protection
➤ Store and dispose of operating materials and replaced parts in accordance with local environ‐ mental protection regulations. ➤ Observe relevant regulations. This applies particularly to parts contaminated with fuel, oil, coolants and acids. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 54: Design And Function Bodywork
Safe and reliable operation is only ensured when the bodywork is closed. The wing doors are provided with handles for opening. Release the doors by the snap fasteners. The doors are held open by gas springs. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 55: Component Identification
Pressure relief valve Tool box Lifting eye cover Airend Lifting eye Inlet valve Machine function Machine function (without options) Item numbers correspond to the pipe and instrument flow diagram (P&ID) in chapter 13.2. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 56: Fig. 6 Machine Layout
. The minimum pressure / check valve ensures that there is always a minimum internal pressure sufficient to maintain cooling oil circulation in the ma‐ chine. The cooling fan ensures optimum cooling of all components within the enclosure. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 57: Operating Modes And Control Mode
This stepless delivery regulation minimises fuel consumption of the engine. The load and fuel con‐ sumption of the engine rises and falls with the air demand. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 58: Safety Devices
Safety devices 4.5.1 Monitoring functions with shutdown The following functions are monitored automatically. ■ Engine oil pressure ■ Coolant temperature ■ Airend discharge temperature ■ Fuel level ■ Engine alternator Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 59: Further Safety Devices
(red) to indicate an alarm. The alarm is saved and the engine cannot be restarted. You can restart the machine only after deactivating and refilling the machine. Options The options available for your machine are described below. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 60: Compressed Air Treatment Options
The oil/air heat exchanger is fed with hot compressor cooling oil that warms the outgoing moisture- reduced compressed air. This warm, dry compressed air is ideal for sand blasting, for example. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 61 The oil flow can be stopped by a shut-off valve. The oil flow adjusts automatically to changes in air demand (one or more tools/consumers on line). Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 62: Fig. 10 Tool Lubricator
Fig. 11 Principle tool lubricator Compressed air inlet Tool lubricator upper part with oil filling port Oil tank Filler plug with dipstick and integrated riser Tool oil outlet tube Metering knob Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 63: Low Temperature Equipment Options
Option bc Frost protection Control air is mixed with an alcohol-based antifreeze to prevent control and regulating devices freezing. This considerably lowers the freezing point of any moisture in the air. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 64: Optional Battery Isolating Switch
Damage to the machine’s electrical components is possible. ➤ Use the «battery isolating switch» only when the machine is shut down. ➤ Do not use the «battery isolating switch» as a main or emergency switch. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 65: Options For Operating In Fire Hazard Areas
A spark arrestor on the exhaust silencer is required when operating a diesel engine in a fire hazard area and in forestry and agricultural applications. In such applications, a spark may ignite flamma‐ ble materials. The spark arrestor prevents the exhaust silencer emitting any glowing fuel residue. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 66: Generator Option
Engine run-on time of approximately 2 mi‐ nutes at maximum speed Advantages Fuel saving Continuous generator power Constant oscillation between maximum and available without delay minimum speed avoided Tab. 67 Generator operating modes Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 67: Fig. 15 Instrument Panel - Generator Control Box, 400 V Ac
Instrument panel – generator control box, 230 V AC «Mode selector switch» Generator control box 32 A three-phase power socket «Generator main switch» Single-phase power sockets «Safety cut-out» 16 A three-phase power socket «Safety cut-out» (with overcurrent release) Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 68: Transport Options
Option rb/rk/rm/rs Chassis Option rb - chassis EU version Option rk - Chassis with low axle load Option rm - chassis with height-adjustable tow bar Option rs - chassis with overrun brake Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 69 Option rb/rl/rm/rs Chassis Option rb - chassis EU version Option rl - Chassis with higher axle load Option rm - chassis with height-adjustable tow bar Option rs - chassis with overrun brake Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 70: Sealed Floor Pan Option
When other components are removed from the sealed floor pan, (for example the sheet metal cover) they must be properly re-sealed prior to installation. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 71: Optional Anti-Theft Device
The machine is fitted with a security chain as theft protection. 4.7.9 Option sg Pedestrian protection option The machine is fitted with a special protective guard that prevents pedestrians from being run over. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 72: Instrument Panel Cover Option
To prevent unauthorized 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) Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 73: Installation And Operating Conditions
Installation conditions Precondition The floor must be level, firm and capable of bearing the weight of the machine. Fig. 21 Minimum distance from excavations/slopes and walls Wind direction Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 74 ➤ Use winter grade engine oil. ➤ Use winter diesel fuel. ➤ Use low viscosity compressor cooling oil. 10. At ambient temperatures below 32 °F, follow the instructions in chapter 7.4. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 75: Installation
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. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 76: Fitting The Height Adjustable Towbar
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 Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 77: Fitting A Non-Adjustable Tow Bar
2. Remove the bag with the brake transfer cable and fastenings, unpack and lay out ready. 3. Close the doors. 4. Remove all transport securing items (screw fastenings, duct tape, foam pads) from the tow bar components. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 78: Fig. 25 Fitting The Overrun Braking Mechanism Of The Non-Adjustable Tow Bar
6. Screw the the brake-rod linkage onto the rear screw fastening of the brake transfer cable and secure with a lock nut. Further information Further information on setting the brake actuating rod is to be found in chapter 10.7.3.3. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 79: Adjusting The Chassis
The machine is disconnected from the towing vehicle and safely parked. Danger of pinching! Severe injury to fingers is possible if they become trapped in the adjusting mechanism. ➤ Always wear protective gloves. ➤ Work carefully. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 80: Adjusting The Towbar Height
The serrated joint will not disengage. The serrations are corroded together. ➤ Free the serrations by jerking the towbar horizontally and vertically. 6.4.2 Changing the towing eye/ball hitch The towbar can be fitted with various towing eyes or couplings. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 81: Fig. 28 Changing The Towing Eye (Height-Adjustable Drawbar)
2. Unscrew the nuts of both screw connec‐ 2. Remove the coupling from the towbar tions and withdraw the bolts 3. Remove the towing eye from the tow‐ Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 82: Fig. 29 Changing The Towing Eye/Ball Hitch (Fixed Height Towbar)
Fig. 29 Changing the towing eye/ball hitch (fixed height towbar) Self-locking hexagon nut Towbar Hex-head screw Shock absorber Shock absorber fixing eye Mounting pin Hex-head screw Ball coupling Protective sleeve Towing eye Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 83: Fig. 30 Changing The Towing Eye (Fixed Height Towbar, Usa Chassis Version)
10. Draw the protective sleeve over the fixings. Checking the overrun braking mechanism ➤ Push the towbar tube in and out by hand. If resistance is felt, the shock absorber is properly connected. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 84: Initial Start-Up Ensuring Safety
➤ Remove all packing materials on and in the machine. ➤ Observe the machine during the first few hours of operation to ensure that it is operating cor‐ rectly. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 85: Special Measures For Re-Commissioning After Storage
➤ Clean the bodywork with a grease and dirt dissolving agent. ➤ Check the tire pressures. 36 months ➤ Have the overall technical condition checked by an authorised KAESER Serv‐ ice Technician. Tab. 68 Measures for re-commissioning the compressor after a long period of storage Checking installation and operating conditions ➤...
Page 86: Low-Temperature Operation (Winter)
➤ Observe the instructions provided with the battery jumper cables. ➤ Do not connect the battery jumper cables to the negative pole of the discharged battery or to the bodywork of the machine. ➤ Work with caution. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 87: Fig. 31 Jumper Cable Connection Diagram
1. Park the assisting vehicle in close distance to the engine, without their bodywork touching each other. 2. Stop the engine of the assisting vehicle. 3. Open the accesses to the batteries (remove maintenance panels/bonnet and pole caps). 4. Switch off all power consumers. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 88: Starting Up Low-Temperature Equipment
Operating the engine cooling water pre-heater The engine coolant can be pre-heated to improve starting under cold conditions. The connection for the power supply is located on the machine's instrument panel. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 89: Fig. 32 Engine Coolant Pre-Heating
Frost protector Ball valve (closed) Level of antifreeze ➤ Use the checklist when initially starting the frost protector. To be checked see chapter Confirmed? Level of antifreeze in the frost protector. 10.8.5 Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 90: Activating The Generator
«Mode selection switch» («Circuit breaker» designed as automatic Test button «Insulation monitor» with indi‐ circuit-breaker with shunt trip) ground short cator light for Three-phase AC power sockets Single-phase AC power sockets Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 91: Fig. 36 Insulation Monitoring - 115 V, Single-Phase Generator
1. Activate the machine. Danger of fatal injury caused by contact with live components! ➤ The generator may only be used if the «circuit breaker» («main circuit breaker») has trip‐ ped during the test! Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 92: Tab. 71 Test Instructions For A Generator With An Ground Short Detection Device
The «main circuit breaker» trips. Problem: The «main circuit breaker» does not trip out? ➤ Shut down the generator and call your authorized KAESER service representative. Tab. 71 Test instructions for a generator with an ground short detection device. Operator Manual...
Page 93: Operation
The hose length represents a cooling section. With increasing cooling, the compressed air gives off moisture capable of damaging the air tool. ➤ Use short compressed air hoses. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 94: Starting And Stopping
Fuel level monitoring light – On – – Preheat – START LOAD – «Load On» key with integrated mode indicating light Back-pressure indicating light – Charging indicating light, group alarm lamp Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 95: Starting The Machine
To avoid unnecessary wear, the engine should be run in IDLE until the airend discharge tempera‐ ture reaches +86 °F. The airend discharge temperature is shown at the remote thermometer con‐ tact on the instrument panel. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 96: Switching To Load
The required pressure can be seen on the gauge on the instrument panel. The pressure setting on the proportional controller can only be lower than the maximum working pressure of the machine. Precondition The machine is switched off. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 97: Shutting Down The Machine
The engine runs in IDLE and the turbo charger can cool down. 3. After approx. 2 to 3 minutes, switch the «starter switch» to the "STOP/Off" position. The engine turns off. Shutting down the machine: 1. Open the right-hand access door. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 98: Monitoring Fuel Level In The Fuel Tank
The machine is switched off. Tool lubricator is filled with oil Fig. 41 Setting the tool lubricator Shut-off valve I – open 0 – closed Metering knob ➤ Open the right-hand access door. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 99: Using The Low-Temperature Equipment
Using the low-temperature equipment ➤ Ascertain which low temperature equipment is fitted to the machine. 8.5.1 Option bb Pre-warms the engine cooling water ➤ Start the engine coolant pre-heating as described in chapter 7.4.2. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 100: Operating The Machine With Frost Protector
See chapter 10.8.5 for filling the frost protector with antifreeze. Using with the frost protector switched off Operating at temperatures above 32 °F (summer operation). 1. Leave the frost protector shut-off valve open permanently (position I). 2. Close the door. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 101: Operating The Battery Isolating Switch
➤ Check correct function of the insulation monitoring device daily (see chapter 7.5). ➤ Have the generator and control box checked annually by a qualified electrician (see chapter 13.9). ➤ Follow instructions in chapter 3.9. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 102: Note When Operating The Generator
■ Switch off electrical consumers and unplug them one-by-one. ■ Switch off consumers drawing the highest current last. ■ Check that the protective covers on the power sockets are correctly closed. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 103: Cleaning The Machine After Operation
Water has accumulated in the sealed floor pan. ➤ Drain the water. Catch the liquid and dispose in accordance with applicable environmental regulations. Further information See chapter 10.8.9 for information to the draining of liquids within the machine. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 104: Fault Recognition And Rectification
1. Do not attempt fault rectification measures other than those given in this manual! 2. In all other cases: Have the fault rectified by an authorized KAESER service representative. Further information Observe the instructions in chapter 3 "Safety and Responsibility" and prevailing local safety regula‐...
Page 105: Engine Does Not Reach Full Speed
Tighten the connection or have – bles loose or broken the cable replaced. Defective alternator. Have repaired or replaced if – necessary. Defective alternator regulator. Have repaired or replaced if – necessary. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 106: Compressor Faults And Alarms
Pressure relief valve maladjus‐ Have repaired or replaced if – ted and/or leaking. necessary. Venting valve does not close. Check the connections and – function and have repaired or replaced as necessary. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 107: Pressure Relief Valve Blowing Off
1 psi. See chap‐ ter 10.4.6 for changing. Compressor oil filter clogged. Change, see chapter 10.4.4. – – Compressor cooling oil level too Topping up, see chapter 10.4.2. – – low. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 108: Too Much Oil Residue In The Compressed Air
Specialized KAESER workshop Service Defective non-return function of Repair or have replaced if nec‐ – the inlet valve. essary. Tab. 80 Fault: Oil flows from the compressor air filter after shutdown Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 109: High Moisture Content In The Compressed Air
There is no voltage or too low a voltage from the generator 9.4.2 Generator voltage too high Possible cause Remedy Where can I get help? Specialized KAESER- workshop Service Generator / regulator defective Have repaired. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 110 Generator faults and alarms Possible cause Remedy Where can I get help? Specialized KAESER- workshop Service Engine speed too high. Have reset to rated speed. Tab. 83 Generator voltage too high Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 111: 10.1 Maintenance
The following safety concerns relate to any work on components that could be under pressure. ➤ Disconnect the air consumers. ➤ Depressurize all pressurized components and enclosures. ■ Wait until the machine has automatically vented. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 112: Maintenance Schedules
10.2 Maintenance schedules 10.2.1 Logging maintenance work The maintenance intervals given are those recommended for KAESER original components with average operating conditions. ➤ In adverse conditions, perform maintenance work (e.g. oil and filter changes) at shorter intervals. Adverse conditions are, e.g.: ■...
Page 113: Regular Maintenance Tasks
The table below lists regular maintenance tasks. 1. Carry out maintenance tasks punctually taking ambient and operating conditions into consider‐ ation. 2. Change consumables and operating fluids according to each site. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 114 Check/empty the water trap. 10.3.3 Check fuel lines and hose clamping bands, have replaced if necessary. Have fuel lines and clamps re‐ placed. Engine SM = engine manufacturer's service manual; SW = specialized workshop. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 115 Check wheel bolts and nut for tightness. Carry out chassis maintenance. 10.7 Grease the ball coupling, joints 10.7.2 and towbar. Brake maintenance 10.7.3 Engine SM = engine manufacturer's service manual; SW = specialized workshop. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 116: Tab. 87 Regular Machine Maintenance Tasks
Option da, db, dc, dd – cyclone separator Clean and check the dirt trap. 10.8.2 Options da, db, dc, dd – compressed air aftercooler Clean the cooler. 10.5.2 EL = qualified electrician; SW = specialist workshop Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 117: Tab. 88 Regular Maintenance Task Options
Option oe – sealed floor pan Check the machine interior for 10.8.9 liquid accumulations and drain, if required. EL = qualified electrician; SW = specialist workshop Tab. 88 Regular maintenance task options Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 118: Engine Maintenance
■ The tank is semi-transparent so the coolant level can be seen from outside. minimum and maximum markings when the engine has ■ The level should be between the cooled down. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 119: Fig. 44 Checking Coolant Level
Maximum frost protection is ensured with an antifreeze concentration of 55% by volume, as frost protection and heat transfer properties deteriorate beyond this point. Higher concentration also leads to higher operating temperature. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 120: Tab. 89 Kaeser Coolant Mixture Table
➤ Follow coolant recommendations in chapter 2.6.4. Preparing coolant Precondition Coolant must meet the specification of ASTM D4985. ➤ The coolant should be mixed in the proportions given by the manufacturer. KAESER coolant mixture table Antifreeze Water Frost protection to [°F] 1 part 2 parts −0.4...
Page 121 In machines with chassis (no closed floor pan, no stationary machine), the entire cooling oil of the cooling circuit is drained directly at the engine's water cooler. This is done from a drain valve with the aid of a separate drain hose. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 122: Fig. 45 Draining The Coolant From The Radiator
The cooling oil is drained via a pipe which is screwed into the drain opening of the cooler and closed with a shut-off valve. The pipe is sealed with a screwed sealing plug at the drain end. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 123: Engine Air Filter Maintenance
Do not use an air filter element with damaged folds or gasket. ■ The use of an unsuitable air filter can permit dirt to ingress the engine and cause prema‐ ture wear and damage. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 124: Fig. 47 Engine Air Filter Maintenance
Fig. 47 Engine air filter maintenance Maintenance indicator Filter element Red zone indicator scale Retaining clip Indicating piston of the maintenance indi‐ Filter cap cator Reset knob for the maintenance indicator Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 125: Fig. 48 Cleaning The Filter Element
The yellow piston within the indicator is reset and the maintenance indicator is ready for use again. ➤ Close the doors. Dispose of old parts and contaminated materials according to environmental regulations. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 126: Fuel System Maintenance
➤ Keep fuel away from hot machine parts. Fig. 49 Fuel system maintenance Fuel pump Fuel tank Fuel de-watering filter Fuel strainer Fuel pre-filter Fuel fine filter ➤ Open the right-hand access door. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 127: Fig. 50 Bleeding The Fuel System
Fuel filter with water trap maintenance A water trap is installed between the tank and the fuel pump. The separator tank is semi-transpar‐ ent so the fuel level can be seen from outside. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 128: Fig. 51 Fuel Filter With Water Trap Maintenance
4. Remove the receptacle. 5. Reconnect the battery. 6. Close the door. The mixture of fuel and water and any materials contaminated with fuel must be disposed of in accordance with environment protection regulations. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 129: Fig. 52 Changing The Fuel Pre-Filter
2. Use a filter wrench to loosen then unscrew the filter cartridge. Catch fuel in the receptacle. 3. Clean the sealing faces of the micro-filter cartridges and the opposite site of the filter mount with lint-free cloth. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 130: Checking The Engine Oil Level
The machine is standing level. The machine is fully vented, the pressure gauge reads 0 psig. Engine cooled down. All compressed air consumers are disconnected and the air outlet valves are open. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 131: Engine Oil Filling And Topping Up
See chapter 2.6.5 for engine oil filling volume. The oil dipstick is marked with the «maximum oil level». 1. Open the right-hand access door. 2. Remove the filler cap and fill with fresh oil. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 132: Changing The Engine Oil
All compressed air consumers are disconnected and the air outlet valves are open. The negative cable to the battery is disconnected. Danger of burns from hot components and escaping engine oil! ➤ Wear long-sleeved clothing and protective gloves. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 133: Fig. 55 Draining The Engine Oil
The pipe is sealed with a screwed sealing plug at the drain end. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 134: Fig. 56 Draining The Engine Oil (Closed Floor Pan - Stationary Machine)
Dispose of old oil and oil-soaked working materials according to environmental protection regulations. Further information See chapter 10.3.5 for engine oil filling. Further information regarding changing the engine oil is provided in the engine manufacturer's op‐ erating manual. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 135: Replace The Engine Oil Filter
Further information The engine service manual gives further information on oil filter changing. Dispose of old oil filters, old oil and materials contaminated with oil according to environmen‐ tal protection regulations. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 136: Drive Belt Maintenance
Removing the belt guard: Fig. 58 Belt guard attachment Belt guard Washer Hexagon bolt Hexagon socket screw 1. Unscrew the securing screws of the belt guard and remove the belt guard. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 137: Fig. 59 Checking The Drive Belt Seating
The belt tension can be checked by hand: To check the tension, press the belt inwards with the thumb at the mid-point between pulleys. Fig. 60 Manually checking the belt tension Drive belt testing position - Compressive load approximately: 22 Kg Play approximately: 0.28 – 0.35 in Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 138: Fig. 61 Changing/Tensioning The Drive Belt
1. Loosen the alternator securing screw and clamping nut until the drive belt can be taken off the pulleys. 2. Take off the belt. 3. Check the pulleys for dirt and wear. Dirty pulley: Clean pulley. Worn pulley: Have the pulley changed. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 139: Battery Maintenance
When working on the battery comply with the following safety signs: A warning label with safety signs is attached to the battery. Fig. 62 Safety signs - warning stickers on the battery. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 140 The acid quantity is generally sufficient for the life of the battery. Nevertheless, the fluid level should be checked annually. The level should be up to the mark, 0.4 inches above the plates. Replace the battery immediately if the casing leaks. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 141 ➤ Carry out work on batteries only with the machine shut down. 3. Open the left-hand door. 4. Disconnect the negative cable first, then the positive cable. 5. Unscrew the battery fixing clamp. 6. Replace in the reverse order. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 142: Checking The Fastening Of The Fuel Tank
10 daN (approx. 25 lbf), slightly hand-tighten only. ➤ Hand-tighten the lashing strip with the integrated ratchet and push the ratchet to the strip. 10.4 Compressor Maintenance ➤ Perform maintenance tasks according to the schedule in chapter 10.2.3.1. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 143: Checking Cooling Oil Level
2. Slowly unscrew and withdraw the plug from the oil filler port. 3. Check the cooling oil level. Top up if no oil is visible. 4. Replace the plug in the filler port. 5. Close the access door. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 144: Cooling Oil Filling And Topping Up
5. Open the outlet valves. 6. Open the right-hand access door. 7. Check the oil level after about 5 minutes. Top up if necessary. 8. Visually inspect for leaks. 9. Close the access door. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 145: Changing The Cooling Oil
Draining the cooling oil (machine with chassis) In machines with chassis (no closed floor pan, no stationary machine), the cooling oil is drained directly at the oil separator tank and the oil cooler. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 146: Fig. 64 Draining The Compressor Cooling Oil
1. Replace the plug in the oil separator tank filling port. 2. Close the door. Dispose of used oil and oil-contaminated working materials according to environmental pro‐ tection regulations. Further information See chapter 10.4.2 for cooling oil filling. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 147: Fig. 65 Draining The Oil From The Heat Exchanger
The pipes are sealed with a screwed sealing plug at the drain end. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 148: Fig. 66 Draining The Cooling Oil (Closed Floor Pan - Stationary Machine)
2. Close the door. Dispose of used oil and oil-contaminated working materials according to environmental pro‐ tection regulations. Further information See chapter 10.4.2 for oil filling. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 149: Replace The Compressor Oil Filter
Top up if necessary. 8. Reconnect the negative battery terminal. 9. Close the access door. Dispose of old cooling oil and any materials or parts contaminated with oil according to envi‐ ronment protection regulations. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 150: Oil Separator Tank Dirt Trap Maintenance
The negative cable to the battery is disconnected. Fig. 68 Oil separator tank dirt trap maintenance Oil separator tank cover Nozzle Control valve Screw-in connector Union nut Gasket Oil return line Strainer ➤ Open the right-hand access door. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 151: Changing The Oil Separator Cartridge
The life of the oil separator cartridge is influenced by: ■ contamination in the air drawn into the compressor, ■ and adherence to the changing intervals for: ─ Cooling oil ─ Oil filter ─ Air filter Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 152: Fig. 69 Changing The Oil Separator Cartridge
2. Pull out the plug to the solenoid valve and withdraw the cable. 3. Unscrew the fitting and turn the air pipe to one side. 4. Remove the screws securing the cover to the tank. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 153 5. Open the outlet valves. 6. Open the right-hand access door. 7. Check the oil level after about 5 minutes. Top up if necessary. 8. Visually inspect for leaks. 9. Close the access door. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 154: Fig. 70 Changing The Oil Separator Cartridge (Option Ba)
Take particular care with the following components: ■ The frost protector connected to the control line, ■ The oil scavenge line screwed to the underside of the cover. 7. Take out the old cartridge and gaskets Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 155: Compressor Air Filter Maintenance
Clean the filter according to the maintenance schedule or if the maintenance indicator shows this to be necessary. Renew the air filter element after 2 years at the latest or after it has been cleaned 5 times. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 156: Fig. 71 Compressor Air Filter Maintenance
Fig. 71 Compressor air filter maintenance Maintenance indicator Filter element Red zone indicator scale Retaining clip Indicating piston of the maintenance indi‐ Filter cap cator Reset knob for the maintenance indicator Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 157: Fig. 72 Cleaning The Filter Element
The yellow piston within the indicator is reset and the maintenance indicator is ready for use again. ➤ Close the doors. Dispose of old parts and contaminated materials according to environmental regulations. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 158: Checking Safety Relief Valves
Maintenance 10.5 Cleaning the cooler 10.4.8 Checking safety relief valves ➤ Have safety relief valves checked by KAESER Service in accordance with the maintenance schedule. 10.5 Cleaning the cooler The frequency of cleaning is mainly dependent on local operating conditions.
Page 159: Cleaning The Compressed Air Aftercooler
2. Visually inspect for leaks. Does oil or cooling water escape? Is a cooler leaking? ➤ Have the defective cooler repaired or replaced immediately by KAESER Service. ➤ Close the doors. Clean the cooler blades only in a washing area equipped with an oil separator.
Page 160: Maintenance Of Rubber Sealing Strips
2. Clean the rubber sealing strips with a lint-free cloth and check for cracks, holes and other dam‐ age. Have any damaged gasket replaced. 3. Properly grease the rubber strips. 4. Close the doors. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 161: Chassis Maintenance
Clean and lubricate all sliding and rotating bearings as necessary but at least every 6 months. Material Lithium-enriched multi-purpose grease Acid-free oil Cleaning cloth Precondition The machine is shut down. The machine is disconnected from the towing vehicle and safely parked. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 162: Fig. 75 Towbar Maintenance
➤ If necessary, free the teeth by jerking the towbar horizontally and vertically. ➤ Clean the toothed coupling and smear with water-repellent grease. Further information See chapter 6.4.1 for towbar height adjustment. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 163: Fig. 77 Ball Coupling (Ec Version)
■ Oil leaks out. 10.7.2.3 Ball coupling maintenance Option rb/rk/rm/rs, rb/rl/rm/rs, rc/ro/rs Fig. 77 Ball coupling (EC version) Lubricating points Greasing points Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 164: Brake Maintenance
2. Turn the wheels in the forward direction. 3. Check that there is the same braking resistance on both wheels. Brake resistance not even: adjust brake system. 4. Release the parking brake. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 165: Fig. 79 Checking The Brake Lining Thickness
3. Apply the parking brake a number of times to centre the brake linings. 4. Use the screwdriver to turn the adjusting wheel back (3 to 5 notches) until there is no more braking resistance to the wheels turning forward. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 166: Fig. 81 Brake Rod Adjustment
1. To free the brake rod, remove the hexagon nut at the equaliser and loosen the sleeve 2. Clean and grease the brake rod threads. 3. Manually tighten the connecting sleeve. 4. Pull and release the parking brake three times. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 167: Maintenance For Optional Items
The machine is standing level. The machine is fully vented, the pressure gauge reads 0 psig. The machine has cooled down. All compressed air consumers are disconnected and the air outlet valves are open. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 168: Fig. 82 Tool Lubricator Maintenance
2. Use a funnel to pour in the oil to the maximum level (0.4 – 0.6 inches below the top of the tank). 3. Check the oil level. 4. Check the filler plug O-ring for external damage. Skadet O-ring: replace the O-ring. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 169: Cyclone Separator Maintenance
2. Loosen the union nut and detach the condensate drain hose from the dirt trap. 3. Use the small screwdriver to unscrew the nozzle from the dirt trap housing. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 170: Combination Filter Maintenance
Filter combination is pressurised during operation. Serious injury can result from loosening or opening components under pressure. ➤ Wait until the machine has automatically vented (check: pressure gauge reads 0 psig! ➤ De-pressurise the combination filter. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 171: Fig. 84 Filter Combination
Pressure differential gauge (check fittings Microfilter for Service personnel) Pre-filter Filter head Cyclone separator Casing gasket Condensate drain hose fittings Filter element Shut-off ball valve for condensate drain‐ Filter housing ➤ Open the left-hand door. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 172 Changing the prefilter element 1. Unscrew the filter housing counter-clockwise. 2. Draw the filter element down and out. 3. Clean the filter head, housing and sealing surface with a lint-free cloth. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 173 3. Wait until the machine has automatically vented. Pressure gauge reads 0 psig! 4. Open the outlet valves. 5. Open the left-hand door. 6. Check the combination filter housing and hose lines for leaks. 7. Close the door. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 174: Fresh Air Filter Maintenance
2. Open the condensate drain valve. 3. Close the doors. 4. Switch the machine on and run it in IDLE mode for approx. 2 minutes. The condensate collecting in the filter housings is blown out. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 175 2. Draw the filter element down and out. 3. Clean the lower housing and sealing surface with a lint-free cloth. 4. Check the housing gasket. When damaged, replace the housing gasket. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 176 3. Wait until the machine has automatically vented. Pressure gauge reads 0 psig! 4. Open the outlet valves. 5. Open both doors. 6. Check the fresh air filter housing and hose line for leaks. 7. Close the doors. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 177: Frost Protector Maintenance
Filling the frost protector Frost protector clamp ring Frost protector bowl Antifreeze container 1. Open both doors. 2. Unscrew the clamp ring and remove the bowl. 3. Fill the bowl ¾ full with antifreeze. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 178: Spark Arrestor Maintenance
Cleaning the spark arrestor (floor pan with service openings) Exhaust silencer end pipe Soot drain port with plug Opening in floor panel to access drain port Exhaust silencer with integrated spark ar‐ restor Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 179: Fig. 89 Cleaning The Spark Arrestor (Sealed Floor Pan)
7. Remove the hose and replace the plug. 8. Screw the service plug back into the floor pan. It is recommended to blow out the spark arrestor with compressed air once a year. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 180: Engine Air Intake Shut-Off Valve Maintenance
The machine does not shut down? Destruction of the engine and explosion and/or fire are possible! ➤ Do not move the valve adjusting screw. ➤ Have the valve set by a specialist workshop or KAESER Service. Fig. 90 Engine air intake shut-off valve maintenance...
Page 181: Generator Drive Belt Maintenance
Blow out any dirt with compressed air. If necessary, clean the valve with petroleum ether or spirit and allow to dry. Refer to a specialised workshop or KAESER Service if dirt cannot be removed. Checking the engine air intake shut-off valve for correct function and movement: 1.
Page 182: Fig. 91 Securing The Belt Guard At The Generator
2. Replace the belt guard. 3. Reconnect the negative battery terminal. 4. Close the doors. 10.8.8.2 Checking belt tension Check belt tension when they are warm, not hot, to avoid length variations through tempera‐ ture. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 183: Fig. 92 Generator Belt Tensioning
3. Tighten the locknuts 4. Replace the belt guard. 5. Reconnect the negative battery terminal. 6. Close the doors. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 184: Draining Liquid Accumulation Within The Machine
All compressed air consumers are disconnected and the air outlet valves are open. 1. Place a receptacle underneath the maintenance opening(s). 2. Unscrew and remove the bung(s) from the maintenance openings. The liquid will drain. 3. Clean the bungs and maintenance openings. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 185 4. Close all maintenance openings with bungs. The machine body is sealed. 5. Using the cleaning cloth, remove any dirt within the machine. Dispose of collected liquid and contaminated working materials according to environmental protection regulations. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 186: Documenting Maintenance And Service Work
Documenting maintenance and service work Machine model/part number: ➤ Enter maintenance and service work carried out in this list. Date Maintenance task carried out Operating hours Signature Tab. 90 Maintenance log Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 187: 11 Spares, Operating Materials, Service
11.2 Ordering consumable parts and operating fluids/materials KAESER consumable parts and operating materials are original Kaeser products. They are match‐ ed to application in our machines and ensure trouble-free operation. Unsuitable or poor quality consumable parts and operating fluids/materials may damage the ma‐...
Page 188: Kaeser Air Service
Lower costs and higher compressed air availability. 11.4 Service Addresses Addresses of KAESER representatives are given at the end of this manual. 11.5 Replacement parts for service and repair With the help of the parts list you can plan your material requirement according to operating condi‐...
Page 189 ➤ 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, carried out by motor vehicle workshops or KAESER Service. Operator Manual Screw Compressor No.: 9_6999 23 USE...
Page 190 Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 191 Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 192 Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 193 Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 194 Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 195 Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 196 Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 197 Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 198 Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 199 Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 200 Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 201 Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 202 Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 203 Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 204 Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 205 Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 206 Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 207 Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 208 Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 209 Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 210 Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 211 Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 212 Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 213 Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 214 Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 215 Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 216 Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 217 Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 218 Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 219 Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 220 Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 221 Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 222 Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 223 Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 224 Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 225 Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 226 Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 227 Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 228 Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 229 Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 230 Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 231 Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 232 Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 233 Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 234 Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 235 Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 236 Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 237 Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 238 Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 239: 12 Decommissioning, Storage And Transport
Decommissioning of the compressor for several weeks during severe frost Danger of batteries freezing! Discharged batteries are subject to frost damage and can freeze at 14 °F. ➤ Store batteries in a frost-free place. ➤ Store batteries preferably fully charged. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 240: Long-Term Decommissioning And Storage
➤ Clean the bodywork and treat with preservative. – ➤ Hang a notice on the instrument panel to inform of the decommis‐ – sioning measures taken. Tab. 96 Long-term decommissioning and storage checklist Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 241: Transport
Chassis with overrun brake ■ Lighting and signaling system. All other machines may be transported only on non-public roads! National and local regulations must be observed when towing the machine on public high‐ ways. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 242 Option rb/rk/rm/rs, Adjust the towing bar to suit the height of the towing vehicle hitch. rb/rl/rm/rs When the machine is coupled up, the towing bar must be parallel with the ground. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 243: Fig. 93 Towing Position
To hitch up the machine, lower the open coupling onto the ball of the towing vehicle so that it clicks into place. The coupling is fully locked when the green locking indicator protrudes and is visible from the side. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 244: Fig. 94 Ball Coupling (Alko-Eu)
Checking the ball coupling wear indicator (EU version): The ball coupling is equipped with a wear indicator. The wear indicator shows: ■ Wear on the ball hitch. ■ Wear on the coupling. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 245: Fig. 95 Wear Alert, Ball Coupling (Alko-Eu)
Option rd/ro/rs Coupling machine with ball coupling (US version): To couple up the compressor, lower the open coupling onto the ball hitch of the towing vehicle so that it clicks into place. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 246: Fig. 96 Ball Coupling (Alko-Usa)
Ensure transport readiness of the coupled machine. Fig. 97 Release the parking brake. Parking brake with gas spring assistance Parking brake with ratchet and spring load‐ Parking brake lever Dead point zone Brake lever release button Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 247: Fig. 98 Automatic Jockey Wheel In Transport Position
(see Ill. 97, figure b). ■ Pull the brake lever a little further on and press the release button. ■ Hold in the release button and push the lever fully down. 6. Remove the chocks. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 248: Fig. 99 Safety Sign - Secure The Chocks
5. Attach the lighting and indicator systems and carry out a function check. 6. Remove the chocks and secure them in the transport securing device. Replacement chocks can be purchased from KAESER representatives. A list is given at the end of this manual. The part number of the chock is 5.1325.0.
Page 249: Fig. 100 Breakaway Cable Attachment
➤ Attach safety chains to the towing vehicle. ■ Both chains must be crossed under the ball coupling/towing eye. ■ Allow slack for towed machine to turn. ■ Attach chain hooks securely to tow vehicle frame. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 250: Parking The Machine
➤ Wind the automatic jockey wheel up only as far as the bead does not touch the cam. ➤ Do not place your feet beneath the towing device. Fig. 102 Warning "Injury can occur if the towbar is allowed to fall." Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 251: Fig. 103 Towbar With Automatic Jockey Wheel
Slowly forward the towing vehicle to separate from the parked machine. Option rb/rk/rm/rs, Parking the machine (height-adjustable chassis): rb/rl/rm/rs 1. Use a coupled towing vehicle to move the machine into position. 2. Disconnect the lighting and signaling cable. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 252: Fig. 105 Safety Sign - Secure The Chocks
➤ As a general rule, the machine should always be blocked with chocks when it is not being moved. ➤ The machine should not be manoeuvred by hand. 2. Use a coupled towing vehicle to move the machine into position. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 253: Transport With A Crane
➤ Do not set down unevenly. 2. Set the machine down slowly and carefully. 12.2.5 Option rw Transport with a forklift truck Precondition The machine is shut down. All connecting lines and hoses disconnected and removed. Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 254: Transporting The Machine As Load
Packing 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 air. Please contact KAESER SERVICE for more information. Material Chocks...
Page 255: Storage
3. The loads must be secured against rolling, tipping, slipping and falling. Contact KAESER Service with any questions regarding transporting or load securing. KAESER accepts no liability and provides no guarantee for damage arising from incorrect transport or insufficient or incorrect load securing provisions.
Page 256: Disposal
Decommissioning, Storage and Transport 12.4 Disposal Please consult with KAESER if you have questions to the appropriate storage and commis‐ sioning. Moisture and frost can damage the machine! ➤ Prevent ingress of moisture and formation of condensation. ➤ Maintain a storage temperature of >32 °F.
Page 257: 13 Annex
Fig. 108 Identification Machine nameplate with serial number Options label VIN* (stamped in the bodywork) Engine nameplate with serial number *Vehicle Identification Number 13.2 Pipeline and instrument flow diagram (P+I diagram) Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 258 Annex 13.2 Pipeline and instrument flow diagram (P+I diagram) Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 259 Annex 13.2 Pipeline and instrument flow diagram (P+I diagram) Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 260 Annex 13.2 Pipeline and instrument flow diagram (P+I diagram) Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 261 Annex 13.2 Pipeline and instrument flow diagram (P+I diagram) Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 262 Annex 13.2 Pipeline and instrument flow diagram (P+I diagram) Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 263: Dimensional Drawings
Dimensional drawings 13.3.1 Option rb/rm/rs Dimensional drawing, chassis options ■ Option rb - Chassis EU version ■ Option rm - Chassis with height-adjustable towbar ■ Option rs - Chassis with overrun brake Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 264 Annex 13.3 Dimensional drawings Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 265: Dimensional Drawing, Chassis Options
13.3.2 Option rc/ro/rs Dimensional drawing, chassis options ■ Option rc - Chassis GB version ■ Option ro - Chassis with fixed height towbar ■ Option rs - Chassis with overrun brake Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 266 Annex 13.3 Dimensional drawings Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 267: Dimensional Drawing, Chassis Options
13.3.3 Option rd/ro/rs Dimensional drawing, chassis options ■ Option rd - Chassis USA version ■ Option ro - Chassis with fixed height towbar ■ Option rs - Chassis with overrun brake Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 268 Annex 13.3 Dimensional drawings Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 269: Dimensional Drawing, Chassis Options
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 Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 270 Annex 13.3 Dimensional drawings Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 271: Dimensional Drawing, Stationary Version
Annex 13.3 Dimensional drawings 13.3.5 Option rw Dimensional drawing, stationary version ■ Option rw - Skid frame on runners Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 272 Annex 13.3 Dimensional drawings Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 273: Dimensional Drawing, Stationary Version
Annex 13.3 Dimensional drawings 13.3.6 Option rx Dimensional drawing, stationary version ■ Option rx - On frame Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 274 Annex 13.3 Dimensional drawings Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 275: Wiring Diagrams
Annex 13.4 Wiring diagrams 13.4 Wiring diagrams 13.4.1 Electrical Diagram Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 276 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 277 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 278 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 279 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 280 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 281 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 282 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 283 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 284 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 285 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 286 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 287 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 288 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 289: Lighting And Signaling System Connection
Annex 13.4 Wiring diagrams 13.4.2 Option tc Lighting and signaling system connection Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 290 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 291 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 292 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 293 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 294 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 295 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 296 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 297: Lighting And Signaling System Connection
Annex 13.4 Wiring diagrams 13.4.3 Option te Lighting and signaling system connection Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 298 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 299 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 300 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 301 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 302: Generator Electrical Diagram, 400V, 3-Ph
Annex 13.4 Wiring diagrams 13.4.4 Option ga Generator electrical diagram, 400V, 3-ph Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 303 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 304 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 305 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 306 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 307 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 308 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 309 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 310 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 311: Generator Electrical Diagram, 230V, 3-Ph
Annex 13.4 Wiring diagrams 13.4.5 Option ga Generator electrical diagram, 230V, 3-ph Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 312 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 313 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 314 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 315 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 316 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 317 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 318 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 319 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 320: Generator Electrical Diagram, 115 V, 2-Ph
Annex 13.4 Wiring diagrams 13.4.6 Option ga Generator electrical diagram, 115 V, 2-ph Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 321 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 322 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 323 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 324 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 325 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 326 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 327 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 328 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 329: Generator Electrical Diagram, 230 V, 2-Ph
Annex 13.4 Wiring diagrams 13.4.7 Option ga Generator electrical diagram, 230 V, 2-ph Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 330 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 331 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 332 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 333 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 334 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 335 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 336 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 337 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 338: Fuel Circulation Diagram
Annex 13.5 Fuel circulation diagram 13.5 Fuel circulation diagram Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 339 Annex 13.5 Fuel circulation diagram Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 340 Annex 13.5 Fuel circulation diagram Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 341: Assembly Diagrams - Chassis
Annex 13.6 Assembly diagrams - chassis 13.6 Assembly diagrams - chassis 13.6.1 Assembly diagrams - chassis EU version Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 342 Annex 13.6 Assembly diagrams - chassis Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 343: Assembly Diagrams - Chassis Gb/Us Version
Annex 13.6 Assembly diagrams - chassis 13.6.2 Assembly diagrams - chassis GB/US version Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 344 Annex 13.6 Assembly diagrams - chassis Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 345 Annex 13.6 Assembly diagrams - chassis Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 346: Assembly Diagram Brake Rod
Annex 13.6 Assembly diagrams - chassis 13.6.3 Assembly diagram brake rod Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 347 Annex 13.6 Assembly diagrams - chassis Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 348: Operating Instructions For Compressed Air Filter (Combination Filter)
Annex 13.7 Operating instructions for compressed air filter (combination filter) 13.7 Option dd Operating instructions for compressed air filter (combination filter) Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 349 FA (D), FB (D&E), FC (D&E), FD (E), FE (D&E), FF (D&E), FG STANDARD D-Pack D-PACK E-PACK Basic (OPTION) (OPTION) (OPTION) Kaeser Kompressoren GmbH Postfach 2143 96410 Coburg Tel.: 09561/640-0 Fax: 09561/640130 http://www.kaeser.com , 2 . 3 . 9 n u t...
Page 350 E-pack: Filter with filtermonitor and ECO-DRAIN Anzahl Filterelemente siehe Kapitel 3. „Technische Daten“. Quantity of filter cartridges see chapter 3. „Technical data“. - 2 - t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 351 E-Pack: Filter mit Filtermonitor E-Pack: Filter with filtermonitor Anzahl Filterelemente siehe Kapitel 3. „Technische Daten“. Quantity of filter cartridges see chapter 3. „Technical data“. - 3 - t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 352 E-pack: Filter with filtermonitor and ECO-DRAIN Anzahl Filterelemente siehe Kapitel 3. „Technische Daten“. Quantity of filter cartridges see chapter 3. „Technical data“. - 4 - t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 353 E-pack: Filter series FF with filtermonitor and ECO-DRAIN Anzahl Filterelemente siehe Kapitel 3. „Technische Daten“. Quantity of filter cartridges see chapter 3. „Technical data“. - 5 - t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 354 We reserve the right to alter the specifications without prior notice Technische Änderungen vorbehalten. - 6 - t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 355 Ausführende Tätigkeit. Changes sequence of operation Vom Bediener auszuführende Bedienschritte. 1.3 Erklärung der Symbole am Gerät 1.3 Symbols used in the filter - 7 - t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 356 ∗ Es besitzt als solches eine zur Inbetriebnahme und War- tung derartiger Einrichtungen befähigende Ausbildung bzw. Berechtigung. - 8 - t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 357 Filter/ -systeme zur Aufbereitung von Atemluft dürfen nur nach approved from manufacturer. Genehmigung des Herstellers der Filter/ -systeme eingesetzt und betrieben werden. - 9 - t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 358 Annex 13.7 Operating instructions for compressed air filter (combination filter) 3. Technical data 3. Technische Daten - 10 - t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 359 The coalesced liquids then drain to the bottom of Coalescings ausgefiltert. Die Luft tritt durch den perforierten äuße- the cartridge for removal. ren Stützmantel aus. - 13 - t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 360 Filters und tropfen dann in den Filterbehälter ab. downstream to the bottom of the sleeve and drain to the bottom of the filter bowl. - 15 - t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 361 Bei den Filtern FD, FG entfällt der Kondensatableitungsanschluß. Condensate drain does not exist in filters FD, FG. - 21 - t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 362 Close the shut-off device in the bypass (if installed). Das Filter/ -system ist nun in BETRIEB. The filter/ -system is now OPERATIVE. - 24 - t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 363 (Siehe Kapitel 9) The FG filter does not require a differential pressure gauge. Das Filter FG benötigt keine Differenzdruckanzeige. - 25 - t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 364 F r e t i t a Bh = Kompressor-Betriebsstunden / Working hours - 32 - t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 365 The filter(s) contain(s) systems under high pressure. hende Systeme. Alle pressure must be let off before servicing Vor Servicearbeiten sind sie drucklos zu machen. - 33 - t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 366 Place filter under pressure again by slowly opening the Filter durch langsames Öffnen der Absperrvorrichtungen shut-off device. wieder mit Druck beaufschlagen. - 34 - t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 367 ß i s l i Nähere Informationen finden Sie auch im Anhang ECO DRAIN. For more details please see annexe ECO DRAIN. - 35 - t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 368 Personen unsachgemäß geöffnet oder repariert wurde und/oder mechanische Beschädigungen irgendwelcher Art aufweist. - 36 - t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 369: Operating Instructions For Compressed Air Filter (Fresh Air Filter)
Annex 13.8 Operating instructions for compressed air filter (fresh air filter) 13.8 Option dc Operating instructions for compressed air filter (fresh air filter) Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 370 ALYVOS GARŲ IR KVAPO ŠALINIMO FILTRAI ФИЛЬТРЫ ДЛЯ УСТРАНЕНИЯ ЗАПАХА И ПАРОВ МАСЛА FILTRI ZA ODSTRANJEVANJE OLJNIH HLAPOV IN VONJAV YAĞ BUHARI VE KOKUSU GİDERİCİ FİLTRELER FILTRI LI JNE{{U L-FWAR TA}-}JUT U L-IRWEJJA{ FILTER-DH-OIL-XEVOLUTION 01 Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 371 Annex 13.8 Operating instructions for compressed air filter (fresh air filter) Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 372 Указывает на требования по уничтожению использованных деталей и отходов • Označuje zahteve za odlaganje rabljenih delov in odpadkov. • Kullanılmış parçaların ve atıkların atılmasına ilişkin gereklilikleri vurgular • Tissottolinea l-kundizzjonijiet biex wie[ed jarmi l-partijiet u]ati u l-iskart FILTER-DH-OIL-XEVOLUTION 01 Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 373 • Įsitikinkite, kad naudojamas reikiamas įrankis • Убедитесь, что используется правильный инструмент • Poskrbite, da boste uporabili ustrezno orodje • Doğru alet kullanılmasını sağlayın • Kun ]gur li tintu]a l-g[odda t-tajba FILTER-DH-OIL-XEVOLUTION 01 Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 374 A instalação e a manutenção deste produto só deve ser realizada por pessoal autorizado e competente, sob estrita observância destas instruções de utilização e de quaisquer normas e requisitos legais relevantes, quando adequado. Conserve este guia do utilizador para referência futura FILTER-DH-OIL-XEVOLUTION 01 Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 375 I huma ffittjati b’indikatur tal-volum ta]-]ejt. Kemm l-elementi tal-filtru kif ukoll l-indikatur g[andhom jinbidlu jekk l- indikatur isir ta’ kulur blu. Jekk Jog[;bok Innota - Dan hu indikatur tal-volum ta]-]ejt u ma jindikax i]-]mien li jdum iservi l-element tal-filtru. FILTER-DH-OIL-XEVOLUTION 01 Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 376 Annex 13.8 Operating instructions for compressed air filter (fresh air filter) AC010 - AC030 1/4” 1/2” FILTER-DH-OIL-XEVOLUTION 01 Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 377 020 C 020 D 020AA 020AC 020 E 025AA 025DAC 025 D 025AA 025EAC 025 E 030 E BOIE1 AC010 I - AC030 030AA 030AC 030 F 030 G FILTER-DH-OIL-XEVOLUTION 01 Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 378 I sono provvisti di un indicatore degli oli misti. Sostituire gli elementi filtranti e l'indicatore quando il secondo assume una colorazione blu. Nota - L'indicatore segnala la presenza di oli misti, ma non la durata dell'elemento filtrante. FILTER-DH-OIL-XEVOLUTION 01 Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 379 Annex 13.8 Operating instructions for compressed air filter (fresh air filter) AC010 - AC030 0 bar 0 bar 0 psi 0 psi FILTER-DH-OIL-XEVOLUTION 01 Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 380 13.8 Operating instructions for compressed air filter (fresh air filter) AC010 - AC030 0 bar 0 psi 0 bar 0 bar 0 psi 0 psi 0 bar 0 psi FILTER-DH-OIL-XEVOLUTION 01 Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 381 Annex 13.8 Operating instructions for compressed air filter (fresh air filter) AC010 - AC030 FILTER-DH-OIL-XEVOLUTION 01 Operator Manual Screw Compressor No.: 9_6999 23 USE M100...
Page 382 Annex 13.8 Operating instructions for compressed air filter (fresh air filter) AC010 - AC030 Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...
Page 383: Service Tasks - Generator
In order to ensure a safe operation of the machine, the generator must be inspected once every year by a trained and authorized electrician. Have the following tasks performed by a specialist electrician or an authorized KAESER service representative: ■...
Page 384 Annex 13.9 Service tasks - Generator Operator Manual Screw Compressor M100 No.: 9_6999 23 USE...

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