KAESER KOMPRESSOREN MOBILAIR M27 User manual

Operator Manual
Screw Compressor
MOBILAIR M27
No.: 9_9547 13 USE
Manufacturer:
KAESER KOMPRESSOREN SE
96410 Coburg • PO Box 2143 • GERMANY • Tel. [phone] • Fax [phone]
http://www.kaeser.com

Original instructions
/KKW/M27 2.13 en Z1 SBA-MOBILAIR
20180522 100010

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 Data
2.1 Nameplate ........................................................................................................................ 4
2.2 Options ............................................................................................................................. 4
2.2.1 Air Treatment ...................................................................................................... 5
2.2.2 Tool lubricator ..................................................................................................... 5
2.2.3 Compressed air distributor .................................................................................. 5
2.2.4 Non-return function ............................................................................................. 6
2.2.5 Low temperature equipment ............................................................................... 6
2.2.6 Equipment for fire hazard areas ......................................................................... 6
2.2.7 Fuel de-watering filter ......................................................................................... 6
2.2.8 Battery isolating switch ....................................................................................... 6
2.2.9 Generator ............................................................................................................ 7
2.2.10 Chassis ............................................................................................................... 7
2.2.11 Lighting ............................................................................................................... 7
2.2.12 Frame design for stationary machines ................................................................ 8
2.2.13 Sealed floor pan .................................................................................................. 8
2.2.14 Hose reels ........................................................................................................... 8
2.2.15 Anti-theft device .................................................................................................. 8
2.3 Machine (without options) ................................................................................................ 9
2.3.1 Sound pressure level .......................................................................................... 9
2.3.2 Tightening torques for screws ............................................................................. 9
2.3.3 Ambient conditions ............................................................................................. 9
2.3.4 Additional specifications ..................................................................................... 10
2.4 Chassis ............................................................................................................................ 10
2.4.1 Chassis options .................................................................................................. 10
2.5 Machines with stationary frame design ............................................................................ 10
2.5.1 Weight of machines with stationary frame design .............................................. 10
2.6 Compressor ...................................................................................................................... 10
2.6.1 Working pressure and FAD ................................................................................ 10
2.6.2 Compressed air outlet ......................................................................................... 11
2.6.3 Air quality at the compressed air outlets ............................................................. 11
2.6.4 Safety relief valve ............................................................................................... 12
2.6.5 Select temperature ............................................................................................. 12
2.6.6 Cooling oil recommendation ............................................................................... 12
2.6.7 Cooling oil charge ............................................................................................... 14
2.7 Engine .............................................................................................................................. 14
2.7.1 Engine data ......................................................................................................... 14
2.7.2 Oil recommendation ............................................................................................ 14
2.7.3 Fuel recommendation ......................................................................................... 15
2.7.4 Engine coolant recommendation ........................................................................ 15
2.7.5 Fluid volumes ...................................................................................................... 16
2.7.6 Batteries .............................................................................................................. 16
2.8 Options ............................................................................................................................. 17
2.8.1 Tool lubricator ..................................................................................................... 17
2.8.2 Low temperature equipment ............................................................................... 17
2.8.3 Generator ............................................................................................................ 18
Contents
No.: 9_9547 13 USE
Operator Manual Screw Compressor
MOBILAIR M27 i

2.8.4 Air hose with hose reel ....................................................................................... 22
3 Safety and Responsibility
3.1 Basic instructions ............................................................................................................. 23
3.2 Specified use .................................................................................................................... 23
3.3 Incorrect Use .................................................................................................................... 23
3.4 User's Responsibilities ..................................................................................................... 23
3.4.1 Observe statutory and universally accepted regulations .................................... 23
3.4.2 Determining personnel ........................................................................................ 24
3.4.3 Adherence to inspection schedules and accident prevention regulations .......... 24
3.5 Dangers ............................................................................................................................ 24
3.5.1 Safely dealing with sources of danger ................................................................ 25
3.5.2 Safe machine operation ...................................................................................... 27
3.5.3 Organizational Measures .................................................................................... 31
3.5.4 Danger areas ...................................................................................................... 31
3.6 Safety devices .................................................................................................................. 31
3.7 Safety signs ...................................................................................................................... 31
3.8 Generator operation ......................................................................................................... 35
3.8.1 Comply with the protective measures against dangerous electric current ......... 35
3.8.2 Instructions for safe generator operation ............................................................ 35
3.8.3 Connecting extension cables .............................................................................. 35
3.8.4 Do not exceed the maximum supply system load .............................................. 36
3.8.5 Perform regular generator inspections ............................................................... 36
3.9 Emergency situations ....................................................................................................... 36
3.9.1 Correct fire fighting ............................................................................................. 36
3.9.2 Injury from handling operating fluids/materials ................................................... 37
3.10 Warranty ........................................................................................................................... 37
3.11 Environmental protection ................................................................................................. 38
4 Design and Function
4.1 Bodywork ......................................................................................................................... 39
4.2 Component identification .................................................................................................. 40
4.3 Machine function .............................................................................................................. 41
4.4 Operating modes and control mode ................................................................................. 42
4.4.1 Machine operating modes .................................................................................. 42
4.4.2 MODULATING control ........................................................................................ 42
4.5 Safety devices .................................................................................................................. 43
4.5.1 Monitoring functions with shutdown .................................................................... 43
4.5.2 Further safety devices ........................................................................................ 43
4.6 Options ............................................................................................................................. 43
4.6.1 Air treatment options ........................................................................................... 43
4.6.2 Generator option ................................................................................................. 45
4.6.3 Low temperature equipment options .................................................................. 47
4.6.4 Options for operating in fire hazard areas .......................................................... 49
4.6.5 Fuel de-watering filter option .............................................................................. 50
4.6.6 Sealed floor pan option ....................................................................................... 50
4.6.7 Battery isolating switch option ............................................................................ 50
4.6.8 Hose reel option .................................................................................................. 51
4.6.9 Anti-theft device option ....................................................................................... 51
4.7 Frame design options for stationary machines ................................................................ 52
4.7.1 Chassis types of stationary machines ................................................................ 52
5 Installation and Operating Conditions
5.1 Ensuring safety ................................................................................................................ 53
5.2 Installation conditions ....................................................................................................... 53
5.3 Requirements for positioning on a lorry platform ............................................................. 55
Contents
ii
Operator Manual Screw Compressor
MOBILAIR M27 No.: 9_9547 13 USE

6 Installation
6.1 Ensuring safety ................................................................................................................ 56
6.2 Reporting Transport Damage ........................................................................................... 56
6.3 Installing the options ........................................................................................................ 56
6.3.1 Fastening a stationary machine .......................................................................... 56
7 Initial Start-up
7.1 Ensuring safety ................................................................................................................ 58
7.2 Before initial start-up (or recommissioning) ...................................................................... 58
7.2.1 Instructions to be observed before commissioning or recommissioning ............ 58
7.2.2 Special measures for recommissioning after storage ......................................... 59
7.3 Checking installation and operating conditions ................................................................ 59
7.4 Low-temperature operation (winter) ................................................................................. 60
7.4.1 Starting assistance ............................................................................................. 60
7.4.2 Starting up low-temperature equipment .............................................................. 62
7.5 Activating the generator ................................................................................................... 63
7.5.1 Generator control box 400V with insulation monitoring ...................................... 64
7.5.2 Generator control box 115V with insulation monitoring ...................................... 64
7.5.3 Testing the insulation monitor ............................................................................. 64
8 Operation
8.1 Ensuring safety ................................................................................................................ 66
8.2 Starting and stopping ....................................................................................................... 67
8.2.1 Commissioning the machine ............................................................................... 67
8.2.2 Starting the machine ........................................................................................... 68
8.2.3 Allow the machine to run up to operating temperature ....................................... 68
8.2.4 Running the machine under load ........................................................................ 68
8.2.5 Shutting down the machine ................................................................................ 69
8.3 Ending the reverse engine run ......................................................................................... 69
8.4 Cleaning the machine after operation .............................................................................. 69
8.5 Operating the options ....................................................................................................... 70
8.5.1 Operating the battery isolating switch ................................................................. 70
8.5.2 Operating the tool lubricator ............................................................................... 71
8.5.3 Using the low-temperature equipment ................................................................ 72
8.5.4 Generator operation ............................................................................................ 74
8.5.5 Using the hose reel ............................................................................................. 76
9 Fault Recognition and Rectification
9.1 Basic instructions ............................................................................................................. 78
9.2 Evaluating engine faults and alarms ................................................................................ 78
9.2.1 Engine refuses to start or does not turn over ...................................................... 78
9.2.2 Engine does not reach full speed ....................................................................... 79
9.2.3 Indicator lamp remains on .................................................................................. 79
9.2.4 Engine running backwards ................................................................................. 80
9.3 Compressor faults and alarms ......................................................................................... 80
9.3.1 Working pressure too high .................................................................................. 80
9.3.2 Working pressure too low ................................................................................... 80
9.3.3 Safety relief valve blowing off ............................................................................. 81
9.3.4 Machine overheating .......................................................................................... 81
9.3.5 Too much oil residue in the compressed air ....................................................... 82
9.3.6 Oil flows from the compressor air filter after shutdown ....................................... 82
9.3.7 High moisture content in the compressed air ..................................................... 83
9.4 Generator faults and alarms ............................................................................................. 83
9.4.1 No voltage or too low a voltage from the generator ............................................ 83
9.4.2 Generator voltage too high ................................................................................. 83
Contents
No.: 9_9547 13 USE
Operator Manual Screw Compressor
MOBILAIR M27 iii

10 Maintenance
10.1 Ensuring safety ................................................................................................................ 85
10.2 Following the maintenance plans ..................................................................................... 87
10.2.1 Logging maintenance work ................................................................................. 87
10.2.2 Maintenance tasks after commissioning ............................................................. 87
10.2.3 Regular maintenance tasks ................................................................................ 87
10.3 Drive engine maintenance ............................................................................................... 93
10.3.1 Water cooler maintenance .................................................................................. 93
10.3.2 Engine air filter maintenance .............................................................................. 97
10.3.3 Fuel system maintenance ................................................................................... 100
10.3.4 Changing the engine oil ...................................................................................... 107
10.3.5 Changing the engine oil filter .............................................................................. 110
10.3.6 Drive belt maintenance ....................................................................................... 111
10.3.7 Having the anti-vibration mount checked ............................................................ 113
10.3.8 Battery maintenance ........................................................................................... 113
10.3.9 Checking the fastening of the fuel tank .............................................................. 116
10.4 Compressor Maintenance ................................................................................................ 117
10.4.1 Checking cooling oil level ................................................................................... 117
10.4.2 Filling or topping off the cooling oil ..................................................................... 118
10.4.3 Changing the cooling oil ..................................................................................... 119
10.4.4 Replacing the compressor oil filter ...................................................................... 123
10.4.5 Oil separator tank dirt trap maintenance ............................................................. 124
10.4.6 Changing the oil separator cartridge ................................................................... 126
10.4.7 Compressor air filter maintenance ...................................................................... 128
10.4.8 Checking safety relief valves .............................................................................. 130
10.5 Cooler maintenance ......................................................................................................... 131
10.5.1 Cleaning the compressor cooler and engine radiator ......................................... 131
10.6 Checking the enclosure .................................................................................................... 133
10.6.1 Check sound proofing material ........................................................................... 134
10.6.2 Maintain rubber sealing strips. ............................................................................ 134
10.6.3 Checking function of closed enclosure ............................................................... 134
10.6.4 Checking connecting elements of enclosure ...................................................... 134
10.7 Check/replace hose lines ................................................................................................. 135
10.7.1 Replace the fuel lines of the drive engine ........................................................... 136
10.7.2 Replace the pressure hoses of the drive engine ................................................ 136
10.7.3 Replace the pressure hoses of the compressor ................................................. 136
10.8 Maintenance for Optional Items ....................................................................................... 136
10.8.1 Tool lubricator maintenance ............................................................................... 136
10.8.2 Compressed air aftercooler maintenance ........................................................... 138
10.8.3 Compressed air water separator maintenance ................................................... 140
10.8.4 Combination filter maintenance .......................................................................... 142
10.8.5 Frost protector maintenance ............................................................................... 146
10.8.6 Engine air intake shut-off valve maintenance ..................................................... 147
10.8.7 Draining liquid accumulation within the machine ................................................ 149
10.8.8 Generator drive belt maintenance ...................................................................... 149
10.9 Documenting maintenance and service work .................................................................. 152
11 Spares, Operating Materials, Service
11.1 Note the nameplate .......................................................................................................... 153
11.2 Ordering consumable parts and operating fluids/materials .............................................. 153
11.3 KAESER AIR SERVICE ................................................................................................... 154
11.4 Replacement parts for service and repair ........................................................................ 154
12 Decommissioning, Storage and Transport
12.1 De-commissioning ............................................................................................................ 201
Contents
iv
Operator Manual Screw Compressor
MOBILAIR M27 No.: 9_9547 13 USE

12.1.1 Temporary de-commissioning ............................................................................ 201
12.1.2 Long-term decommissioning and storage ........................................................... 202
12.2 Transport .......................................................................................................................... 203
12.2.1 Safety .................................................................................................................. 203
12.2.2 Transporting with a crane ................................................................................... 204
12.2.3 Transport with a forklift truck ............................................................................... 204
12.2.4 Transporting as load ........................................................................................... 206
12.3 Storage ............................................................................................................................. 209
12.4 Disposal ........................................................................................................................... 209
13 Annex
13.1 Identification ..................................................................................................................... 210
13.2 Pipeline and instrument flow diagram (P+I diagram) ....................................................... 210
13.3 Dimensional drawings ...................................................................................................... 215
13.3.1 Dimensional drawing – chassis ........................................................................... 215
13.3.2 Dimensional drawing – chassis ........................................................................... 217
13.3.3 Dimensional drawing – chassis ........................................................................... 219
13.3.4 Dimensional drawing – chassis ........................................................................... 221
13.3.5 Dimensional drawing – chassis ........................................................................... 223
13.3.6 Dimensional drawing – chassis ........................................................................... 225
13.3.7 Dimensional drawing, stationary machine (skids) ............................................... 227
13.3.8 Dimensional drawing, stationary version (frame) ................................................ 229
13.4 Wiring diagrams ............................................................................................................... 231
13.4.1 Electrical Diagram ............................................................................................... 231
13.4.2 Generator electrical diagram, 400V, 3-ph ........................................................... 241
13.4.3 Generator electrical diagram, 115 V, 2-ph .......................................................... 247
13.4.4 Lighting and signaling system connection .......................................................... 252
13.4.5 Lighting and signaling system connection .......................................................... 257
13.5 Fuel circulation diagram ................................................................................................... 262
13.6 Maintenance tasks for the generator ................................................................................ 265
13.7 Operating instructions for compressed air filter (combination filter) ................................. 265
Contents
No.: 9_9547 13 USE
Operator Manual Screw Compressor
MOBILAIR M27 v

Contents
vi
Operator Manual Screw Compressor
MOBILAIR M27 No.: 9_9547 13 USE

Fig. 1 Location of safety signs .............................................................................................................. 32
Fig. 2 Bodywork .................................................................................................................................... 39
Fig. 3 Side view (canopy removed) ...................................................................................................... 40
Fig. 4 Machine overview ....................................................................................................................... 41
Fig. 5 Compressed air options ............................................................................................................. 44
Fig. 6 Tool lubricator ............................................................................................................................. 45
Fig. 7 Instrument panel, generator control box 400 V/3~/N/PE, 50 Hz ................................................ 47
Fig. 8 Instrument panel, generator control box 115 V/1~/N/PE, 50 Hz, 32 A ....................................... 47
Fig. 9 Coolant pre-heating .................................................................................................................... 48
Fig. 10 Frost protector ............................................................................................................................ 49
Fig. 11 Battery isolating switch ............................................................................................................... 51
Fig. 12 Container for safety chain .......................................................................................................... 51
Fig. 13 Minimum distance from excavations, slopes, or walls ................................................................ 54
Fig. 14 Fitting the Mounting Pads ........................................................................................................... 57
Fig. 15 Jumper cable connection diagram ............................................................................................. 61
Fig. 16 Coolant pre-heating .................................................................................................................... 63
Fig. 17 Insulation monitoring – 400V, 3-phase generator ....................................................................... 64
Fig. 18 Insulation monitoring - 115V, single-phase generator ................................................................ 64
Fig. 19 Starting instruments ................................................................................................................... 67
Fig. 20 Warm-up period when ambient temperatures are below 14 °F .................................................. 68
Fig. 21 Battery isolating switch ............................................................................................................... 71
Fig. 22 Adjusting the tool lubricator ........................................................................................................ 72
Fig. 23 Frost protector on and off ........................................................................................................... 73
Fig. 24 Generator cut-in pictogram ......................................................................................................... 75
Fig. 25 Hose reel .................................................................................................................................... 76
Fig. 26 Checking the coolant level ......................................................................................................... 94
Fig. 27 Recommended mixture ratio for coolant .................................................................................... 95
Fig. 28 Draining the coolant ................................................................................................................... 97
Fig. 29 Maintenance indicator ................................................................................................................ 98
Fig. 30 Engine air filter maintenance ...................................................................................................... 99
Fig. 31 Cleaning the filter element .......................................................................................................... 99
Fig. 32 Bleeding the fuel system ............................................................................................................ 102
Fig. 33 Fuel pre-filter maintenance ......................................................................................................... 102
Fig. 34 Changing the filter cartridge ....................................................................................................... 103
Fig. 35 Fuel water separator .................................................................................................................. 104
Fig. 36 Fuel water separator .................................................................................................................. 106
Fig. 37 Changing the engine oil .............................................................................................................. 108
Fig. 38 Oil drain valve ............................................................................................................................. 108
Fig. 39 Changing the engine oil filter ...................................................................................................... 110
Fig. 40 Checking belt tension by hand ................................................................................................... 112
Fig. 41 Example for anti-vibration mount of drive engine ....................................................................... 113
Fig. 42 Safety signs - warning stickers on the battery ............................................................................ 114
Fig. 43 Checking cooling oil level ........................................................................................................... 118
Fig. 44 Plugs, oil separator tank ............................................................................................................. 120
Fig. 45 Draining the compressor cooling oil ........................................................................................... 121
Fig. 46 Changing the oil filter .................................................................................................................. 123
Fig. 47 Oil separator tank dirt trap maintenance .................................................................................... 125
Fig. 48 Changing the oil separator cartridge .......................................................................................... 126
Fig. 49 Maintenance indicator ................................................................................................................ 129
Fig. 50 Compressor air filter maintenance ............................................................................................. 130
Fig. 51 Cleaning the cooler .................................................................................................................... 132
Fig. 52 Connecting rod alignment .......................................................................................................... 135
Fig. 53 Tool lubricator maintenance ....................................................................................................... 137
Fig. 54 Cleaning the compressed air after-cooler .................................................................................. 139
List of Illustrations
No.: 9_9547 13 USE
Operator Manual Screw Compressor
MOBILAIR M27 vii

Fig. 55 Cleaning the dirt trap .................................................................................................................. 141
Fig. 56 Combination filter maintenance .................................................................................................. 143
Fig. 57 Changing the prefilter element ................................................................................................... 144
Fig. 58 Filter combination ....................................................................................................................... 145
Fig. 59 Filling the frost protector ............................................................................................................. 147
Fig. 60 Engine air intake shut-off valve maintenance ............................................................................. 148
Fig. 61 Replacing the generator belt ...................................................................................................... 150
Fig. 62 Preparing for transport using a forklift truck ............................................................................... 205
Fig. 63 Lifting the machine with a forklift truck ....................................................................................... 205
Fig. 64 Transport with a forklift truck ...................................................................................................... 206
Fig. 65 Bracket systems as load securing (machine with chassis) ........................................................ 208
Fig. 66 Bracket systems as load securing (machine in stationary frame-type design) ........................... 208
Fig. 67 Identification ............................................................................................................................... 210
List of Illustrations
viii
Operator Manual Screw Compressor
MOBILAIR M27 No.: 9_9547 13 USE

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 Options label .............................................................................................................................. 5
Tab. 5 Air treatment options .................................................................................................................. 5
Tab. 6 Tool lubricator option .................................................................................................................. 5
Tab. 7 Compressed air distributor option .............................................................................................. 5
Tab. 8 Non-return option ....................................................................................................................... 6
Tab. 9 Low temperature equipment options .......................................................................................... 6
Tab. 10 Optional equipment for fire hazard areas ................................................................................... 6
Tab. 11 Option ne: Fuel de-watering filter .............................................................................................. 6
Tab. 12 Battery isolating switch option .................................................................................................... 6
Tab. 13 Generator option ........................................................................................................................ 7
Tab. 14 Chassis options .......................................................................................................................... 7
Tab. 15 Lighting options .......................................................................................................................... 7
Tab. 16 Options for stationary frame design ........................................................................................... 8
Tab. 17 Sealed floor pan option .............................................................................................................. 8
Tab. 18 Hose reel option ......................................................................................................................... 8
Tab. 19 Anti-theft device option ............................................................................................................... 8
Tab. 20 Sound pressure level ................................................................................................................. 9
Tab. 21 Tightening torques for screws (property class 8.8, coefficient of friction µ = 0.12) .................... 9
Tab. 22 Torque cover fixing screws oil separator tank ............................................................................ 9
Tab. 23 Torques for lifting eye screws ..................................................................................................... 9
Tab. 24 Ambient conditions ..................................................................................................................... 9
Tab. 25 Weight of the machine ................................................................................................................ 10
Tab. 26 Working gauge pressure and FAD ............................................................................................. 10
Tab. 27 Compressed air distributor ......................................................................................................... 11
Tab. 28 Interrelation between compressed air treatment and compressed air quality ............................ 11
Tab. 29 Relief valve activating pressure .................................................................................................. 12
Tab. 30 Machine temperatures ................................................................................................................ 12
Tab. 31 Airend package discharge temperature ..................................................................................... 12
Tab. 32 Cooling oil recommendation ....................................................................................................... 12
Tab. 33 Cooling oil recommendation (food processing) .......................................................................... 13
Tab. 34 Cooling oil charge ....................................................................................................................... 14
Tab. 35 Engine data ................................................................................................................................ 14
Tab. 36 Engine oil recommendation ........................................................................................................ 14
Tab. 37 Water quality parameters for cooling water ................................................................................ 15
Tab. 38 Initial filling of engine water cooler ............................................................................................. 16
Tab. 39 Fluid volumes ............................................................................................................................. 16
Tab. 40 Batteries ..................................................................................................................................... 16
Tab. 41 Road breaker lubricant recommendation ................................................................................... 17
Tab. 42 Ambient conditions, low temperature equipment ....................................................................... 17
Tab. 43 Coolant pre-heater ..................................................................................................................... 17
Tab. 44 Recommended anti-freeze ......................................................................................................... 17
Tab. 45 Generator data, 400V ................................................................................................................. 18
Tab. 46 Compressed air delivery in generator mode .............................................................................. 18
Tab. 47 Connection sockets .................................................................................................................... 19
Tab. 48 Circuit breaker ............................................................................................................................ 19
Tab. 49 Maximum 3-phase power supply ................................................................................................ 19
Tab. 50 Maximum single phase power supply ........................................................................................ 19
Tab. 51 Generator data 115V .................................................................................................................. 20
Tab. 52 Compressed air delivery in generator mode .............................................................................. 20
Tab. 53 Connection sockets .................................................................................................................... 21
Tab. 54 Circuit breaker ............................................................................................................................ 21
List of Tables
No.: 9_9547 13 USE
Operator Manual Screw Compressor
MOBILAIR M27 ix

Tab. 55 Maximum single-phase power supply loading ............................................................................ 21
Tab. 56 Generator operating limits .......................................................................................................... 21
Tab. 57 Output power reduction .............................................................................................................. 22
Tab. 58 Additional discharge valve for the air hose ................................................................................. 22
Tab. 59 Danger areas .............................................................................................................................. 31
Tab. 60 Safety signs ................................................................................................................................ 32
Tab. 61 Generator mode selector switch ................................................................................................. 46
Tab. 62 Generator operating modes ....................................................................................................... 46
Tab. 63 Stationary machines ................................................................................................................... 52
Tab. 64 Special measures for recommissioning after storage ................................................................ 59
Tab. 65 Checking installation and operating conditions .......................................................................... 59
Tab. 66 Low-temperature equipment checklist ........................................................................................ 63
Tab. 67 Test instructions for a generator with a ground leak detection device. ...................................... 65
Tab. 68 Fault: engine refuses to start or comes to a stop. ...................................................................... 78
Tab. 69 Alarm: "engine does not reach full speed". ................................................................................ 79
Tab. 70 Alarm: "Control lamp remains on" .............................................................................................. 79
Tab. 71 Fault "Motor running backwards" ............................................................................................... 80
Tab. 72 Alarm: Working pressure too high .............................................................................................. 80
Tab. 73 Alarm: Working pressure too low ............................................................................................... 80
Tab. 74 Alarm: Safety relief valve blowing off ......................................................................................... 81
Tab. 75 Alarm: Machine overheating ....................................................................................................... 81
Tab. 76 Fault: Too much oil residue in the compressed air ..................................................................... 82
Tab. 77 Fault: Oil flows from the compressor air filter after shutdown .................................................... 82
Tab. 78 Fault: High moisture content in the compressed air ................................................................... 83
Tab. 79 Fault: No voltage or too low a voltage from the generator ......................................................... 83
Tab. 80 Fault: Generator voltage too high ............................................................................................... 83
Tab. 81 Advise others that the machine is being serviced. ..................................................................... 85
Tab. 82 Maintenance tasks after commissioning .................................................................................... 87
Tab. 83 Maintenance intervals and regular maintenance tasks .............................................................. 87
Tab. 84 Regular machine maintenance tasks ......................................................................................... 88
Tab. 85 Regular maintenance tasks for options ...................................................................................... 91
Tab. 86 Coolant mixture table ................................................................................................................. 96
Tab. 87 Oil drain valve ............................................................................................................................. 109
Tab. 88 Oil drain valve ............................................................................................................................. 121
Tab. 89 Maintenance log ......................................................................................................................... 152
Tab. 90 Compressor spare parts ............................................................................................................. 153
Tab. 91 Engine spare parts ..................................................................................................................... 153
Tab. 92 "Temporarily decommissioned" information notice .................................................................... 201
Tab. 93 "Long-term decommissioning and storage" checklist ................................................................. 202
Tab. 94 “Long-term decommissioning and storage” information notice .................................................. 203
List of Tables
x
Operator Manual Screw Compressor
MOBILAIR M27 No.: 9_9547 13 USE

1 Regarding this Document
1.1 Using this document
The operating manual is a component of the product. It describes the machine as it was at the time
of first delivery after manufacture.
➤ Keep the operating manual in a safe place throughout the life of the machine.
➤ Supply any successive owner or user with this operating manual.
➤ Please insert any amendment or revision of the operating manual sent to you.
➤ Enter details from the machine nameplate and individual items of equipment in the table in
chapter 2.
1.2 Further documents
Further documents included with this operating manual are:
■ Certificate of acceptance / operating instructions for the pressure vessel
■ 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 operator manual is copyright protected. Queries regarding use or duplication of the documen‐
tation should be referred to KAESER. Correct use of information will be fully supported.
1.4 Symbols and labels
➤ Please note the symbols and labels used in this document.
1.4.1 Warnings
Warning notices indicate 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 ignoring the warning
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_9547 13 USE
Operator Manual Screw Compressor
MOBILAIR M27 1

Some warning notes may precede a chapter. They apply to the entire chapter including all sub-sec‐
tions.
Example:
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.
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:
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
Operator Manual Screw Compressor
MOBILAIR M27 No.: 9_9547 13 USE

➤ 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 2.2.
Information referring to potential problems is identified by a question mark.
The cause is named in the help text ...
➤ ... and a remedy given.
This symbol refers to important information or measures concerning environmental protec‐
tion.
Further information Further topics are introduced here.
1 Regarding this Document
1.4 Symbols and labels
No.: 9_9547 13 USE
Operator Manual Screw Compressor
MOBILAIR M27 3
Option da

2 Technical Data
2.1 Nameplate
The machine's nameplate provides the model designation and important technical information.
The nameplate is located on the outside of the machine (see illustration in chapter 13.1).
➤ Enter the nameplate data here as a reference:
Feature Value
Vehicle Identification No.
Permissible total weight
Permissible coupling load
Permissible axle load
Portable compressor
Part no.
Serial no.
Year of manufacture
Total weight
Lifting point load capacity
Rated engine power
Engine speed
Maximum working pressure
Tab. 3 Nameplate
2.2 Options
A list of the options fitted to your machine helps to relate the information in this service manual.
Options fitted to the machine are listed on the options label (as code letters).
The nameplate can be found:
■ On the outside of the machine
■ On the front of the machine (see chapter 13.1)
The following table lists all possible options.
Only the codes for those options fitted on the machine appear on the nameplate.
2 Technical Data
2.1 Nameplate
4
Operator Manual Screw Compressor
MOBILAIR M27 No.: 9_9547 13 USE

MOBILAIR M27 Part Number Serial no.
Options fitted
02-M0277
r1= rb; rc; rd; rg
r3= rm; ro
r4= rr; rs; rt
r5= rw; rx
*
tctbta
r5r4r3r1
ba
oa
bb bc
la lb
gb
oe
ne
te
da db
ea
fa
sf
ha
ua
*r1 - r5 = place holders for chassis options
Tab. 4 Options label
➤ Take note of fitted options from the options label and enter them here for reference.
2.2.1 Option da, db, dd
Air Treatment
Option Option code Available?
Aftercooler and water separator da
Heat exchanger db
Filter combination dd
Tab. 5 Air treatment options
2.2.2 Option ea, ec
Tool lubricator
Option Option code Available?
Tool lubricator (with option fa) ea
Tool lubricator (with option fc) ec
Tab. 6 Tool lubricator option
2.2.3 Option fa, fc
Compressed air distributor
Option Option code Available?
Non-separated compressed air distribution line fa
2 Technical Data
2.2 Options
No.: 9_9547 13 USE
Operator Manual Screw Compressor
MOBILAIR M27 5

Option Option code Available?
Separated compressed air distribution lines, down‐
stream of the option
fc
Tab. 7 Compressed air distributor option
2.2.4 Option ha
Non-return function
Option Option code Available?
Check valve ha
Tab. 8 Non-return option
2.2.5 Option ba
Low temperature equipment
Option Option code Available?
Low temperature equipment ba
Engine coolant pre-heating bb
Defroster bc
Tab. 9 Low temperature equipment options
2.2.6 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
2.2.7 Option ne
Fuel de-watering filter
Option Option code Equipped?
Fuel de-watering filter ne
Tab. 11 Option ne: Fuel de-watering filter
2.2.8 Option oa
Battery isolating switch
Option Option code Available?
Battery isolating switch oa
Tab. 12 Battery isolating switch option
2 Technical Data
2.2 Options
6
Operator Manual Screw Compressor
MOBILAIR M27 No.: 9_9547 13 USE

2.2.9 Option ga, gb
Generator
Option Option code Available?
Machine without FAD limitation with generator in op‐
eration
ga
Machine with FAD limitation with generator in opera‐
tion
gb
Tab. 13 Generator option
2.2.10 Option rb/rm/rr, rb/rm/rs, rc/ro/rr, rg/rp/rr, rc/ro/rs, rd/ro/rr, rd/rn/rr
Chassis
Chassis are defined by the combination of several option designations as follows:
Model/Height adjustment/Anti-twist protection/Service brake
Example: rb/rm/rs means:
Chassis in European design, with height adjustment and overrun brake.
Chassis
Chassis Option code Available?
Model (rb, rc, rd):
EG chassis rb
GB chassis rc
GB chassis rg
USA chassis rd
Height adjustment (rm, rn, ro):
With height adjustment rm
Ajustable coupling height rn
Without height adjustment ro
Anti-twist protection, tow bar tube (rp)
Adapter, mounted rotatable rp
Service brake (rr, rs):
Without service brake rr
With overrun brake rs
EC = Europe, GB = Great Britain, US = United States of America
Tab. 14 Chassis options
2.2.11 Option ta, tb, tc, te
Lighting
Option Option code Available?
None (stationary) ta
Reflective warning triangle tb
2 Technical Data
2.2 Options
No.: 9_9547 13 USE
Operator Manual Screw Compressor
MOBILAIR M27 7

Option Option code Available?
EG - 12 V tc
USA - 12 V (DOT conformity) te
Tab. 15 Lighting options
2.2.12 Option rw,rx
Frame design for stationary machines
The frame design for stationary machines is defined by the option designations as follows:
Frame designs
Frame Option code Equipped?
Stationary (rw, rx):
On skids rw
On frame rx
Tab. 16 Options for stationary frame design
2.2.13 Option oe
Sealed floor pan
Option Option code Available?
Sealed floor pan oe
Tab. 17 Sealed floor pan option
2.2.14 Option ua
Hose reels
Option Option code Available?
Hose reels ua
Tab. 18 Hose reel option
2.2.15 Option sf
Anti-theft device
Option Option code Available?
Anti-theft device sf
Tab. 19 Anti-theft device option
2 Technical Data
2.2 Options
8
Operator Manual Screw Compressor
MOBILAIR M27 No.: 9_9547 13 USE