KAESER M100 User manual

Operator Manual
Screw Compressor
M100
No.: 9_6999 23 USE
Manufacturer:
KAESER KOMPRESSOREN SE
96410 Coburg • PO Box 2143 • GERMANY • Tel. [phone] • Fax [phone]
http://www.kaeser.com

Original instructions
/KKW/M100 2.03 en Z1 SBA-MOBILAIR
20150112 161243

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 Data
2.1 Nameplate ........................................................................................................................ 4
2.2 Options ............................................................................................................................. 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 Check valve function ........................................................................................... 6
2.2.5 Proportional controller ......................................................................................... 6
2.2.6 Low temperature equipment ............................................................................... 6
2.2.7 Equipment for fire hazard areas ......................................................................... 6
2.2.8 Battery isolating switch ....................................................................................... 7
2.2.9 Chassis ............................................................................................................... 7
2.2.10 Lighting ............................................................................................................... 8
2.2.11 Generator ............................................................................................................ 8
2.2.12 Sealed floor pan .................................................................................................. 8
2.2.13 Anti-theft device .................................................................................................. 8
2.2.14 Pedestrian protection .......................................................................................... 8
2.2.15 Instrument panel cover ....................................................................................... 9
2.3 Machine (without options) ................................................................................................ 9
2.3.1 Sound pressure level .......................................................................................... 9
2.3.2 Tightening torques for screws ............................................................................. 9
2.3.3 Ambient conditions ............................................................................................. 9
2.3.4 Additional specifications ..................................................................................... 9
2.4 Chassis ........................................................................................................................... 10
2.4.1 Weight ................................................................................................................. 10
2.4.2 Tires .................................................................................................................... 10
2.4.3 Wheel nut/bolt tightening torque ......................................................................... 11
2.4.4 Towbar tightening torque .................................................................................... 11
2.5 Compressor ..................................................................................................................... 11
2.5.1 Working pressure and FAD ................................................................................ 11
2.5.2 Compressed air outlet ......................................................................................... 11
2.5.3 Safety relief valves .............................................................................................. 12
2.5.4 Temperature ....................................................................................................... 12
2.5.5 Cooling oil recommendation ............................................................................... 12
2.5.6 Cooling oil charge ............................................................................................... 14
2.6 Engine ............................................................................................................................. 14
2.6.1 Engine specification ............................................................................................ 14
2.6.2 Oil recommendation ............................................................................................ 14
2.6.3 Fuel recommendation ......................................................................................... 15
2.6.4 Recommended Cooling Fluid ............................................................................. 15
2.6.5 Fluid volumes ...................................................................................................... 15
2.6.6 Battery ................................................................................................................ 15
2.7 Options ............................................................................................................................ 16
2.7.1 Air treatment options ........................................................................................... 16
2.7.2 Low temperature equipment ............................................................................... 17
2.7.3 Generator (50 Hz version) .................................................................................. 18
Contents
No.: 9_6999 23 USE
Operator Manual Screw Compressor
M100 i

2.7.4 Generator (60 Hz version) .................................................................................. 21
3 Safety and Responsibility
3.1 Basic instructions ............................................................................................................. 24
3.2 Specified use .................................................................................................................... 24
3.3 Incorrect Use .................................................................................................................... 24
3.4 User's Responsibilities ..................................................................................................... 24
3.4.1 Observe statutory and universally accepted regulations .................................... 24
3.4.2 Determining personnel ........................................................................................ 25
3.4.3 Adherence to inspection schedules and accident prevention regulations .......... 25
3.4.4 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 Organizational Measures .................................................................................... 32
3.5.4 Danger areas ...................................................................................................... 33
3.6 Safety devices .................................................................................................................. 33
3.7 Safety signs ...................................................................................................................... 33
3.8 Noise control requirements .............................................................................................. 37
3.9 Generator operation ......................................................................................................... 37
3.9.1 Comply with the protective measures against dangerous electric current ......... 37
3.9.2 Safe generator operation .................................................................................... 37
3.9.3 Connecting extension cables .............................................................................. 38
3.9.4 Do not exceed the maximum supply system load .............................................. 38
3.9.5 Perform regular generator inspections ............................................................... 38
3.10 Emergencies .................................................................................................................... 39
3.10.1 Correct fire fighting ............................................................................................. 39
3.10.2 Injury from handling operating fluids/materials ................................................... 39
3.11 Warranty ........................................................................................................................... 40
3.11.1 Noise emissions warranty ................................................................................... 40
3.12 Identifying the effects of improper modifications .............................................................. 40
3.13 Environmental protection ................................................................................................. 41
4 Design and Function
4.1 Bodywork ......................................................................................................................... 42
4.2 Component identification .................................................................................................. 43
4.3 Machine function .............................................................................................................. 43
4.4 Operating modes and control mode ................................................................................. 45
4.4.1 Operating modes ................................................................................................ 45
4.4.2 MODULATING control ........................................................................................ 45
4.5 Safety devices .................................................................................................................. 46
4.5.1 Monitoring functions with shutdown .................................................................... 46
4.5.2 Further safety devices ........................................................................................ 47
4.6 Fuel level monitoring ........................................................................................................ 47
4.7 Options ............................................................................................................................. 47
4.7.1 Compressed air treatment options ...................................................................... 48
4.7.2 Low temperature equipment options .................................................................. 51
4.7.3 Optional battery isolating switch ......................................................................... 52
4.7.4 Options for operating in fire hazard areas .......................................................... 53
4.7.5 Generator option ................................................................................................. 54
4.7.6 Transport options ................................................................................................ 56
4.7.7 Sealed floor pan option ....................................................................................... 58
4.7.8 Optional anti-theft device ................................................................................... 59
4.7.9 Pedestrian protection option ............................................................................... 59
4.7.10 Instrument panel cover option ............................................................................ 60
Contents
ii
Operator Manual Screw Compressor
M100 No.: 9_6999 23 USE

5 Installation and Operating Conditions
5.1 Ensuring safety ................................................................................................................ 61
5.2 Installation conditions ....................................................................................................... 61
6 Installation
6.1 Ensuring safety ................................................................................................................ 63
6.2 Reporting Transport Damage ........................................................................................... 63
6.3 Fitting the towbar .............................................................................................................. 63
6.3.1 Fitting the height adjustable towbar .................................................................... 64
6.3.2 Fitting a non-adjustable tow bar .......................................................................... 65
6.4 Adjusting the chassis ....................................................................................................... 67
6.4.1 Adjusting the towbar height ................................................................................ 68
6.4.2 Changing the towing eye/ball hitch ..................................................................... 68
7 Initial Start-up
7.1 Ensuring safety ................................................................................................................ 72
7.2 Before initial start-up (or recommissioning) ...................................................................... 72
7.2.1 Instructions to be observed before commissioning or recommissioning ............ 72
7.2.2 Special measures for re-commissioning after storage ........................................ 73
7.3 Checking installation and operating conditions ................................................................ 73
7.4 Low-temperature operation (winter) ................................................................................. 74
7.4.1 Starting assistance ............................................................................................. 74
7.4.2 Starting up low-temperature equipment .............................................................. 76
7.5 Activating the generator ................................................................................................... 78
8 Operation
8.1 Ensuring safety ................................................................................................................ 81
8.2 Starting and stopping ....................................................................................................... 82
8.2.1 Starting the machine ........................................................................................... 83
8.2.2 Engine pre-heating ............................................................................................. 83
8.2.3 Starting the machine ........................................................................................... 83
8.2.4 Allow the machine to run up to operating temperature ....................................... 83
8.2.5 Switching to LOAD ............................................................................................. 84
8.2.6 Manually setting the discharge pressure ............................................................ 84
8.2.7 Shutting down the machine ................................................................................ 85
8.3 Monitoring fuel level in the fuel tank ................................................................................. 86
8.4 Operating the tool lubricator ............................................................................................. 86
8.5 Using the low-temperature equipment ............................................................................. 87
8.5.1 Pre-warms the engine cooling water .................................................................. 87
8.5.2 Operating the machine with frost protector ......................................................... 88
8.6 Operating the battery isolating switch .............................................................................. 89
8.7 Generator operation ......................................................................................................... 89
8.7.1 Note when operating the generator .................................................................... 90
8.7.2 Switching in the generator .................................................................................. 90
8.7.3 Switching off the generator ................................................................................. 90
8.8 Cleaning the machine after operation .............................................................................. 91
9 Fault Recognition and Rectification
9.1 Basic instructions ............................................................................................................. 92
9.2 Engine faults and alarms .................................................................................................. 92
9.2.1 Engine refuses to start or comes to a stop ......................................................... 92
9.2.2 Engine does not reach full speed ....................................................................... 93
9.2.3 Indicator lamp remains on .................................................................................. 93
9.3 Compressor faults and alarms ......................................................................................... 94
9.3.1 Working pressure too high .................................................................................. 94
9.3.2 Working pressure too low. .................................................................................. 94
Contents
No.: 9_6999 23 USE
Operator Manual Screw Compressor
M100 iii

9.3.3 Pressure relief valve blowing off ......................................................................... 95
9.3.4 Machine overheating .......................................................................................... 95
9.3.5 Too much oil residue in the compressed air ....................................................... 96
9.3.6 Oil flows from the compressor air filter after shutdown ....................................... 96
9.3.7 High moisture content in the compressed air ..................................................... 97
9.4 Generator faults and alarms ............................................................................................. 97
9.4.1 There is no voltage or too low a voltage from the generator .............................. 97
9.4.2 Generator voltage too high ................................................................................. 97
10 Maintenance
10.1 Ensuring safety ................................................................................................................ 99
10.2 Maintenance schedules ................................................................................................... 100
10.2.1 Logging maintenance work ................................................................................. 100
10.2.2 Maintenance tasks after commissioning ............................................................. 100
10.2.3 Regular maintenance tasks ................................................................................ 101
10.3 Engine maintenance ........................................................................................................ 106
10.3.1 Water cooler maintenance .................................................................................. 106
10.3.2 Engine air filter maintenance .............................................................................. 111
10.3.3 Fuel system maintenance ................................................................................... 114
10.3.4 Checking the engine oil level .............................................................................. 118
10.3.5 Engine oil filling and topping up .......................................................................... 119
10.3.6 Changing the engine oil ...................................................................................... 120
10.3.7 Replace the engine oil filter ................................................................................ 123
10.3.8 Drive belt maintenance ....................................................................................... 124
10.3.9 Battery maintenance ........................................................................................... 127
10.3.10 Checking the fastening of the fuel tank .............................................................. 130
10.4 Compressor Maintenance ................................................................................................ 130
10.4.1 Checking cooling oil level ................................................................................... 131
10.4.2 Cooling oil filling and topping up ......................................................................... 132
10.4.3 Changing the cooling oil ..................................................................................... 133
10.4.4 Replace the compressor oil filter ........................................................................ 137
10.4.5 Oil separator tank dirt trap maintenance ............................................................. 138
10.4.6 Changing the oil separator cartridge ................................................................... 139
10.4.7 Compressor air filter maintenance ...................................................................... 143
10.4.8 Checking safety relief valves .............................................................................. 146
10.5 Cleaning the cooler .......................................................................................................... 146
10.5.1 Cleaning the compressor cooler and engine radiator ......................................... 146
10.5.2 Cleaning the compressed air aftercooler ............................................................ 147
10.6 Maintenance of rubber sealing strips ............................................................................... 148
10.7 Chassis maintenance ....................................................................................................... 149
10.7.1 Wheel checks ..................................................................................................... 149
10.7.2 Towbar maintenance .......................................................................................... 149
10.7.3 Brake maintenance ............................................................................................. 152
10.8 Maintenance for Optional Items ....................................................................................... 155
10.8.1 Tool lubricator maintenance ............................................................................... 155
10.8.2 Cyclone separator maintenance ......................................................................... 157
10.8.3 Combination filter maintenance .......................................................................... 158
10.8.4 Fresh air filter maintenance ................................................................................ 162
10.8.5 Frost protector maintenance ............................................................................... 165
10.8.6 Spark arrestor maintenance ............................................................................... 166
10.8.7 Engine air intake shut-off valve maintenance ..................................................... 168
10.8.8 Generator drive belt maintenance ...................................................................... 169
10.8.9 Draining liquid accumulation within the machine ................................................ 172
10.9 Documenting maintenance and service work .................................................................. 174
Contents
iv
Operator Manual Screw Compressor
M100 No.: 9_6999 23 USE

11 Spares, Operating Materials, Service
11.1 Note the nameplate .......................................................................................................... 175
11.2 Ordering consumable parts and operating fluids/materials .............................................. 175
11.3 KAESER AIR SERVICE .................................................................................................. 176
11.4 Service Addresses ........................................................................................................... 176
11.5 Replacement parts for service and repair ........................................................................ 176
12 Decommissioning, Storage and Transport
12.1 De-commissioning ............................................................................................................ 227
12.1.1 Temporary de-commissioning ............................................................................ 227
12.1.2 Long-term decommissioning and storage ........................................................... 228
12.2 Transport .......................................................................................................................... 229
12.2.1 Safety .................................................................................................................. 229
12.2.2 Towing the compressor on the road ................................................................... 229
12.2.3 Parking the machine ........................................................................................... 238
12.2.4 Transport with a crane ........................................................................................ 241
12.2.5 Transport with a forklift truck ............................................................................... 241
12.2.6 Transporting the machine as load ...................................................................... 242
12.3 Storage ............................................................................................................................. 243
12.4 Disposal ........................................................................................................................... 244
13 Annex
13.1 Identification ..................................................................................................................... 245
13.2 Pipeline and instrument flow diagram (P+I diagram) ....................................................... 245
13.3 Dimensional drawings ...................................................................................................... 251
13.3.1 Dimensional drawing, chassis options ................................................................ 251
13.3.2 Dimensional drawing, chassis options ............................................................... 253
13.3.3 Dimensional drawing, chassis options ............................................................... 255
13.3.4 Dimensional drawing, chassis options ................................................................ 257
13.3.5 Dimensional drawing, stationary version ............................................................ 259
13.3.6 Dimensional drawing, stationary version ............................................................ 261
13.4 Wiring diagrams .............................................................................................................. 263
13.4.1 Electrical Diagram ............................................................................................... 263
13.4.2 Lighting and signaling system connection .......................................................... 277
13.4.3 Lighting and signaling system connection .......................................................... 285
13.4.4 Generator electrical diagram, 400V, 3-ph ........................................................... 290
13.4.5 Generator electrical diagram, 230V, 3-ph ........................................................... 299
13.4.6 Generator electrical diagram, 115 V, 2-ph .......................................................... 308
13.4.7 Generator electrical diagram, 230 V, 2-ph .......................................................... 317
13.5 Fuel circulation diagram ................................................................................................... 326
13.6 Assembly diagrams - chassis ........................................................................................... 329
13.6.1 Assembly diagrams - chassis EU version ........................................................... 329
13.6.2 Assembly diagrams - chassis GB/US version .................................................... 331
13.6.3 Assembly diagram brake rod .............................................................................. 334
13.7 Operating instructions for compressed air filter (combination filter) ................................. 336
13.8 Operating instructions for compressed air filter (fresh air filter) ....................................... 357
13.9 Service tasks - Generator ................................................................................................ 371
Contents
No.: 9_6999 23 USE
Operator Manual Screw Compressor
M100 v

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

Fig. 1 Example for Tire information on the side wall ............................................................................ 10
Fig. 2 Location of safety signs .............................................................................................................. 34
Fig. 3 Overview Bodywork .................................................................................................................... 42
Fig. 4 Right-hand door opened ............................................................................................................. 43
Fig. 5 Left-hand door opened ............................................................................................................... 43
Fig. 6 Machine layout ........................................................................................................................... 44
Fig. 7 Stepless regulation of FAD (standstill) ....................................................................................... 46
Fig. 8 Fuel level monitoring .................................................................................................................. 47
Fig. 9 Compressed air options ............................................................................................................. 48
Fig. 10 Tool lubricator ............................................................................................................................. 50
Fig. 11 Principle tool lubricator ............................................................................................................... 50
Fig. 12 Coolant pre-heating .................................................................................................................... 51
Fig. 13 Frost protector ............................................................................................................................ 52
Fig. 14 Battery isolating switch ............................................................................................................... 53
Fig. 15 Instrument panel – generator control box, 400 V AC ................................................................. 55
Fig. 16 Instrument panel – generator control box, 230 V AC ................................................................. 55
Fig. 17 Generator instrument panel - control box, 115 V, single-phase (50 Hz) .................................... 56
Fig. 18 Generator instrument panel - control box, 230 V, single-phase (60 Hz) .................................... 56
Fig. 19 Position of service openings in the sealed floor pan .................................................................. 59
Fig. 20 Drain points for oil and coolant from engine and compressor .................................................... 59
Fig. 21 Minimum distance from excavations/slopes and walls ............................................................... 61
Fig. 22 Height adjustable towbar, fitted .................................................................................................. 64
Fig. 23 Fitting the height adjustable towbar ............................................................................................ 64
Fig. 24 Non-adjustable tow bar fitted ...................................................................................................... 65
Fig. 25 Fitting the overrun braking mechanism of the non-adjustable tow bar ....................................... 66
Fig. 26 Fitting the jockey wheel of the non-adjustable tow bar ............................................................... 67
Fig. 27 Towbar height adjustment .......................................................................................................... 68
Fig. 28 Changing the towing eye (height-adjustable drawbar) ............................................................... 69
Fig. 29 Changing the towing eye/ball hitch (fixed height towbar) ........................................................... 70
Fig. 30 Changing the towing eye (fixed height towbar, USA chassis version) ....................................... 71
Fig. 31 Jumper cable connection diagram ............................................................................................. 75
Fig. 32 Engine coolant pre-heating ........................................................................................................ 77
Fig. 33 Operating the frost protector ...................................................................................................... 77
Fig. 34 Insulation monitoring - 400 V AC, 3-phase generator ................................................................ 78
Fig. 35 Insulation monitoring - 230 V AC, 3-phase generator ................................................................ 78
Fig. 36 insulation monitoring - 115 V, single-phase generator ............................................................... 79
Fig. 37 insulation monitoring - 230 V, single-phase generator ............................................................... 79
Fig. 38 Starting instruments ................................................................................................................... 82
Fig. 39 Label referring to the warm-up period when ambient temperatures are below -50 °F ............... 84
Fig. 40 Proportional controller ................................................................................................................ 85
Fig. 41 Setting the tool lubricator ............................................................................................................ 86
Fig. 42 Frost protector on and off ........................................................................................................... 88
Fig. 43 Battery isolating switch ............................................................................................................... 89
Fig. 44 Checking coolant level ............................................................................................................... 107
Fig. 45 Draining the coolant from the radiator ........................................................................................ 110
Fig. 46 Draining the coolant from the radiator (closed floor pan - stationary machine) .......................... 111
Fig. 47 Engine air filter maintenance ...................................................................................................... 112
Fig. 48 Cleaning the filter element .......................................................................................................... 113
Fig. 49 Fuel system maintenance .......................................................................................................... 114
Fig. 50 Bleeding the fuel system ............................................................................................................ 115
Fig. 51 Fuel filter with water trap maintenance ....................................................................................... 116
Fig. 52 Changing the fuel pre-filter. ........................................................................................................ 117
Fig. 53 Fuel micro-filter maintenance ..................................................................................................... 117
Fig. 54 Checking the engine oil level ...................................................................................................... 119
List of Illustrations
No.: 9_6999 23 USE
Operator Manual Screw Compressor
M100 vii

Fig. 55 Draining the engine oil ................................................................................................................ 121
Fig. 56 Draining the engine oil (closed floor pan - stationary machine) ................................................. 122
Fig. 57 Changing the oil filter .................................................................................................................. 123
Fig. 58 Belt guard attachment ................................................................................................................ 124
Fig. 59 Checking the drive belt seating .................................................................................................. 125
Fig. 60 Manually checking the belt tension ............................................................................................ 125
Fig. 61 Changing/tensioning the drive belt ............................................................................................. 126
Fig. 62 Safety signs - warning stickers on the battery. ........................................................................... 127
Fig. 63 Checking cooling oil level ........................................................................................................... 131
Fig. 64 Draining the compressor cooling oil ........................................................................................... 134
Fig. 65 Draining the oil from the heat exchanger ................................................................................... 135
Fig. 66 Draining the cooling oil (closed floor pan - stationary machine) ................................................. 136
Fig. 67 Changing the oil filter .................................................................................................................. 137
Fig. 68 Oil separator tank dirt trap maintenance .................................................................................... 138
Fig. 69 Changing the oil separator cartridge .......................................................................................... 140
Fig. 70 Changing the oil separator cartridge (Option ba) ....................................................................... 142
Fig. 71 Compressor air filter maintenance ............................................................................................. 144
Fig. 72 Cleaning the filter element .......................................................................................................... 145
Fig. 73 Cleaning the compressor cooler and engine radiator ................................................................. 147
Fig. 74 Cleaning the compressed air aftercooler .................................................................................... 148
Fig. 75 Towbar maintenance .................................................................................................................. 150
Fig. 76 Maintaining the fixed height towbar ............................................................................................ 150
Fig. 77 Ball coupling (EC version) .......................................................................................................... 151
Fig. 78 Ball coupling (USA version) ........................................................................................................ 152
Fig. 79 Checking the brake lining thickness ........................................................................................... 153
Fig. 80 Brake system adjustment ........................................................................................................... 153
Fig. 81 Brake rod adjustment ................................................................................................................. 154
Fig. 82 Tool lubricator maintenance ....................................................................................................... 156
Fig. 83 Cleaning the dirt trap .................................................................................................................. 157
Fig. 84 Filter combination ....................................................................................................................... 159
Fig. 85 Combination filter maintenance .................................................................................................. 159
Fig. 86 Fresh air filter maintenance ........................................................................................................ 162
Fig. 87 Filling the frost protector ............................................................................................................. 165
Fig. 88 Cleaning the spark arrestor (floor pan with service openings) ................................................... 166
Fig. 89 Cleaning the spark arrestor (sealed floor pan) ........................................................................... 167
Fig. 90 Engine air intake shut-off valve maintenance ............................................................................. 168
Fig. 91 Securing the belt guard at the generator .................................................................................... 170
Fig. 92 Generator belt tensioning ........................................................................................................... 171
Fig. 93 Towing position .......................................................................................................................... 231
Fig. 94 Ball coupling (ALKO-EU) ............................................................................................................ 232
Fig. 95 Wear alert, ball coupling (ALKO-EU) .......................................................................................... 233
Fig. 96 Ball coupling (ALKO-USA) ......................................................................................................... 234
Fig. 97 Release the parking brake. ........................................................................................................ 234
Fig. 98 Automatic jockey wheel in transport position ............................................................................. 235
Fig. 99 Safety sign - secure the chocks ................................................................................................. 236
Fig. 100 Breakaway cable attachment ..................................................................................................... 237
Fig. 101 ................................................................................................................................................... 237
Fig. 102 Warning "Injury can occur if the towbar is allowed to fall." ......................................................... 238
Fig. 103 Towbar with automatic jockey wheel .......................................................................................... 239
Fig. 104 Actuating the parking brake ........................................................................................................ 239
Fig. 105 Safety sign - secure the chocks ................................................................................................. 240
Fig. 106 Transporting using a forklift truck ............................................................................................... 242
Fig. 107 Guys to secure the freight .......................................................................................................... 243
Fig. 108 Identification ............................................................................................................................... 245
List of Illustrations
viii
Operator Manual Screw Compressor
M100 No.: 9_6999 23 USE

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 Check valve option ..................................................................................................................... 6
Tab. 9 Proportional controller option ..................................................................................................... 6
Tab. 10 Low temperature equipment options .......................................................................................... 6
Tab. 11 Optional equipment for fire hazard areas ................................................................................... 6
Tab. 12 Battery isolating switch option .................................................................................................... 7
Tab. 13 Chassis options .......................................................................................................................... 7
Tab. 14 Options, stationary frame ........................................................................................................... 7
Tab. 15 Lighting options .......................................................................................................................... 8
Tab. 16 Generator options ....................................................................................................................... 8
Tab. 17 Sealed floor pan option .............................................................................................................. 8
Tab. 18 Anti-theft device option ............................................................................................................... 8
Tab. 19 Pedestrian protection option ....................................................................................................... 8
Tab. 20 Instrument panel cover options .................................................................................................. 9
Tab. 21 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 Weight of the machine ................................................................................................................ 10
Tab. 25 Tires ........................................................................................................................................... 10
Tab. 26 Wheel nut/bolt tightening torque ................................................................................................. 11
Tab. 27 Towbar tightening torque ............................................................................................................ 11
Tab. 28 Working pressure and FAD ........................................................................................................ 11
Tab. 29 Compressed air distributor ......................................................................................................... 11
Tab. 30 Safety relief valve activating pressure ........................................................................................ 12
Tab. 31 Machine temperatures ................................................................................................................ 12
Tab. 32 Airend discharge temperature .................................................................................................... 12
Tab. 33 Cooling oil recommendations ..................................................................................................... 13
Tab. 34 Cooling oil recommendation (food processing) .......................................................................... 13
Tab. 35 Cooling oil charge ....................................................................................................................... 14
Tab. 36 Engine specification ................................................................................................................... 14
Tab. 37 Engine oil recommendation ........................................................................................................ 15
Tab. 38 Fluid volumes ............................................................................................................................. 15
Tab. 39 Battery ........................................................................................................................................ 15
Tab. 40 Road breaker lubricant recommendation ................................................................................... 16
Tab. 41 Fresh air filter conditions ............................................................................................................ 16
Tab. 42 Interrelation between compressed air treatment and compressed air quality ............................ 16
Tab. 43 Environmental conditions, low temperature equipment .............................................................. 17
Tab. 44 Coolant pre-heater ..................................................................................................................... 17
Tab. 45 Recommended antifreeze .......................................................................................................... 17
Tab. 46 Battery, low-temperature equipment .......................................................................................... 17
Tab. 47 Generator data ........................................................................................................................... 18
Tab. 48 Compressed air delivery with generator in operation (generator without FAD limitation) .......... 18
Tab. 49 Compressed air delivery with generator in operation (generator with FAD limitation) ............... 19
Tab. 50 Connection sockets .................................................................................................................... 19
Tab. 51 Circuit breaker ............................................................................................................................ 19
Tab. 52 Generator operating limits .......................................................................................................... 19
Tab. 53 Maximum three-phase mains loading ........................................................................................ 20
Tab. 54 Maximum single-phase mains loading ....................................................................................... 20
List of Tables
No.: 9_6999 23 USE
Operator Manual Screw Compressor
M100 ix

Tab. 55 Power reduction at elevated ambient temperatures ................................................................... 20
Tab. 56 Generator data ........................................................................................................................... 21
Tab. 57 Compressed air delivery with generator in operation (generator without FAD limitation) .......... 21
Tab. 58 Compressed air delivery with generator in operation (generator with FAD limitation) ............... 22
Tab. 59 Connection sockets .................................................................................................................... 22
Tab. 60 Circuit breaker ............................................................................................................................ 22
Tab. 61 Generator operating limits .......................................................................................................... 22
Tab. 62 Maximum power supply load ...................................................................................................... 23
Tab. 63 Power reduction at elevated ambient temperatures ................................................................... 23
Tab. 64 Danger areas .............................................................................................................................. 33
Tab. 65 Safety signs ................................................................................................................................ 34
Tab. 66 Generator / Compressor operation ............................................................................................. 54
Tab. 67 Generator operating modes ....................................................................................................... 54
Tab. 68 Measures for re-commissioning the compressor after a long period of storage ........................ 73
Tab. 69 Positioning and operating conditions checklist ........................................................................... 73
Tab. 70 Low-temperature equipment checklist ........................................................................................ 77
Tab. 71 Test instructions for a generator with an ground short detection device. ................................... 80
Tab. 72 Alarm: Engine refuses to start or comes to a stop. .................................................................... 92
Tab. 73 Alarm: Engine does not reach full speed .................................................................................... 93
Tab. 74 Indicator lamp remains on .......................................................................................................... 93
Tab. 75 Fault: Working pressure too high ............................................................................................... 94
Tab. 76 Fault: Working pressure too low ................................................................................................. 94
Tab. 77 Fault: Pressure relief valve blowing off ....................................................................................... 95
Tab. 78 Fault: Machine overheating ........................................................................................................ 95
Tab. 79 Fault: Too much oil residue in the compressed air ..................................................................... 96
Tab. 80 Fault: Oil flows from the compressor air filter after shutdown .................................................... 96
Tab. 81 Fault: High moisture content in the compressed air ................................................................... 97
Tab. 82 There is no voltage or too low a voltage from the generator ...................................................... 97
Tab. 83 Generator voltage too high ......................................................................................................... 97
Tab. 84 Advise others that the machine is being serviced ...................................................................... 99
Tab. 85 Maintenance tasks after commissioning .................................................................................... 100
Tab. 86 Maintenance intervals and regular maintenance tasks .............................................................. 101
Tab. 87 Regular machine maintenance tasks ......................................................................................... 102
Tab. 88 Regular maintenance task options ............................................................................................. 104
Tab. 89 KAESER coolant mixture table ................................................................................................... 108
Tab. 90 Maintenance log ......................................................................................................................... 174
Tab. 91 Compressor consumables .......................................................................................................... 175
Tab. 92 Consumable engine parts .......................................................................................................... 175
Tab. 93 Replacement parts, combination filter ........................................................................................ 176
Tab. 94 Replacement parts, fresh-air filter .............................................................................................. 176
Tab. 95 "Temporarily decommissioned" information notice .................................................................... 227
Tab. 96 Long-term decommissioning and storage checklist ................................................................... 228
Tab. 97 Text for the long-term decommissioned and storage information notice .................................... 229
Tab. 98 Ball coupling wear indicator ........................................................................................................ 233
List of Tables
x
Operator Manual Screw Compressor
M100 No.: 9_6999 23 USE

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
■ Manufacturer’s declaration / declaration of conformity in accordance with applicable directives
■ Engine documentation (compressors driven by internal combustion engine)
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 operator manual is copyright protected. Queries regarding use or duplication of the documen‐
tation should be referred to KAESER. Correct use of information will be fully supported.
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.
For example,
1 Regarding this Document
1.1 Using this document
No.: 9_6999 23 USE
Operator Manual Screw Compressor
M100 1

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.
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 death 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
Unlike the warnings shown above, damage warnings do not indicate a potential personal injury.
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,
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 placed by lists of actions comprising one stage of a task.
1. For instructions with several steps ...
2. ... the sequence of actions is numbered.
1 Regarding this Document
1.4 Symbols and labels
2
Operator Manual Screw Compressor
M100 No.: 9_6999 23 USE

Result Shows the expected conclusion of the previous action.
➤ Information relating to one option only is 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 moisture separator"). Option codes used in this service manual are explained in chap‐
ter 2.2.
Information referring to potential problems are identified by a question mark.
The cause is named in the help text ...
➤... and a remedy given.
This symbol refers to important information or measures concerning environmental protec‐
tion.
Further information Further topics are introduced here.
1 Regarding this Document
1.4 Symbols and labels
No.: 9_6999 23 USE
Operator Manual Screw Compressor
M100 3
Option da

2 Technical Data
2.1 Nameplate
The machine's nameplate provides the model designation and important technical information.
The nameplate is located on the outside of the machine (see illustration in chapter 13.1).
➤ Enter the nameplate data here as a reference:
Feature Value
Vehicle Identification No.
Permissible total weight
Permissible coupling load
Permissible axle load
Portable compressor
Part 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
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 (as code letters).
The nameplate can be found:
■On the outside of the machine
■ On the front of the machine (see chapter 13.1)
The following table lists all possible options.
Only the codes for those options fitted on the machine appear on the nameplate.
2 Technical Data
2.1 Nameplate
4
Operator Manual Screw Compressor
M100 No.: 9_6999 23 USE

M100 Part Number Serial no.
Options fitted
02-M0277
tctb
sg
ta
sf
r5r4r3r1
r1= rb; rc; rd
r3= rm; ro
r4= rr; rs; rt
r5= rw; rx
ba
la
oa
lb
ga gb
oe
hc hd
pa pb
te
dddcda
ec
fc
ea
fa
db
bb bc bd
ca cb
*
*r1 - r5 = place holders for chassis options
Tab. 4 Options label
➤ Take note of fitted options from the options label and enter them here for 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 ea, ec
Tool lubricator
Option Option code Available?
Tool lubricator (with option fa) ea
Tool lubricator (with option fc) 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 Data
2.2 Options
No.: 9_6999 23 USE
Operator Manual Screw Compressor
M100 5

Option Option code Available?
Separated compressed air distribution lines, down‐
stream of the option
fc
Tab. 7 Compressed air distributor option
2.2.4 Option hc, hd
Check valve function
Option Option code Available?
Pressure/check valve (without option dd) hc
Pressure/check valve (with option dd) hd
Tab. 8 Check valve option
2.2.5 Option ca, cb
Proportional controller
Option Option code Available?
Without manual adjustment (100 psi) ca
With manual adjustment (≥145 psi) cb
Tab. 9 Proportional controller option
2.2.6 Option ba
Low temperature equipment
Option Option code Available?
Low temperature equipment ba
Engine coolant pre-heating bb
Frost protector bc
Stronger battery bd
Tab. 10 Low temperature equipment options
2.2.7 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. 11 Optional equipment for fire hazard areas
2 Technical Data
2.2 Options
6
Operator Manual Screw Compressor
M100 No.: 9_6999 23 USE

2.2.8 Option oa
Battery isolating switch
Option Option code Available?
Battery isolating switch oa
Tab. 12 Battery isolating switch option
2.2.9 Option rb/rk/rm/rs, rc/ro/rs, rd/ro/rs, rb/rl/rm/rs, rw, rx
Chassis
Chassis are defined by the combination of several option designations as follows:
Version/axle load/hight adjustment/service brake
Example: rb/rk/rm/rs means
EU chassis with low axle load, with height-adjustable tow bar and overrun brake
Chassis
Chassis Option code Available?
Model (rb, rc, rd):
EU chassis rb
GB chassis rc
US chassis rd
Axle load (rk, rl):
low axle load rk
higher axle load rl
Height adjustment (rm, ro):
With height adjustment rm
Without height adjustment ro
Service brake (rs):
With overrun brake rs
Tab. 13 Chassis options
Stationary frame
Chassis Option code Available?
Stationary (rw, rx):
on skids rw
on frame rx
Tab. 14 Options, stationary frame
2 Technical Data
2.2 Options
No.: 9_6999 23 USE
Operator Manual Screw Compressor
M100 7

2.2.10 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. 15 Lighting options
2.2.11 Option ga, gb
Generator
Option Option code Available?
Generator without FAD limitation ga
Generator with FAD limitation gb
Tab. 16 Generator options
2.2.12 Option oe
Sealed floor pan
Option Option code Available?
Sealed floor pan oe
Tab. 17 Sealed floor pan option
2.2.13 Option sf
Anti-theft device
Option Option code Available?
Anti-theft device sf
Tab. 18 Anti-theft device option
2.2.14 Option sg
Pedestrian protection
Option Option code Available?
Pedestrian protection sg
Tab. 19 Pedestrian protection option
2 Technical Data
2.2 Options
8
Operator Manual Screw Compressor
M100 No.: 9_6999 23 USE