KAESER KOMPRESSOREN M43 Compressor Manuals

Manuals and User Guides for KAESER KOMPRESSOREN M43 Compressor. We have 1 KAESER KOMPRESSOREN M43 Compressor manual available for free PDF download: Service Manual

KAESER KOMPRESSOREN M43 Service Manual (246 pages)

Brand: KAESER KOMPRESSOREN | Category: Compressor | Size: 12.78 MB

Table of Contents
3
Regarding this Document
11
Using the Document
11
Further Documents
11
Copyright
11
Symbols and Identification
11
Warnings
11
Other Instructions and Symbols
12
Tab. 1 the Levels of Danger and Their Meaning
12
Technical Specification
13
Nameplate
13
Options
13
Tab. 2 Nameplate
13
Tool Lubricator
14
Non-Return Function
14
Fuel Filter with Water Trap
14
Tab. 3 Combined Label for Coupling Load and Options Fitted
14
Tab. 4 Tool Lubricator
14
Tab. 5 Non-Return Function
14
Tab. 6 Fuel Filter with Water Trap
14
Low Temperature Equipment
15
Battery Isolating Switch
15
Sealed Floor Pan
15
Equipment for Fire Hazard Areas
15
Chassis
15
Tab. 7 Low Temperature Equipment
15
Tab. 8 Battery Isolating Switch
15
Tab. 9 Sealed Floor Pan
15
Tab. 10 Equipment for Fire Hazard Areas
15
Lighting
16
Pedestrian Protection
16
Hose Reel
16
Anti-Theft Device
16
Tab. 11 Chassis
16
Tab. 12 Lighting
16
Tab. 13 Pedestrian Protection
16
Tab. 14 Hose Reel
16
Tab. 15 Anti-Theft Device
16
Machine (Without Options)
17
Sound Emission
17
Torques
17
Ambient Conditions
17
Tab. 16 Sound Emission
17
Tab. 17 Sound Pressure Level
17
Tab. 18 Torques for Hex-Head Screws
17
Tab. 19 Ambient Conditions
17
Dimensions
18
Chassis
18
Weights
18
Tyres
18
Wheel Fixing Tightening Torque
18
Tab. 20 Machine Weights
18
Tab. 21 Tyres
18
Tab. 22 Wheel Fixing Tightening Torque
18
Compressor
19
Working Pressure and FAD
19
Compressed Air Outlet
19
Pressure Relief Valve
19
Temperature
19
Cooling Oil Recommendation
19
Tab. 23 Working Pressure and FAD
19
Tab. 24 Compressed Air Distributor
19
Tab. 25 Relief Valve Activating Pressure
19
Tab. 26 Machine Temperatures
19
Cooling Oil Charge
20
Engine
20
Engine Data
20
Tab. 27 Cooling Oil Recommendation
20
Tab. 28 Cooling Oil Charge
20
Oil Recommendation
21
Engine Coolant Recommendation
21
Fluid Volumes
21
Battery
21
Tab. 29 Engine Specification
21
Tab. 30 Engine Oil Recommendation
21
Tab. 31 Engine Fluid Volumes
21
Options
22
Tool Lubricator
22
Low Temperature Equipment
22
Tab. 32 Battery
22
Tab. 33 Road Breaker Lubricant Recommendation
22
Tab. 34 Ambient Conditions
22
Tab. 35 Antifreeze Recommendation
22
Tab. 36 Coolant Pre-Heater
22
Safety and Responsibility
23
Basic Information
23
Specified Use
23
Improper Use
23
User's Responsibilities
23
Observe Statutory and Universally Accepted Regulations
23
Defining Personnel
24
Adherence to Inspection Schedules and Accident Prevention Regulations
24
Dangers
25
Safely Dealing with Sources of Danger
25
Tab. 37 Inspection Intervals According to Ordinance on Industrial Safety and Health
25
Safe Machine Operation
27
Organisational Measures
29
Danger Areas
29
Tab. 38 Danger Areas
29
Safety Devices
30
Safety Signs
30
Fig. 1 Location of Safety Signs
30
Tab. 39 Safety Signs
31
In Emergency
32
Correct Fire Fighting
32
Contact with Operating Materials
32
Warranty
32
Environmental Protection
33
Design and Function Bodywork
34
Fig. 2 Overview Bodywork
34
Component Identification
35
Fig. 3 Side View (Canopy Removed)
35
Machine Function
36
Fig. 4 General Design
37
Operating Modes and Control Modes
38
Operating Modes
38
MODULATING Control
39
Safety Devices
39
Monitoring Functions with Shutdown
39
Further Safety Devices
39
Options
39
Tool Lubricator
39
Low Temperature Equipment
40
Fig. 5 Tool Lubricator
40
Fig. 6 Frost Protector
41
Fig. 7 Coolant Pre-Heating
41
Sealed Floor Pan
42
Battery Isolating Switch
42
Fuel Filter with Water Trap
43
Option for Operating in Fire Hazard Areas
43
Fig. 8 Battery Isolating Switch
43
Optional Anti-Theft Device
44
Transportation Option
44
Tab. 40 Chassis - Overview
45
Installation and Operating Conditions Safety
46
Installation Conditions
46
Fig. 9 Minimum Distance from Excavations/Slopes and Walls
46
Installation
48
Safety
48
Reporting Transport Damage
48
Adjusting the Chassis
48
Tab. 41 Height Adjustable Towbar
48
Adjusting the Towbar Height
49
Fig. 10 Height Adjustable Towbar Sa
49
Adjusting the Towbar Height
50
Fig. 11 Towbar Height Adjustment Sb
51
Changing the Towing Eye or Coupling
52
Tab. 42 Choice of Ball Couplings
52
Fig. 12 Change from Eye to Ball Coupling (Height Adjustable Towbar)
53
Fig. 13 Change from Eye to Ball Coupling (Height Adjustable Towbar with Overrun Brake)
55
Fig. 14 Change from Eye to Ball Coupling (Fixed Height Towbar)
57
Fig. 15 Changing from Eye to Ball Coupling (Fixed Height Towbar with Overrun Brake)
58
Initial Start-Up
60
Safety
60
Instructions to be Observed before Commissioning or Recommissioning
60
Checking Installation and Operating Conditions
60
After Storing the Machine for a Long Period
61
Low-Temperature Operation (Winter)
61
Tab. 43 Installation and Operating Conditions Checklist
61
Tab. 44 Measures for Re-Commissioning the Compressor after a Long Period of Storage
61
Starting Assistance
62
Fig. 16 Jumper Cable Connection Diagram
62
Starting up Low-Temperature Equipment
63
Tab. 45 Low-Temperature Equipment Checklist
64
Operation
65
Starting and Stopping
65
Starting
65
Fig. 17 Starting Instruments
65
Allow the Machine to Run up to Operating Temperature
66
Shutting down
66
Fig. 18 Warm-Up Period When Ambient Temperatures Are below -10 °C
66
Operating the Battery Isolating Switch
67
Fig. 19 Battery Isolating Switch
67
Operating the Tool Lubricator
68
Using the Low-Temperature Equipment
68
Using the Frost Protector
68
Fig. 20 Setting the Tool Lubricator
68
Coolant Pre-Heating
69
Fig. 21 Switching on the Frost Protector
69
Using the Hose Reel
70
Using the Hose Reel (EC Version)
70
Fig. 22 Hose Reel (EC Design)
70
Fault Recognition and Rectification
72
Basic Instructions
72
Engine Faults and Alarms
72
Engine Refuses to Start or Comes to a Stop
72
Engine Does Not Reach Full Speed
73
Indicator Lamp Remains on
73
Tab. 46 Alarm: Engine Refuses to Start or Comes to a Stop
73
Tab. 47 Alarm: Engine Does Not Reach Full Speed
73
Tab. 48 Indicator Lamp Remains on
73
Compressor Faults and Alarms
74
Working Pressure too High
74
Working Pressure too Low
74
Tab. 49 Fault: Working Pressure too High
74
Tab. 50 Fault: Working Pressure too Low
74
Pressure Relief Valve Blowing off
75
Machine Overheating
75
Tab. 51 Fault: Pressure Relief Valve Blowing off
75
Tab. 52 Fault: Machine Overheating
75
Too Much Oil Residue in the Compressed Air
76
Oil Flows from the Compressor Air Filter after Shutdown
76
Tab. 53 Fault: too Much Oil Residue in the Compressed Air
76
Tab. 54 Fault: Oil Flows from the Compressor Air Filter after Shutdown
76
10 Maintenance
77
Safety
77
Maintenance Schedules
77
Logging Maintenance Work
77
Maintenance Tasks after Commissioning
78
Regular Maintenance Tasks
78
Tab. 55 Maintenance Tasks after Commissioning
78
Tab. 56 Maintenance Intervals and Regular Maintenance Tasks
78
Tab. 57 Regular Maintenance Tasks
81
Engine
82
Cooler Maintenance
82
Tab. 58 Regular Maintenance Tasks for Options
82
Fig. 23 Checking Coolant Level
83
Tab. 59 Coolant Frost Protection
84
Air Filter Maintenance
85
Fig. 24 Draining the Coolant from the Radiator
85
Fig. 25 Engine Air Filter Maintenance
86
Fuel System Maintenance
87
Fig. 26 Bleeding the Fuel System
88
Fig. 27 Fuel Filter with Water Trap
90
Changing the Engine Oil
91
Fig. 28 Changing the Engine Oil
92
Fig. 29 Engine Sump Drain Valve
93
Fig. 30 Changing the Engine Oil Filter
94
Motor Belt Maintenance
95
Battery Maintenance
95
Fig. 31 Warning Stickers on the Battery
95
Compressor
97
Checking Cooling Oil Level
97
Topping up the Cooling Oil
98
Fig. 32 Checking Cooling Oil Level
98
Changing the Cooling Oil
99
Fig. 33 Changing the Cooling Oil
100
Fig. 34 Shut-Off Valves for Oil Cooler and Separator Tank
101
Changing the Oil Filter
102
Fig. 35 Changing the Oil Filter
102
Changing the Oil Separator Cartridge
103
Fig. 36 Changing the Oil Separator Cartridge
104
Fig. 37 Oil Separator Tank Dirt Trap Maintenance
105
Air Filter Maintenance
106
Fig. 38 Compressor Air Filter Maintenance
107
Pressure Relief Valve Checking
108
Cooler/Radiator Cleaning
108
Chassis
109
Wheel Checks
109
Fig. 39 Cooler/Radiator Cleaning
109
Towbar Maintenance
110
Overrun Braking Mechanism Maintenance
110
Tab. 60 Overrun Brake Mechanism Lubricating Point
110
Greasing the Brake Rods
111
Checking Brake Linings
111
Fig. 40 Checking the Brake Lining Thickness
111
Maintain Rubber Sealing Strips
112
Options
112
Tool Lubricator Maintenance
112
Fig. 41 Tool Lubricator Maintenance
112
Frost Protector Maintenance
113
Spark Arrestor Cleaning
114
Fig. 42 Filling the Frost Protector
114
Fig. 43 Spark Arrestor Cleaning
115
Engine Air Intake Shut-Off Valve Maintenance
116
Fig. 44 Engine Air Intake Shut-Off Valve Maintenance
116
Document Maintenance and Service Work
118
Tab. 61 Logged Maintenance Tasks
118
11 Spares, Operating Materials, Service
119
Note the Nameplate
119
Ordering Consumable Parts and Operating Fluids/Materials
119
Tab. 62 Compressor Consumables
119
Tab. 63 Consumable Engine Parts
119
Kaeser Air Service
120
Service Addresses
120
Spares for Service and Repair
120
Decommissioning, Storage and Transport 12.1 De-Commissioning
202
Temporary Decommissioning
202
Tab. 64 "Temporarily Decommissioned" Information Notice
202
Long-Term Decommissioning
203
Transporting
204
Towing the Compressor on the Road
204
Tab. 65 Long-Term Decommissioning Checklist
204
Tab. 66 "Long-Term Decommissioned" Information Notice
204
Fig. 45 Towing Alignment
205
Fig. 46 Ball Coupling Function
206
Fig. 47 Safety Signs: Secure the Chocks
208
Fig. 48 Breakaway Cable Attachment
208
Parking the Compressor
209
Fig. 49 Injury Can Occur if the Towbar Is Unsupported and Allowed to Fall
209
Fig. 50 Safety Sign - Secure the Chocks
210
Transporting with a Crane
211
Transporting as a Load
212
Fig. 51 Load Secured by Straps
212
Storage
213
Disposal
213
Annex 13.1 Marking
215
Pipeline and Instrument Flow Diagram (P+I Diagram)
215
Fig. 52 Marking
215
Dimensional Drawings
219
Dimensional Drawing - Chassis with Height-Adjustable Tow Bar
219
Dimensional Drawing - Chassis with Height-Adjustable Tow Bar
221
Dimensional Drawing - Fixed Height Towbar and Parking Brake
223
Dimensional Drawing - Fixed Height Towbar and Overrun Brake
225
Electrical Diagram
227
Lighting and Signalling System Connection
237
Fuel Circulation Diagram
243

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