KAESER M27 Operator'S Manual Download

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11 Spares, Operating Materials, Service

11.5 Replacement parts for service and repair

198

Operator Manual Screw Compressor
M27

No.: 9_9548 05 USE

Summary of Contents for M27

Page 1: ...Operator Manual Screw Compressor M27 No 9_9548 05 USE Manufacturer KAESER KOMPRESSOREN SE 96410 Coburg PO Box 2143 GERMANY Tel 49 0 9561 6400 Fax 49 0 9561 640130 http www kaeser com...

Page 2: ...2 3 1 Sound pressure level 8 2 3 2 Tightening torques for screws 8 2 3 3 Ambient conditions 9 2 3 4 Additional specifications 9 2 4 Chassis 9 2 4 1 Weight of machines approved for towing on public ro...

Page 3: ...inspections 33 3 9 Emergency situations 34 3 9 1 Correct fire fighting 34 3 9 2 Injury from handling operating fluids materials 34 3 10 Warranty 35 3 11 Environmental protection 35 4 Design and Functi...

Page 4: ...itor 81 8 Operation 8 1 Ensuring safety 83 8 2 Starting and stopping 84 8 2 1 Running the machine 85 8 2 2 Starting the machine 85 8 2 3 Allow the machine to run up to operating temperature 85 8 2 4 T...

Page 5: ...fuel tank 129 10 4 Compressor Maintenance 129 10 4 1 Checking cooling oil level 129 10 4 2 Filling or topping off the cooling oil 130 10 4 3 Changing the cooling oil 131 10 4 4 Replace the compressor...

Page 6: ...dentification 233 13 2 Pipeline and instrument flow diagram P I diagram 233 13 3 Dimensional drawing 237 13 3 1 Dimensional drawing chassis options 237 13 3 2 Dimensional drawing chassis options 239 1...

Page 7: ...e towing eye towbar US version 73 Fig 27 Jumper cable connection diagram 78 Fig 28 Coolant pre heating 79 Fig 29 Insulation monitoring 400V 3 phase generator 80 Fig 30 Insulation monitoring 115V singl...

Page 8: ...70 Engine air intake shut off valve maintenance 160 Fig 71 Replacing the generator belt 162 Fig 72 Transport position 219 Fig 73 Ball coupling EU version 220 Fig 74 Wear alert ball coupling EU versio...

Page 9: ...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 Interrelation between compressed air tr...

Page 10: ...il flows from the compressor air filter after shutdown 99 Tab 77 Fault High moisture content in the compressed air 100 Tab 78 Fault No voltage or too low a voltage from the generator 100 Tab 79 Fault...

Page 11: ...ns 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 doc...

Page 12: ...or 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 leve...

Page 13: ...or 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...

Page 14: ...ure 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 infor...

Page 15: ...able Aftercooler and water separator da Heat exchanger db 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...

Page 16: ...ard areas Option Option code Available Spark arrestor la Spark arrestor and engine air intake shut off valve automatic lb Tab 10 Optional equipment for fire hazard areas 2 2 7 Option ne Fuel de wateri...

Page 17: ...adjustable towbar and overrun brake Chassis Chassis Option code Available Model rb rc rd EU chassis rb GB chassis rc GB chassis rg US chassis rd Height adjustment options rm rn ro Height adjustable to...

Page 18: ...ion 2 3 Machine without options 2 3 1 Sound pressure level Sound pressure levels comply with the American EPA Standard Measurement distance 23 ft M27 Guaranteed sound pressure level dB A 76 Tab 19 Sou...

Page 19: ...ximum ambient temperature F 113 Higher altitudes are permissible only after consultation with the manufacturer Tab 23 Ambient conditions 2 3 4 Additional specifications For specifications according to...

Page 20: ...nited States of America Tab 24 Weight of the machine 2 4 2 Tires The tire s dimensions are shown on the side wall see also Fig 1 Fig 1 Example for tire information on the side wall 1 Section tire side...

Page 21: ...M12 8 8 760 Towing eye M12 8 8 760 Towbar M12 8 8 760 M16 8 8 1860 Tab 27 Towbar tightening torque 2 5 Compressor 2 5 1 Working pressure and FAD Maximum working pressure psig 100 SIGMA airend 11 G Fre...

Page 22: ...ng pressure psig 130 The safety relief valve is fitted onto the oil separator tank Tab 31 Relief valve activating pressure 2 5 5 Temperature Machine temperatures Values Recommended airend discharge te...

Page 23: ...at 59 F 864 kg m3 ISO 12185 Pour point 50 8 F D 97 ASTM test 27 4 F ISO 3016 Demulsibility at 29 F 40 40 0 10 min D 1401 ASTM test Tab 33 Cooling oil recommendation 2 5 7 Cooling oil charge Cooling o...

Page 24: ...Fuel recommendation The diesel fuel must meet the requirements of EN 590 and ASTM D975 respectively According to these standards a specific portion of bio diesel is permitted in the fuel Depending on...

Page 25: ...ries Further information Depending on machine equipment a higher capacity battery may be required See chapter 2 7 2 2 7 Options 2 7 1 Option ea ec Tool lubricator Name Temperature range F Fluid volume...

Page 26: ...wing connections are provided on the generator control cabinet 1 x 400V 3 phase AC 2 x 230V AC Generator specification Voltage V 400V 3 phase 230V 1 phase Rated power kVA 3 phase 6 5 Rated power kW Si...

Page 27: ...0 Tab 44 Compressed air delivery in generator mode Connections Voltage V 400V 3 phase 230V 1 phase Power sockets Number Number 16 A 400 V 3 N PE 1 16 A 230 V 1 N PE 2 Tab 45 Connection sockets Circuit...

Page 28: ...ontrol box 1 x 115V AC 32 A 2 x 115V AC 16 A Generator specification Voltage V 115V 2 phase Rated power kW 2 phase 6 0 Voltage constant Balanced load 5 Voltage constant Single phase unbal anced load 6...

Page 29: ...PE 2 Tab 51 Connection sockets Circuit breaker Voltage V 115V 2 phase Safety cut out A Number 32 1 16 2 Tab 52 Circuit breaker Maximum power loading by consumers Resistive consumers include lamps and...

Page 30: ...ng limits 2 7 3 4 Factor of output power reduction The output power is dependent on installation altitude and ambient temperature Output power reduction Ambient temperature F 104 113 Altitude AMSL ft...

Page 31: ...Keep to the specifications listed in this service manual Operate the machine only within its performance limits and under the permitted ambient condi tions Do not use compressed air for breathing pur...

Page 32: ...nd authorization for the safe installation and maintenance of this machine Authorized transport personnel possess the following qualifications are of legal age are familiar with and adhere to the safe...

Page 33: ...engine at running temperature is under high pressure Cool ant can spray out when the filler cap is opened causing severe burns Let the machine cool down before opening the cooling system Unscrew the f...

Page 34: ...r the belt drive while the machine is switched on can result in serious injury Do not open the access doors or panels while the machine is running Switch off and lock out the machine and check that no...

Page 35: ...oved by the manufacturer for use in this machine Use only genuine KAESER replacement parts on pressure bearing parts Conversion or modification of the machine Modifications additions to or conversions...

Page 36: ...iler on public roads Do not tow machines without illumination and signaling equipment on public roads Ensure all running gear including chassis wheels brakes signalling and lighting is in safe conditi...

Page 37: ...vapors Acid or base forming substances such as ammonia chlorine or hydrogen sulfide Do not position the machine in warm cooling outlet air from other machines Keep suitable fire extinguishing agents...

Page 38: ...cause injury At working pressures 100 psig compressed air hoses should be secured by a cable to their respective outlet valves 3 5 2 4 Parking the compressor Improper parking and use of the parked ma...

Page 39: ...e Maintenance personnel Operation Within a 3 ft radius of the machine Operating personnel Maintenance Within the machine Within a 3 ft radius of the machine Maintenance personnel Tab 57 Danger areas 3...

Page 40: ...lothing or painted sur faces Do not attempt to jump start if battery fluid is frozen Bring temperature of battery up to at least 60 F before attempting to jump start it may explode 303 Fire or explosi...

Page 41: ...mendations to verify that they reduce pressure in case of hose failure and will not nuisance trip with the hose and tool combinations in use 440 Compressed air quality Injury and or contamination can...

Page 42: ...measures 1650 Machine damage if switched while the engine is running Use the Battery isolating switch only with the engine stopped Do not use the Battery isolating switch as a main or emergency switch...

Page 43: ...he generator however renders an additional ground fault current protection switch unnecessary Follow the regulations of the local electricity supply utility and obtain any necessary permits When clean...

Page 44: ...ect fire fighting Suitable measures Calm and prudent action can safe lives in the event of a fire Keep calm Give the alarm Shut down the machine from the instrument panel if possible Warn and move end...

Page 45: ...apply with regard to warranty A condition of our warranty is that the machine is used for the purpose for which it is intended un der the conditions specified Due to the multitude applications for whi...

Page 46: ...with local environ mental protection regulations Observe relevant regulations This applies particularly to parts contaminated with fuel oil coolants and acids 3 Safety and Responsibility 3 11 Environ...

Page 47: ...Bodywork 1 Canopy 2 Cooling air inlet 3 Snap fastener 4 Instrument panel 5 Lower body 6 Cooling air outlet 7 Cover for lifting eye The canopy 1 can be opened when all the snap fasteners 3 are released...

Page 48: ...ic valve 4 Compressor air filter 5 Lifting eye 6 Coolant expansion tank 7 Water cooler 8 Engine 9 Engine air filter 10 Airend 11 Compressed air outlet valve 12 Oil separator tank 13 Fuel tank 14 Oil c...

Page 49: ...rator tank 7 Oil separator cartridge 10 Compressed air distributor 13 Safety pressure relief valve 15 Engine 19 Combination valve thermostatic valve 20 Oil cooler 23 Proportional controller 24 Engine...

Page 50: ...machine operates in the following modes LOAD The inlet valve is open The engine runs at maximum speed The airend delivers compressed air MODULATING With the help of a control valve the proportional c...

Page 51: ...en an alarm occurs The engine comes to a stop and the venting valve releases pressure from the machine 4 5 2 Further safety devices The following safety devices are provided and may not be modified in...

Page 52: ...with hot compressor cooling oil that warms the outgoing moisture reduced compressed air This warm dry compressed air is ideal for sand blasting for example 4 6 1 4 Option ea Tool lubricator Compresse...

Page 53: ...Version without FAD limitation Activating the generator does not influence the volume of compressed air delivered The compres sor delivers its full capacity regardless of current being drawn from the...

Page 54: ...eed Permanent maximum speed en gine under full load Power consumption below minimum value Engine run on time of approximately 2 mi nutes at maximum speed Advantages Fuel saving Constant oscillation be...

Page 55: ...1 Generator control box 2 Generator main switch 3 Power socket 115 V 1 N PE 50 Hz 16 A 4 Power socket 115 V 1 N PE 50 Hz 32 A 5 Test button insulation monitor with indi cator light for ground short 6...

Page 56: ...ter 3 Motor block 4 Coolant pre heating The ideal coolant pre heating period is 2 3 hours before the machine is started A pre heating peri od of more than 3 hours is not necessary as the maximum effec...

Page 57: ...enerated innate heat counteracts a potential freezing of individual components Machine operation in Summer Antifreeze is not required for the regulating air at ambient temperatures of more than 32 F 4...

Page 58: ...e watering filter option A fuel de watering filter is installed to remove water from the fuel to prevent lower quality fuel reaching the pump 4 6 6 Option oe Sealed floor pan option The machine is fit...

Page 59: ...rovided for safe storage of this hose 4 6 9 Option sf Optional anti theft device The machine is fitted with a security chain as theft protection The supplied safety chain is stored in a container at t...

Page 60: ...ked The stopping distance is significantly less than for a trailer without overrun brake Function The overrun device activates the relay lever The relay lever pulls the brake actuating rod with the br...

Page 61: ...ke Parking brake Breakaway cable rd ro rr US chassis Single axle Axle rubber sprung Prop stand Fixed height towbar Without parking brake EU Europe GB Great Britain US United States of America country...

Page 62: ...inity of the machine The machine is not explosion proof Do not operate in areas in which specific requirements with regard to explosion protection are applied Keep suitable fire extinguishing agents o...

Page 63: ...d up that could damage the machine Do not position the machine directly against a wall Ensure always sufficient ventilation space around the machine 5 Position the machine as far as possible from any...

Page 64: ...chine Use winter grade engine oil Use low viscosity compressor cooling oil Allow the machine to warm up in IDLE low speed see chapter 8 2 3 10 At ambient temperatures below 32 F follow instructions in...

Page 65: ...dden transport damage 2 Inform the carrier and the manufacturer in writing of any damage found 6 3 Fitting the towbar For space reasons the machine is mounted on a transport frame when delivered Shift...

Page 66: ...1 Delivery state towing device rb rm rr 2 Delivery state towing device rb rm rs 3 Transport frame 4 Split pin 5 Locking lever 6 Joint 7 Towbar adapter 8 Towbar tube 9 Prop stand 10 Jockey wheel 11 Su...

Page 67: ...both locking levers with a tap of a hammer 13 Insert both split pins 1 Crank the jockey wheel downward until the machine is standing horizontally 2 Draw out both split pins 3 Loosen the lower locking...

Page 68: ...own 8 Parking brake 9 Adapter mounted rotatable 10 Overrun braking mechanism 1 Check whether the clamping levers are properly tightened 2 Crank down the jockey wheel 3 Check whether the machine is in...

Page 69: ...ise 4 Insert the safety cotter pin The support is secured 5 Lower the support 6 4 Adjusting the chassis Height adjustable towbar Option Type Representation rb rm rr unbraked 06 M0553 rb rm rs braked 0...

Page 70: ...arallel to the ground Height adjustment is by two serrated joints Serrated joint 1 Adjustable position of the center piece relative to the chassis Maximum adjustment upwards 50 Maximum adjustment down...

Page 71: ...osition of the split pin The split pin must be fully inserted so that it is trapped by its bow over the axis of the locking lever see 18 Check locking position 11 Split pin 1 properly inserted Split p...

Page 72: ...until the serrated joint 6 is disengaged 7 Adjust the angle of the serrated joint 6 to bring the towing eye or coupling parallel to the ground at the height of the towing vehicle hitch 8 Tighten the...

Page 73: ...an be fitted with various towing eyes or ball couplings Material Protective gloves New self locking nuts Wrench Hammer Mounting pin Precondition The machine is switched off The machine is disconnected...

Page 74: ...tem 1 Ball coupling 2 Adapter for ball coupling 3 Split pin 4 Locking lever 5 Locking lever 6 Serrated joint 7 Hex head bolt 8 Side part 9 Towing eye 6 Installation 6 4 Adjusting the chassis 64 Operat...

Page 75: ...en the locking lever 4 10 Check if Both side parts are correctly seated The ball coupling is correctly seated 11 Insert both split pins 1 Position the towing eye between the two serrated joints of the...

Page 76: ...pin 6 Retaining screw shock absorber 7 Fastening screw 8 Distance bow for ball coupling 9 Towbar tube 10 Distance bush for towing eye 11 Fastening eye of the shock absorber 12 Towing eye 13 New self...

Page 77: ...AK160 B Distance bow Towing eye D40 F Distance bush Tab 63 Distance elements Fig 22 Distance elements towing adapter 1 Distance bow 2 Towbar tube 3 Diameter towbar tube 4 Maximum length mounting pin 5...

Page 78: ...nto the towbar 2 Place the distance bow in such a manner that the bores of the bow and the towbar tube are aligned 3 Push the ball coupling onto the towbar tube 4 Adjust the ball coupling until the bo...

Page 79: ...ing the ball coupling Removing the towing eye 1 Unscrew and remove the nuts 1 of the hori zontal screw connections 2 Remove the screws 2 3 Remove the coupling 8 from the adapt er 3 4 Unscrew and remov...

Page 80: ...that the bolts can be freely inserted 9 Insert the screws through the horizontal fix ing holes 10 Secure the screws with the self locking nuts 1 Fit the new towing eye in the towbar 2 Position the tow...

Page 81: ...locking nut 2 Screw 3 Towing eye 4 Distance bush for towing eye 5 Towbar mounted rotatable 6 Towbar tube 7 Ball coupling 8 New self locking nut 6 Installation 6 4 Adjusting the chassis No 9_9548 05 U...

Page 82: ...distance bush over the towbar 2 Position the distance bush so that the bolts can be freely inserted 3 Push the towing eye onto the distance bush 4 Position the towing eye so that the bolts can be fre...

Page 83: ...ontal screw connections 2 Remove the screws 2 3 Remove the coupling 8 from the adap tor 3 4 Unscrew and remove the nuts 4 of the ver tical screw connections 5 Remove the prop stand 6 6 Remove the scre...

Page 84: ...s 7 Slide the new ball coupling onto the adapt er 8 Position the ball coupling so that the bolts can be freely inserted 9 Insert the screws through the horizontal fix ing holes 10 Secure the screws wi...

Page 85: ...l are found in chapter 3 4 2 Details of dangers and their avoidance are found in chapter 3 5 7 2 Before initial start up or recommissioning Incorrect or improper commissioning can cause injury to pers...

Page 86: ...for recommissioning the compressor after a long period of storage 7 3 Checking installation and operating conditions Check and confirm all the items in the checklist before starting the machine Task S...

Page 87: ...until an airend discharge tem perature of 86 F is reached The airend discharge temperature is shown at the remote ther mometer contact on the instrument panel 7 4 1 Starting assistance If the machine...

Page 88: ...its battery is frozen Allow the battery to thaw first Do not try to start the machine with a boost charger 2 Comply with the safety instruction shown when using starting aids and starter batteries Pre...

Page 89: ...jumper cables in the reverse order first negative then positive 3 Place the pole caps 4 Close the maintenance panels and or bonnet A stop of the compressor engine as soon as the cables are disconnect...

Page 90: ...the tap on the frost protector 8 4 Tab 66 Low temperature equipment checklist 7 5 Activating the generator The generator can be operated without electrical grounding Test the insulation monitor daily...

Page 91: ...as trip ped during the test 3 Check the insulation monitor according to instructions Test instructions are provided on the label attached to the generator control box DANGER Electrical power Danger of...

Page 92: ...4 Turn the starter switch of the machine to the 0 position Warning lamp extinguishes 7 Initial Start up 7 5 Activating the generator 82 Operator Manual Screw Compressor M27 No 9_9548 05 USE...

Page 93: ...s can result in electric shocks burns or death Work on electrical equipment may only be carried out by authorized electricians Safe working with compressed air tools and hoses Open pressurized compres...

Page 94: ...age to engine from cold starting sprays Cold start assists such as ether or other sprays can cause severe engine damage Do not use cold start sprays Fig 31 Starting instruments 1 Controller On switch...

Page 95: ...e starter switch to II and hold max 5 10 seconds The engine s glow plugs are energised and the engine pre heated 4 Turn the starter switch to III and release it as soon as the engine starts The chargi...

Page 96: ...t valves on the air distributor The engine runs in IDLE 2 Turn the starter switch to 0 position The engine turns off Shutting down the machine 1 Raise the cover 2 Turn the controller ON switch to 0 po...

Page 97: ...by the user It depends on the nature of the air consumers and the supply hoses The metering valve controls the flow of oil into the air Turning clockwise reduces the oil flow Turning counter clockwise...

Page 98: ...ation at temperatures below 32 F winter operation Subsequently to the daily operation of the machine the compressed air conduits and valves must be moistened with antifreeze For this purpose the defro...

Page 99: ...is switched off 1 Raise the cover 2 Keep the frost protector shut off valve permanently closed position 0 3 Close the canopy 8 5 Option ga gb Generator operation Risk of fatal injury caused by contac...

Page 100: ...r operation LOAD mode A pictogram beneath the generator main switch indicates the correct cutting in of the generator Fig 35 Generator cut in pictogram 1 Compressed air outlet valve closed 2 Turn the...

Page 101: ...The motor runs in IDLE and the generator can cool down After running about 2 minutes in IDLE the generator has cooled down sufficiently for the en gine to be stopped 8 6 Option oa Operating the batte...

Page 102: ...e for the compressed air extension hose facilitates activating the compressed air at the front of the machine Fig 37 Hose reel 1 Front side machine 2 Hose reel 3 Winding handle fold out 4 Hose 5 Hose...

Page 103: ...sport securing bolt with one of the securing bores 12 at the side wall of the hose reel 6 4 Engage the securing screw fully 5 Tighten the clamping knob 6 Plug the hose coupling onto the bracket 9 8 8...

Page 104: ...sitive components Work carefully 2 Carefully clean the machine with the high pressure cleaner Water has accumulated in the sealed floor pan Drain the water Catch the liquid and dispose in accordance w...

Page 105: ...service manual Defective starter Have changed X The fuel cut off device has not opened Check the coil and electrics and have changed if necessary X Fuel tank empty Fill up the fuel tank Airlock in the...

Page 106: ...een fuel tank and injector pump Bleed the fuel line see chap ter 10 3 3 X Fuel filter clogged Clean or replace see chap ter 10 3 3 X Fuel line broken Have changed X X Speed adjustment cylinder mal adj...

Page 107: ...ced if necessary X Venting valve does not blow off Check the connections and function and have repaired or replaced as necessary X Tab 71 Alarm Working pressure too high 9 3 2 Working pressure too low...

Page 108: ...laced if nec essary X Tab 73 Alarm Safety relief valve blowing off 9 3 4 Machine overheating Possible cause Remedy Where can I get help Specialized workshop KAESER Service Defective cooling fan Have t...

Page 109: ...trap or replace the strainer and nozzle if necessary See chapter 10 4 5 X Fractured oil separator car tridge Change see chapter 10 4 6 Oil level in the oil separator tank too high Reduce to maximum le...

Page 110: ...he power requirement of the connected consumers and reduce if necessary check the consumers for short circuits X Check the overload protection switch and have changed if nec essary X X Engine speed to...

Page 111: ...lized workshop KAESER Service Engine speed too high Have reset to rated speed X X Tab 79 Fault Generator voltage too high 9 Fault Recognition and Rectification 9 4 Generator faults and alarms No 9_954...

Page 112: ...ced Before switching on make sure that nobody is working on the machine all protective guards and cover panels are attached all doors canopy and panels are closed all tools have been removed from the...

Page 113: ...gh temperatures a lot of dust frequent use Adjust the maintenance intervals with regard to local installation and operating condi tions Logging all maintenance work This enables the frequency of indiv...

Page 114: ...10 2 3 Regular maintenance tasks The following table lists the various maintenance intervals Maintenance interval Short description Daily Every 250 h at least annually A250 Every 500 h at least annua...

Page 115: ...ilter X 10 3 2 Have the engine mounts checked X SW Have the valve clearance adjus ted X SW Engine SM Replace the drive belt X 10 3 6 SW Engine SM Have the multi ribbed belt jock ey wheel checked repla...

Page 116: ...X 10 4 1 Clean the compressor air filter X 10 4 7 Clean the oil cooler X 10 5 Have the safety relief valve s checked X 10 4 8 Check clean the oil separator tank dirt trap X 10 4 5 Change the compress...

Page 117: ...eck all accessible screw fit tings pipes and clamps for wear and tightness X Check hoses for proper seating leaks and wear X Have hose lines replaced X SW Check that all electrical connec tions are ti...

Page 118: ...ntake shut off valve Clean check the engine air in take shut off valve X 10 8 4 Option oe Sealed floor pan Checking the machine interior for liquid accumulations X 10 8 5 Option ga gb Generator Carry...

Page 119: ...contact with coolant If the eyes are affected rinse immediately with running water Wear protective glasses and gloves Insufficient coolant can damage the engine Insufficient coolant will cause the eng...

Page 120: ...ce schedule to ensure quality and op erational life Coolant quality can be determined by the following parameters Visual check Antifreeze concentration measurement Unscrew and remove the expansion tan...

Page 121: ...sh water and antifreeze with corrosion inhibitor For reasons of corrosion protection and the need to raise the boiling point the coolant must remain in the cooling system throughout the year The maxim...

Page 122: ...9 Check the coolant level Top up if the coolant level in the expansion tank has fallen 10 Carry out a visual check for leaks 11 Close the canopy 10 3 1 5 Draining the coolant Precondition The machine...

Page 123: ...ter element with damaged folds or gasket The use of an unsuitable air filter can permit dirt to ingress the engine and cause prema ture wear and damage Material Compressed air for blowing out Spare pa...

Page 124: ...filter element Cleaning the air filter The dust evacuator valve must be at the bottom The dust evacuation valve 2 is on the filter cap Fig 41 Engine air filter maintenance 1 Filter cap 2 Dust evacuat...

Page 125: ...empty the dust evacuator valve 2 Pinch the valve part 4 above the drain slit 3 drain slit opens Remove any dust clumps Clean the slit 6 Insert the cleaned or new filter element into the filter housin...

Page 126: ...t the place of use Stop the engine Wipe up escaped fuel Keep fuel away from hot machine parts Ensure that the maximum ambient temperature is not exceeded at the place of use Bleeding the fuel system T...

Page 127: ...able to the battery is disconnected 1 Place the fuel receptacle under the prefilter 2 Loosen the hose clamp on the filter cap 3 Pull off the fuel line 4 Catch fuel in the receptacle 5 Remove the prefi...

Page 128: ...nents contami nated with fuel according to environmental regulations Starting the machine and performing a test run 1 Start the machine and allow it to idle for about 1 minute 2 Visually check the fue...

Page 129: ...r trap The water trap should be emptied when dirty 3 Close the canopy Emptying the water trap 1 Place a receptacle under the drain plug 4 2 Unscrew the drain plug and allow water and dirt to drain out...

Page 130: ...e oil see chapter 2 6 5 for engine oil filling quantity Receptacle Hose coupling Cleaning cloth Funnel Precondition The machine is shut down The machine is standing level The machine is fully vented t...

Page 131: ...ain the oil by screwing the hose coupling on the oil drain valve Machine status Oil drain valve status Protective cap Hose coupling 1 Mode machine runs closed connected removed 2 Oil drain machine doe...

Page 132: ...valve 1 Pour in the specified volume of fresh oil into the oil filler 2 Screw on the filler cap 1 Checking the engine oil level It takes a few minutes for oil to reach the sump Wait 5 minutes then use...

Page 133: ...3 Engine 4 Oil dipstick 1 Open the canopy 2 Prepare a receptacle 3 Note the direction of rotation 2 to unscrew the filter 4 Unscrew the filter 1 Catch any escaping oil 5 Carefully clean sealing surfac...

Page 134: ...anger of serious injury from pinching Never check the drive belts unless the engine is at standstill Never run the machine without a belt guard Open the cover 10 3 6 1 Visual inspection Precondition B...

Page 135: ...push the belt between the belt pulleys see illustration 48 3 Tensioning a loose belt Loosen both securing screws 3 on the engine alternator 4 Using a suitable lever pull the engine alternator 2 in the...

Page 136: ...al 10 3 7 Battery maintenance Check the charging system if the battery discharges without a reason 10 3 7 1 Safety Danger of acid burns from escaping electrolyte Wear appropriate protective clothing i...

Page 137: ...ee batteries need a degree of care to maintain their maximum operational life The outside of the battery and the terminals should be cleaned regularly with a soft cloth This avoids current leaks and m...

Page 138: ...heavy duty cold start batteries and or additional batteries is rec ommended 10 3 7 3 Battery removal and installation Precondition The machine is shut down The machine is standing level The machine is...

Page 139: ...strips Slightly hand tighten the lashing strips Carry out visual check 1 Check the lashing strips for tears and fraying in the fabric and for damages to the ratchet Change any damaged lashing strip i...

Page 140: ...aw the plug from the oil filler port 3 Check the cooling oil level Top up if no oil is visible 4 Replace the plug in the filler port 5 Close the canopy 10 4 2 Filling or topping off the cooling oil Ma...

Page 141: ...he negative battery terminal 9 Close the canopy Starting the machine and performing a test run 1 Start the machine and run in IDLE until the operating temperature is reached 2 Close the outlet valves...

Page 142: ...nents and escaping oil Wear long sleeved clothing and protective gloves Open the cover 10 4 3 1 Draining the cooling oil All cooling oil is drained via the oil discharge valve The oil discharge valve...

Page 143: ...ose coupling The oil drain valve is again closed 8 Close the oil discharge valve with the sealing cap 9 In Option oe sealed floor pan you must also close the opening in the floor panel using the bung...

Page 144: ...new filter s gasket 6 Turn the oil filter clockwise by hand to tighten 7 Check the oil level in the oil separator tank Top up if necessary 8 Reconnect the negative battery terminal 9 Close the canopy...

Page 145: ...re open Negative cable to the batteries disconnected Fig 53 Oil separator tank dirt trap maintenance 1 Oil return line 2 Union nut 3 Dirt trap housing 4 Strainer 5 O ring 6 Screw fitting Open the cano...

Page 146: ...Close the canopy 10 4 6 Changing the oil separator cartridge The oil separator cartridge cannot be cleaned The life of the oil separator cartridge is influenced by contamination in the air drawn into...

Page 147: ...ne side 5 Remove the fixing screws 6 and carefully lift the cover 7 and lay it to one side 6 Take out the old cartridge 8 and gaskets 9 7 Clean all sealing surfaces taking care that no foreign bodies...

Page 148: ...In addition the frost protector must be emptied and its fittings undone Be careful of the frost protector control lines when removing the separator tank cover 1 Empty the lower part of the frost prot...

Page 149: ...unsuitable air filter can permit dirt to ingress into the pressure system and cause premature wear and damage to the machine Material Spares Cleaning cloth Precondition The machine is shut down The m...

Page 150: ...Replacing the filter element Fig 56 Compressor air filter maintenance 1 Filter cap 2 Filter element 3 Filter housing 4 Retaining clip 5 Inlet valve 6 Airend 7 Maintenance indicator 1 Release the reta...

Page 151: ...dependent on local operating conditions Severe clogging of the coolers causes overheating and machine damage Check coolers regularly for clogging Avoid creating dust eddies Wear breathing protection i...

Page 152: ...aw the ball cup from the ball head Keep the clip on the ball cup Connection elements po sitions Ball head Ball cup with clip Ball cup Cover interior X Gas strut cylinder X Body interior X Gas strut pi...

Page 153: ...Start the machine and run up to operating temperature so that excess water is evaporated Check the cooler for leaks 1 Raise the cover 2 Visually check for leaks does oil or cooling water escape Is a c...

Page 154: ...om sticking and tearing when the canopy is opened Material Cleaning cloth Silicone or Vaseline Precondition The machine is shut down The machine is fully vented the pressure gauge reads 0 psig The mac...

Page 155: ...pecified maintenance intervals Otherwise towing the machine may create a hazard in public road traffic Maintain a driving log and regularly enter the distances that your mobile compressor has trav ell...

Page 156: ...ntervals Overview Adjust bearing play Remove wheel bearing Clean check and lubricate the tapered roller bearings Install wheel bearing Secure the lock nut against loosening Comply with all instruction...

Page 157: ...the specified torque see also subsequent description Installing the wheel bearing 6 Drive the collar of the locknut see also subsequent description Securing the locknut against loosening Fig 61 7 Plac...

Page 158: ...ered roller bearing 2 Check the tapered roller bearing for wear 3 Lubricate the tapered roller bearing 4 Clean the bearing journal 5 Lubricate the bearing journal The tapered roller bearing exhibits w...

Page 159: ...ghten the locknut at simultaneous turning of the wheel hub applying the specified torque 5 Turn the locknut back by 30 6 Check the bearing play Result The axial play is in permissible range Securing t...

Page 160: ...her the collar of the locknut is flush in the groove of the bearing journal The collar of the locknut is flush with the groove of the bearing journal The locknut is secured against loosening 10 Place...

Page 161: ...ater repellent grease Further information See chapter 6 4 for towbar height adjustment Maintaining the parking brake Lightly lubricate the pins and adjustment joints 10 7 3 2 Overrun braking mechanism...

Page 162: ...asing points Fig 63 Ball coupling US version 1 Lubricating points 2 Greasing points 1 Check the ball coupling for correct function and movement 2 Clean the ball coupling Grease or oil the ball cup joi...

Page 163: ...is the same braking resistance on both wheels Adjust the braking system if the resistance is not the same 4 Release the parking brake 10 7 4 2 Checking wheel brake lining wear Fig 64 Checking the bra...

Page 164: ...heels turning forward 5 Pull up the parking brake 6 Check the position of the equalizer 2 on the brake rod 1 If the equalizer is perpendicular to the brake rod the brake clearance is the same on each...

Page 165: ...to manually turn the wheel in forward driving direction 6 Screw the hexagon nut onto the brake rod and lock the ball nut Test by applying the brake a number of times 10 7 4 4 Greasing the brake rods G...

Page 166: ...5 Compressed air inlet 6 Tool oil outlet Open the canopy Checking the tool lubricator oil level Check the oil level daily A dip stick is attached to the underside of the oil filler plug with which to...

Page 167: ...aning The compressed air water separator 2 is integrated in the com pressed air aftercooler 1 Material Cleaning cloth Wrench Small screwdriver Dirt trap maintenance kit Petroleum ether or spirit Preco...

Page 168: ...oximately 5 minutes 2 Shut down the machine 3 Wait until the machine has automatically vented Pressure gauge reads 0 psig 4 Open the outlet valves 5 Open the cover 6 Check the housing of the water sep...

Page 169: ...Fill the bowl full with antifreeze 4 Screw the bowl carefully back into place 5 Close the canopy 10 8 4 Option lb Engine air intake shut off valve maintenance Material Compressed air for blowing out P...

Page 170: ...truction of the engine and explosion and or fire are pos sible Do not grease the valve as this may cause a build up of dust and valve sticking 2 Loosen the hose clamp on the filter side of the valve 3...

Page 171: ...ickly as possible in order to avoid potential machine faults For draining the liquid maintenance openings have been added to the floor panel of the machine which are closed with bungs Material Recepta...

Page 172: ...shut down The machine is fully vented the pressure gauge reads 0 psig The machine is cooled down All compressed air consumers are disconnected and the air outlet valves are open Beware of rotating pul...

Page 173: ...ff to side from the tension pulley 3 4 Permit the swing frame to slowly spring back 5 Remove the old drive belt Checking the pulleys 1 Dirty pulley Clean pulley 2 Worn pulley Change the pulley Install...

Page 174: ...mber Enter maintenance and service work carried out in this list Date Maintenance task carried out Operating hours Signature Tab 92 Maintenance log 10 Maintenance 10 9 Documenting maintenance and serv...

Page 175: ...lt from machine damage There is risk of personal injury or damage to the machine resulting from the use of unsuita ble spares or operating fluids materials Use only original KAESER parts and operating...

Page 176: ...ual 11 5 Replacement parts for service and repair Use these parts lists to plan your material requirement according to operating conditions and to or der the required spare parts Personal injury or ma...

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Page 226: ...e off the following openings with plastic foil and moisture resistant adhesive tape Engine air inlet Compressor air inlet Exhaust silencer 3 Attach the following notice on the instrument panel showing...

Page 227: ...10 minutes to coat all parts with a protec tive oil film Disconnect the battery the negative terminal first and then the posi tive terminal and store in a frost free room Check the battery fluid level...

Page 228: ...ined in safely dealing with motor vehicles and the transporting of goods 1 There is danger of being run over or crushed by an overturning vehicle Death or serious injury can result from being crushed...

Page 229: ...w or ice may build up on the machine under low temperature conditions 1 Accident hazard due to snow or ice falling off the machine Snow or ice falling from the towed machine can endanger following veh...

Page 230: ...onsiderable danger of injury caused by trapped fingers They can be trapped in the spring loaded closing mechanism Never place your fingers inside an open ball coupling Always wear protective gloves 2...

Page 231: ...dent from worn coupling The machine may detach from the towing vehicle Do not tow the machine Have the ball coupling and ball hitch checked Replace worn parts 2 Couple up the machine and tow slowly an...

Page 232: ...ded closing mechanism Never place your fingers inside an open ball coupling Always wear protective gloves 2 Check if the security pin is removed from the coupling and draw it out if not 3 Pull up the...

Page 233: ...The relieved automatic jockey wheel of the coupled machine swivels into transport position see illustration 77 3 Check that the wheels are securely fitted and the tires are in good condition 4 Check t...

Page 234: ...ks in the transport securing device before transporting the machine Replace missing chocks immediately 2 Raise the support to its uppermost position end stop 3 Check that the wheels are securely fitte...

Page 235: ...cle the cable tightens and pulls on the emer gency brake parking brake It is essential that the breakaway cable is threaded through its guides for correct emergency brak ing Fig 80 Breakaway cable att...

Page 236: ...ope securely chock the machine before uncoupling Machine without parking brake Serious injury or death can result from an unsecured machine rolling away Securely chock the machine before uncoupling As...

Page 237: ...und potentially causing severe injuries to legs and or feet Wind the automatic jockey wheel only up when the machine is coupled to a towing vehi cle Wind the automatic jockey wheel up only as far as t...

Page 238: ...m the towing device of the towing vehicle 8 Check whether the ball coupling is positioned higher than the towing device of the towing vehi cle 9 If necessary lower the jockey wheel further 10 Slowly r...

Page 239: ...1 Machine 2 Position of the container for the safety chain 3 Safety chain 1 Open the container cover 2 Take the safety chain and pull it out 3 Wrap the safety chain around a suitable object 4 Secure t...

Page 240: ...e of packing and securing Packing and securing methods must be such that assuming proper handling the goods arrive in perfect condition at the destination Other measures must be taken for the transpor...

Page 241: ...s for air freight purposes any disregard can result in a heavy fine 1 Danger of fire or explosion from operating fluids materials The machine incorporates an internal combustion engine Any dangerous f...

Page 242: ...ompletely drain the cooling oil and engine oil from the machine 3 Remove used filters and the oil separator cartridge 4 Drain the coolant from water cooled engines and systems 5 The battery has been r...

Page 243: ...odywork Vehicle Identification Number 2 Options label 3 Machine nameplate with serial number 4 Engine nameplate with serial number 13 2 Pipeline and instrument flow diagram P I diagram 13 Annex 13 1 I...

Page 244: ...13 Annex 13 2 Pipeline and instrument flow diagram P I diagram 234 Operator Manual Screw Compressor M27 No 9_9548 05 USE...

Page 245: ...13 Annex 13 2 Pipeline and instrument flow diagram P I diagram No 9_9548 05 USE Operator Manual Screw Compressor M27 235...

Page 246: ...13 Annex 13 2 Pipeline and instrument flow diagram P I diagram 236 Operator Manual Screw Compressor M27 No 9_9548 05 USE...

Page 247: ...r Dimensional drawing chassis options Option rb Chassis EU version Option rm Chassis with height adjustable towbar Option rr Chassis without service brake 13 Annex 13 3 Dimensional drawing No 9_9548 0...

Page 248: ...zug nglich gemacht werden Entwicklungsbedingte nderungen vorbehalten Zeichnung darf nur ber CAD ge ndert werden 02 02 2012 Projektion A3 10226212 USE 00 nderungs Nr Ma stab Original Dokument TZM Dokum...

Page 249: ...al drawing chassis options Option rb Chassis EU version Option rm Chassis with height adjustable towbar Option rs Chassis with overrun brake 13 Annex 13 3 Dimensional drawing No 9_9548 05 USE Operator...

Page 250: ...zug nglich gemacht werden Entwicklungsbedingte nderungen vorbehalten Zeichnung darf nur ber CAD ge ndert werden 02 02 2012 Projektion A3 10226250 USE 00 nderungs Nr Ma stab Original Dokument TZM Dokum...

Page 251: ...nal drawing chassis options Option rc Chassis GB version Option ro Chassis with fixed height towbar Option rr Chassis without service brake 13 Annex 13 3 Dimensional drawing No 9_9548 05 USE Operator...

Page 252: ...ise zug nglich gemacht werden Entwicklungsbedingte nderungen vorbehalten Zeichnung darf nur ber CAD ge ndert werden 02 02 2012 Projektion A3 10226379 USE 00 nderungs Nr Ma stab Original Dokument TZM D...

Page 253: ...drawing chassis options Option rg Chassis GB version Option rp Chassis with adapter mounted rotatable Option rr Chassis without service brake 13 Annex 13 3 Dimensional drawing No 9_9548 05 USE Operat...

Page 254: ...iger Weise zug nglich gemacht werden Entwicklungsbedingte nderungen vorbehalten Zeichnung darf nur ber CAD ge ndert werden Status Dokument TZD Bezeichnung Freigeg Bearb Gez Original Blatt Sprache Name...

Page 255: ...onal drawing chassis options Option rc Chassis GB version Option ro Chassis with fixed height towbar Option rs Chassis with overrun brake 13 Annex 13 3 Dimensional drawing No 9_9548 05 USE Operator Ma...

Page 256: ...zug nglich gemacht werden Entwicklungsbedingte nderungen vorbehalten Zeichnung darf nur ber CAD ge ndert werden 02 02 2012 Projektion A3 10226349 USE 00 nderungs Nr Ma stab Original Dokument TZM Doku...

Page 257: ...al drawing chassis options Option rd Chassis USA version Option ro Chassis with fixed height towbar Option rr Chassis without service brake 13 Annex 13 3 Dimensional drawing No 9_9548 05 USE Operator...

Page 258: ...onstiger Weise zug nglich gemacht werden Entwicklungsbedingte nderungen vorbehalten Zeichnung darf nur ber CAD ge ndert werden 02 02 2012 Projektion A3 10226394 USE 00 nderungs Nr Ma stab Original Dok...

Page 259: ...13 4 Wiring diagrams 13 4 1 Electrical Diagram 13 Annex 13 4 Wiring diagrams No 9_9548 05 USE Operator Manual Screw Compressor M27 249...

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Page 269: ...13 4 2 Option ga Generator electrical diagram 400V 3 ph 13 Annex 13 4 Wiring diagrams No 9_9548 05 USE Operator Manual Screw Compressor M27 259...

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Page 275: ...13 4 3 Option ga Generator electrical diagram 115 V 2 ph 13 Annex 13 4 Wiring diagrams No 9_9548 05 USE Operator Manual Screw Compressor M27 265...

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Page 280: ...13 4 4 Option tc Lighting and signaling system connection 13 Annex 13 4 Wiring diagrams 270 Operator Manual Screw Compressor M27 No 9_9548 05 USE...

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Page 284: ...13 Annex 13 4 Wiring diagrams 274 Operator Manual Screw Compressor M27 No 9_9548 05 USE...

Page 285: ...13 4 5 Option te Lighting and signaling system connection 13 Annex 13 4 Wiring diagrams No 9_9548 05 USE Operator Manual Screw Compressor M27 275...

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Page 290: ...13 Annex 13 5 Fuel circulation diagram No 9_9548 05 USE Operator Manual Screw Compressor M27 281...

Page 291: ...13 Annex 13 5 Fuel circulation diagram 282 Operator Manual Screw Compressor M27 No 9_9548 05 USE...

Page 292: ...13 6 Option rd ro rr Assambly diagrams chassis US chassis option rd ro rr 13 Annex 13 6 Assambly diagrams chassis No 9_9548 05 USE Operator Manual Screw Compressor M27 283...

Page 293: ...oku Homologierung Mobilair Montagebilder M 27 31 Montagebild Fahrgestell M27 31 ubr US KAESER Dok Nr TDB 8 2706 1 MON_01D 13 Annex 13 6 Assambly diagrams chassis 284 Operator Manual Screw Compressor M...

Page 294: ...the protective conductor Measurement of the dielectric resistance Measurement of the substitute leakage current Inspection of generator functionality Inspection of the proper functioning of the gener...

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KAESER M27, Operator'S Manual

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