Related Manuals for KAESER KOMPRESSOREN M 121
Summary of Contents for KAESER KOMPRESSOREN M 121
- Page 1 SERVICE MANUAL Screw Compressor Model: M 121 GL---Nr.: 1_9968_00230---00 01 Serial No.: ..........
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Page 3: Table Of Contents
Table of Contents Chapter --- Page Technical Specification ......... 1 --- 1 Compressor Unit . - Page 4 Table of Contents Chapter --- Page Installation ........... . 6 --- 24 Setting Up Instructions .
- Page 5 Table of Contents Chapter --- Page 9.3.7 Cleaning the cooler ........... 9 --- 49 9.3.8 Maintenance of rubber sealing strips...
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Page 7: Technical Specification
..........M 121 Maximum working pressure . -
Page 8: Battery
Technical Specification Battery Voltage ..........24 V (2 x 12V) Capacity . -
Page 9: Torque
Technical Specification Notes regarding compressor oil filled at the factory: KAESER screw compressors are filled with the following cooling oil. This oil is highly suited for operation in KAESER compressors: KAESER SIGMA S-- 460 Compressor Oil This oil is also recommended for unsuitable operating conditions such as minor gaseous contamination of the inlet air and for high ambient temperatures. -
Page 10: Identification
Technical Specification 1.10 Identification Engine serial number Chassis serial number (see nameplate on engine block) (below reflector) Portable compressor serial number Airend serial number (see nameplate) (see nameplate on airend) German portable compressors only 1.11 Dimensional Diagram (see following page) 1 --- 4... -
Page 13: Safety Regulations
Safety Safety Regulations Read this service manual and the engine service manual carefully and observe cautionary references before putting this mobile compressor unit into operation and before carrying out any maintenance on the unit. Explanation of Symbols and References This symbol is placed before all references to safety where danger to life and limb can occur during work . - Page 14 Safety Optional: 2 --- 7...
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Page 15: General Instructions Concerning Accident Prevention Regulations
Safety General Instructions Concerning Accident Prevention Regulations During installation, operation, maintenance and repair of the compressor unit, OSHA Stan- dards or any applicable Federal, State and Local codes, standards and regulations must be complied with. Users of compressor units are obliged to comply with the safety and accident prevention regulations concerning the compressor unit that are valid in the country of use. -
Page 16: Regular Check Of Hoisting Gear
Safety Ensure that the compressor unit cannot be inadvertently started before carrying out any repair work. Remove the starter battery or place insulating caps over the battery terminals. A notice with the words ‘‘This machine is under repair, do not start!’’ must be attached to the compressor unit. -
Page 17: General References
Safety General References Work on power driven systems may only be carried out by trained or specialized personnel. Splashing oil can cause injuries and fires. Check all pipes, hoses and screw fittings for leaks and visible damage every three to four weeks. -
Page 19: General
General General Attention! The service manual must be kept with the compressor at all times. This service manual refers to portable screw compressors only. Kaeser Compressors, Inc., reserves the right to change specifications affecting this service manual without notification. If the compressor package is operated in an air distribution network, the maximum network pressure may not exceed 232 psig. -
Page 21: Transport
Transport Transport Transport of the Mobile Compressor Unit as a Towed Vehicle on the Road Attention! When towing the compressor unit with a towing vehicle observe the road traffic regulations (see chapter 2.4). Precautions to be taken before towing the compressor unit: Check that the compressor unit is shut down and secured against accidental restart- ing. -
Page 22: Removing The Compressor Unit From Towing Vehicle
Transport Emergency brake operation: Attention! If the portable compressor should accidentally break away from the towing vehicle, the breakaway cable tightens and activates the com- pressor’s braking system (emergency braking). To ensure that this emergency brake functions perfectly, the breakaway cable must be fed through the cable guide. -
Page 23: Transporting With A Crane
On rented, hired or trade fair packages the transport restraints should be used again for the return journey. KAESER KOMPRESSOREN will be pleased to answer any queries with regard to transport and securing of equipment. KAESER KOMPRESSOREN can accept no liability whatsoever for damages arising through incorrect transport methods or insufficient or wrong securing of freight. -
Page 25: Construction And Operation
Construction and Operation Construction and Operation Principle of Compression The Mobilair compressor unit is fitted with a single stage, oil injected airend. Two rotors, the driven male rotor and the female rotor, both mounted in roller bearings, are fitted into the airend. -
Page 26: Identification Of The Components
Construction and Operation Identification of the Components Position details in ( ) correspond with the Pipe and Instrument Flow Diagram (P & I Diagram) 10 11 Instrument panel Fuel tank Minimum pressure/check valve (37) Motor Proportional controller (23) 10 Fuel filter with water separator Oil separator tank (5) 11 Fan (28) Oil filler with dipstick (11) -
Page 27: Piping And Instrument Flow Diagram (P & I Diagram)
Construction and Operation Piping and Instrument Flow Diagram (P & I Diagram) (see following pages) 1. P & I Diagram, machine 2. P & I Diagram, compressed air outlet 5 --- 17... -
Page 35: Description Of The Piping And Instrument Flow Diagram
Appendix Description of the Piping and Instrument Flow Diagram Details in ( ) correspond to the component identification number on the P & I Diagram. 5.5.1 Air Circulation Atmospheric air flows in through the inlet air filter (1) of the compressor, the inlet valve (3) and is compressed in the airend (4). -
Page 36: Modulating Control
Appendix 5.5.4 Modulating control Description of the operating modes Full Load: As long as the working pressure is around 7,5 psi below maximum (see chapter 1.1 for the value), the compressor runs under full load. The pressure in the control line to the inlet valve (3) downstream of the proportional controller (23) is so low that the inlet valve is open and the motor speed adjustment lever is in the “max. - Page 37 Appendix Modulating control (Standstill) Inlet valve (3) Vent valve (27) Screw compressor (4) Air circulation valve (63) Engine speed adjusting cylinder (26) Shut ---off valve --- Vent line (57) Proportional controler (23) 10 Silencer (50) Oil separator tank (5) 11 Nozzle (46) Combined control valve (Changeover valve) (62) 5 --- 23...
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Page 39: Installation
Installation Installation Setting Up Instructions Observe the following instructions when setting up the compressor unit: Maintain sufficient distance (at least 5 ft.) to building trenches, banks, ramps, etc. Locate the compressor unit on a flat, horizontal surface (max. 15• slope in the longi- tudinal or cross direction!). -
Page 40: Changing The Towing Eye
Installation Tighten the clamp again after 30 miles. The the parallel (control rod) adjustment ensures that the overrun brake stays in its basic horizontal position (fig 1). Adjustment aid: The towbar is provided with an adjustment aid (fig 2). It allows an easy and effortless ad- justment to the coupling height. - Page 41 Installation Fit the new towing eye (11) or coupling (10) to the towbar (9) Insert the fixing bolt (2) through the front hole in the eye or coupling and fasten with the washer (3) and nut (4). In order to insert the rear screw, the overrun brake must be pushed in so that the shock absorber runs back again.
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Page 43: Initial Start
Initial Start Putting into Operation Points to be Observed before Putting into Operation Every compressor unit is test run in the factory and carefully checked before shipment. The test run confirms that the compressor unit conforms to the specification data and runs per- fectly. -
Page 44: Storage
Initial Start Storage 7.3.1 Short term storage (less than four months) Disconnect the battery (first the negative cable, then the positive cable). Seal the air intake openings of the engine, the air intake openings of the compressor and the engine exhaust with plastic foil and moisture resistant adhesive tape. Secure a warning notice on the instrument panel stating the actions taken to store the unit and the date. -
Page 45: Putting Into Operation After A Long Period Of Shutdown
Initial Start Seal the air intake openings of the engine, the air intake openings of the compressor and the engine exhaust with plastic foil and moisture resistant adhesive tape. Clean the bodywork and then treat with a preserving agent. Secure a warning notice on the instrument panel informing of the shutdown measures taken. -
Page 47: Operation
Operation Operation Details in ( ) correspond to the component identification number on the P & I Diagram. Operating Controls “Control ON” switch Back pressure control lamp Starter switch Charging lamp (group alarm lamp) STOP / off Compressed air outlet pressure gauge Temperature gauge switch Start Operating hours counter... -
Page 48: Shutting Down
Operation Release the switch as soon as the engine starts. During the start phase additional fuel is injected into the engine. When the engine starts and runs normally, the charging lamp should extinguish after a few seconds. Attention! If the charging lamp does not extinguish, there is a fault! (see chapters 8.7.7) If the “Back Pressure”... -
Page 49: Monitoring Fuel Level
Operation Monitoring fuel level If the fuel level falls below the set minimum a relay is energised that, after a set time delay, activates the fuel shut ---off device. This actuates the engine shut ---off lever and the engine comes to a stop. The alarm is registered and the indicator lamp ”Fuel level low”... -
Page 50: Measures For Freezing Conditions (Winter Operation)
Operation 1 Maintenance indicator Engine air filter for engine air filter Compressor air filter 2 Maintenance indicator for compressor air filter Measures for Freezing Conditions (Winter Operation) The electrical system starts the unit without problem at temperatures down to 17,6•F. Attention! If the compressor is operated at ambient temperatures below 32•F, then the following points must be observed:... -
Page 51: Starting Help (Starter Battery Discharged)
Operation 8.6.2 Starting help (starter battery discharged) If the starter battery is discharged, the compressor unit can be started with the help of the starter battery in another vehicle or another portable compressor. Pay attention to safety requirements of batteries Attention! Connect batteries of the same voltage only. -
Page 52: Trouble Shooting
Operation Trouble shooting When attempting to repair a malfunction, the instructions in the ‘Safety’ chapter and the appropriate local safety regulations (see chapter 2) must be complied with! Re -- starting after a malfunction: See chapter 7.2 ‘Putting into Operation’ and chapter 8.2.1 ‘Starting’. Explanation of symbols for the following fault finding help: %1 --- have checked by a specialist. -
Page 53: Working Pressure Too High
Operation 8.7.3 Working pressure too high Possible causes: Remedy: Proportional controller maladjusted or Check the diaphragm, clean the defective. nozzle, replace proportional controller if necessary %2. Inlet valve not closing. Repair, replace if necessary. Replace %2. Pressure gauge giving false reading. Venting valve does not blowing off. -
Page 54: Control Lamp Always Illuminated
Operation Possible cause: Remedy: Working pressure too high (proportio- Reset to the permissible value or re- place; %2. nal controller maladjusted). Compressor oil separator cartridge Measure the differential pressure, if it contaminated. is higher than 15 psig, replace (see chapter 9.3.4.) Compressor oil filter cartridge contami- Replace, see chapter 9.3.3. -
Page 55: Maintenance
Maintenance Maintenance Observe the following rules during all maintenance and servicing: Only specialized or trained personnel may work on power driven equipment. Before starting work, disconnect the negative terminal of the battery to prevent an inadvertent start of the compressor unit. DO NOT remove caps, plugs, and/or other components when com- pressor is running or pressurized. - Page 56 Maintenance Interval Maintenance work see chapter every 125 h clean the compressor air filter* 9.3.5 clean the oil cooler* 9.3.7 clean the engine cooling fins* engine SM check the wheel nuts for tightness check the tyre pressures grease the regulating rod every 250 h check all accessible screw connections, pipes and clamps for wear and tightness...
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Page 57: Maintenance Instructions
Maintenance Maintenance Instructions The maintenance instructions for the diesel engine are found in the diesel engine service manual! Before starting repair work or maintenance clean the compressor unit, especially con- nections and screw joints of all oil, diesel fuel or protective agents (preservation grease, etc). -
Page 58: Compressor Oil Change (Oil Separator Tank And Oil Cooler)
Maintenance Top off the oil: Attention! The oil should never exceed the normal quantity otherwise operational malfunctions could occur. If too much oil is added, oil will enter the air control valve upon restarting, cause malfunctioning regulation and en- richment of the compressed air with excess oil. Always use the same type of oil (see label on the oil separator tank, or Attention! chapter 1.7). - Page 59 Maintenance Open the right ---hand access door. Disconnect the minus pole of the battery. Uncouple all consumers and open the discharge valve. Unscrew the oil filler plug. Capture the used oil in a suitable container and dispose according to environmental regulations! Drain the oil separator tank by unscrewing the oil drain plug, located on the underside of the tank (accessible from underneath through the access hole in the floor panel).
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Page 60: Compressor Oil Filter Cartridge Change
Maintenance 9.3.3 Compressor oil filter cartridge change Replace the oil filter cartridge after approximately 50 operating hours. It is recommended that the oil filter cartridge is then changed every 500 operating hours. The compressor oil can get very hot, beware of scalding! 1 Oil cooler Oil filter 2 Combination valve... -
Page 61: Oil Separator Cartridge Change
Maintenance Exact check of oil level and for leaks: There is a danger of injury through contact with: -- very hot surfaces. -- rotating parts. -- electrically conductive components. The sound proofing measures are ineffective when the maintenance panels are open! Hearing protection should be worn. - Page 62 Maintenance Attention! When cleaning the sealing surfaces take care that no foreign bodies (dirt particles) fall into the oil separator tank. The used oil separator cartridge cannot be cleaned and must be dis- posed of according to environmental regulations. Dispose of the used oil separator cartridge. Insert the new oil separator cartridge (19), with new gaskets (17).
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Page 63: Clean / Replace The Compressor Air Intake Filter
Maintenance Exact check of oil level and for leaks: There is a danger of injury through contact with: -- very hot surfaces. -- rotating parts. -- electrically conductive components. The sound proofing measures are ineffective when the maintenance panels are open! Hearing protection should be worn. - Page 64 Maintenance To open the filter housing: Undo the spring clamp on the cap. Remove the cap and gently pull out the air filter cartridge. Clean the filter housing, cap and sealing surfaces. Cleaning the air filter cartridge by tapping: Tap the air filter cartridge several times on the front with the ball of the hand so that the dust falls out.
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Page 65: Clean/Replace The Engine Air Intake Filter
Maintenance 9.3.6 Clean/replace the engine air intake filter Clean the engine air filter at least every 125 operating hours, at the latest when the main- tenance indicator activates. Engine air filter, rear Air filter element Maintenance indicator Retaining clamp Reset knob for the maintenance indica- Filter cap Filter housing, open Shut down the compressor (see chapter 8.2.2). -
Page 66: Cleaning The Cooler
Maintenance Resetting the maintenance indicator: When filter maintenance is finished, press the reset button of the maintenance indicator. The maintenance indicator is ready for operation again. Insert the cleaned or new air filter cartridge into the filter housing. Reassemble the air filter in the reverse order of opening (see ‘‘To open the filter hous- ing’’). -
Page 67: Maintenance Of Rubber Sealing Strips
Maintenance Attention! Do not direct water or steam jets directly at sensitive components such as the generator, starter or the instruments. Clean the cooler with compressed air, water or steam jet in the opposite direction to the cooling air flow. Screw on the soundproofing again. -
Page 68: Checking The Engine Coolant
Maintenance Winter operation: Be advised that the available battery power is lower during the winter. Only a fraction of the original starting energy is available at low temperatures. Attention! A discharged battery is endangered by freezing temperatures and could freeze at a temperature of 14 •F. Check the battery charge with a hydrometer before the start of the cold season and recharge, if required. - Page 69 Maintenance The expansion tank is located directly above the radiator. 1 Cooler Coolant expansion tank 2 Coolant level eye glass Filler cap Open the left ---hand door. Attention! Never unscrew the filler cap on the engine cooling system unless the coolant temperature has fallen below 194•F;...
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Page 70: Bleeding The Fuel System
Maintenance Checking the antifreeze/corrosion inhibitor in the coolant: The antifreeze protection must be ---34•F throughout the whole year. Check the component of antifreeze agent in the coolant with an antifreeze tester. If the antifreeze component is below 40% then top up with pure antifreeze agent or change the coolant. -
Page 71: Fuel Filter Maintenance
Maintenance 9.3.12 Fuel Filter Maintenance Cleaning The fuel filter should be cleaned when necessary. Shut down the compressor (see chapter 8.2). Wait until the compressor has automatically vented. (the pressure gauge must read zero psig) Open the doors. Loosen the venting screw in the top of the filter cover. -
Page 72: Engine Oil Change
Maintenance Any contaminated fuel must be collected and disposed of, along with the old filter element, in accordance with local environmental regula- tions. Allow the filter to empty. Unscrew and remove the filter lower part. Remove the old filter element. Clean the sealing face in the filter upper part. -
Page 73: Chassis Maintenance
Maintenance Catch the used oil in a suitable container and dispose of according to environmental regulations. A square drip tray with a drainage opening is located in the floor panel directly below the oil drain plug. Place a suitable container beneath this opening to catch the used oil. Position the container. -
Page 74: Checking Engine Fan Belt Tension
Maintenance Servicing the overrun brake: Oil and/or grease all hinged joints and sliding surfaces. Pump in grease until fresh grease escapes from the bearing points. See fig 7 for grease points, see chapter 1.7 for grease. Brake actuating rod: Grease the brake actuating rod every 500 operating hours or at least annually. -
Page 75: Spare Parts And After Sales Service
Spare Parts and After Sales Service Spare Parts and After Sales Service 10.1 Service parts and expendable parts Name Quantity Part no. Compressor parts: Air filter element 6.3564.0 Oil filter 6.3464.0 Oil separator cartridge set 6.3668.0 Complete set, comprising: Separator cartridge 6.4507.0 Gasket 5.2769.0... -
Page 76: Motor Servicing
Spare Parts and After Sales Service Package type: ......Serial no.: ......Part no.: . -
Page 77: Appendix
Appendix Appendix 11.1 Wiring Diagram 11 --- 60... -
Page 93: Lighting And Signalling System Diagram
Appendix 11.2 Lighting and signalling system diagram 11 --- 73... -
Page 99: Fuel Circulation Schematic Diagram
Appendix 11.3 Fuel circulation schematic diagram 11 --- 76... -
Page 105: Maintenance Schedule
Appendix 11.4 Maintenance Schedule Model: Serial number of the compressor unit: Date Description of work Operating hours Signature 11 --- 79...
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