KAESER M 64 User manual

Operator manual
Portable compressor
M 64
No.: 9_5898 26 E
Manufacturer:
KAESER KOMPRESSOREN SE
96410 Coburg • PO Box 2143 • GERMANY • Tel. [phone] • Fax [phone]
http://www.kaeser.com
RAMIRENT

Original instructions
/KKW/M64 2.06 en SBA-MOBILAIR
20160428 104438
RAMIRENT

1 Regarding this document
1.1 Using this document ......................................................................................................... 1
1.2 Further documents ........................................................................................................... 1
1.3 Copyright .......................................................................................................................... 1
1.4 Symbols and labels .......................................................................................................... 1
1.4.1 Warnings ............................................................................................................. 1
1.4.2 Potential damage warnings ................................................................................ 2
1.4.3 Other alerts and their symbols ............................................................................ 2
2 Technical Specifications
2.1 Nameplate ........................................................................................................................ 4
2.2 Options – options label ..................................................................................................... 4
2.2.1 Compressed air treatment devices ..................................................................... 5
2.2.2 Tool lubricator ..................................................................................................... 5
2.2.3 Compressed air distributor .................................................................................. 5
2.2.4 Low temperature equipment ............................................................................... 6
2.2.5 Equipment for fire hazard areas ......................................................................... 6
2.2.6 Battery isolating switch ....................................................................................... 6
2.2.7 Chassis ............................................................................................................... 6
2.2.8 Lighting ............................................................................................................... 7
2.2.9 Generator ............................................................................................................ 7
2.2.10 Hose reels ........................................................................................................... 8
2.2.11 Anti-theft device .................................................................................................. 8
2.2.12 Pedestrian protection .......................................................................................... 8
2.2.13 Instrument panel cover ....................................................................................... 8
2.2.14 Diesel particulate filter ........................................................................................ 8
2.3 Machine (without options) ................................................................................................ 9
2.3.1 Noise emission ................................................................................................... 9
2.3.2 Tightening torques for screws ............................................................................. 9
2.3.3 Ambient conditions ............................................................................................. 9
2.3.4 Additional specifications according to the machine's operating licence ............. 9
2.4 Chassis ........................................................................................................................... 10
2.4.1 Chassis options .................................................................................................. 10
2.5 Machines with stationary frame design ............................................................................ 10
2.5.1 Mass of machines with stationary frame design ................................................. 10
2.6 Compressor ..................................................................................................................... 10
2.6.1 Working pressure and FAD ................................................................................ 10
2.6.2 Compressed air outlet ......................................................................................... 11
2.6.3 Pressure relief valves ......................................................................................... 11
2.6.4 Temperature ....................................................................................................... 11
2.6.5 Cooling oil recommendation ............................................................................... 11
2.6.6 Cooling oil charge ............................................................................................... 13
2.7 Engine ............................................................................................................................. 13
2.7.1 Engine specification ............................................................................................ 13
2.7.2 Oil recommendation ............................................................................................ 13
2.7.3 Fuel recommendation ......................................................................................... 14
2.7.4 Engine coolant recommendation ........................................................................ 14
2.7.5 Fluid volumes ...................................................................................................... 15
2.7.6 Battery ................................................................................................................ 15
2.8 Options ............................................................................................................................ 15
2.8.1 Air treatment options ........................................................................................... 15
2.8.2 Low temperature equipment ............................................................................... 16
2.8.3 Diesel particulate filter ........................................................................................ 17
2.8.4 Generator (50 Hz version) .................................................................................. 17
2.8.5 Generator (60 Hz version) .................................................................................. 20
Contents
No.: 9_5898 26 E
Operator manual Portable compressor
M 64 i
RAMIRENT

3 Safety and Responsibility
3.1 Basic instructions ............................................................................................................. 23
3.2 Specified use .................................................................................................................... 23
3.3 Incorrect Use .................................................................................................................... 23
3.4 User's responsibilities ....................................................................................................... 23
3.4.1 Observe statutory and universally accepted regulations .................................... 23
3.4.2 Determining personnel ........................................................................................ 24
3.4.3 Keeping to Inspection Schedules and Accident Prevention Regulations ........... 24
3.4.4 Complying with inspection intervals for diesel particulate filters ......................... 25
3.4.5 Attachment of a "Hazardous goods" label .......................................................... 25
3.5 Dangers ............................................................................................................................ 26
3.5.1 Safely dealing with sources of danger ................................................................ 26
3.5.2 Safe machine operation ...................................................................................... 29
3.5.3 Organisational Measures .................................................................................... 32
3.5.4 Danger areas ...................................................................................................... 32
3.6 Safety devices .................................................................................................................. 33
3.7 Safety signs ...................................................................................................................... 33
3.8 Generator operation ......................................................................................................... 36
3.8.1 Comply with the protective measures against dangerous electric current ......... 36
3.8.2 Safe generator operation .................................................................................... 36
3.8.3 Connecting extension cables .............................................................................. 36
3.8.4 Do not exceed the maximum supply system load .............................................. 37
3.8.5 Perform regular generator inspections ............................................................... 37
3.9 Emergencies .................................................................................................................... 37
3.9.1 Correct fire fighting ............................................................................................. 37
3.9.2 Injury from handling operating fluids/materials ................................................... 38
3.10 Warranty ........................................................................................................................... 38
3.11 Identifying the effects of improper modifications .............................................................. 39
3.12 Environment protection .................................................................................................... 40
4 Design and Function
4.1 Bodywork ......................................................................................................................... 41
4.2 Machine structure ............................................................................................................. 42
4.3 Machine function .............................................................................................................. 43
4.4 Operating modes and control mode ................................................................................. 44
4.4.1 Operating modes ................................................................................................ 44
4.4.2 MODULATING control ........................................................................................ 44
4.5 Safety devices .................................................................................................................. 45
4.5.1 Monitoring functions with shutdown .................................................................... 45
4.5.2 Further safety devices ........................................................................................ 46
4.6 Options ............................................................................................................................. 46
4.6.1 Air treatment options ........................................................................................... 46
4.6.2 Low temperature equipment options .................................................................. 49
4.6.3 Optional battery isolating switch ......................................................................... 51
4.6.4 Options for operating in fire hazard areas .......................................................... 51
4.6.5 Generator option ................................................................................................. 52
4.6.6 Diesel particulate filter option .............................................................................. 54
4.6.7 Hose reel option .................................................................................................. 55
4.6.8 Optional anti-theft device ................................................................................... 55
4.6.9 Pedestrian protection option ............................................................................... 55
4.6.10 Instrument panel cover option ............................................................................ 56
4.7 Frame design options for stationary machines ................................................................ 56
4.7.1 Chassis types of stationary machines ................................................................ 56
Contents
ii Operator manual Portable compressor
M 64 No.: 9_5898 26 E
RAMIRENT

5 Installation and Operating Conditions
5.1 Ensuring safety ................................................................................................................ 57
5.2 Installation conditions ....................................................................................................... 57
6 Installation
6.1 Ensuring safety ................................................................................................................ 59
6.2 Reporting Transport Damage ........................................................................................... 59
7 Initial Start-up
7.1 Ensuring safety ................................................................................................................ 60
7.2 Before Initial Start-up (or Recommissioning) ................................................................... 60
7.2.1 Note when commissioning .................................................................................. 60
7.2.2 Special measures for re-commissioning after storage or de-commissioning ..... 61
7.3 Checking installation and operating conditions ................................................................ 61
7.4 Low-temperature operation (winter) ................................................................................. 62
7.4.1 Starting assistance ............................................................................................. 62
7.4.2 Starting up low-temperature equipment .............................................................. 64
7.5 Putting the generator into operation ................................................................................. 66
8 Operation
8.1 Ensuring safety ................................................................................................................ 69
8.2 Starting and stopping ....................................................................................................... 70
8.2.1 Running the machine .......................................................................................... 70
8.2.2 Engine pre-heating ............................................................................................. 71
8.2.3 Starting the machine ........................................................................................... 71
8.2.4 Allow the machine to run up to operating temperature ....................................... 72
8.2.5 Switching to LOAD ............................................................................................. 72
8.2.6 Regulating the shut-off valve .............................................................................. 72
8.2.7 Shutting down the machine ................................................................................ 73
8.3 Ending the reverse engine run ......................................................................................... 74
8.4 Using the hose reel .......................................................................................................... 74
8.4.1 Using the hose reel (EC version) ........................................................................ 74
8.4.2 Using the hose reel (USA version) ..................................................................... 76
8.5 Operating the tool lubricator ............................................................................................. 77
8.6 Using the low-temperature equipment ............................................................................. 78
8.6.1 Coolant pre-heating ............................................................................................ 78
8.6.2 Operating the machine with frost protector ......................................................... 78
8.7 Operating the battery isolating switch .............................................................................. 79
8.8 Generator operation ......................................................................................................... 80
8.8.1 Note when operating the generator .................................................................... 80
8.8.2 Switching in the generator .................................................................................. 80
8.8.3 Switching off the generator ................................................................................. 81
8.9 Cleaning the machine after operation .............................................................................. 81
9 Fault Recognition and Rectification
9.1 Basic instructions ............................................................................................................. 83
9.2 Evaluating engine faults and alarms ................................................................................ 83
9.2.1 Engine refuses to start or does not turn over ...................................................... 83
9.2.2 Engine does not reach full speed ....................................................................... 84
9.2.3 Indicator lamp remains on .................................................................................. 84
9.2.4 Motor running backwards ................................................................................... 85
9.3 Analysing compressor faults and alarms ......................................................................... 85
9.3.1 Working pressure too high .................................................................................. 85
9.3.2 Working pressure too low. .................................................................................. 85
9.3.3 Pressure relief valve blowing off ......................................................................... 86
9.3.4 Machine overheating .......................................................................................... 86
Contents
No.: 9_5898 26 E
Operator manual Portable compressor
M 64 iii
RAMIRENT

9.3.5 Too much oil residue in the compressed air ....................................................... 87
9.3.6 Oil flows from the compressor air filter after shutdown ....................................... 87
9.3.7 High moisture content in the compressed air ..................................................... 88
9.4 Evaluate faults in the diesel particulate filter .................................................................... 88
9.5 Evaluate generator faults and alarms .............................................................................. 89
9.5.1 There is no voltage or too low a voltage from the generator .............................. 89
9.5.2 Generator voltage too high ................................................................................. 89
10 Maintenance
10.1 Ensuring safety ................................................................................................................ 91
10.2 Following the maintenance plans ..................................................................................... 92
10.2.1 Logging maintenance work ................................................................................. 92
10.2.2 Maintenance tasks after commissioning ............................................................. 92
10.2.3 Regular maintenance tasks ................................................................................ 93
10.3 Engine maintenance ........................................................................................................ 97
10.3.1 Water cooler maintenance .................................................................................. 98
10.3.2 Engine air filter maintenance .............................................................................. 103
10.3.3 Fuel system maintenance ................................................................................... 105
10.3.4 Checking the engine oil level .............................................................................. 109
10.3.5 Engine oil filling and topping up .......................................................................... 110
10.3.6 Changing the engine oil ...................................................................................... 111
10.3.7 Replace the engine oil filter ................................................................................ 114
10.3.8 Drive belt maintenance ....................................................................................... 115
10.3.9 Battery maintenance ........................................................................................... 118
10.3.10 Checking the fastening of the fuel tank .............................................................. 121
10.4 Compressor Maintenance ................................................................................................ 122
10.4.1 Checking cooling oil level ................................................................................... 122
10.4.2 Cooling oil filling and topping up ......................................................................... 123
10.4.3 Changing the cooling oil ..................................................................................... 124
10.4.4 Replacing the compressor oil filter ...................................................................... 126
10.4.5 Oil separator tank dirt trap maintenance ............................................................. 128
10.4.6 Changing the Oil Separator Cartridge ................................................................ 129
10.4.7 Compressor air filter maintenance ...................................................................... 133
10.4.8 Check pressure relief valves ............................................................................... 136
10.4.9 Fit the flexible pipe connection ........................................................................... 136
10.5 Cleaning the cooler .......................................................................................................... 137
10.5.1 Cleaning the compressor cooler and engine radiator ......................................... 137
10.5.2 Cleaning the compressed air aftercooler ............................................................ 138
10.6 Maintenance of rubber sealing strips ............................................................................... 139
10.7 Maintenance of Optional Items ........................................................................................ 140
10.7.1 Tool lubricator maintenance ............................................................................... 140
10.7.2 Cyclone separator maintenance ......................................................................... 141
10.7.3 Combination filter maintenance .......................................................................... 143
10.7.4 Fresh air filter maintenance ................................................................................ 146
10.7.5 Frost protector maintenance ............................................................................... 149
10.7.6 Spark arrestor cleaning ....................................................................................... 151
10.7.7 Engine air shut-off valve maintenance ................................................................ 152
10.7.8 Generator drive belt maintenance ...................................................................... 154
10.8 Documenting maintenance and service work .................................................................. 161
11 Spares, Operating Materials, Service
11.1 Note the nameplate .......................................................................................................... 162
11.2 Ordering consumable parts and operating fluids/materials .............................................. 162
11.3 KAESER AIR SERVICE .................................................................................................. 163
11.4 Service Addresses ........................................................................................................... 163
Contents
iv Operator manual Portable compressor
M 64 No.: 9_5898 26 E
RAMIRENT

11.5 Replacement parts for service and repair ........................................................................ 163
12 Decommissioning, Storage and Transport
12.1 De-commissioning ............................................................................................................ 196
12.1.1 Temporary de-commissioning ............................................................................ 196
12.1.2 Long-term de-commissioning and storage ......................................................... 197
12.2 Transport .......................................................................................................................... 198
12.2.1 Safety .................................................................................................................. 199
12.2.2 Transport with a crane ........................................................................................ 199
12.2.3 Transport with a forklift truck ............................................................................... 199
12.2.4 Transporting the machine as load ...................................................................... 202
12.3 Storage ............................................................................................................................. 203
12.4 Disposal ........................................................................................................................... 204
13 Annex
13.1 Marking ............................................................................................................................ 205
13.2 Pipeline and instrument flow diagram (P+I diagram) ....................................................... 205
13.3 Dimensional drawings ...................................................................................................... 210
13.3.1 Drawing chassis .................................................................................................. 210
13.3.2 Drawing chassis .................................................................................................. 212
13.3.3 Dimensional drawing – chassis ........................................................................... 214
13.3.4 Dimensional drawing, stationary version ............................................................ 216
13.3.5 Dimensional drawing, stationary version ............................................................ 218
13.4 Wiring diagrams .............................................................................................................. 220
13.4.1 Electrical Diagram ............................................................................................... 220
13.4.2 Connection adapter for the diesel particulate filter ............................................. 233
13.4.3 Lighting and signalling system connection ......................................................... 238
13.4.4 Lighting and signalling system connection ......................................................... 246
13.4.5 Generator electrical diagram, 400V, 3-ph ........................................................... 251
13.4.6 Generator electrical diagram, 230V, 3-ph ........................................................... 260
13.4.7 Generator electrical diagram, 115V, 2-ph ........................................................... 269
13.4.8 Generator electrical diagram, 230V, 2-ph ........................................................... 278
13.5 Fuel circulation diagram ................................................................................................... 287
13.6 Operating instructions for compressed air filter (combination filter) ................................. 290
13.7 Operating instructions for compressed air filter (fresh air filter) ....................................... 318
13.8 Service tasks on the diesel particulate filter ..................................................................... 332
13.9 Service tasks - Generator ................................................................................................ 332
Contents
No.: 9_5898 26 E
Operator manual Portable compressor
M 64 v
RAMIRENT

Contents
vi Operator manual Portable compressor
M 64 No.: 9_5898 26 E
RAMIRENT

Fig. 1 Location of safety signs .............................................................................................................. 34
Fig. 2 Overview Bodywork .................................................................................................................... 41
Fig. 3 Right-hand door opened ............................................................................................................. 42
Fig. 4 Left-hand door opened ............................................................................................................... 42
Fig. 5 Machine overview ....................................................................................................................... 43
Fig. 6 Stepless regulation of FAD (standstill) ....................................................................................... 45
Fig. 7 Compressed air options ............................................................................................................. 46
Fig. 8 Tool lubricator ............................................................................................................................. 48
Fig. 9 Principle tool lubricator ............................................................................................................... 49
Fig. 10 Coolant pre-heating .................................................................................................................... 50
Fig. 11 Frost protector ............................................................................................................................ 50
Fig. 12 Battery isolating switch ............................................................................................................... 51
Fig. 13 Instrument panel – generator control box, 400 V AC ................................................................. 53
Fig. 14 Instrument panel – generator control box, 230 V AC ................................................................. 53
Fig. 15 Generator instrument panel - control box, 115 V, single-phase (50 Hz) .................................... 54
Fig. 16 Generator instrument panel - control box, 230 V, single-phase (60 Hz) .................................... 54
Fig. 17 General design of the diesel particulate filter system ................................................................. 55
Fig. 18 Minimum distance from excavations/slopes and walls ............................................................... 58
Fig. 19 Jumper cable connection diagram ............................................................................................. 63
Fig. 20 Coolant pre-heating .................................................................................................................... 65
Fig. 21 Operating the frost protector ...................................................................................................... 65
Fig. 22 Insulation monitoring – 400 V three-phase Generator ................................................................ 66
Fig. 23 Insulation monitoring – 230 V three-phase Generator ................................................................ 66
Fig. 24 Insulation monitoring - 115 V, single-phase generator (50 Hz) .................................................. 67
Fig. 25 insulation monitoring - 230 V, single-phase generator (60 Hz) .................................................. 67
Fig. 26 Starting instruments ................................................................................................................... 70
Fig. 27 Label referring to the warm-up period when ambient temperatures are below -10 °C ............... 72
Fig. 28 Control line shut-off valve ........................................................................................................... 73
Fig. 29 Hose reel (EC design) ................................................................................................................ 75
Fig. 30 Hose reel (EC design) ................................................................................................................ 76
Fig. 31 Setting the tool lubricator ............................................................................................................ 77
Fig. 32 Frost protector on and off ........................................................................................................... 78
Fig. 33 Battery isolating switch ............................................................................................................... 79
Fig. 34 Checking coolant level ............................................................................................................... 99
Fig. 35 Draining the coolant from the radiator ........................................................................................ 102
Fig. 36 Engine air filter maintenance ...................................................................................................... 103
Fig. 37 Cleaning the filter element .......................................................................................................... 104
Fig. 38 Fuel system maintenance .......................................................................................................... 105
Fig. 39 Bleeding the fuel system ............................................................................................................ 106
Fig. 40 Fuel water separator maintenance ............................................................................................. 107
Fig. 41 Changing the fuel pre-filter ......................................................................................................... 108
Fig. 42 Fuel fine filter maintenance ........................................................................................................ 108
Fig. 43 Checking the engine oil level ...................................................................................................... 110
Fig. 44 Draining the engine oil ................................................................................................................ 112
Fig. 45 Changing the engine oil .............................................................................................................. 113
Fig. 46 Change the oil filter .................................................................................................................... 114
Fig. 47 Belt guard attachment ................................................................................................................ 115
Fig. 48 Checking the drive belt seating .................................................................................................. 116
Fig. 49 Manually checking the belt tension ............................................................................................ 116
Fig. 50 Changing/tensioning the drive belt ............................................................................................. 117
Fig. 51 Safety signs - warning stickers on the battery. ........................................................................... 118
Fig. 52 Checking cooling oil level ........................................................................................................... 122
Fig. 53 Draining the compressor cooling oil ........................................................................................... 125
Fig. 54 Draining the oil from the heat exchanger ................................................................................... 126
List of Illustrations
No.: 9_5898 26 E
Operator manual Portable compressor
M 64 vii
RAMIRENT

Fig. 55 Change the oil filter .................................................................................................................... 127
Fig. 56 Oil separator tank dirt trap maintenance .................................................................................... 128
Fig. 57 Changing the Oil Separator Cartridge ........................................................................................ 130
Fig. 58 Changing the oil separator cartridge (Option ba) ....................................................................... 132
Fig. 59 Compressor air filter maintenance ............................................................................................. 134
Fig. 60 Cleaning the filter element .......................................................................................................... 135
Fig. 61 Fit the flexible pipe connection ................................................................................................... 136
Fig. 62 Cleaning the compressor cooler and engine radiator ................................................................. 138
Fig. 63 Cleaning the compressed air aftercooler .................................................................................... 139
Fig. 64 Tool lubricator maintenance ....................................................................................................... 140
Fig. 65 Cleaning the dirt trap .................................................................................................................. 142
Fig. 66 Filter combination ....................................................................................................................... 143
Fig. 67 Combination filter maintenance .................................................................................................. 144
Fig. 68 Fresh air filter maintenance ........................................................................................................ 147
Fig. 69 Filling the frost protector ............................................................................................................. 150
Fig. 70 Spark arrestor cleaning .............................................................................................................. 151
Fig. 71 Maintain the engine air shut-off valve ......................................................................................... 153
Fig. 72 Securing the belt guard at the generator .................................................................................... 155
Fig. 73 Belt tension checking by hand .................................................................................................... 156
Fig. 74 Generator belt tensioning ........................................................................................................... 157
Fig. 75 Generator belt tensioner ............................................................................................................. 157
Fig. 76 Checking the pulley alignment ................................................................................................... 159
Fig. 77 Aligning the generator ................................................................................................................ 160
Fig. 78 Preparing for transport using a forklift truck ............................................................................... 200
Fig. 79 Lifting the machine with a forklift truck ....................................................................................... 201
Fig. 80 Transport with a forklift truck ...................................................................................................... 202
Fig. 81 Guys to secure the freight .......................................................................................................... 203
Fig. 82 Marking ....................................................................................................................................... 205
List of Illustrations
viii Operator manual Portable compressor
M 64 No.: 9_5898 26 E
RAMIRENT