Page 1 Service manual Portable compressor M122 No.: 9_6974 20 E Manufacturer: KAESER KOMPRESSOREN GmbH 96410 Coburg • PO Box 2143 • GERMANY • Tel. +49-(0)9561-6400 • Fax +49-(0)9561-640130 http://www.kaeser.com...
Page 2 Original instructions /KKW/M122 2.00 en SBA-MOBILAIR 20110303 105803...
Page 3: Table Of Contents
Recommended Cooling Fluid ................2.6.4 Fluid volumes ...................... 2.6.5 Batteries ......................Options ..........................2.7.1 Tool lubricator ..................... 2.7.2 Fresh air filter ...................... 2.7.3 Low temperature equipment ................2.7.4 Diesel particulate filter ..................Service manual Portable compressor No.: 9_6974 20 E M122...
Page 4 Ensuring safety ........................ Installation conditions ....................... Installation Ensuring safety ........................ Reporting Transport Damage ................... Fitting the towbar ......................6.3.1 Fitting the height adjustable towbar ..............6.3.2 Fitting a non-adjustable towbar ................Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 5 10.2.1 Logging maintenance work ................. 10.2.2 Maintenance tasks after commissioning ............. 10.2.3 Regular maintenance tasks ................10.3 Engine maintenance ......................10.3.1 Water cooler maintenance .................. 10.3.2 Engine air filter maintenance ................Service manual Portable compressor No.: 9_6974 20 E M122...
Page 6 Spares, Operating Materials, Service 11.1 Note the Nameplate ......................149 11.2 Ordering consumable parts and operating fluids/materials ..........149 11.3 KAESER AIR SERVICE ....................150 11.4 Service Addresses ......................150 11.5 Spares for service and repair ................... 150 Decommissioning, Storage and Transport 12.1 De-commissioning ......................
Page 7 13.6 Operating instructions for compressed air filter (combination filter) ......... 300 13.7 Operating instructions for compressed air filter (fresh air filter) ........321 13.8 Service tasks on the diesel particulate filter ..............335 Service manual Portable compressor No.: 9_6974 20 E M122...
Page 8 Contents Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 9 Belt tension checking by hand ....................105 Fig. 52 Changing/tensioning the drive belt ..................... 106 Fig. 53 Safety signs - warning stickers on the battery................107 Fig. 54 Checking cooling oil level ......................110 Service manual Portable compressor No.: 9_6974 20 E M122...
Page 10 Safety sign - secure the chocks ....................235 Fig. 90 Transport using a forklift truck ....................236 Fig. 91 Load secured by strapping ......................237 Fig. 92 Identification ..........................240 Service manual Portable compressor viii M122 No.: 9_6974 20 E...
Page 11 Positioning and operating conditions checklist ................Tab. 52 Low-temperature equipment checklist ..................Tab. 53 Fault: engine refuses to start or comes to a stop............... Tab. 54 Fault: engine does not reach full speed..................Service manual Portable compressor No.: 9_6974 20 E M122...
Page 12 Maintenance intervals and regular maintenance tasks .............. Tab. 68 Regular machine maintenance tasks ..................Tab. 69 Regular maintenance task options ..................... Tab. 70 KAESER coolant mixture table ....................Tab. 71 Maintenance log ......................... 148 Tab. 72 Compressor consumables ......................149 Tab. 73 Consumable engine parts ......................
Page 13: Regarding This Document Using This Document
Copyright This service manual is copyright protected. Queries regarding use or duplication of the documenta‐ tion should be referred to KAESER. Correct use of information will be fully supported. Symbols and labels ➤ Please note the symbols and labels used in this document.
Page 14: Potential Damage Warnings
➤ This symbol is is placed by lists of actions comprising one stage of a task. 1. In process instructions with several steps ... 2..the sequence of action steps is numbered. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 15 The cause is named in the help text ... ➤ ... as is a solution. This symbol refers to important information or measures concerning environmental protec‐ tion. Further information Further subjects are introduced here. Service manual Portable compressor No.: 9_6974 20 E M122...
Page 16: Technical Specifications Nameplate
■ on the front (see chapter 13.1) The following table lists all possible options. Only the codes for those options fitted appear on the label. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 17: Compressed Air Treatment Devices
Technical Specifications Options summary M122 part number Serial number: Options fitted Here is given the specified coupling load. ba bb lb lc sc sd 02-M0277 Tab. 4 Combined label for coupling load and options fitted. ➤ Take a list of fitted options from the combined coupling load / options label and enter the fitted options as reference.
Page 18: Check Valve Function
Diesel particulate filter Option Option code Available? Diesel particulate filter Tab. 11 Diesel particulate filter option 2.2.8 Option la, lb Equipment for fire hazard areas Option Option code Available? Spark arrestor Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 19: Battery Isolating Switch
EG - 12 V USA - 12 V (DOT conformity) Tab. 15 Lighting options 2.2.12 Option oe Sealed floor pan Option Option code Available? Sealed floor pan Tab. 16 Sealed floor pan Service manual Portable compressor No.: 9_6974 20 E M122...
Page 20: Anti-Theft Device
Tab. 19 Instrument panel cover option Machine (without options) 2.3.1 Sound emission 2.3.1.1 Sound emission [dB(A)] type M122 Guaranteed sound power level* [dB(A)] * To Directive 2000/14/EC Tab. 20 Guaranteed sound power level [dB(A)] type M122 Emission sound pressure level* [dB(A)] 81.0...
Page 21: Torques
Technical Specifications Chassis Sound Pressure Level M122 Guaranties sound pressure level [dB (A)] Tab. 22 Sound pressure level [dB(A)] 2.3.2 Torques Recommended values for hexagonal bolts of strength category 8.8 Hex-head screws Thread Torque [Nm] Tab. 23 Torques for hex-head screws 2.3.3...
Page 22: Tyres
Tab. 28 Towbar tightening torque Compressor 2.5.1 Working pressure and FAD Maximum working pressure [bar] SIGMA airend 29-G 27-G 11.1 10.1 Free air delivery [m /min] Tab. 29 Working pressure and FAD Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 23: Compressed Air Outlet
A sticker showing the type of oil used is located near the oil separator tank filler. Information on ordering cooling oil is found in chapter 11. Characteristic SIGMA FLUID Oil grade S–460 Classification Silicone-free, Mineral oil synthetic oil Service manual Portable compressor No.: 9_6974 20 E M122...
Page 24: Cooling Oil Charge
Speed at LOAD mode [min 1600 speed at IDLE mode [min * Use only diesel fuel to EN 590 or ASTM D975. Consult the engine manufacturer on the use of other fuels if necessary. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 25: Oil Recommendation
* Use only engine with low white ash build up. Tab. 37 Recommended oil for engines with diesel particulate filters 2.6.3 Recommended Cooling Fluid The engine coolant must meet the requirements of specification ASTM D4985. Service manual Portable compressor No.: 9_6974 20 E M122...
Page 26: Fluid Volumes
Tab. 40 Road breaker lubricant recommendation 2.7.2 Option dc Fresh air filter Feature Value Maximum working pressure [bar] Minimum ambient temperature [°C] Maximum ambient temperature [°C] Tab. 41 Fresh air filter conditions Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 27: Low Temperature Equipment
Data Fuel Diesel * Operating voltage [V] Filter element SiC monolith * Use only diesel fuel to EN 590 or ASTM D975. Consult the engine manufacturer on the use of additives. Service manual Portable compressor No.: 9_6974 20 E M122...
Page 28: Tab. 46 Diesel Particulate Filter Data
−20 ..+50 Protection rating IP 65 * Use only diesel fuel to EN 590 or ASTM D975. Consult the engine manufacturer on the use of additives. Tab. 46 Diesel particulate filter data Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 29: Safety And Responsibility Basic Instructions
These are, for example, nationally applied European directives and/or valid national laws and safe‐ ty and accident prevention regulations. ➤ Observe relevant statutory and accepted regulations during operation, transporting and main‐ tenance of the machine. Service manual Portable compressor No.: 9_6974 20 E M122...
Page 30: Determining Personnel
Health, paragraph 14. ➤ Recurring inspections according to BGR 500, chapter 2.11: The user must ensure that the machine's safety devices are checked for function as required or at least annually. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 31: Complying With Inspection Intervals For Diesel Particulate Filters
Option lc Complying with inspection intervals for diesel particulate filters The machine is subject to local inspection schedules. Inspecting authority: e.g. KAESER Service. ➤ Have the TRGS 554 inspection carried out annually and the TÜV (or local equivalent) every two years.
Page 32 The safety of the machine is then no longer ensured. Compressed air quality The composition of the compressed air must be suitable for the actual application in order to pre‐ clude health and life-threatening dangers. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 33 The used operating fluids and materials can cause adverse health effects. Suitable safety meas‐ ures must be taken in order to prevent injuries. ➤ Strictly forbid fire, open flame and smoking. Service manual Portable compressor No.: 9_6974 20 E M122...
Page 34: Safe Machine Operation
Unsuitable spare parts compromise the safety of the machine. ➤ Use only spare parts approved 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 and conversions of the machine can result in unpredictable dangers.
Page 35 A suitable installation location for the machine prevents accidents and faults. ➤ Do not position the machine directly against a wall. A build up of heat from the exhaust can damage the machine. Service manual Portable compressor No.: 9_6974 20 E M122...
Page 36 ➤ Allow the machine to cool down. ➤ Do not open the bodywork while the machine is switched on. ➤ Do not open or dismantle any valves. ➤ Use only spare parts approved by KAESER for use in this machine. ➤ Carry out regular inspections: ■...
Page 37: Organisational Measures
Within a 1 m radius of the machine. Operating personnel Maintenance Within the machine. Maintenance personnel Within a 1 m radius of the machine. Tab. 48 Danger areas Safety devices Various safety devices ensure safe working with the machine. Service manual Portable compressor No.: 9_6974 20 E M122...
Page 38: Safety Signs
➤ Wear hearing protectors and protective clothing. ➤ Close the canopy or doors. ➤ Work with caution. * Location within the machine ** Portable machines only *** Only machines with option dc Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 39 ➤ Operate the machine only with closed safety guards, access doors and panels. ➤ Shut down the machine before opening a door or canopy. * Location within the machine ** Portable machines only *** Only machines with option dc Service manual Portable compressor No.: 9_6974 20 E M122...
Page 40: Emergencies
Strong jet of water 3.8.2 Injury from handling operating fluids/materials The following operating fluids/materials are in the machine: ■ fuel ■ Lubricating oil ■ Compressor cooling oil ■ Engine coolant ■ Battery electrolyte Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 41: Warranty
■ incorrect repair. Correct maintenance and repair includes the use of original spare parts and operating materials. ➤ Obtain confirmation from KAESER that your specific operating conditions are suitable. 3.10 Environment protection The operation of this machine may cause dangers for the environment.
Page 42 ➤ Store and dispose of operating materials and replaced parts in accordance with local environ‐ ment protection regulations. ➤ Observe national regulations. This applies particularly to parts contaminated with fuel, oil, coolants and acids. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 43: Design And Function Bodywork
Safe and reliable operation is only ensured when the bodywork is closed. The wing doors are provided with handles for opening. Release the doors by the snap fasteners. The doors are held open by gas springs. Service manual Portable compressor No.: 9_6974 20 E M122...
Page 44: Machine Installation
Lifting eye Electric control cubicle Coolant expansion tank Compressor air filter Machine function Machine function (without options) Item numbers correspond to the pipe and instrument flow diagram (P&ID) in chapter 13.2. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 45: Fig. 5 Machine Layout
. The minimum pressure / check valve ensures that there is always a minimum internal pressure sufficient to maintain cooling oil circulation in the ma‐ chine. The cooling fan ensures optimum cooling of all components within the enclosure. Service manual Portable compressor No.: 9_6974 20 E M122...
Page 46: Operating Modes And Control Modes
The compressor block provides compressed air for connected consumers. This stepless delivery regulation minimises fuel consumption of the engine. Motorbelastningen og drivstofforbruket stiger/faller med trykkluftbehovet. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 47: Safety Devices
Safety devices 4.5.1 Monitoring functions with shutdown The following functions are monitored automatically. ■ Engine oil pressure ■ Coolant temperature ■ Airend discharge temperature ■ Fuel level ■ Engine alternator Service manual Portable compressor No.: 9_6974 20 E M122...
Page 48: Further Safety Devices
The alarm is saved and the engine cannot be restarted. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 49: Fuel Pre-Filter Level Monitoring
Compressed air aftercooler The aftercooler lowers the compressed air temperature to only 5 K to 10 K above ambient. Most of the moisture carried in the air is removed in the aftercooler. Service manual Portable compressor No.: 9_6974 20 E M122...
Page 50 Tool lubricator Compressed air containing lubricating oil is needed for the lubrication of certain air tools. The tool lubricator introduces a fine oil mist into the compressed air for this purpose. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 51: Low Temperature Equipment Options
Option ba Frost protection Control air is mixed with an alcohol-based antifreeze to prevent control and regulating devices freezing. This considerably lowers the freezing point of any moisture in the air. Service manual Portable compressor No.: 9_6974 20 E M122...
Page 52: Fig. 10 Frost Protector
The power supply to the coolant preheater takes place via a separate network connector. A flexible power cable (supplied) connects the machine's power plug to the user's power socket. The coolant pre-heater works according to the principle of self-circulation. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 53: Optional Battery Isolating Switch
➤ Use the «battery isolating switch» only when the machine is shut down. ➤ Do not use the «battery isolating switch» as a main or emergency switch. Fig. 12 Battery isolating switch «Battery isolating switch» Service manual Portable compressor No.: 9_6974 20 E M122...
Page 54: Options For Operating In Fire Hazard Areas
➤ Use the wire pull handle only in an emergency when the surrounding air contains a flam‐ mable gas. ➤ Do not use the wire pull handle as the normal means of shutting down the machine. Fig. 13 Pull handle of engine air shut-off valve Handle Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 55: Diesel Particulate Filter Option
The diesel particulate filter system meets the requirements of TRGS 554, TA and VERT (Switzerland). 4.7.6 Option sa, sc, sd, sh, si Transport options 4.7.6.1 Option sa Chassis The chassis has the following features: ■ Single-axle Service manual Portable compressor No.: 9_6974 20 E M122...
Page 56: Closed Floor Pan Option
In the event of a leak, all liquids required for the machine's operation are caught in the floor pan. Service openings in the floor pan are closed with plugs. These openings must be tightly re-closed after performing any cleaning work. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 57: Optional Anti-Theft Device
The machine is fitted with a security chain as theft protection. 4.7.9 Option sg Pedestrian protection option The machine is provided with pedestrian protection that functions both as a deflector and against pedestrians being run-over. Service manual Portable compressor No.: 9_6974 20 E M122...
Page 58: Installation And Operating Conditions
The floor must be level, firm and capable of bearing the weight of the machine. Fig. 17 Minimum distance from excavations/slopes and walls 1. Keep sufficient distance (at least 1.5 m) from the edges of excavations and slopes. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 59 ➤ 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 0 °C, follow instructions in chapter 7.4. Service manual Portable compressor No.: 9_6974 20 E M122...
Page 60: Installation
The machine is standing firm and level. The machine is switched off. CAUTION Danger of pinching! Severe pinching injury to fingers is possible. ➤ Wear safety gloves. ➤ Work with caution. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 61: Fitting The Height Adjustable Towbar
10. Tighten the locking lever. Make sure the teeth in the adjustment joint mesh together. 11. Fully tighten the lever with a few hammer blows and insert the split pin. 12. Pull up the parking brake (pull the hand brake lever up). Service manual Portable compressor No.: 9_6974 20 E M122...
Page 62: Fitting A Non-Adjustable Towbar
2. Remove the bag with the brake transfer cable and fastenings, unpack and lay out ready. 3. Close the doors. 4. Remove all transport securing items (screw fastenings, duct tape, foam pads) from the towbar components. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 63: Fig. 21 Fitting The Overrun Braking Mechanism Of The Non-Adjustable Towbar
6. Screw the the brake-rod linkage onto the rear screw fastening of the brake transfer cable and secure with a lock nut. Further information Further information on setting the brake actuating rod is to be found in chapter 10.7.3.3. Service manual Portable compressor No.: 9_6974 20 E M122...
Page 64: Adjusting The Chassis
The machine is disconnected from the towing vehicle and safely parked. CAUTION Danger of pinching! Severe injury to fingers is possible if they become trapped in the adjusting mechanism. ➤ Wear safety gloves. ➤ Work with caution. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 65: Adjusting The Towbar Height
The serrations joint will not disengage. The serrations are corroded together. ➤ Free the serrations by jerking the towbar horizontally and vertically. 6.4.2 Changing the towing eye The towbar can be fitted with various towing eyes or couplings. Service manual Portable compressor No.: 9_6974 20 E M122...
Page 66: Fig. 24 Changing The Towing Eye (Height-Adjustable Drawbar)
2. Unscrew the nuts of both screw connec‐ 2. Remove the coupling from the towbar tions and withdraw the bolts 3. Remove the towing eye from the tow‐ Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 67: Fig. 25 Changing The Towing Eye (Fixed Height Towbar, Gb Chassis Version)
Changing the towing eye (fixed height towbar, GB chassis version) Self-locking hexagon nut Tension rod Hex-head screw Damper Damper fixing eye Installation pin Hex-head screw Ball coupling Protective sleeve Towing eye Service manual Portable compressor No.: 9_6974 20 E M122...
Page 68: Fig. 26 Changing The Towing Eye (Fixed Height Towbar, Usa Chassis Version)
10. Draw the protective sleeve over the fixings. Checking the overrun braking mechanism ➤ Push the towbar tube in and out by hand. If resistance is felt, the shock absorber is properly connected. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 69: Initial Start-Up Ensuring Safety
➤ Remove all packing materials on and in the machine. ➤ Observe the machine during the first few hours of operation to ensure that it is operating cor‐ rectly. Service manual Portable compressor No.: 9_6974 20 E M122...
Page 70: Special Measures For Re-Commissioning After Storage
➤ Clean the bodywork with a grease and dirt dissolving agent. ➤ Check the tyre pressures. 36 months ➤ Have the overall technical condition checked by an authorised KAESER Ser‐ vice Technician. Tab. 50 Measures for re-commissioning the compressor after a long period of storage Checking installation and operating conditions ➤...
Page 71: Low-Temperature Operation (Winter)
➤ Observe the instructions provided with the jumper cables. ➤ Do not connect the battery jumper cables to the negative pole of the discharged battery or to the bodywork of the machine. ➤ Work with caution. Service manual Portable compressor No.: 9_6974 20 E M122...
Page 72: Fig. 27 Jumper Cable Connection Diagram
1. Park the assisting vehicle in close distance to the engine, without their bodywork touching each other. 2. Stop the engine of the assisting vehicle. 3. Open the accesses to the batteries (remove maintenance panels/bonnet and pole caps). 4. Switch off all power consumers. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 73: Starting Up Low-Temperature Equipment
7.4.2 Option ba, bb Starting up low-temperature equipment ➤ Ascertain which low temperature equipment is fitted to the machine. Service manual Portable compressor No.: 9_6974 20 E M122...
Page 74: Fig. 28 Coolant Pre-Heating
➤ Have the coolant pre-heating and associated wiring checked according to the mainte‐ nance schedule. 2. Connect the coolant pre-heater to the user's power socket with the power cable supplied. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 75: Operation
All doors and panals are locked. NOTICE Serious damage 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. Service manual Portable compressor No.: 9_6974 20 E M122...
Page 76: Commissioning The Machine
Commissioning the machine 1. Open the right-hand access door. 2. Turn the «Controller On» switch. 3. Close the access door. 4. Turn the «starter switch» to "ON". charging indicating light must light. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 77: Starting The Machine
Option ba Fig. 30 Label referring to the warm-up period when ambient temperatures are below -10 °C ➤ Allow the machine to warm up in IDLE (low speed). Service manual Portable compressor No.: 9_6974 20 E M122...
Page 78: Switching To Load
■ Turn clockwise to increase pressure. ■ Turn counter-clockwise to decrease pressure. 4. Re-tighten the locking device. 5. Close the access door. 6. Start the machine and switch to LOAD mode. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 79: Shutting Down The Machine
(water trap). Fuel level monitoring indicating lamp. ➤ Check the The indicating lamp is dark: sufficient fuel in the tank, no condensate in the fuel pre-filter (water trap). Service manual Portable compressor No.: 9_6974 20 E M122...
Page 80: Operating The Tool Lubricator
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: increases the oil flow. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 81: Using The Low-Temperature Equipment
The machine is switched off. ➤ Open the right-hand access door. Machine operation with activated frost protector: Operation at temperatures below 0 °C (winter operation). Precondition Frost protector filled with antifreeze Service manual Portable compressor No.: 9_6974 20 E M122...
Page 82: Coolant Pre-Heating
2. Close the access door. Shutting down the machine: 1. Switch the «battery isolating switch» to the 'off' position The battery is disconnected from the machine's electrical system. 2. Close the access door. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 83: Shut Down The Machine If Any Dangerous Situation Arises
The pull wire is completely drawn in: The machine can now be started. If the pull wire has not returned the handle to its withdrawn position, wait until this is completed. Service manual Portable compressor No.: 9_6974 20 E M122...
Page 84: Fault Recognition And Rectification
1. Do not attempt fault rectification measures other than those given in this manual! 2. In all other cases: Have the fault rectified by an authorized KAESER service representative. Further information Observe the instructions in chapter 3 "Safety and Responsibility" and prevailing local safety regula‐...
Page 85: Engine Does Not Reach Full Speed
-service service work‐ manual shop Electrical connections and/or ca‐ Tighten the connection or have – bles loose or broken. the cable replaced. Defective alternator. Have repaired or replaced if – necessary. Service manual Portable compressor No.: 9_6974 20 E M122...
Page 86: Evaluate Compressor Faults And Alarms
Repair or have replaced if nec‐ – opening partially. essary. Pressure gauge indicating false Have repaired or replaced if – pressure. necessary. Pressure relief valve maladjus‐ Have repaired or replaced if – ted and/or leaking. necessary. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 87: Pressure Relief Valve Blowing Off
(proportional controller mal‐ or have replaced. adjusted). Oil separator cartridge heavily Measure the pressure differen‐ – clogged. tial and change the cartridge if greater than 1 bar. See chap‐ ter 10.4.6 for changing. Service manual Portable compressor No.: 9_6974 20 E M122...
Page 88: Too Much Oil Residue In The Compressed Air
Specialised KAESER-ser‐ workshop vice Defective non-return function of Repair or have replaced if nec‐ – the inlet valve. essary. Tab. 61 Fault: oil flows from the compressor air filter after shutdown Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 89: High Moisture Content In The Compressed Air
IDLE run‐ ning. Illuminates for about 10 sec‐ Maintenance due on the diesel Contact KAESER Service. onds every minute. particulate filter. Remains illuminated Fault in the diesel particulate fil‐ Disabling the machine ter system Contact KAESER Service.
Page 90: Tab. 65 Grey Or Brownish Exhaust Gas
The exhaust contains residues Have the fuel injection system of hydrocarbons or sulphate. checked. Use an engine oil that produces low white ash. Tab. 65 Grey or brownish exhaust gas Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 91: 10.1 Maintenance
➤ Disconnect the negative terminals on the batteries. ➤ Ensure that the machine is cooled down. Further information Details of authorised personnel are found in chapter 3.4.2. Details of dangers and their avoidance are found in chapter 3.5. Service manual Portable compressor No.: 9_6974 20 E M122...
Page 92: Following The Maintenance Plans
➤ The machine must be shut down immediately if any damage or functional defect in the diesel particulate filter is noticed. ➤ Only authorised specialists, such as KAESER Service Technicians may carry out main‐ tenance work on the diesel particulate filter.
Page 93: Regular Maintenance Tasks
10.3.2 nance indicator Check engine oil level. 10.3.4 Engine Clean the engine air filter 10.3.2 Change the engine oil 10.3.6 Engine SM = engine manufacturer's service manual; SW = specialised workshop. Service manual Portable compressor No.: 9_6974 20 E M122...
Page 94 Clean the fuel filter. 10.3.3 Engine Have the fuel pump cleaned. Clean the tank fuel strainer. Clean the fuel tank. Engine SM = engine manufacturer's service manual; SW = specialised workshop. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 95 Check wheel bolts and nut for tightness. Carry out chassis maintenance. 10.7 Grease the ball coupling, joints 10.7.2 and towbar. Brake maintenance 10.7.3 Engine SM = engine manufacturer's service manual; SW = specialised workshop. Service manual Portable compressor No.: 9_6974 20 E M122...
Page 96: Tab. 68 Regular Machine Maintenance Tasks
Clean and check the dirt trap. 10.8.2 Options da, db, dc, dd – compressed air aftercooler: Clean the radiator. 10.5.2 SW = refer to a specialised workshop; KS = call KAESER Service Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 97: Engine Maintenance
Have the diesel engine emission 3.4.4 checked according to TRGS 554. SW = refer to a specialised workshop; KS = call KAESER Service Tab. 69 Regular maintenance task options 10.3 Engine maintenance ➤ Perform maintenance tasks according to the schedule in chapter 10.2.3.1.
Page 98: Water Cooler Maintenance
The level is checked on the coolant expansion tank: ■ The tank is semi-transparent so the coolant level can be seen from outside. minimum and maximum markings with the engine cooled ■ The level should be between the down. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 99: Fig. 36 Checking Coolant Level
Maximum frost protection is ensured with an antifreeze concentration of 55% by volume, as frost protection and heat transfer properties deteriorate beyond this point. Higher concentration also leads to higher operating temperature. Service manual Portable compressor No.: 9_6974 20 E M122...
Page 100: Tab. 70 Kaeser Coolant Mixture Table
➤ Follow coolant recommendations in chapter 2.6.3. Preparing coolant Precondition Coolant must meet the specification of ASTM D4985. ➤ The coolant should be mixed in the proportions given by the manufacturer. KAESER coolant mixture table Antifreeze Water Frost protection to [°C] 1 part 2 parts −18...
Page 101: Fig. 37 Draining The Coolant From The Radiator
Fig. 37 Draining the coolant from the radiator Filler cap Shut-off ball valve Coolant expansion tank I – open Radiator 0 – closed Radiator drain Quick-release coupling Drain hose with male fitting Service manual Portable compressor No.: 9_6974 20 E M122...
Page 102: Fig. 38 Draining The Coolant From The Radiator (Closed Floor Pan - Stationary Machine)
➤ Dispose of used coolant in accordance with environmental protection regulations. Further information The operating manual supplied by the engine manufacturer provides further information on coolant change and cleaning the cooling system. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 103: Engine Air Filter Maintenance
Fig. 39 Engine air filter maintenance Maintenance indicator Filter element Red zone indicator scale Retaining clip Indicating piston of the maintenance indi‐ Filter cap cator Reset knob for the maintenance indicator Service manual Portable compressor No.: 9_6974 20 E M122...
Page 104: Fig. 40 Cleaning The Filter Element
The yellow piston within the indicator is reset and the maintenance indicator is ready for use again. ➤ Close the doors. Dispose of old parts and contaminated materials according to environmental regulations. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 105: Fuel System Maintenance
Fuel system maintenance Fuel tank – Combined indicating lamp (LED yel‐ Fuel fine filter low): Fuel pre-filter with integrated water trap Fuel level monitoring Instrument panel ➤ Open the right-hand access door. Service manual Portable compressor No.: 9_6974 20 E M122...
Page 106: Fig. 42 Bleeding The Fuel System
The water trap is connected to an indicator lamp on the instrument panel. If the water in the recep‐ fuel level monitoring on the instrument panel lights. It tacle rises to a set level, the indicator lamp indicates that the water trap must be emptied immediately. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 107: Fig. 43 Emptying The Fuel Pre-Filter Water Trap
The indicator lamp trap is emptied. The mixture of fuel and water and any materials contaminated with fuel must be disposed of in accordance with environment protection regulations. Service manual Portable compressor No.: 9_6974 20 E M122...
Page 108: Fig. 44 Changing The Fuel Pre-Filter Cartridge
13. Close the access door. The fuel system must be bled after the filter cartridge has been changed. Dispose of fuel and any materials and components contaminated with it in accordance with environmental protection regulations. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 109: Checking The Engine Oil Level
The engine oil is indicated by a dipstick in the oil sump. The oil level should ideally be between the two marks on the dipstick. The oil level should not be allowed to fall below the minimum level . Service manual Portable compressor No.: 9_6974 20 E M122...
Page 110: Engine Oil Filling And Topping Up
The machine is standing level. The machine is fully vented, the pressure gauge reads 0 bar. All compressed air consumers are disconnected and the air outlet valves are open. Negative cable to the batteries disconnected. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 111: Changing The Engine Oil
■ at least once a year. Check the operating manual of the engine manufacturer for information on oil change in very dusty environments. Service manual Portable compressor No.: 9_6974 20 E M122...
Page 112: Fig. 47 Draining The Engine Oil
4. Unscrew the drain plug and allow the engine oil to drain into the receptacle. 5. Clean the drain plug and screw in with a new gasket. 6. Close the oil filler with the cover. 7. Close the access door. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 113: Fig. 48 Draining The Engine Oil (Closed Floor Pan - Stationary Machine)
8. Close the access door. Dispose of old oil and oil-soaked working materials according to environmental protection regulations. Further information See chapter 10.3.5 for oil filling. The engine service manual gives instructions on oil changing. Service manual Portable compressor No.: 9_6974 20 E M122...
Page 114: Replace The Engine Oil Filter
Top up if the level is too low. 8. Reconnect the negative terminals to the batteries. 9. Close the access door. Further information The engine service manual gives further information on oil filter changing. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 115: Drive Belt Maintenance
There is danger 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 both doors. Service manual Portable compressor No.: 9_6974 20 E M122...
Page 116: Fig. 50 Belt Guard Attachment
The engine manufacturer recommends a tension measuring device for belts. For operation see the engine service manual. The belt tension may also be checked by hand if no tension measuring device is available. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 117: Fig. 51 Belt Tension Checking By Hand
3. Close the doors. 10.3.8.3 Changing/tensioning the drive belt The drive belt is pre-tensioned by the spring force in the jockey wheel. By turning the jockey wheel you can adjust the belt tension. Service manual Portable compressor No.: 9_6974 20 E M122...
Page 118: Fig. 52 Changing/Tensioning The Drive Belt
A belt that has been replaced may not be used again. Check the belt tension after running for approximately 15 minutes. Old belts should be disposed of in accordance with the latest environmental regulations. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 119: Battery Maintenance
– Wear protective gloves, batteries are filled with caustic electrolyte! ■ – Observe the battery manufacturer's instructions! ■ – Follow the safety rules, explosion hazard! Further instructions on working with batteries: ➤ Do not remove battery terminal covers unnecessarily. Service manual Portable compressor No.: 9_6974 20 E M122...
Page 120 ➤ Top up only with distilled water. 2. Check the electrolyte level. If the level does not reach the mark: ➤ Top up with distilled water. ➤ Close the access door. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 121 8. Close the access door. Replacing batteries Replacement batteries must have the same capacity, current strength and form as the original bat‐ teries. ➤ Always replace a battery with one of the same type. Service manual Portable compressor No.: 9_6974 20 E M122...
Page 122: Compressor Maintenance
2. Slowly unscrew and withdraw 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 access door. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 123: Cooling Oil Filling And Topping Up
5. Open the outlet valves. 6. Open the right-hand access door. 7. Check the oil level after about 5 minutes. Top up if necessary. 8. Visually inspect for leaks. 9. Close the access door. Service manual Portable compressor No.: 9_6974 20 E M122...
Page 124: Changing The Cooling Oil
Draining the cooling oil (machine with chassis) In machines with chassis (no closed floor pan, no stationary machine), the cooling oil is drained directly at the oil separator tank and the oil cooler. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 125: Fig. 55 Draining Cooling Oil
1. Replace the plug in the oil separator tank filling port. 2. Close the doors. Dispose of used oil and oil-contaminated working materials according to environmental pro‐ tection regulations. Further information See chapter 10.4.2 for oil filling. Service manual Portable compressor No.: 9_6974 20 E M122...
Page 126: Fig. 56 Draining The Cooling Oil (Closed Floor Pan - Stationary Machine)
3. Open the shut-off valve at the drain connection of the oil cooler and catch the draining cool‐ ing oil. 4. Close the shut-off valve and replace the screwed sealing cap. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 127: Replace The Compressor Oil Filter
Changing the oil filter: 1. Open the left-hand door. 2. Prepare a receptacle. 3. Loosen the filter by turning counter-clockwise and catch any escaping oil. 4. Carefully clean sealing surfaces using lint-free cloth. Service manual Portable compressor No.: 9_6974 20 E M122...
Page 128: Oil Separator Tank Dirt Trap Maintenance
The machine is fully vented, the pressure gauge reads 0 bar. Machine is cooled down. All compressed air consumers are disconnected and the air outlet valves are open. Negative cable to the batteries disconnected. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 129: Fig. 58 Oil Separator Tank Dirt Trap Maintenance
Pressure gauge reads 0 bar! 4. Open the outlet valves. 5. Open the right-hand access door. 6. Visually inspect for leaks. 7. Shut down the machine. 8. Close the access door. Service manual Portable compressor No.: 9_6974 20 E M122...
Page 130: Changing The Oil Separator Cartridge
The machine is fully vented, the pressure gauge reads 0 bar. Machine is cooled down. All compressed air consumers are disconnected and the air outlet valves are open. Negative cable to the batteries disconnected. ➤ Open the right-hand access door. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 131: Fig. 59 Changing The Oil Separator Cartridge
8. Insert the new oil separator cartridge with gaskets and screw down the cover. 9. Re-position the air pipe 10. Replace and tighten all loosened fittings. Service manual Portable compressor No.: 9_6974 20 E M122...
Page 132 5. Open the outlet valves. 6. Open the right-hand access door. 7. Check the oil level after about 5 minutes. Top up if necessary. 8. Visually inspect for leaks. 9. Close the access door. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 133: Fig. 60 Changing The Oil Separator Cartridge (Option Ba)
Take particular care with the following components: ■ The frost protector connected to the control line, ■ The oil scavenge line screwed to the underside of the cover. 7. Take out the old cartridge and gaskets Service manual Portable compressor No.: 9_6974 20 E M122...
Page 134: Compressor Air Filter Maintenance
Clean the filter according to the maintenance schedule or if the maintenance indicator shows this to be necessary. Renew the air filter element after 2 years at the latest or after it has been cleaned 5 times. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 135: Fig. 61 Compressor Air Filter Maintenance
Fig. 61 Compressor air filter maintenance Maintenance indicator Filter element Red zone indicator scale Retaining clip Indicating piston of the maintenance indi‐ Filter cap cator Reset knob for the maintenance indicator Service manual Portable compressor No.: 9_6974 20 E M122...
Page 136: Fig. 62 Cleaning The Filter Element
The yellow piston within the indicator is reset and the maintenance indicator is ready for use again. ➤ Close the doors. Dispose of old parts and contaminated materials according to environmental regulations. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 137: Checking Pressure Relief Valves
Maintenance 10.5 Clean cooler/radiator 10.4.8 Checking pressure relief valves ➤ Have pressure relief valves checked by KAESER Service in accordance with the maintenance schedule. 10.5 Clean cooler/radiator The frequency of cleaning is mainly dependent on local operating conditions. Heavy clogging of the cooler/radiator can cause oil overheating and overheating of the engine.
Page 138: Cleaning The Compressed Air Aftercooler
2. Visually inspect for leaks. Does oil/cooling water flow out? Is a cooler leaking? ➤ Have the defective cooler repaired immediately by KAESER Service. ➤ Close the doors. Clean the cooler/radiator only in a washing area equipped with an oil separator.
Page 139: Maintenance Of Rubber Sealing Strips
2. Clean the rubber sealing strips with a lint-free cloth and check for cracks, holes and other dam‐ age. Have any damaged gasket replaced. 3. Properly grease the rubber strips. 4. Close the doors. Service manual Portable compressor No.: 9_6974 20 E M122...
Page 140: Chassis Maintenance
Clean and lubricate all sliding and rotating bearings as necessary but at least every 6 months. Material Lithium-enriched multi-purpose grease Acid-free oil Cleaning cloth Precondition The machine is shut down. The machine is disconnected from the towing vehicle and safely parked. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 141: Fig. 65 Towbar Maintenance
➤ Pump fresh grease into the nipple until old grease is squeezed out. Further information For greasing points see figure 65. Checking the shock absorber 1. Loosen the transfer cable one side. Service manual Portable compressor No.: 9_6974 20 E M122...
Page 142: Brake System Maintenance
2. Clean the ball coupling. Grease or oil the ball cup, joints and bearings. 10.7.3 Brake system maintenance The brake adjusting procedure ensures even wear on the brake linings by adjusting the brake shoes. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 143: Fig. 68 Checking The Brake Lining Thickness
There is an arrow pressed into the brake back plate near the adjustment hole. ■ Turning in the direction of the arrow increases brake force. ■ Turning in the opposite direction to the arrow releases brake force. Service manual Portable compressor No.: 9_6974 20 E M122...
Page 144: Fig. 69 Brake System Adjustment
If the braking force on the wheels is not equal, the brakes must be adjusted again. 8. Replace the plug in the inspection hole. A light rubbing sound when the wheels turn is permissible if it does not affect free turning. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 145: Maintenance Of Optional Items
The machine is disconnected from the towing vehicle and safely parked. ➤ Clean and grease the brake rods sliding and adjustment joints. 10.8 Maintenance of Optional Items ➤ Perform maintenance tasks according to the schedule in chapter 10.2.3.2. Service manual Portable compressor No.: 9_6974 20 E M122...
Page 146: Tool Lubricator Maintenance
The oil level should be in the upper third of the dipstick. 1. Slowly unscrew and withdraw the oil filler plug. 2. Wipe off the dipstick with a lint-free cloth or rag and screw the plug fully in again. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 147: Cyclone Separator Maintenance
Machine is cooled down. The machine is fully vented, the pressure gauge reads 0 bar. All compressed air consumers are disconnected and the air outlet valves are open. Negative cable to the batteries disconnected. Service manual Portable compressor No.: 9_6974 20 E M122...
Page 148: Fig. 72 Cleaning The Dirt Trap
1. Switch the machine on and run it in IDLE mode for approx. 5 minutes. 2. Shut down the machine. 3. Wait until the machine has automatically vented. Pressure gauge reads 0 bar! 4. Open the outlet valves. 5. Open the left-hand door. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 149: Combination Filter Maintenance
Pressure differential gauge (check fittings Pre-filter for Service personnel) Microfilter Filter head Cyclone separator Casing gasket Shut-off ball valve for condensate drain‐ Filter element Filter housing Condensate drain hose fittings ➤ Open the left-hand door. Service manual Portable compressor No.: 9_6974 20 E M122...
Page 150 3. Draw the filter element down and out. 4. Clean the filter head, housing and sealing surface with a lint-free cloth. 5. Check the housing gasket. When damaged, replace the housing gasket. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 151 Pressure gauge reads 0 bar! 4. Open the outlet valves. 5. Open the left-hand door. 6. Check the combination filter housing and hose lines for leaks. 7. Close the access door. Service manual Portable compressor No.: 9_6974 20 E M122...
Page 152: Fresh Air Filter Maintenance
2. Open the condensate drain valve. 3. Close the doors. 4. Switch the machine on and run it in IDLE mode for approx. 2 minutes. The condensate collecting in the filter housings is blown out. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 153 2. Draw the filter element down and out. 3. Clean the lower housing and sealing surface with a lint-free cloth. 4. Check the housing gasket. When damaged, replace the housing gasket. Service manual Portable compressor No.: 9_6974 20 E M122...
Page 154 3. Wait until the machine has automatically vented. Pressure gauge reads 0 bar! 4. Open the outlet valves. 5. Open both doors. 6. Check the fresh air filter housing and hose line for leaks. 7. Close the doors. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 155: Frost Protector Maintenance
1. Open the right-hand access door. 2. Unscrew the clamp ring and remove the bowl. 3. Fill the bowl ¾ full with antifreeze. 4. Carefully screw the bowl back into place. 5. Close the access door. Service manual Portable compressor No.: 9_6974 20 E M122...
Page 156: Spark Arrestor Cleaning
1. Unscrew the soot drain plug. 2. Push one end of the hose over the drain port and place the other end in the receptacle. 3. Start the compressor engine. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 157: Fig. 77 Cleaning The Spark Arrestor (Closed Floor Pan)
8. Screw the bung into the floor pan. It is recommended to blow out the spark arrestor with compressed air once a year. Dispose of soot according to environment protection regulations. Service manual Portable compressor No.: 9_6974 20 E M122...
Page 158: Engine Air Intake Shut-Off Valve Maintenance
The machine does not shut down? Destruction of the engine and explosion and/or fire are possible! ➤ Do not move the valve adjusting screw. ➤ Have the valve set by a specialist workshop or KAESER Service. Fig. 78 Engine air intake shut-off valve maintenance...
Page 159: Fig. 79 Checking Manual Operation Of The Engine Air Intake Valve
The engine should stop in a few seconds. Engine does not stop. ➤ Have the engine air intake valve checked by a specialist workshop or KAESER Service. Further information Further information on manual valve operation is given in chapter 8.7"Shut down the machine if any dangerous situation arises".
Page 160: Documenting Maintenance And Service Work
10.9 Documenting maintenance and service work Machine number: ➤ Enter maintenance and service work carried out in the list. Date Maintenance task carried out Operating hours Signature Tab. 71 Maintenance log Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 161: 11 Spares, Operating Materials, Service
11.2 Ordering consumable parts and operating fluids/materials KAESER consumable parts and operating materials are original Kaeser products. They are match‐ ed to application in our machines and ensure trouble-free operation. Unsuitable or poor quality maintenance parts and operating materials may damage the machine or impair its proper function.
Page 162: Kaeser Air Service
Lower costs and higher compressed air availability. 11.4 Service Addresses Addresses of KAESER agents are given at the end of this manual. 11.5 Spares for service and repair With the help of this parts list you can plan your material requirement according to operating condi‐...
Page 163 Spares, Operating Materials, Service 11.5 Spares for service and repair Service manual Portable compressor No.: 9_6974 20 E M122...
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Page 236: 12 Decommissioning, Storage And Transport
2. The following machine openings have been covered: ■ Engine air inlet ■ Compressor air inlet ■ Exhaust silencer 3. Recommission according to service manual. Date / signature Tab. 74 "Temporarily decommissioned" information notice Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 237: Long-Term De-Commissioning And Storage
➤ Use plastic sheeting and moisture-resistant adhesive tape to seal off – the following openings: ■ Engine air inlet ■ Compressor air inlet ■ Exhaust silencer ➤ Clean the bodywork and treat with preservative. – Service manual Portable compressor No.: 9_6974 20 E M122...
Page 238: Transport
Machines with appropriate chassis versions and running gear are approved for towing on public roads. The machine is designed for a maximum towing speed of 100 km/h. National and local regu‐ lations must be observed when towing the machine on public highways. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 239 5. Close and lock the access doors. Option sa Adjust the tow bar to suit the height of the towing vehicle hitch: When the machine is coupled up, the tow bar must be parallel with the ground. Service manual Portable compressor No.: 9_6974 20 E M122...
Page 240: Fig. 80 Towing Alignment
They can be trapped in the spring-loaded closing mechanism. ➤ Never place your fingers inside an open ball coupling. ➤ Wear safety gloves. 2. Pull up the coupling handle. The coupling opens. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 241: Fig. 82 Ball Coupling Wear Indicator Alko-Eu
Danger of accident from worn coupling! The machine may detach from the towing vehicle. ➤ Do not tow the machine. ➤ Have the ball coupling and ball hitch checked. ➤ Worn parts must be replaced. Service manual Portable compressor No.: 9_6974 20 E M122...
Page 242: Fig. 83 Ball Coupling (Alko-Usa)
➤ Never place your fingers inside an open ball coupling. ➤ Wear safety gloves. 2. Check if the security pin is removed from the coupling and draw it out if not. 3. Pull up the coupling handle. The coupling opens. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 243: Fig. 84 Release The Parking Brake
Pull the brake lever a little further on and press the release button. ■ Hold the release button in and push the lever down past the dead point zone. 7. Remove the chocks. Service manual Portable compressor No.: 9_6974 20 E M122...
Page 244: Fig. 85 Safety Sign - Secure The Chocks
5. Attach the lighting and indicator systems and carry out a function check. 6. Remove the chocks and secure them in the transport securing device. Replacement chocks can be purchased from KAESER representatives. A list is given at the end of this manual. The part number of the chock is 5.1325.0.
Page 245: Parking The Compressor
If the jockey wheel is raised completely, the spindle can disengage and allow the towbar to fall to the ground. ➤ Do not wind the jockey wheel completely out when the machine is uncoupled from the towing vehicle. Service manual Portable compressor No.: 9_6974 20 E M122...
Page 246: Fig. 87 Warning "Risk Of Injury Due To Falling Towbar
Option sd Parking the machine with fixed-height chassis (with parking brake): When parking on a slope, securely chock the machine before uncoupling. 1. Disconnect the lighting and signaling cable. Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 247: Transport With A Crane
Considerable snow or ice may build up on the machine under low temperature conditions. This may adversely effect the machine's centre of gravity. It is possible that the permissible loading on the crane or lifting eye is exceeded. Service manual Portable compressor No.: 9_6974 20 E M122...
Page 248: Transporting With A Forklift Truck
➤ Only stationary machines with skids may be transported with a fork truck. ➤ Pick up the machine only from the side with the forks through the lifting lugs. Option sc Fig. 90 Transport using a forklift truck Skids Lifting lugs Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 249: Transporting As A Load
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 transport of machines by sea or air. Please contact KAESER Service for more information. Material Chocks...
Page 250: Storage
Moisture can lead to corrosion, particularly in the engine, airend and oil separator tank. Frozen moisture can damage components, valve diaphragms and gaskets. The following measures also apply to machines not yet commissioned. Please consult with KAESER if you have questions to the appropriate storage and commis‐ sioning. NOTICE Moisture and frost can damage the machine! ➤...
Page 251 ➤ Operating materials and components contaminated with fuel, cooling oil or engine oil must be disposed of in accordance with local environment protection regulations. ➤ Old batteries are hazardous waste and must be disposed of correctly in accordance with local environment protection regulations Service manual Portable compressor No.: 9_6974 20 E M122...
Page 252: 13 Annex
*Vehicle identity number Option lc only: Combined label for coupling loading and Inspection label for the diesel particle filter built-in options (on fan casing) 13.2 Pipeline and instrument flow diagram (P+I diagram) Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 253 Annex 13.2 Pipeline and instrument flow diagram (P+I diagram) Service manual Portable compressor No.: 9_6974 20 E M122...
Page 254 Annex 13.2 Pipeline and instrument flow diagram (P+I diagram) Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 255 Annex 13.2 Pipeline and instrument flow diagram (P+I diagram) Service manual Portable compressor No.: 9_6974 20 E M122...
Page 256 Annex 13.2 Pipeline and instrument flow diagram (P+I diagram) Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 257: Dimensional Drawings
Annex 13.3 Dimensional drawings 13.3 Dimensional drawings 13.3.1 Option sa Dimensional drawing - chassis with height-adjustable tow bar Service manual Portable compressor No.: 9_6974 20 E M122...
Page 258 Annex 13.3 Dimensional drawings Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 259: Dimensional Drawing, Chassis With Fixed Height Tow Bar
Annex 13.3 Dimensional drawings 13.3.2 Option sd Dimensional drawing, chassis with fixed height tow bar Service manual Portable compressor No.: 9_6974 20 E M122...
Page 260 Annex 13.3 Dimensional drawings Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 261: Dimensional Drawing, Chassis Without Parking Brake
Annex 13.3 Dimensional drawings 13.3.3 Option sh Dimensional drawing, chassis without parking brake Service manual Portable compressor No.: 9_6974 20 E M122...
Page 262 Annex 13.3 Dimensional drawings Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 263: Dimensional Drawings Of Stationary Machine (Skids)
Annex 13.3 Dimensional drawings 13.3.4 Option sc Dimensional drawings of stationary machine (skids) Service manual Portable compressor No.: 9_6974 20 E M122...
Page 264 Annex 13.3 Dimensional drawings Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 265: Dimensional Drawings Of Stationary Machine (Base Frame)
Annex 13.3 Dimensional drawings 13.3.5 Option si Dimensional drawings of stationary machine (base frame) Service manual Portable compressor No.: 9_6974 20 E M122...
Page 266 Annex 13.3 Dimensional drawings Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 267: Wiring Diagrams
Annex 13.4 Wiring diagrams 13.4 Wiring diagrams 13.4.1 Electrical Diagram Service manual Portable compressor No.: 9_6974 20 E M122...
Page 268 Annex 13.4 Wiring diagrams Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 269 Annex 13.4 Wiring diagrams Service manual Portable compressor No.: 9_6974 20 E M122...
Page 270 Annex 13.4 Wiring diagrams Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 271 Annex 13.4 Wiring diagrams Service manual Portable compressor No.: 9_6974 20 E M122...
Page 272 Annex 13.4 Wiring diagrams Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 273 Annex 13.4 Wiring diagrams Service manual Portable compressor No.: 9_6974 20 E M122...
Page 274 Annex 13.4 Wiring diagrams Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 275 Annex 13.4 Wiring diagrams Service manual Portable compressor No.: 9_6974 20 E M122...
Page 276 Annex 13.4 Wiring diagrams Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 277 Annex 13.4 Wiring diagrams Service manual Portable compressor No.: 9_6974 20 E M122...
Page 278 Annex 13.4 Wiring diagrams Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 279 Annex 13.4 Wiring diagrams Service manual Portable compressor No.: 9_6974 20 E M122...
Page 280 Annex 13.4 Wiring diagrams Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 281 Annex 13.4 Wiring diagrams Service manual Portable compressor No.: 9_6974 20 E M122...
Page 282 Annex 13.4 Wiring diagrams Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 283 Annex 13.4 Wiring diagrams Service manual Portable compressor No.: 9_6974 20 E M122...
Page 284 Annex 13.4 Wiring diagrams Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 285 Annex 13.4 Wiring diagrams Service manual Portable compressor No.: 9_6974 20 E M122...
Page 286 Annex 13.4 Wiring diagrams Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 287 Annex 13.4 Wiring diagrams Service manual Portable compressor No.: 9_6974 20 E M122...
Page 288 Annex 13.4 Wiring diagrams Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 289 Annex 13.4 Wiring diagrams Service manual Portable compressor No.: 9_6974 20 E M122...
Page 290 Annex 13.4 Wiring diagrams Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 291 Annex 13.4 Wiring diagrams Service manual Portable compressor No.: 9_6974 20 E M122...
Page 292: Connection Adapter For The Diesel Particulate Filter
Annex 13.4 Wiring diagrams 13.4.2 Option lc Connection adapter for the diesel particulate filter Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 293 Annex 13.4 Wiring diagrams Service manual Portable compressor No.: 9_6974 20 E M122...
Page 294 Annex 13.4 Wiring diagrams Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 295 Annex 13.4 Wiring diagrams Service manual Portable compressor No.: 9_6974 20 E M122...
Page 296 Annex 13.4 Wiring diagrams Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 297: Lighting And Signalling System Connection
Annex 13.4 Wiring diagrams 13.4.3 Option tc Lighting and signalling system connection Service manual Portable compressor No.: 9_6974 20 E M122...
Page 298 Annex 13.4 Wiring diagrams Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 299 Annex 13.4 Wiring diagrams Service manual Portable compressor No.: 9_6974 20 E M122...
Page 300 Annex 13.4 Wiring diagrams Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 301 Annex 13.4 Wiring diagrams Service manual Portable compressor No.: 9_6974 20 E M122...
Page 302 Annex 13.4 Wiring diagrams Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 303 Annex 13.4 Wiring diagrams Service manual Portable compressor No.: 9_6974 20 E M122...
Page 304 Annex 13.4 Wiring diagrams Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 305: Lighting And Signalling System Connection
Annex 13.4 Wiring diagrams 13.4.4 Option te Lighting and signalling system connection Service manual Portable compressor No.: 9_6974 20 E M122...
Page 306 Annex 13.4 Wiring diagrams Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 307 Annex 13.4 Wiring diagrams Service manual Portable compressor No.: 9_6974 20 E M122...
Page 308 Annex 13.4 Wiring diagrams Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 309 Annex 13.4 Wiring diagrams Service manual Portable compressor No.: 9_6974 20 E M122...
Page 310: Fuel Circulation Diagram
Annex 13.5 Fuel circulation diagram 13.5 Fuel circulation diagram Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 311 Annex 13.5 Fuel circulation diagram Service manual Portable compressor No.: 9_6974 20 E M122...
Page 312: Operating Instructions For Compressed Air Filter (Combination Filter)
Annex 13.6 Operating instructions for compressed air filter (combination filter) 13.6 Option dd Operating instructions for compressed air filter (combination filter) Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 313: Instruction Manual
FA (D), FB (D&E), FC (D&E), FD (E), FE (D&E), FF (D&E), FG STANDARD D-Pack D-PACK E-PACK Basic (OPTION) (OPTION) (OPTION) Kaeser Kompressoren GmbH Postfach 2143 96410 Coburg Tel.: 09561/640-0 Fax: 09561/640130 http://www.kaeser.com , 2 . 3 . 9 n u t...
Page 314 E-pack: Filter with filtermonitor and ECO-DRAIN Anzahl Filterelemente siehe Kapitel 3. „Technische Daten“. Quantity of filter cartridges see chapter 3. „Technical data“. - 2 - t l l FI HANK-MOB_02 D E Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 315 E-Pack: Filter mit Filtermonitor E-Pack: Filter with filtermonitor Anzahl Filterelemente siehe Kapitel 3. „Technische Daten“. Quantity of filter cartridges see chapter 3. „Technical data“. - 3 - t l l FI HANK-MOB_02 D E Service manual Portable compressor No.: 9_6974 20 E M122...
Page 316 E-pack: Filter with filtermonitor and ECO-DRAIN Anzahl Filterelemente siehe Kapitel 3. „Technische Daten“. Quantity of filter cartridges see chapter 3. „Technical data“. - 4 - t l l FI HANK-MOB_02 D E Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 317 E-pack: Filter series FF with filtermonitor and ECO-DRAIN Anzahl Filterelemente siehe Kapitel 3. „Technische Daten“. Quantity of filter cartridges see chapter 3. „Technical data“. - 5 - t l l FI HANK-MOB_02 D E Service manual Portable compressor No.: 9_6974 20 E M122...
Page 318 We reserve the right to alter the specifications without prior notice Technische Änderungen vorbehalten. - 6 - t l l FI HANK-MOB_02 D E Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 319 Ausführende Tätigkeit. Changes sequence of operation Vom Bediener auszuführende Bedienschritte. 1.3 Erklärung der Symbole am Gerät 1.3 Symbols used in the filter - 7 - t l l FI HANK-MOB_02 D E Service manual Portable compressor No.: 9_6974 20 E M122...
Page 320 ∗ Es besitzt als solches eine zur Inbetriebnahme und War- tung derartiger Einrichtungen befähigende Ausbildung bzw. Berechtigung. - 8 - t l l FI HANK-MOB_02 D E Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 321: Safety Rules
Filter/ -systeme zur Aufbereitung von Atemluft dürfen nur nach approved from manufacturer. Genehmigung des Herstellers der Filter/ -systeme eingesetzt und betrieben werden. - 9 - t l l FI HANK-MOB_02 D E Service manual Portable compressor No.: 9_6974 20 E M122...
Page 322: Technical Data
Annex 13.6 Operating instructions for compressed air filter (combination filter) 3. Technical data 3. Technische Daten - 10 - t l l FI HANK-MOB_02 D E Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 323: Description Of Operation
The coalesced liquids then drain to the bottom of Coalescings ausgefiltert. Die Luft tritt durch den perforierten äuße- the cartridge for removal. ren Stützmantel aus. - 13 - t l l FI HANK-MOB_02 D E Service manual Portable compressor No.: 9_6974 20 E M122...
Page 324 Filters und tropfen dann in den Filterbehälter ab. downstream to the bottom of the sleeve and drain to the bottom of the filter bowl. - 15 - t l l FI HANK-MOB_02 D E Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 325: Condensate Drain
Bei den Filtern FD, FG entfällt der Kondensatableitungsanschluß. Condensate drain does not exist in filters FD, FG. - 21 - t l l FI HANK-MOB_02 D E Service manual Portable compressor No.: 9_6974 20 E M122...
Page 326 Close the shut-off device in the bypass (if installed). Das Filter/ -system ist nun in BETRIEB. The filter/ -system is now OPERATIVE. - 24 - t l l FI HANK-MOB_02 D E Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 327 (Siehe Kapitel 9) The FG filter does not require a differential pressure gauge. Das Filter FG benötigt keine Differenzdruckanzeige. - 25 - t l l FI HANK-MOB_02 D E Service manual Portable compressor No.: 9_6974 20 E M122...
Page 328 F r e t i t a Bh = Kompressor-Betriebsstunden / Working hours - 32 - t l l FI HANK-MOB_02 D E Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 329 The filter(s) contain(s) systems under high pressure. hende Systeme. Alle pressure must be let off before servicing Vor Servicearbeiten sind sie drucklos zu machen. - 33 - t l l FI HANK-MOB_02 D E Service manual Portable compressor No.: 9_6974 20 E M122...
Page 330 Place filter under pressure again by slowly opening the Filter durch langsames Öffnen der Absperrvorrichtungen shut-off device. wieder mit Druck beaufschlagen. - 34 - t l l FI HANK-MOB_02 D E Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 331 ß i s l i Nähere Informationen finden Sie auch im Anhang ECO DRAIN. For more details please see annexe ECO DRAIN. - 35 - t l l FI HANK-MOB_02 D E Service manual Portable compressor No.: 9_6974 20 E M122...
Page 332 Personen unsachgemäß geöffnet oder repariert wurde und/oder mechanische Beschädigungen irgendwelcher Art aufweist. - 36 - t l l FI HANK-MOB_02 D E Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 333: Operating Instructions For Compressed Air Filter (Fresh Air Filter)
Annex 13.7 Operating instructions for compressed air filter (fresh air filter) 13.7 Option dc Operating instructions for compressed air filter (fresh air filter) Service manual Portable compressor No.: 9_6974 20 E M122...
Page 334 ALYVOS GARŲ IR KVAPO ŠALINIMO FILTRAI ФИЛЬТРЫ ДЛЯ УСТРАНЕНИЯ ЗАПАХА И ПАРОВ МАСЛА FILTRI ZA ODSTRANJEVANJE OLJNIH HLAPOV IN VONJAV YAĞ BUHARI VE KOKUSU GİDERİCİ FİLTRELER FILTRI LI JNE{{U L-FWAR TA}-}JUT U L-IRWEJJA{ FILTER-DH-OIL-XEVOLUTION 01 Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 335 Annex 13.7 Operating instructions for compressed air filter (fresh air filter) Service manual Portable compressor No.: 9_6974 20 E M122...
Page 336 Указывает на требования по уничтожению использованных деталей и отходов • Označuje zahteve za odlaganje rabljenih delov in odpadkov. • Kullanılmış parçaların ve atıkların atılmasına ilişkin gereklilikleri vurgular • Tissottolinea l-kundizzjonijiet biex wie[ed jarmi l-partijiet u]ati u l-iskart FILTER-DH-OIL-XEVOLUTION 01 Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 337 • Įsitikinkite, kad naudojamas reikiamas įrankis • Убедитесь, что используется правильный инструмент • Poskrbite, da boste uporabili ustrezno orodje • Doğru alet kullanılmasını sağlayın • Kun ]gur li tintu]a l-g[odda t-tajba FILTER-DH-OIL-XEVOLUTION 01 Service manual Portable compressor No.: 9_6974 20 E M122...
Page 338 A instalação e a manutenção deste produto só deve ser realizada por pessoal autorizado e competente, sob estrita observância destas instruções de utilização e de quaisquer normas e requisitos legais relevantes, quando adequado. Conserve este guia do utilizador para referência futura FILTER-DH-OIL-XEVOLUTION 01 Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 339 I huma ffittjati b’indikatur tal-volum ta]-]ejt. Kemm l-elementi tal-filtru kif ukoll l-indikatur g[andhom jinbidlu jekk l- indikatur isir ta’ kulur blu. Jekk Jog[;bok Innota - Dan hu indikatur tal-volum ta]-]ejt u ma jindikax i]-]mien li jdum iservi l-element tal-filtru. FILTER-DH-OIL-XEVOLUTION 01 Service manual Portable compressor No.: 9_6974 20 E M122...
Page 340 Annex 13.7 Operating instructions for compressed air filter (fresh air filter) AC010 - AC030 1/4” 1/2” FILTER-DH-OIL-XEVOLUTION 01 Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 341 020 C 020 D 020AA 020AC 020 E 025AA 025DAC 025 D 025AA 025EAC 025 E 030 E BOIE1 AC010 I - AC030 030AA 030AC 030 F 030 G FILTER-DH-OIL-XEVOLUTION 01 Service manual Portable compressor No.: 9_6974 20 E M122...
Page 342 I sono provvisti di un indicatore degli oli misti. Sostituire gli elementi filtranti e l'indicatore quando il secondo assume una colorazione blu. Nota - L'indicatore segnala la presenza di oli misti, ma non la durata dell'elemento filtrante. FILTER-DH-OIL-XEVOLUTION 01 Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 343 Annex 13.7 Operating instructions for compressed air filter (fresh air filter) AC010 - AC030 0 bar 0 bar 0 psi 0 psi FILTER-DH-OIL-XEVOLUTION 01 Service manual Portable compressor No.: 9_6974 20 E M122...
Page 344 13.7 Operating instructions for compressed air filter (fresh air filter) AC010 - AC030 0 bar 0 psi 0 bar 0 bar 0 psi 0 psi 0 bar 0 psi FILTER-DH-OIL-XEVOLUTION 01 Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 345 Annex 13.7 Operating instructions for compressed air filter (fresh air filter) AC010 - AC030 FILTER-DH-OIL-XEVOLUTION 01 Service manual Portable compressor No.: 9_6974 20 E M122...
Page 346 Annex 13.7 Operating instructions for compressed air filter (fresh air filter) AC010 - AC030 Service manual Portable compressor M122 No.: 9_6974 20 E...
Page 347: Service Tasks On The Diesel Particulate Filter
Service tasks on the diesel particulate filter To ensure the proper functioning of the diesel particulate filter, an authorised service technician must perform annual maintenance. Have the following tasks performed by a specialist shop or the KAESER Service: ■ Pressure lines: ─...
Page 348 Annex 13.8 Service tasks on the diesel particulate filter Service manual Portable compressor M122 No.: 9_6974 20 E...

KAESER M122 Service Manual

1 Regarding this Document Using this Document

2 Technical Specifications Nameplate

3 Safety and Responsibility Basic Instructions

4 Design and Function Bodywork

5 Installation and Operating Conditions

6 Installation

7 Initial Start-Up Ensuring Safety

8 Operation

9 Fault Recognition and Rectification

10 1 Maintenance

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Summary of Contents for KAESER M122