HPC MOBILAIR M27 PE User manual

Operating Manual
Portable Rotary Screw Compressor
MOBILAIR M27 PE
No.: 9_9548 22 HCE
Manufacturer:
KAESER KOMPRESSOREN SE
96410 Coburg • PO Box 2143 • GERMANY • Tel. [phone] • Fax [phone]
www.kaeser.com

Original instructions
/KKW/M27 2.23 en Z2 SBA-MOBILAIR-PE
20211108 100635

1 Regarding this document
1.1 Using this document ......................................................................................................... 1
1.2 Further documents ........................................................................................................... 1
1.3 Copyright .......................................................................................................................... 1
1.4 Symbols and labels .......................................................................................................... 1
1.4.1 Warnings ............................................................................................................. 1
1.4.2 Potential damage warnings ................................................................................ 2
1.4.3 Other alert notes and their symbols .................................................................... 2
2 Technical Specifications
2.1 Nameplate ........................................................................................................................ 4
2.2 Vehicle identification number ........................................................................................... 4
2.3 Options overview .............................................................................................................. 4
2.3.1 Air Treatment ...................................................................................................... 5
2.3.2 Tool lubricator ..................................................................................................... 5
2.3.3 Compressed air distributor .................................................................................. 5
2.3.4 Proportional controller ......................................................................................... 6
2.3.5 Non-return function ............................................................................................. 6
2.3.6 Low temperature equipment ............................................................................... 6
2.3.7 Equipment for fire hazard areas ......................................................................... 6
2.3.8 Fuel de-watering filter ......................................................................................... 7
2.3.9 Battery isolating switch ....................................................................................... 7
2.3.10 Generator ............................................................................................................ 7
2.3.11 Chassis ............................................................................................................... 7
2.3.12 Lighting ............................................................................................................... 8
2.3.13 Sealed floor pan .................................................................................................. 8
2.3.14 Hose reels ........................................................................................................... 8
2.3.15 Anti-theft device .................................................................................................. 8
2.4 Machine (without options) ................................................................................................ 9
2.4.1 Noise emission ................................................................................................... 9
2.4.2 Tightening torque ................................................................................................ 9
2.4.3 Ambient conditions ............................................................................................. 10
2.4.4 Additional specifications according to the machine's operating licence ............. 10
2.5 Chassis ............................................................................................................................ 11
2.5.1 Chassis options .................................................................................................. 11
2.6 Compressor ...................................................................................................................... 11
2.6.1 Working gauge pressure and volumetric flow rate .............................................. 11
2.6.2 Compressed air outlet ......................................................................................... 11
2.6.3 Air quality at the compressed air outlets ............................................................. 11
2.6.4 Safety valves ...................................................................................................... 12
2.6.5 Select temperature ............................................................................................. 12
2.6.6 Cooling oil recommendation ............................................................................... 13
2.6.7 Cooling oil charge ............................................................................................... 14
2.7 Engine .............................................................................................................................. 14
2.7.1 Engine specification ............................................................................................ 14
2.7.2 Carbon dioxide emissions ................................................................................... 15
2.7.3 Oil recommendation ............................................................................................ 15
2.7.4 Fuel recommendation ......................................................................................... 16
2.7.5 Engine coolant recommendation ........................................................................ 16
2.7.6 Fluid volumes ...................................................................................................... 17
2.7.7 Batteries .............................................................................................................. 17
2.8 Options ............................................................................................................................. 18
2.8.1 Tool lubricator ..................................................................................................... 18
2.8.2 Low temperature equipment ............................................................................... 18
2.8.3 Generator ............................................................................................................ 18
Contents
No.: 9_9548 22 HCE
Operating Manual Portable Rotary Screw Compressor
MOBILAIR M27 PE i

2.8.4 Compressed air hose with hose reel .................................................................. 23
3 Safety and Responsibility
3.1 Basic instructions ............................................................................................................. 24
3.2 Specified use .................................................................................................................... 24
3.3 Incorrect Use .................................................................................................................... 24
3.4 Operator responsibilities .................................................................................................. 24
3.4.1 Observe statutory and accepted regulations ...................................................... 24
3.4.2 Determining suitable personnel .......................................................................... 25
3.4.3 Complying with inspection schedules and accident prevention regulations ....... 26
3.5 Dangers ............................................................................................................................ 26
3.5.1 Safely dealing with sources of danger ................................................................ 26
3.5.2 Safe machine operation ...................................................................................... 29
3.5.3 Organisational Measures .................................................................................... 33
3.5.4 Danger areas ...................................................................................................... 33
3.6 Safety devices .................................................................................................................. 33
3.7 Safety signs ...................................................................................................................... 33
3.8 Generator operation ......................................................................................................... 35
3.8.1 Comply with the protective measures against dangerous electric current ......... 35
3.8.2 Safe generator operation .................................................................................... 36
3.8.3 Connecting extension cables .............................................................................. 36
3.8.4 Do not exceed the maximum supply system load .............................................. 36
3.8.5 Perform regular generator inspections ............................................................... 36
3.9 Emergencies .................................................................................................................... 37
3.9.1 Correct actions in the event of a fire ................................................................... 37
3.9.2 Treating injuries from handling operating fluids/materials .................................. 37
3.10 Warranty ........................................................................................................................... 38
3.11 Environmental protection ................................................................................................. 38
4 Design and Function
4.1 Bodywork ......................................................................................................................... 40
4.2 Machine layout ................................................................................................................. 41
4.3 Machine function .............................................................................................................. 42
4.4 Operating modes and control mode ................................................................................. 43
4.4.1 Machine operating modes .................................................................................. 43
4.4.2 MODULATING control ........................................................................................ 43
4.5 Safety devices .................................................................................................................. 44
4.5.1 Monitoring functions with shut-down ................................................................... 44
4.5.2 Further safety devices ........................................................................................ 44
4.6 Options ............................................................................................................................. 44
4.6.1 Manually setting the output pressure .................................................................. 44
4.6.2 Air treatment options ........................................................................................... 45
4.6.3 Generator option ................................................................................................. 46
4.6.4 Low temperature equipment ............................................................................... 48
4.6.5 Options for operating in fire hazard areas .......................................................... 50
4.6.6 Fuel de-watering filter option .............................................................................. 51
4.6.7 Closed floor pan option ....................................................................................... 51
4.6.8 Optional battery isolating switch ......................................................................... 51
4.6.9 Hose reel option .................................................................................................. 52
4.6.10 Optional anti-theft device .................................................................................... 52
5 Installation and Operating Conditions
5.1 Ensuring safety ................................................................................................................ 53
5.2 Installation conditions ....................................................................................................... 53
Contents
ii
Operating Manual Portable Rotary Screw Compressor
MOBILAIR M27 PE No.: 9_9548 22 HCE

6 Installation
6.1 Ensuring safety ................................................................................................................ 56
6.2 Reporting Transport Damage ........................................................................................... 56
6.3 Installing the options ........................................................................................................ 56
6.3.1 Perform regular maintenance on the chassis: .................................................... 56
7 Initial Start-up
7.1 Ensuring safety ................................................................................................................ 57
7.2 Before Initial Start-up (or Recommissioning) ................................................................... 57
7.2.1 Note when commissioning .................................................................................. 57
7.2.2 Special measures for re-commissioning after storage or de-commissioning ..... 58
7.3 Checking installation and operating conditions ................................................................ 58
7.4 Low-temperature operation .............................................................................................. 59
7.4.1 Carrying out warming-up when temperatures are low ........................................ 59
7.4.2 Starting assistance ............................................................................................. 60
7.4.3 Starting up low-temperature equipment .............................................................. 62
7.5 Putting the generator into operation ................................................................................. 64
7.5.1 Generator control box 400 V with insulation monitoring ..................................... 64
7.5.2 Generator control box 115 V with insulation monitoring ..................................... 65
7.5.3 Testing the insulation monitor ............................................................................. 65
8 Operation
8.1 Ensuring safety ................................................................................................................ 67
8.2 Starting up and shutting down .......................................................................................... 68
8.2.1 Commissioning the machine ............................................................................... 68
8.2.2 Starting the machine ........................................................................................... 69
8.2.3 Running the machine up to operating temperature ............................................ 69
8.2.4 Setting the discharge pressure by using the hand wheel ................................... 70
8.2.5 Operating the machine under load ..................................................................... 71
8.2.6 Shutting down the machine ................................................................................ 71
8.3 Refuelling the machine ..................................................................................................... 71
8.3.1 Using the correct type of fuel .............................................................................. 71
8.3.2 Filling the fuel tank at a pump by means of a refuelling nozzle .......................... 73
8.3.3 Filling the fuel tank on a construction site by means of a canister ..................... 74
8.4 Cleaning the machine after operation .............................................................................. 75
8.4.1 Cleaning the exterior of the machine .................................................................. 75
8.4.2 Cleaning the interior of the machine ................................................................... 77
8.5 Operating the options ....................................................................................................... 78
8.5.1 Operating the battery isolating switch ................................................................. 79
8.5.2 Operating the tool lubricator ............................................................................... 79
8.5.3 Using the low-temperature equipment ................................................................ 81
8.5.4 Generator operation ............................................................................................ 82
8.5.5 Using the hose reel ............................................................................................. 84
9 Fault Recognition and Rectification
9.1 Basic instructions ............................................................................................................. 86
9.2 Evaluating engine faults and alarms ................................................................................ 86
9.2.1 Engine stops or fails to start ............................................................................... 86
9.2.2 Drive engine does not reach full speed .............................................................. 87
9.2.3 Indicator lamp remains on .................................................................................. 87
9.2.4 Drive engine knocking or fails to start ................................................................. 88
9.3 Analysing compressor faults and alarms ......................................................................... 88
9.3.1 Working pressure too high .................................................................................. 88
9.3.2 Working pressure too low ................................................................................... 88
9.3.3 Safety valve blows off ......................................................................................... 89
9.3.4 Machine overheating .......................................................................................... 89
Contents
No.: 9_9548 22 HCE
Operating Manual Portable Rotary Screw Compressor
MOBILAIR M27 PE iii

9.3.5 Too much oil residue in the compressed air ....................................................... 90
9.3.6 Oil flows from the compressor air filter after shutdown ....................................... 90
9.3.7 High moisture content in the compressed air ..................................................... 91
9.4 Evaluate generator faults and alarms .............................................................................. 91
9.4.1 There is no voltage or too low a voltage from the generator .............................. 91
9.4.2 Generator voltage too high ................................................................................. 92
10 Maintenance
10.1 Ensuring safety ................................................................................................................ 93
10.2 Following the maintenance plans ..................................................................................... 95
10.2.1 Logging maintenance work ................................................................................. 95
10.2.2 Maintenance tasks after commissioning ............................................................. 95
10.2.3 Regular maintenance tasks ................................................................................ 95
10.3 Drive engine maintenance ............................................................................................... 101
10.3.1 Coolant cooler maintenance ............................................................................... 101
10.3.2 Engine air filter maintenance .............................................................................. 106
10.3.3 Fuel system maintenance ................................................................................... 108
10.3.4 Changing the engine oil ...................................................................................... 113
10.3.5 Changing the engine oil filter .............................................................................. 116
10.3.6 Drive belt maintenance ....................................................................................... 117
10.3.7 Having the antivibration mount checked ............................................................. 119
10.3.8 Battery maintenance ........................................................................................... 119
10.3.9 Checking the fastening of the fuel tank .............................................................. 123
10.4 Compressor Maintenance ................................................................................................ 123
10.4.1 Checking cooling oil level ................................................................................... 123
10.4.2 Cooling oil filling and topping up ......................................................................... 124
10.4.3 Changing the cooling oil ..................................................................................... 125
10.4.4 Replacing the compressor oil filter ...................................................................... 129
10.4.5 Oil separator tank dirt trap maintenance ............................................................. 130
10.4.6 Changing the oil separator cartridge ................................................................... 132
10.4.7 Compressor air filter maintenance ...................................................................... 134
10.4.8 Check pressure relief valves ............................................................................... 136
10.5 Cooler maintenance ......................................................................................................... 137
10.5.1 Unhinge the gas struts of the enclosure ............................................................. 138
10.5.2 Cleaning the oil cooler and coolant cooler .......................................................... 138
10.5.3 Hinge the gas struts of the enclosure ................................................................. 139
10.5.4 Preparing for operation ....................................................................................... 139
10.5.5 Commissioning the machine ............................................................................... 139
10.5.6 Inspect both coolers for leaks ............................................................................. 140
10.6 Checking the screw connections ...................................................................................... 140
10.6.1 General guideline values for tightening torques ................................................. 140
10.6.2 Specific guideline values for tightening torques ................................................. 140
10.6.3 Sealed screw connections .................................................................................. 141
10.7 Checking the enclosure .................................................................................................... 141
10.7.1 Check sound proofing material ........................................................................... 141
10.7.2 Maintain rubber sealing strips. ............................................................................ 142
10.7.3 Checking function of closed enclosure ............................................................... 142
10.7.4 Checking connecting elements of enclosure ...................................................... 142
10.8 Check/replace hose lines ................................................................................................. 143
10.8.1 Replace the fuel lines of the drive engine. .......................................................... 143
10.8.2 Replace the pressure hoses of the drive engine. ............................................... 144
10.8.3 Replace the pressure hoses of the compressor ................................................. 144
10.9 Maintenance of Optional Items ........................................................................................ 144
10.9.1 Tool lubricator maintenance ............................................................................... 144
10.9.2 Compressed air aftercooler maintenance ........................................................... 146
Contents
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Operating Manual Portable Rotary Screw Compressor
MOBILAIR M27 PE No.: 9_9548 22 HCE

10.9.3 Compressed air water separator maintenance ................................................... 148
10.9.4 Combination filter maintenance .......................................................................... 150
10.9.5 Defroster maintenance ....................................................................................... 154
10.9.6 Engine air shut-off valve maintenance ................................................................ 156
10.9.7 Draining liquid accumulation within the machine ................................................ 157
10.9.8 Generator drive belt maintenance ...................................................................... 158
10.10 Document maintenance and service work. ...................................................................... 161
11 Spares, Operating Materials, Service
11.1 Note the nameplate .......................................................................................................... 164
11.2 Ordering consumable parts and operating fluids/materials .............................................. 164
11.3 HPC AIR SERVICE .......................................................................................................... 165
11.4 Replacement parts for service and repair ........................................................................ 165
11.4.1 Spare parts overview .......................................................................................... 165
12 Decommissioning, Storage and Transport
12.1 De-commissioning ............................................................................................................ 211
12.1.1 Temporary de-commissioning ............................................................................ 211
12.1.2 Long-term de-commissioning and storage ......................................................... 212
12.2 Transportation .................................................................................................................. 213
12.2.1 Safety .................................................................................................................. 214
12.2.2 Transporting the machine by crane .................................................................... 214
12.2.3 Transported as load ............................................................................................ 217
12.3 Storage ............................................................................................................................. 218
12.4 Disposal ........................................................................................................................... 219
12.4.1 Removing the batteries ....................................................................................... 219
12.4.2 Draining operating fluids ..................................................................................... 220
12.4.3 Draining condensate ........................................................................................... 220
12.4.4 Removing filters/filter elements ........................................................................... 221
12.4.5 Disposing of the machine ................................................................................... 221
13 Annex
13.1 Identification ..................................................................................................................... 222
13.1.1 Identification of the machine ............................................................................... 222
13.1.2 Identification of the drive engine ......................................................................... 222
13.2 Pipeline and instrument flow diagram (P+I diagram) ....................................................... 222
13.3 Dimensional drawing ........................................................................................................ 227
13.3.1 Dimensional drawing – chassis ........................................................................... 227
13.3.2 Dimensional drawing – chassis ........................................................................... 229
13.3.3 Dimensional drawing – chassis ........................................................................... 231
13.3.4 Dimensional drawing – Chassis .......................................................................... 233
13.3.5 Dimensional drawing – chassis ........................................................................... 235
13.3.6 Dimensional drawing – chassis ........................................................................... 237
13.4 Wiring diagrams ............................................................................................................... 239
13.4.1 Electrical Diagram ............................................................................................... 239
13.4.2 Generator electrical diagram, 400V, 3-ph ........................................................... 249
13.4.3 Generator electrical diagram, 115V, 2-ph ........................................................... 255
13.4.4 Lighting and signalling system connection ......................................................... 260
13.4.5 Lighting and signalling system connection ......................................................... 265
13.5 Fuel circulation diagram ................................................................................................... 270
13.6 Service tasks - Generator ................................................................................................ 273
13.7 Operating instructions for compressed air filter (combination filter) ................................. 273
Contents
No.: 9_9548 22 HCE
Operating Manual Portable Rotary Screw Compressor
MOBILAIR M27 PE v

Contents
vi
Operating Manual Portable Rotary Screw Compressor
MOBILAIR M27 PE No.: 9_9548 22 HCE

Fig. 1 Option label MOBILAIR M27 PE with options ............................................................................ 5
Fig. 2 Location of safety signs .............................................................................................................. 34
Fig. 3 Bodywork .................................................................................................................................... 40
Fig. 4 Side view (enclosure removed) .................................................................................................. 41
Fig. 5 Machine overview ....................................................................................................................... 42
Fig. 6 Compressed air options ............................................................................................................. 45
Fig. 7 Tool lubricator ............................................................................................................................. 46
Fig. 8 Instrument panel – generator control box, 400 V AC ................................................................. 48
Fig. 9 Instrument panel – generator control box, 115 V AC ................................................................. 48
Fig. 10 Device connection on the machine ............................................................................................ 49
Fig. 11 Position of the defroster shut-off valve ....................................................................................... 50
Fig. 12 Battery isolating switch ............................................................................................................... 52
Fig. 13 Container for safety chain .......................................................................................................... 52
Fig. 14 Minimum distance from excavations/slopes and walls ............................................................... 54
Fig. 15 Jumper cable connection diagram ............................................................................................. 60
Fig. 16 Coolant pre-heating .................................................................................................................... 62
Fig. 17 Shut-off valve of switching position ............................................................................................ 63
Fig. 18 Insulation monitoring – 400 V three-phase Generator ................................................................ 64
Fig. 19 Insulation monitoring - 115 V single phase generator ................................................................ 65
Fig. 20 Starting instruments ................................................................................................................... 68
Fig. 21 Warm-up period label for ambient temperatures below -10 °C .................................................. 69
Fig. 22 Proportional controller ................................................................................................................ 70
Fig. 23 Filling the tank with the correct fuel type .................................................................................... 73
Fig. 24 Battery isolating switch ............................................................................................................... 79
Fig. 25 Adjusting the tool lubricator ........................................................................................................ 80
Fig. 26 "Generator cut-in" pictogram ...................................................................................................... 83
Fig. 27 Additional shut-off valve for compressed air extension hose ..................................................... 84
Fig. 28 Checking the coolant level ......................................................................................................... 102
Fig. 29 Recommended mixture ratio for coolant .................................................................................... 103
Fig. 30 Draining the coolant ................................................................................................................... 105
Fig. 31 Maintenance indicator ................................................................................................................ 106
Fig. 32 Engine air filter maintenance ...................................................................................................... 107
Fig. 33 Cleaning the filter element .......................................................................................................... 107
Fig. 34 Bleeding the fuel system ............................................................................................................ 109
Fig. 35 Fuel prefilter maintenance .......................................................................................................... 110
Fig. 36 Changing the filter cartridge ....................................................................................................... 111
Fig. 37 Fuel/water separator .................................................................................................................. 112
Fig. 38 Changing the engine oil .............................................................................................................. 114
Fig. 39 Detail oil drain valve ................................................................................................................... 114
Fig. 40 Changing the engine oil filter ...................................................................................................... 116
Fig. 41 Manually checking the belt tension ............................................................................................ 118
Fig. 42 Example for antivibration mount of drive engine ........................................................................ 119
Fig. 43 Safety signs - warning stickers on the battery ............................................................................ 120
Fig. 44 Checking cooling oil level ........................................................................................................... 124
Fig. 45 Plugs, oil separator tank ............................................................................................................. 126
Fig. 46 Draining the compressor cooling oil ........................................................................................... 127
Fig. 47 Change the oil filter .................................................................................................................... 129
Fig. 48 Oil separator tank dirt trap maintenance .................................................................................... 131
Fig. 49 Changing the oil separator cartridge .......................................................................................... 132
Fig. 50 Maintenance indicator ................................................................................................................ 135
Fig. 51 Compressor air filter maintenance ............................................................................................. 136
Fig. 52 Create maximum opening angle ................................................................................................ 138
Fig. 53 Align gas strut ............................................................................................................................. 139
Fig. 54 Connecting rod alignment .......................................................................................................... 143
List of Illustrations
No.: 9_9548 22 HCE
Operating Manual Portable Rotary Screw Compressor
MOBILAIR M27 PE vii

Fig. 55 Tool lubricator maintenance ....................................................................................................... 145
Fig. 56 Cleaning the compressed air after-cooler .................................................................................. 147
Fig. 57 Cleaning the dirt trap .................................................................................................................. 149
Fig. 58 Combination filter maintenance .................................................................................................. 151
Fig. 59 Replace filter element. ................................................................................................................ 152
Fig. 60 Filter combination ....................................................................................................................... 153
Fig. 61 Top up antifreeze ....................................................................................................................... 155
Fig. 62 Engine air shut-off valve maintenance ....................................................................................... 156
Fig. 63 Replacing the generator belt ...................................................................................................... 159
Fig. 64 Service check sheet ................................................................................................................... 162
Fig. 65 Position of lifting eye .................................................................................................................. 215
Fig. 66 Example: Improperly inserted crane hook .................................................................................. 215
Fig. 67 Insert the crane hook properly .................................................................................................... 216
Fig. 68 Bracket systems as load securing (machine with chassis) ........................................................ 218
Fig. 69 Battery labelling .......................................................................................................................... 220
Fig. 70 Identification of the machine ....................................................................................................... 222
Fig. 71 Identification of the drive engine ................................................................................................. 222
List of Illustrations
viii
Operating Manual Portable Rotary Screw Compressor
MOBILAIR M27 PE No.: 9_9548 22 HCE

Tab. 1 Danger levels and their definition (personal injury) .................................................................... 1
Tab. 2 Danger levels and their definition (damage to property) ............................................................ 2
Tab. 3 Nameplate .................................................................................................................................. 4
Tab. 4 Air treatment options .................................................................................................................. 5
Tab. 5 Tool lubricator option .................................................................................................................. 5
Tab. 6 Compressed air distributor option .............................................................................................. 5
Tab. 7 Proportional controller options .................................................................................................... 6
Tab. 8 Non-return option ....................................................................................................................... 6
Tab. 9 Low temperature equipment options .......................................................................................... 6
Tab. 10 Optional equipment for fire hazard areas ................................................................................... 6
Tab. 11 Fuel de-watering filter option ...................................................................................................... 7
Tab. 12 Optional battery isolating switch ................................................................................................. 7
Tab. 13 Generator option ........................................................................................................................ 7
Tab. 14 Chassis options .......................................................................................................................... 7
Tab. 15 Lighting options .......................................................................................................................... 8
Tab. 16 Closed floor pan option .............................................................................................................. 8
Tab. 17 Hose reel option ......................................................................................................................... 8
Tab. 18 Optional anti-theft device ............................................................................................................ 8
Tab. 19 Guaranteed sound power level .................................................................................................. 9
Tab. 20 Emission sound pressure level ................................................................................................... 9
Tab. 21 Torques for M4–M8 screws ........................................................................................................ 9
Tab. 22 Torques for M10–M24 screws .................................................................................................... 10
Tab. 23 Torque cover fixing screws oil separator tank ............................................................................ 10
Tab. 24 Torques for lifting eye screws ..................................................................................................... 10
Tab. 25 Ambient conditions ..................................................................................................................... 10
Tab. 26 Working gauge pressure and volumetric flow rate ..................................................................... 11
Tab. 27 Compressed air distributor ......................................................................................................... 11
Tab. 28 Interrelation between compressed air treatment and compressed air quality ............................ 11
Tab. 29 Safety valve opening pressure ................................................................................................... 12
Tab. 30 Machine temperatures ................................................................................................................ 12
Tab. 31 Airend package discharge temperature ..................................................................................... 13
Tab. 32 Cooling oil recommendation ....................................................................................................... 13
Tab. 33 Cooling oil recommendation (food processing) .......................................................................... 14
Tab. 34 Cooling oil charge ....................................................................................................................... 14
Tab. 35 Engine specification ................................................................................................................... 14
Tab. 36 CO2 emissions value .................................................................................................................. 15
Tab. 37 Engine oil recommendation ........................................................................................................ 15
Tab. 38 Water quality specification .......................................................................................................... 16
Tab. 39 Initial filling of coolant cooler ...................................................................................................... 17
Tab. 40 Fluid volumes ............................................................................................................................. 17
Tab. 41 Batteries ..................................................................................................................................... 17
Tab. 42 Road breaker lubricant recommendation ................................................................................... 18
Tab. 43 Ambient conditions, low temperature equipment ....................................................................... 18
Tab. 44 Coolant pre-heating device ........................................................................................................ 18
Tab. 45 Recommended antifreeze .......................................................................................................... 18
Tab. 46 Generator data, 400 V ................................................................................................................ 19
Tab. 47 Flow rate in generator mode ...................................................................................................... 19
Tab. 48 Connection sockets .................................................................................................................... 20
Tab. 49 Circuit breaker ............................................................................................................................ 20
Tab. 50 Maximum three-phase mains load ............................................................................................. 20
Tab. 51 Maximum AC mains load ........................................................................................................... 20
Tab. 52 Generator data 115 V ................................................................................................................. 21
Tab. 53 Flow rate in generator mode ...................................................................................................... 21
Tab. 54 Connection sockets .................................................................................................................... 21
List of Tables
No.: 9_9548 22 HCE
Operating Manual Portable Rotary Screw Compressor
MOBILAIR M27 PE ix

Tab. 55 Circuit breaker ............................................................................................................................ 22
Tab. 56 Maximum AC mains load ........................................................................................................... 22
Tab. 57 Generator operating limits .......................................................................................................... 22
Tab. 58 Output power reduction .............................................................................................................. 22
Tab. 59 Additional outlet valve for the compressed air hose ................................................................... 23
Tab. 60 Inspection intervals according to Ordinance on Industrial Health and Safety ............................ 26
Tab. 61 Danger areas .............................................................................................................................. 33
Tab. 62 Safety signs ................................................................................................................................ 34
Tab. 63 Generator / compressor operation ............................................................................................. 47
Tab. 64 Generator operating modes ....................................................................................................... 47
Tab. 65 Low temperature equipment options .......................................................................................... 48
Tab. 66 Measures for re-commissioning the compressor after a long period of storage or de-
commissioning ............................................................................................................................
58
Tab. 67 Checklist for installation and operating conditions ..................................................................... 58
Tab. 68 Block antifreeze .......................................................................................................................... 63
Tab. 69 Test instructions for a generator with an earth leak detection device. ....................................... 65
Tab. 70 Measures required should the fuel tank be filled with the incorrect fuel type ............................. 71
Tab. 71 Fuel / fuel specification ............................................................................................................... 73
Tab. 72 Plug sockets on the exterior of the machine .............................................................................. 76
Tab. 73 High-pressure washer setting ..................................................................................................... 77
Tab. 74 Switch on the antifreeze ............................................................................................................. 81
Tab. 75 Fault: “Engine stops or fails to start” ........................................................................................... 86
Tab. 76 Fault: “Engine not reaching full speed” ....................................................................................... 87
Tab. 77 Alarm: "Control lamp remains on" .............................................................................................. 87
Tab. 78 Fault: “Drive engine knocking or fails to start” ............................................................................ 88
Tab. 79 Fault: working pressure too high ................................................................................................ 88
Tab. 80 Fault: working pressure too low .................................................................................................. 88
Tab. 81 Fault: safety valve blowing off .................................................................................................... 89
Tab. 82 Fault: machine overheating ........................................................................................................ 89
Tab. 83 Alarm: "Too much oil residue in the compressed air" ................................................................. 90
Tab. 84 Alarm: "Oil flows from the compressor air filter after shutdown" ................................................ 90
Tab. 85 Fault: high moisture content in the compressed air .................................................................... 91
Tab. 86 There is no voltage or too low a voltage from the generator ...................................................... 91
Tab. 87 Generator voltage too high ......................................................................................................... 92
Tab. 88 Advise others that the machine is being serviced. ..................................................................... 93
Tab. 89 Maintenance tasks after commissioning .................................................................................... 95
Tab. 90 Maintenance intervals and regular maintenance tasks .............................................................. 95
Tab. 91 Regular machine maintenance tasks ......................................................................................... 96
Tab. 92 Regular maintenance tasks for options ...................................................................................... 99
Tab. 93 Coolant mixture table ................................................................................................................. 104
Tab. 94 Oil drain valve ............................................................................................................................. 115
Tab. 95 Oil drain valve ............................................................................................................................. 127
Tab. 96 Logged maintenance tasks ........................................................................................................ 163
Tab. 97 Compressor consumables .......................................................................................................... 164
Tab. 98 Consumable engine parts .......................................................................................................... 164
Tab. 99 "Temporarily decommissioned" information notice .................................................................... 211
Tab. 100 "Long-term decommissioning and storage" checklist ................................................................. 212
Tab. 101 Text for the "long-term decommissioned and storage" information notice ................................. 213
Tab. 102 Machine fluids ............................................................................................................................ 220
Tab. 103 Machine option fluids .................................................................................................................. 220
Tab. 104 Machine filters/filter elements ..................................................................................................... 221
Tab. 105 Machine option filters/filter elements .......................................................................................... 221
List of Tables
x
Operating Manual Portable Rotary Screw Compressor
MOBILAIR M27 PE No.: 9_9548 22 HCE

1 Regarding this document
1.1 Using this document
The operating manual is a component of the product. It describes the machine as it was at the time
of first delivery after manufacture.
➤ Keep the operating manual in a safe place throughout the life of the machine.
➤ Supply any successive owner or user with this operating manual.
➤ Please insert any amendment or revision of the operating manual sent to you.
➤ Enter details from the machine nameplate and individual items of equipment in the table in
chapter 2.
1.2 Further documents
Further documents included with this operating manual are:
■ Certificate of acceptance / operating instructions for the pressure vessel
■ Declaration of Conformity in accordance with the applicable directive
■ Chassis documentation (where applicable)
Missing documents can be requested from KAESER.
➤ Make sure all documents are complete and observe the instructions contained in them.
➤ Make sure you provide the data from the nameplate when ordering documents.
1.3 Copyright
This operating manual is protected by copyright. Any queries regarding the use or duplication of
this documentation should be referred to KAESER. Correct use of information will be fully suppor‐
ted.
1.4 Symbols and labels
➤ Please note the symbols and labels used in this document.
1.4.1 Warnings
Warnings indicate risks potentially resulting in personal injury, if the measures specified are not
taken.
Warning notices indicate three levels of danger identified by the corresponding signal word:
Signal word Meaning Consequences of non-compliance
DANGER Warns of an imminent danger Will very likely result in death or severe injury
WARNING Warns of a potentially imminent dan‐
ger
May result in death or severe injury
CAUTION Warns of a potentially dangerous sit‐
uation
May result in a moderate physical injury
Tab. 1 Danger levels and their definition (personal injury)
1 Regarding this document
1.1 Using this document
No.: 9_9548 22 HCE
Operating Manual Portable Rotary Screw Compressor
MOBILAIR M27 PE 1

Some warning notes may precede a chapter. They apply to the entire chapter including all sub-sec‐
tions.
Example:
DANGER
The type and source of the imminent danger is shown here!
The possible consequences of ignoring a warning are shown here.
The word "DANGER" indicates that death or severe injury can very likely result from ignoring
the warning.
➤ The measures required to protect yourself from danger are shown here.
Warning notes referring to a sub-section or the subsequent action are integrated into the procedure
and numbered as an action.
Example:
1. WARNING!
The type and source of the imminent danger is shown here!
The possible consequences of ignoring a warning are shown here.
The word "WARNING" indicates that death or severe injury may result from ignoring the warn‐
ing.
➤ The measures required to protect yourself from danger are shown here.
2. Always read and comply with warning instructions.
1.4.2 Potential damage warnings
Contrary to the warnings shown above, damage warnings do not indicate a potential personal in‐
jury.
Damage warnings have only one danger level, identified with this signal word:
Signal word Meaning Consequences of non-compliance
NOTE Warns of a potentially dangerous situation Damage to property is possible
Tab. 2 Danger levels and their definition (damage to property)
Example:
NOTICE
The type and source of the imminent danger is shown here!
Potential effects when ignoring the warning are indicated here.
➤ The protective measures against the damages are shown here.
➤ Carefully read and fully comply with warnings against damages.
1.4.3 Other alert notes and their symbols
This symbol indicates particular important information.
Material Here you will find details on special tools, operating materials or spare parts.
Precondition Here you will find conditional requirements necessary to carry out the task.
The conditions relevant to safety shown here will help you to avoid dangerous situations.
1 Regarding this document
1.4 Symbols and labels
2
Operating Manual Portable Rotary Screw Compressor
MOBILAIR M27 PE No.: 9_9548 22 HCE

➤ This symbol is placed by lists of actions comprising one step of a task.
1. In process instructions with several steps ...
2. ... the sequence of steps is numbered.
Result Shows the expected conclusion of the previous action.
➤ Information relating to one option only is marked with an option code (e.g., "option da" means
that this section is only valid for machines with the air treatment components "aftercooler and
centrifugal separator"). Option codes used in this operating manual are explained in chap‐
ter 2.3.
Information referring to potential problems is identified by a question mark.
The cause is named in the help text ...
➤ ... as is a solution.
This symbol refers to important information or measures concerning environmental protec‐
tion.
Further information Further subjects are introduced here.
1 Regarding this document
1.4 Symbols and labels
No.: 9_9548 22 HCE
Operating Manual Portable Rotary Screw Compressor
MOBILAIR M27 PE 3
Option da

2 Technical Specifications
2.1 Nameplate
The machine's nameplate contains the model type and important technical information.
The nameplate is located on the outside of the machine (see illustration in chapter 13.1).
➤ Enter the data from the nameplate here as a reference:
Feature Value
Portable rotary screw compressor
Material no. / Serial no.
Actual total mass
Lifting point load capacity
Rated power
Rated engine speed
Maximum gauge working pressure PS
Tab. 3 Nameplate
2.2 Vehicle identification number
The vehicle identification number (VIN) is the only unmodifiable and therefore the most important
identification feature on the machine.
The vehicle identification number remains associated with the machine throughout the entire dura‐
tion of its service life. The vehicle identification number is stamped into the bodywork of the ma‐
chine.
Further information For the location of the VIN stamp, see chapter 13.1.
2.3 Options overview
A list of the options built into your machine helps to correlate the information in this Operating Man‐
ual.
Available options are listed on the options label (option: code letters).
This label can be found:
■ on the outside of the machine.
■ see chapter 13.1.
Only the codes for those options fitted appear on the options label!
Options fitted:
2 Technical Specifications
2.1 Nameplate
4
Operating Manual Portable Rotary Screw Compressor
MOBILAIR M27 PE No.: 9_9548 22 HCE

Fig. 1 Option label MOBILAIR M27 PE with options
r1 Place holders for chassis options
r2 Place holders for chassis options
r3 Place holders for chassis options
r4 Place holders for chassis options
➤ See the separate document "Chassis Operating Manual" for information about the option co‐
des.
➤ Take a list of available options from the options label and enter these options as reference in
the below overviews.
2.3.1 Option da, db, dd
Air Treatment
Option Option code Available?
Aftercooler and water separator da
Heat exchanger db
Filter combination dd
Tab. 4 Air treatment options
2.3.2 Option ea, ec
Tool lubricator
Option Option code Available?
Tool lubricator (with option fa) ea
Tool lubricator (with option fc) ec
Tab. 5 Tool lubricator option
2.3.3 Option fa, fc
Compressed air distributor
Option Option code Available?
Non-separated compressed air distribution line fa
2 Technical Specifications
2.3 Options overview
No.: 9_9548 22 HCE
Operating Manual Portable Rotary Screw Compressor
MOBILAIR M27 PE 5

Option Option code Available?
Separated compressed air lines downstream of the
option
fc
Tab. 6 Compressed air distributor option
2.3.4 Option ca, cb
Proportional controller
Option Option code Available?
Without manual adjustment ca
With manual adjustment cb
Tab. 7 Proportional controller options
2.3.5 Option ha
Non-return function
Option Option code Available?
Check valve ha
Tab. 8 Non-return option
2.3.6 Option ba
Low temperature equipment
Option Option code Available?
Low temperature equipment ba
Coolant pre-heating bb
Defroster bc
Tab. 9 Low temperature equipment options
2.3.7 Option la, lb
Equipment for fire hazard areas
Option Option code Available?
Spark arrestor la
Spark arrestor and engine air intake shut-off valve
(automatic)
lb
Tab. 10 Optional equipment for fire hazard areas
2 Technical Specifications
2.3 Options overview
6
Operating Manual Portable Rotary Screw Compressor
MOBILAIR M27 PE No.: 9_9548 22 HCE

2.3.8 Option ne
Fuel de-watering filter
Option Option code Available?
Fuel de-watering filter ne
Tab. 11 Fuel de-watering filter option
2.3.9 Option oa
Battery isolating switch
Option Option code Available?
Battery isolating switch oa
Tab. 12 Optional battery isolating switch
2.3.10 Option ga, gb
Generator
Option Option code Available?
Machine without flow rate limiter with generator in
operation
ga
Machine with flow rate limiter with generator in oper‐
ation
gb
Tab. 13 Generator option
2.3.11 Option rb/rm/rr, rb/rm/rs, rc/ro/rr, rc/ro/rs, rg/rp/rr, rd/ro/rr, rd/rn/rr
Chassis
Chassis are defined by a combination of several option codes, as follows:
Version/Axle load/Height adjustment/Anti-twist protection/Service brake
Example: rb/rm/rs means:
Chassis is European version, with height adjustment and overrun brake
Chassis:
Chassis Code Available?
Version (rb, rc, rg, rd):
EU chassis rb
GB chassis rc
EN chassis rg
US chassis rd
Height adjustment (rm, rn, ro):
With height adjustment rm
Adjustable coupling height rn
EU ≙ Europe, GB ≙ Great Britain, EN ≙ England, US ≙ United States of America
2 Technical Specifications
2.3 Options overview
No.: 9_9548 22 HCE
Operating Manual Portable Rotary Screw Compressor
MOBILAIR M27 PE 7

Chassis Code Available?
Without height adjustment ro
Anti-twist protection, tow bar tube (rp)
Rotatable adapter rp
Service brake (rr, rs):
Without service brake rr
With overrun brake rs
Axle load (rk, rl)
Low rk
High rl
EU ≙ Europe, GB ≙ Great Britain, EN ≙ England, US ≙ United States of America
Tab. 14 Chassis options
2.3.12 Option tb, tc, te
Lighting
Option Option code Available?
Reflective warning triangle tb
EG - 12 V tc
USA - 12 V (DOT conformity) te
Tab. 15 Lighting options
2.3.13 Option oe
Sealed floor pan
Option Option code Available?
Sealed floor pan oe
Tab. 16 Closed floor pan option
2.3.14 Option ua
Hose reels
Option Option code Available?
Hose reels ua
Tab. 17 Hose reel option
2.3.15 Option sf
Anti-theft device
Option Option code Available?
Anti-theft device sf
Tab. 18 Optional anti-theft device
2 Technical Specifications
2.3 Options overview
8
Operating Manual Portable Rotary Screw Compressor
MOBILAIR M27 PE No.: 9_9548 22 HCE