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
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Operator manual Portable compressor
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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

Tab. 1 Danger levels and their definitions (personal injury) .................................................................. 1
Tab. 2 Danger levels and their definition (damage to property) ............................................................ 2
Tab. 3 Nameplate .................................................................................................................................. 4
Tab. 4 Options label .............................................................................................................................. 5
Tab. 5 Compressed air treatment options ............................................................................................. 5
Tab. 6 Tool lubricator option .................................................................................................................. 5
Tab. 7 Compressed air distributor option .............................................................................................. 5
Tab. 8 Low temperature equipment options .......................................................................................... 6
Tab. 9 Optional equipment for fire hazard areas ................................................................................... 6
Tab. 10 Optional battery isolating switch ................................................................................................. 6
Tab. 11 Chassis options .......................................................................................................................... 6
Tab. 12 Options, stationary frame ........................................................................................................... 7
Tab. 13 Lighting options .......................................................................................................................... 7
Tab. 14 Generator option ........................................................................................................................ 7
Tab. 15 Hose reel option ......................................................................................................................... 8
Tab. 16 Optional anti-theft device ............................................................................................................ 8
Tab. 17 Pedestrian protection option ....................................................................................................... 8
Tab. 18 Instrument panel cover options .................................................................................................. 8
Tab. 19 Diesel particulate filter option ..................................................................................................... 8
Tab. 20 Guaranteed sound power level .................................................................................................. 9
Tab. 21 Emission sound pressure level ................................................................................................... 9
Tab. 22 Tightening torques for screws (property class 8.8, coefficient of friction µ = 0,12) ................... 9
Tab. 23 Ambient conditions ..................................................................................................................... 9
Tab. 24 Mass of the machine .................................................................................................................. 10
Tab. 25 Working pressure and FAD ........................................................................................................ 10
Tab. 26 Compressed air distributor ......................................................................................................... 11
Tab. 27 Pressure relief valve opening pressure ...................................................................................... 11
Tab. 28 Machine temperatures ................................................................................................................ 11
Tab. 29 Airend discharge temperature .................................................................................................... 11
Tab. 30 Cooling oil recommendation ....................................................................................................... 12
Tab. 31 Cooling oil recommendation (food processing) .......................................................................... 12
Tab. 32 Cooling oil charge ....................................................................................................................... 13
Tab. 33 Engine specification ................................................................................................................... 13
Tab. 34 Engine oil recommendation ........................................................................................................ 14
Tab. 35 Recommended oil for engines with diesel particulate filters ....................................................... 14
Tab. 36 Fluid volumes ............................................................................................................................. 15
Tab. 37 Battery ........................................................................................................................................ 15
Tab. 38 Road breaker lubricant recommendation ................................................................................... 15
Tab. 39 Fresh air filter conditions ............................................................................................................ 15
Tab. 40 Interrelation between compressed air treatment and compressed air quality ............................ 16
Tab. 41 Environmental conditions, low temperature equipment .............................................................. 16
Tab. 42 Coolant pre-heater ..................................................................................................................... 16
Tab. 43 Recommended antifreeze .......................................................................................................... 17
Tab. 44 Battery, low-temperature equipment .......................................................................................... 17
Tab. 45 Diesel particulate filter data ........................................................................................................ 17
Tab. 46 Generator data ........................................................................................................................... 17
Tab. 47 Delivery in generator mode ........................................................................................................ 18
Tab. 48 Connection sockets .................................................................................................................... 18
Tab. 49 Circuit breaker ............................................................................................................................ 19
Tab. 50 Generator operating limits .......................................................................................................... 19
Tab. 51 Maximum three-phase mains loading ........................................................................................ 20
Tab. 52 Maximum single-phase mains loading ....................................................................................... 20
Tab. 53 Power reduction at elevated ambient temperatures ................................................................... 20
Tab. 54 Generator data ........................................................................................................................... 20
List of Tables
No.: 9_5898 26 E
Operator manual Portable compressor
M 64 ix
RAMIRENT

Tab. 55 Delivery in generator mode ........................................................................................................ 21
Tab. 56 Connection sockets .................................................................................................................... 21
Tab. 57 Circuit breaker ............................................................................................................................ 22
Tab. 58 Generator operating limits .......................................................................................................... 22
Tab. 59 Maximum power supply load ...................................................................................................... 22
Tab. 60 Power reduction at elevated ambient temperatures ................................................................... 22
Tab. 61 Inspection intervals according to Ordinance on Industrial Safety and Health ............................ 25
Tab. 62 Danger areas .............................................................................................................................. 33
Tab. 63 Safety signs ................................................................................................................................ 34
Tab. 64 Generator / Compressor operation ............................................................................................. 52
Tab. 65 Generator operating modes ....................................................................................................... 52
Tab. 66 Stationary machines ................................................................................................................... 56
Tab. 67 Measures for re-commissioning the compressor after a long period of storage or de-
commissioning ............................................................................................................................
61
Tab. 68 Positioning and operating conditions checklist ........................................................................... 61
Tab. 69 Low-temperature equipment checklist ........................................................................................ 65
Tab. 70 Test instructions for a generator with an earth leak detection device. ....................................... 68
Tab. 71 Fault: engine refuses to start or comes to a stop. ...................................................................... 83
Tab. 72 Alarm: "engine does not reach full speed". ................................................................................ 84
Tab. 73 Alarm: "Control lamp remains on" .............................................................................................. 84
Tab. 74 "Motor running backwards" fault ................................................................................................. 85
Tab. 75 Fault: working pressure too high ................................................................................................ 85
Tab. 76 Fault: working pressure too low .................................................................................................. 85
Tab. 77 Fault: pressure relief valve blowing off ....................................................................................... 86
Tab. 78 Fault: machine overheating ........................................................................................................ 86
Tab. 79 Alarm: "Too much oil residue in the compressed air" ................................................................. 87
Tab. 80 Alarm: "Oil flows from the compressor air filter after shutdown" ................................................ 87
Tab. 81 Fault: high moisture content in the compressed air .................................................................... 88
Tab. 82 Faults in the diesel particulate filter ............................................................................................ 88
Tab. 83 Fault 'blue engine exhaust' ......................................................................................................... 88
Tab. 84 Grey or brownish exhaust gas .................................................................................................... 89
Tab. 85 There is no voltage or too low a voltage from the generator ...................................................... 89
Tab. 86 Generator voltage too high ......................................................................................................... 89
Tab. 87 Advise others that the machine is being serviced. ..................................................................... 91
Tab. 88 Maintenance tasks after commissioning .................................................................................... 93
Tab. 89 Maintenance intervals and regular maintenance tasks .............................................................. 93
Tab. 90 Regular machine maintenance tasks ......................................................................................... 94
Tab. 91 Regular maintenance task options ............................................................................................. 96
Tab. 92 KAESER coolant mixture table ................................................................................................... 100
Tab. 93 Dimensions of the flexible pipe connection ................................................................................ 136
Tab. 94 Belt tension values ..................................................................................................................... 156
Tab. 95 Maintenance log ......................................................................................................................... 161
Tab. 96 Compressor consumables .......................................................................................................... 162
Tab. 97 Consumable engine parts .......................................................................................................... 162
Tab. 98 Replacement parts, combination filter ........................................................................................ 163
Tab. 99 Replacement parts, fresh-air filter .............................................................................................. 163
Tab. 100 "Temporarily decommissioned" information notice .................................................................... 196
Tab. 101 "Long-term decommissioning and storage" checklist ................................................................. 197
Tab. 102 Text for the "long-term decommissioned and storage" information notice ................................. 198
List of Tables
xOperator manual Portable compressor
M 64 No.: 9_5898 26 E
RAMIRENT

1 Regarding this document
1.1 Using this document
The operating manual is a component of the product. It describes the machine as it was at the time
of first delivery after manufacture.
➤Keep the operating manual in a safe place throughout the life of the machine.
➤ Supply any successive owner or user with this operating manual.
➤ Please insert any amendment or revision of the operating manual sent to you.
➤ Enter details from the machine nameplate and individual items of equipment in the table in
chapter 2.
1.2 Further documents
Further documents included with this operating manual are:
■Certificate of acceptance / operating instructions for the pressure vessel
■ Declaration of Conformity in accordance with the applicable directive
■ Chassis documentation (where applicable)
Missing documents can be requested from KAESER.
➤ Make sure all documents are complete and observe the instructions contained in them.
➤ Make sure you provide the data from the nameplate when ordering documents.
1.3 Copyright
This operating manual is protected by copyright. Any queries regarding the use or duplication of
this documentation should be referred to KAESER. Correct use of information will be fully suppor‐
ted.
1.4 Symbols and labels
➤ Please note the symbols and labels used in this document.
1.4.1 Warnings
Warning notices indicate dangers that may result in injury when disregarded.
Warning notices indicate three levels of danger identified by the corresponding signal word:
Signal term Meaning Consequences of ignoring the warning
DANGER Warns of an imminent danger Will result in death or severe injury
WARNING Warns of a potentially imminent danger May result in death or severe injury
CAUTION Warns of a potentially dangerous situation May result in a moderate physical injury
Tab. 1 Danger levels and their definitions (personal injury)
Warning notices preceding a chapter apply to the entire chapter, including all sub-sections.
1 Regarding this document
1.1 Using this document
No.: 9_5898 26 E
Operator manual Portable compressor
M 64 1
RAMIRENT

For example,
DANGER
These show the kind of danger and its source.
The possible consequences of ignoring a warning are shown here.
If you ignore the warning notice, the "DANGER" signal word indicates a lethal or severe in‐
jury will occur.
➤The measures required to protect yourself from danger are shown here.
Warning notes referring to a sub-section or the subsequent action are integrated into the procedure
and numbered as an action.
For example,
1. WARNING!
These show the kind of danger and its source.
The possible consequences of ignoring a warning are shown here.
If you ignore the warning notice, the "WARNING" signal word indicates that a lethal or severe
injury may occur.
➤The measures required to protect yourself from danger are shown here.
2. Always read and comply with warning instructions.
1.4.2 Potential damage warnings
Contrary to the warnings shown above, damage warnings do not indicate a potential personal in‐
jury.
Warning notices for damages are identified by their signal term.
Signal term Meaning Consequences of ignoring the warning
NOTE Warns of a potentially dangerous situation Damage to property is possible
Tab. 2 Danger levels and their definition (damage to property)
For example,
NOTICE
These show the kind of danger and its source.
Potential effects when ignoring the warning are indicated here.
➤ The protective measures against the damages are shown here.
➤ Carefully read and fully comply with warnings against damages.
1.4.3 Other alerts and their symbols
This symbol indicates particular important information.
Material Here you will find details on special tools, operating materials or spare parts.
Precondition Here you will find conditional requirements necessary to carry out the task.
The conditions relevant to safety shown here will help you to avoid dangerous situations.
➤ This symbol is is placed by lists of actions comprising one stage of a task.
1 Regarding this document
1.4 Symbols and labels
2Operator manual Portable compressor
M 64 No.: 9_5898 26 E
RAMIRENT

1. In process instructions with several steps ...
2. ... the sequence of action steps is numbered.
Result Shows the expected conclusion of the previous action.
➤ Information relating to one option only are marked with an option code (e.g., "option da" means
that this section is only valid for machines with the air treatment components "aftercooler and
cyclone separator"). Option codes used in this service manual are explained in chapter 2.2.
Information referring to potential problems are identified by a question mark.
The cause is named in the help text ...
➤... as is a solution.
This symbol refers to important information or measures concerning environmental protec‐
tion.
Further information Further subjects are introduced here.
1 Regarding this document
1.4 Symbols and labels
No.: 9_5898 26 E
Operator manual Portable compressor
M 64 3
Option da
RAMIRENT

2 Technical Specifications
2.1 Nameplate
The model designation and important technical information are given on the machine's nameplate.
The nameplate is located on the outside of the machine (see illustration in chapter 13.1).
➤ Enter here the nameplate data as a reference:
Feature Value
Vehicle identity no.
Permissible total weight
Permissible coupling load
Permissible axle load
Portable compressor
Material no.
Serial no.
Year of manufacture
Total weight
Lifting point load capacity
Rated engine power
Engine speed
Maximum working pressure
Tab. 3 Nameplate
2.2 Options – options label
A list of the options fitted to your machine helps to relate the information in this service manual.
Options fitted to the machine are listed on the options label (code letters).
The nameplate is to be found:
■ on the outside of the machine,
■ on the front (see chapter 13.1)
The following table lists all possible options.
Only the codes for those options fitted appear on the nameplate.
2 Technical Specifications
2.1 Nameplate
4Operator manual Portable compressor
M 64 No.: 9_5898 26 E
RAMIRENT

M 64 Material No. Serial no.
Options fitted
02-M0277
tctb
sg ua
ta
sf
r5r4r3r1
r1= rb; rc; rd
r3= rm; ro
r4= rr; rs; rt
r5= rw; rx
ba
la
oa
lb lc
ga
pa pb
te
dddcda
ec
fcfa
db
bb bc bd
*
* r1 - r5 = place holders for chassis options
Tab. 4 Options label
➤ Take a list of fitted options from the options label and enter the fitted options as reference.
2.2.1 Option da, db, dc, dd
Compressed air treatment devices
Option Option code Available?
Aftercooler and cyclone separator da
Heat exchanger db
Fresh air filter dc
Filter combination dd
Tab. 5 Compressed air treatment options
2.2.2 Option ec
Tool lubricator
Option Option code Available?
Tool lubricator ec
Tab. 6 Tool lubricator option
2.2.3 Option fa, fc
Compressed air distributor
Option Option code Available?
Non-separated compressed air distribution line fa
2 Technical Specifications
2.2 Options – options label
No.: 9_5898 26 E
Operator manual Portable compressor
M 64 5
RAMIRENT

Option Option code Available?
Separated compressed air lines downstream of the
option
fc
Tab. 7 Compressed air distributor option
2.2.4 Option ba
Low temperature equipment
Option Option code Available?
Low temperature equipment ba
Engine coolant pre-heating bb
Frost protector bc
stronger batteries bd
Tab. 8 Low temperature equipment options
2.2.5 Option la, lb
Equipment for fire hazard areas
Option Option code Available?
Spark arrestor la
Spark arrestor and engine air intake shut-off valve
(automatic)
lb
Tab. 9 Optional equipment for fire hazard areas
2.2.6 Option oa
Battery isolating switch
Option Option code Available?
Battery isolating switch oa
Tab. 10 Optional battery isolating switch
2.2.7 Option rb/rm/rs, rc/ro/rs, rd/rn/rr, rw, rx
Chassis
Chassis are defined by the combination of several option designations as follows:
Model/Height adjustment/Service brake
Example: rb/rm/rs means
EU chassis with height-adjustable tow bar and overrun brake
Chassis:
Chassis Option code Available?
Model (rb, rc, rd):
EU chassis rb
2 Technical Specifications
2.2 Options – options label
6Operator manual Portable compressor
M 64 No.: 9_5898 26 E
RAMIRENT

Chassis Option code Available?
GB chassis rc
US chassis rd
Height adjustment (rm, ro, rn):
With height adjustment rm
Without height adjustment ro
Height adjustment via adjustable plate rn
Service brake (rs, rr):
With overrun brake rs
Without service brake rr
Tab. 11 Chassis options
Stationary frame
Chassis Option code Available?
Stationary (rw, rx):
on skids rw
on frame rx
Tab. 12 Options, stationary frame
2.2.8 Option ta, tb, tc, te
Lighting
Option Option code Available?
None (stationary) ta
Reflective warning triangle tb
EG - 12 V tc
USA - 12 V (DOT conformity) te
Tab. 13 Lighting options
2.2.9 Option ga
Generator
Option Option code Available?
Generator ga
Tab. 14 Generator option
2 Technical Specifications
2.2 Options – options label
No.: 9_5898 26 E
Operator manual Portable compressor
M 64 7
RAMIRENT

2.2.10 Option ua
Hose reels
Option Option code Available?
Hose reels ua
Tab. 15 Hose reel option
2.2.11 Option sf
Anti-theft device
Option Option code Available?
Anti-theft device sf
Tab. 16 Optional anti-theft device
2.2.12 Option sg
Pedestrian protection
Option Option code Available?
Pedestrian protection sg
Tab. 17 Pedestrian protection option
2.2.13 Option pa, pb
Instrument panel cover
Option Option code Available?
Instrument panel cover pa
Generator control box cover pb
Tab. 18 Instrument panel cover options
2.2.14 Option lc
Diesel particulate filter
Option Option code Available?
Diesel particulate filter lc
Tab. 19 Diesel particulate filter option
2 Technical Specifications
2.2 Options – options label
8Operator manual Portable compressor
M 64 No.: 9_5898 26 E
RAMIRENT