KAESER M122 User manual

Service manual
Portable compressor
M122
No.: 9_6974 20 E
Manufacturer:
KAESER KOMPRESSOREN GmbH
96410 Coburg • PO Box 2143 • GERMANY • Tel. [phone] • Fax [phone]
http://www.kaeser.com
RAMIRENT

Original instructions
/KKW/M122 2.00 en SBA-MOBILAIR
20110303 105803
RAMIRENT

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 alerts and their symbols ............................................................................ 2
2Technical Specifications
2.1 Nameplate ........................................................................................................................ 4
2.2 Options summary ............................................................................................................. 4
2.2.1 Compressed air treatment devices ..................................................................... 5
2.2.2 Tool lubricator ..................................................................................................... 5
2.2.3 Compressed air distributor .................................................................................. 5
2.2.4 Check valve function ........................................................................................... 6
2.2.5 Proportional controller ......................................................................................... 6
2.2.6 Low temperature equipment ............................................................................... 6
2.2.7 Diesel particulate filter ........................................................................................ 6
2.2.8 Equipment for fire hazard areas ......................................................................... 6
2.2.9 Battery isolating switch ....................................................................................... 7
2.2.10 Chassis ............................................................................................................... 7
2.2.11 Lighting ............................................................................................................... 7
2.2.12 Sealed floor pan .................................................................................................. 7
2.2.13 Anti-theft device .................................................................................................. 8
2.2.14 Pedestrian protection .......................................................................................... 8
2.2.15 Instrument panel cover ....................................................................................... 8
2.3 Machine (without options) ................................................................................................ 8
2.3.1 Sound emission ................................................................................................. 8
2.3.2 Torques ............................................................................................................... 9
2.3.3 Ambient conditions ............................................................................................. 9
2.3.4 Additional specifications according to the machine's operating licence ............. 9
2.4 Chassis ........................................................................................................................... 9
2.4.1 Mass ................................................................................................................... 9
2.4.2 Tyres ................................................................................................................... 10
2.4.3 Wheel nut/bolt tightening torque ......................................................................... 10
2.4.4 Towbar tightening torque .................................................................................... 10
2.5 Compressor ..................................................................................................................... 10
2.5.1 Working pressure and FAD ................................................................................ 10
2.5.2 Compressed air outlet ......................................................................................... 11
2.5.3 Pressure relief valves ......................................................................................... 11
2.5.4 Temperature ....................................................................................................... 11
2.5.5 Cooling oil recommendation ............................................................................... 11
2.5.6 Cooling oil charge ............................................................................................... 12
2.6 Engine ............................................................................................................................. 12
2.6.1 Engine data ......................................................................................................... 12
2.6.2 Oil recommendation ............................................................................................ 13
2.6.3 Recommended Cooling Fluid ............................................................................. 13
2.6.4 Fluid volumes ...................................................................................................... 14
2.6.5 Batteries .............................................................................................................. 14
2.7 Options ............................................................................................................................ 14
2.7.1 Tool lubricator ..................................................................................................... 14
2.7.2 Fresh air filter ...................................................................................................... 14
2.7.3 Low temperature equipment ............................................................................... 15
2.7.4 Diesel particulate filter ........................................................................................ 15
Contents
No.: 9_6974 20 E
Service manual Portable compressor
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RAMIRENT

3 Safety and Responsibility
3.1 Basic instructions ............................................................................................................. 17
3.2 Specified use .................................................................................................................... 17
3.3 Incorrect Use .................................................................................................................... 17
3.4 User's Responsibilities ..................................................................................................... 17
3.4.1 Observe statutory and universally accepted regulations .................................... 17
3.4.2 Determining personnel ........................................................................................ 18
3.4.3 Adherence to inspection schedules and accident prevention regulations .......... 18
3.4.4 Complying with inspection intervals for diesel particulate filters ......................... 19
3.5 Dangers ............................................................................................................................ 19
3.5.1 Safely dealing with sources of danger ................................................................ 19
3.5.2 Safe machine operation ...................................................................................... 22
3.5.3 Organisational Measures .................................................................................... 25
3.5.4 Danger areas ...................................................................................................... 25
3.6 Safety devices .................................................................................................................. 25
3.7 Safety signs ...................................................................................................................... 26
3.8 Emergencies .................................................................................................................... 28
3.8.1 Correct fire fighting ............................................................................................. 28
3.8.2 Injury from handling operating fluids/materials ................................................... 28
3.9 Warranty ........................................................................................................................... 29
3.10 Environment protection .................................................................................................... 29
4 Design and Function
4.1 Bodywork ......................................................................................................................... 31
4.2 Machine installation .......................................................................................................... 32
4.3 Machine function .............................................................................................................. 32
4.4 Operating modes and control modes ............................................................................... 34
4.4.1 Operating modes ................................................................................................ 34
4.4.2 PART LOAD control ............................................................................................ 34
4.5 Safety devices .................................................................................................................. 35
4.5.1 Monitoring functions with shutdown .................................................................... 35
4.5.2 Further safety devices ........................................................................................ 36
4.6 Fuel level monitoring ........................................................................................................ 36
4.6.1 Fuel level monitoring ........................................................................................... 36
4.6.2 Fuel pre-filter level monitoring ............................................................................ 37
4.7 Options ............................................................................................................................. 37
4.7.1 Compressed air treatment options ...................................................................... 37
4.7.2 Low temperature equipment options .................................................................. 39
4.7.3 Optional battery isolating switch ......................................................................... 41
4.7.4 Options for operating in fire hazard areas .......................................................... 42
4.7.5 Diesel particulate filter option .............................................................................. 43
4.7.6 Transport options ................................................................................................ 43
4.7.7 Closed floor pan option ....................................................................................... 44
4.7.8 Optional anti-theft device ................................................................................... 45
4.7.9 Pedestrian protection option ............................................................................... 45
5 Installation and Operating Conditions
5.1 Ensuring safety ................................................................................................................ 46
5.2 Installation conditions ....................................................................................................... 46
6 Installation
6.1 Ensuring safety ................................................................................................................ 48
6.2 Reporting Transport Damage ........................................................................................... 48
6.3 Fitting the towbar .............................................................................................................. 48
6.3.1 Fitting the height adjustable towbar .................................................................... 49
6.3.2 Fitting a non-adjustable towbar ........................................................................... 50
Contents
ii Service manual Portable compressor
M122 No.: 9_6974 20 E
RAMIRENT

6.4 Adjusting the chassis ....................................................................................................... 52
6.4.1 Adjusting the towbar height ................................................................................ 53
6.4.2 Changing the towing eye .................................................................................... 53
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 ........................................ 58
7.3 Checking installation and operating conditions ................................................................ 58
7.4 Low-temperature operation (winter) ................................................................................. 59
7.4.1 Starting assistance ............................................................................................. 59
7.4.2 Starting up low-temperature equipment .............................................................. 61
8 Operation
8.1 Ensuring safety ................................................................................................................ 63
8.2 Starting and stopping ....................................................................................................... 63
8.2.1 Commissioning the machine ............................................................................... 64
8.2.2 Starting the machine ........................................................................................... 65
8.2.3 Allow the machine to run up to operating temperature ....................................... 65
8.2.4 Switching to LOAD ............................................................................................. 66
8.2.5 Manual pressure setting ..................................................................................... 66
8.2.6 Shutting down the machine ................................................................................ 67
8.3 Monitoring the fuel level ................................................................................................... 67
8.4 Operating the tool lubricator ............................................................................................. 68
8.5 Using the low-temperature equipment ............................................................................. 69
8.5.1 Using with the frost protector switched on .......................................................... 69
8.5.2 Coolant pre-heating ............................................................................................ 70
8.6 Operating the battery isolating switch .............................................................................. 70
8.7 Shut down the machine if any dangerous situation arises ............................................... 71
9 Fault Recognition and Rectification
9.1 Basic instructions ............................................................................................................. 72
9.2 Evaluate engine faults and alarms ................................................................................... 72
9.2.1 Engine refuses to start or does not turn over ...................................................... 72
9.2.2 Engine does not reach full speed ....................................................................... 73
9.2.3 Indicator lamp remains on .................................................................................. 73
9.3 Evaluate compressor faults and alarms ........................................................................... 74
9.3.1 Working pressure too high .................................................................................. 74
9.3.2 Working pressure too low. .................................................................................. 74
9.3.3 Pressure relief valve blowing off ......................................................................... 75
9.3.4 Machine overheating .......................................................................................... 75
9.3.5 Too much oil residue in the compressed air ....................................................... 76
9.3.6 Oil flows from the compressor air filter after shutdown ....................................... 76
9.3.7 High moisture content in the compressed air ..................................................... 77
9.4 Evaluate faults in the diesel particulate filter .................................................................... 77
10 Maintenance
10.1 Ensuring safety ................................................................................................................ 79
10.2 Following the maintenance plans ..................................................................................... 80
10.2.1 Logging maintenance work ................................................................................. 80
10.2.2 Maintenance tasks after commissioning ............................................................. 80
10.2.3 Regular maintenance tasks ................................................................................ 81
10.3 Engine maintenance ........................................................................................................ 85
10.3.1 Water cooler maintenance .................................................................................. 86
10.3.2 Engine air filter maintenance .............................................................................. 91
Contents
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10.3.3 Fuel system maintenance ................................................................................... 93
10.3.4 Checking the engine oil level .............................................................................. 97
10.3.5 Engine oil filling and topping up .......................................................................... 98
10.3.6 Changing the engine oil ...................................................................................... 99
10.3.7 Replace the engine oil filter ................................................................................ 102
10.3.8 Drive belt maintenance ....................................................................................... 103
10.3.9 Battery maintenance ........................................................................................... 107
10.4 Compressor Maintenance ................................................................................................ 110
10.4.1 Checking cooling oil level ................................................................................... 110
10.4.2 Cooling oil filling and topping up ......................................................................... 111
10.4.3 Changing the cooling oil ..................................................................................... 112
10.4.4 Replace the compressor oil filter ........................................................................ 115
10.4.5 Oil separator tank dirt trap maintenance ............................................................. 116
10.4.6 Changing the oil separator cartridge ................................................................... 118
10.4.7 Compressor air filter maintenance ...................................................................... 122
10.4.8 Checking pressure relief valves ......................................................................... 125
10.5 Clean cooler/radiator ........................................................................................................ 125
10.5.1 Cleaning the cooler/ radiator. .............................................................................. 125
10.5.2 Cleaning the compressed air aftercooler ............................................................ 126
10.6 Maintenance of rubber sealing strips ............................................................................... 127
10.7 Chassis maintenance ....................................................................................................... 128
10.7.1 Wheel checks ..................................................................................................... 128
10.7.2 Towbar maintenance .......................................................................................... 128
10.7.3 Brake system maintenance ................................................................................ 130
10.8 Maintenance of Optional Items ........................................................................................ 133
10.8.1 Tool lubricator maintenance ............................................................................... 134
10.8.2 Cyclone separator maintenance ......................................................................... 135
10.8.3 Combination filter maintenance .......................................................................... 137
10.8.4 Fresh air filter maintenance ................................................................................ 140
10.8.5 Frost protector maintenance ............................................................................... 143
10.8.6 Spark arrestor cleaning ....................................................................................... 144
10.8.7 Engine air intake shut-off valve maintenance ..................................................... 146
10.9 Documenting maintenance and service work .................................................................. 148
11 Spares, Operating Materials, Service
11.1 Note the Nameplate ......................................................................................................... 149
11.2 Ordering consumable parts and operating fluids/materials .............................................. 149
11.3 KAESER AIR SERVICE .................................................................................................. 150
11.4 Service Addresses ........................................................................................................... 150
11.5 Spares for service and repair ........................................................................................... 150
12 Decommissioning, Storage and Transport
12.1 De-commissioning ............................................................................................................ 224
12.1.1 Temporary de-commissioning ............................................................................ 224
12.1.2 Long-term de-commissioning and storage ......................................................... 225
12.2 Transport .......................................................................................................................... 226
12.2.1 Safety .................................................................................................................. 226
12.2.2 Road transport of the machine as a trailer .......................................................... 226
12.2.3 Parking the compressor ...................................................................................... 233
12.2.4 Transport with a crane ........................................................................................ 235
12.2.5 Transporting with a forklift truck .......................................................................... 236
12.2.6 Transporting as a load ........................................................................................ 237
12.3 Storage ............................................................................................................................. 238
12.4 Disposal ........................................................................................................................... 238
Contents
iv Service manual Portable compressor
M122 No.: 9_6974 20 E
RAMIRENT

13 Annex
13.1 Identification ..................................................................................................................... 240
13.2 Pipeline and instrument flow diagram (P+I diagram) ....................................................... 240
13.3 Dimensional drawings ...................................................................................................... 245
13.3.1 Dimensional drawing - chassis with height-adjustable tow bar .......................... 245
13.3.2 Dimensional drawing, chassis with fixed height tow bar ..................................... 247
13.3.3 Dimensional drawing, chassis without parking brake ........................................ 249
13.3.4 Dimensional drawings of stationary machine (skids) .......................................... 251
13.3.5 Dimensional drawings of stationary machine (base frame) ................................ 253
13.4 Wiring diagrams .............................................................................................................. 255
13.4.1 Electrical Diagram ............................................................................................... 255
13.4.2 Connection adapter for the diesel particulate filter ............................................. 280
13.4.3 Lighting and signalling system connection ......................................................... 285
13.4.4 Lighting and signalling system connection ......................................................... 293
13.5 Fuel circulation diagram ................................................................................................... 298
13.6 Operating instructions for compressed air filter (combination filter) ................................. 300
13.7 Operating instructions for compressed air filter (fresh air filter) ....................................... 321
13.8 Service tasks on the diesel particulate filter ..................................................................... 335
Contents
No.: 9_6974 20 E
Service manual Portable compressor
M122 v
RAMIRENT

Contents
vi Service manual Portable compressor
M122 No.: 9_6974 20 E
RAMIRENT

Fig. 1 Location of safety signs .............................................................................................................. 26
Fig. 2 Bodywork .................................................................................................................................... 31
Fig. 3 Right-hand door opened ............................................................................................................. 32
Fig. 4 Left-hand door opened ............................................................................................................... 32
Fig. 5 Machine layout ........................................................................................................................... 33
Fig. 6 Stepless regulation of FAD (standstill) ....................................................................................... 35
Fig. 7 Fuel level monitoring .................................................................................................................. 36
Fig. 8 Compressed air options ............................................................................................................. 37
Fig. 9 Tool lubricator ............................................................................................................................. 39
Fig. 10 Frost protector ............................................................................................................................ 40
Fig. 11 Coolant pre-heating .................................................................................................................... 41
Fig. 12 Battery isolating switch ............................................................................................................... 41
Fig. 13 Pull handle of engine air shut-off valve ...................................................................................... 42
Fig. 14 General design of the diesel particulate filter system ................................................................. 43
Fig. 15 Position of service openings in the closed floor pan .................................................................. 45
Fig. 16 Drains for oil and coolant from engine and compressor ............................................................. 45
Fig. 17 Minimum distance from excavations/slopes and walls ............................................................... 46
Fig. 18 Height adjustable towbar, fitted .................................................................................................. 49
Fig. 19 Fitting the height adjustable towbar ............................................................................................ 49
Fig. 20 Non-adjustable towbar fitted ....................................................................................................... 50
Fig. 21 Fitting the overrun braking mechanism of the non-adjustable towbar ........................................ 51
Fig. 22 Fitting the jockey wheel of the non-adjustable towbar ................................................................ 52
Fig. 23 Towbar height adjustment .......................................................................................................... 53
Fig. 24 Changing the towing eye (height-adjustable drawbar) ............................................................... 54
Fig. 25 Changing the towing eye (fixed height towbar, GB chassis version) ......................................... 55
Fig. 26 Changing the towing eye (fixed height towbar, USA chassis version) ....................................... 56
Fig. 27 Jumper cable connection diagram ............................................................................................. 60
Fig. 28 Coolant pre-heating .................................................................................................................... 62
Fig. 29 Starting instruments ................................................................................................................... 64
Fig. 30 Label referring to the warm-up period when ambient temperatures are below -10 °C ............... 65
Fig. 31 Proportional controller ................................................................................................................ 66
Fig. 32 Setting the tool lubricator ............................................................................................................ 68
Fig. 33 Frost protector on and off ........................................................................................................... 69
Fig. 34 Battery isolating switch ............................................................................................................... 70
Fig. 35 Handle for manually closing the engine air intake valve ............................................................ 71
Fig. 36 Checking coolant level ............................................................................................................... 87
Fig. 37 Draining the coolant from the radiator ........................................................................................ 89
Fig. 38 Draining the coolant from the radiator (closed floor pan - stationary machine) .......................... 90
Fig. 39 Engine air filter maintenance ...................................................................................................... 91
Fig. 40 Cleaning the filter element .......................................................................................................... 92
Fig. 41 Fuel system maintenance .......................................................................................................... 93
Fig. 42 Bleeding the fuel system ............................................................................................................ 94
Fig. 43 Emptying the fuel pre-filter water trap ........................................................................................ 95
Fig. 44 Changing the fuel pre-filter cartridge .......................................................................................... 96
Fig. 45 Fuel filter maintenance ............................................................................................................... 97
Fig. 46 Checking the engine oil level ...................................................................................................... 98
Fig. 47 Draining the engine oil ................................................................................................................ 100
Fig. 48 Draining the engine oil (closed floor pan - stationary machine): ................................................ 101
Fig. 49 Changing the oil filter .................................................................................................................. 102
Fig. 50 Belt guard attachment ................................................................................................................ 104
Fig. 51 Belt tension checking by hand .................................................................................................... 105
Fig. 52 Changing/tensioning the drive belt ............................................................................................. 106
Fig. 53 Safety signs - warning stickers on the battery. ........................................................................... 107
Fig. 54 Checking cooling oil level ........................................................................................................... 110
List of Illustrations
No.: 9_6974 20 E
Service manual Portable compressor
M122 vii
RAMIRENT

Fig. 55 Draining cooling oil ..................................................................................................................... 113
Fig. 56 Draining the cooling oil (closed floor pan - stationary machine) ................................................. 114
Fig. 57 Changing the oil filter .................................................................................................................. 115
Fig. 58 Oil separator tank dirt trap maintenance .................................................................................... 117
Fig. 59 Changing the oil separator cartridge .......................................................................................... 119
Fig. 60 Changing the oil separator cartridge (Option ba) ....................................................................... 121
Fig. 61 Compressor air filter maintenance ............................................................................................. 123
Fig. 62 Cleaning the filter element .......................................................................................................... 124
Fig. 63 Cleaning the cooler/ radiator. ..................................................................................................... 126
Fig. 64 Cleaning the compressed air aftercooler .................................................................................... 127
Fig. 65 Towbar maintenance .................................................................................................................. 129
Fig. 66 Ball coupling (EC version) .......................................................................................................... 130
Fig. 67 Ball coupling (USA version) ........................................................................................................ 130
Fig. 68 Checking the brake lining thickness ........................................................................................... 131
Fig. 69 Brake system adjustment ........................................................................................................... 132
Fig. 70 Brake rod adjustment ................................................................................................................. 133
Fig. 71 Tool lubricator maintenance ....................................................................................................... 134
Fig. 72 Cleaning the dirt trap .................................................................................................................. 136
Fig. 73 Combination filter maintenance .................................................................................................. 137
Fig. 74 Fresh air filter maintenance ........................................................................................................ 140
Fig. 75 Filling the frost protector ............................................................................................................. 143
Fig. 76 Cleaning the spark arrestor (standard) ....................................................................................... 144
Fig. 77 Cleaning the spark arrestor (closed floor pan) ........................................................................... 145
Fig. 78 Engine air intake shut-off valve maintenance ............................................................................. 146
Fig. 79 Checking manual operation of the engine air intake valve ......................................................... 147
Fig. 80 Towing alignment ....................................................................................................................... 228
Fig. 81 Ball coupling (ALKO-EU) ............................................................................................................ 228
Fig. 82 Ball coupling wear indicator ALKO-EU ....................................................................................... 229
Fig. 83 Ball coupling (ALKO-USA) ......................................................................................................... 230
Fig. 84 Release the parking brake. ........................................................................................................ 231
Fig. 85 Safety sign - secure the chocks ................................................................................................. 232
Fig. 86 Breakaway cable attachment ..................................................................................................... 233
Fig. 87 Warning "Risk of injury due to falling towbar" ............................................................................. 234
Fig. 88 Actuating the parking brake ........................................................................................................ 234
Fig. 89 Safety sign - secure the chocks ................................................................................................. 235
Fig. 90 Transport using a forklift truck .................................................................................................... 236
Fig. 91 Load secured by strapping ......................................................................................................... 237
Fig. 92 Identification ............................................................................................................................... 240
List of Illustrations
viii Service manual Portable compressor
M122 No.: 9_6974 20 E
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Tab. 1 Danger levels and their definitions (personal injury) .................................................................. 1
Tab. 2 Danger levels and their definition (damage to property) ............................................................ 2
Tab. 3 Nameplate .................................................................................................................................. 4
Tab. 4 Combined label for coupling load and options fitted. .................................................................. 5
Tab. 5 Compressed 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 Proportional controller option ..................................................................................................... 6
Tab. 10 Low temperature equipment options .......................................................................................... 6
Tab. 11 Diesel particulate filter option ..................................................................................................... 6
Tab. 12 Optional equipment for fire hazard areas ................................................................................... 6
Tab. 13 Optional battery isolating switch ................................................................................................. 7
Tab. 14 Chassis options .......................................................................................................................... 7
Tab. 15 Lighting options .......................................................................................................................... 7
Tab. 16 Sealed floor pan ......................................................................................................................... 7
Tab. 17 Optional anti-theft device ............................................................................................................ 8
Tab. 18 Pedestrian protection option ....................................................................................................... 8
Tab. 19 Instrument panel cover option .................................................................................................... 8
Tab. 20 Guaranteed sound power level [dB(A)] ...................................................................................... 8
Tab. 21 Emission sound pressure level [dB(A)] ...................................................................................... 8
Tab. 22 Sound pressure level [dB(A)] ..................................................................................................... 9
Tab. 23 Torques for hex-head screws ..................................................................................................... 9
Tab. 24 Ambient conditions ..................................................................................................................... 9
Tab. 25 Mass of the machine .................................................................................................................. 10
Tab. 26 Tyres .......................................................................................................................................... 10
Tab. 27 Wheel nut/bolt tightening torque ................................................................................................. 10
Tab. 28 Towbar tightening torque ............................................................................................................ 10
Tab. 29 Working pressure and FAD ........................................................................................................ 10
Tab. 30 Compressed air distributor ......................................................................................................... 11
Tab. 31 Pressure relief valve opening pressure ...................................................................................... 11
Tab. 32 Machine temperatures ................................................................................................................ 11
Tab. 33 Cooling oil recommendation ....................................................................................................... 11
Tab. 34 Cooling oil charge ....................................................................................................................... 12
Tab. 35 Engine data ................................................................................................................................ 12
Tab. 36 Engine oil recommendation ........................................................................................................ 13
Tab. 37 Recommended oil for engines with diesel particulate filters ....................................................... 13
Tab. 38 Fluid volumes ............................................................................................................................. 14
Tab. 39 Batteries ..................................................................................................................................... 14
Tab. 40 Road breaker lubricant recommendation ................................................................................... 14
Tab. 41 Fresh air filter conditions ............................................................................................................ 14
Tab. 42 Environmental conditions, low temperature equipment .............................................................. 15
Tab. 43 Recommended antifreeze .......................................................................................................... 15
Tab. 44 Batteries, low-temperature equipment ....................................................................................... 15
Tab. 45 Coolant pre-heater ..................................................................................................................... 15
Tab. 46 Diesel particulate filter data ........................................................................................................ 15
Tab. 47 Inspection intervals according to regulations ............................................................................. 19
Tab. 48 Danger areas .............................................................................................................................. 25
Tab. 49 Safety signs ................................................................................................................................ 26
Tab. 50 Measures for re-commissioning the compressor after a long period of storage ........................ 58
Tab. 51 Positioning and operating conditions checklist ........................................................................... 58
Tab. 52 Low-temperature equipment checklist ........................................................................................ 62
Tab. 53 Fault: engine refuses to start or comes to a stop. ...................................................................... 72
Tab. 54 Fault: engine does not reach full speed. .................................................................................... 73
List of Tables
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M122 ix
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Tab. 55 Indicator lamp remains on .......................................................................................................... 73
Tab. 56 Fault: working pressure too high ................................................................................................ 74
Tab. 57 Fault: working pressure too low .................................................................................................. 74
Tab. 58 Fault: pressure relief valve blowing off ....................................................................................... 75
Tab. 59 Fault: machine overheating ........................................................................................................ 75
Tab. 60 Fault: too much oil residue in the compressed air ...................................................................... 76
Tab. 61 Fault: oil flows from the compressor air filter after shutdown ..................................................... 76
Tab. 62 Fault: high moisture content in the compressed air .................................................................... 77
Tab. 63 Faults in the diesel particulate filter ............................................................................................ 77
Tab. 64 Fault 'blue engine exhaust' ......................................................................................................... 77
Tab. 65 Grey or brownish exhaust gas .................................................................................................... 78
Tab. 66 Maintenance tasks after commissioning .................................................................................... 80
Tab. 67 Maintenance intervals and regular maintenance tasks .............................................................. 81
Tab. 68 Regular machine maintenance tasks ......................................................................................... 81
Tab. 69 Regular maintenance task options ............................................................................................. 84
Tab. 70 KAESER coolant mixture table ................................................................................................... 88
Tab. 71 Maintenance log ......................................................................................................................... 148
Tab. 72 Compressor consumables .......................................................................................................... 149
Tab. 73 Consumable engine parts .......................................................................................................... 149
Tab. 74 "Temporarily decommissioned" information notice .................................................................... 224
Tab. 75 "Long-term decommissioning and storage" checklist ................................................................. 225
Tab. 76 Text for the "long-term decommissioned and storage" information notice ................................. 226
Tab. 77 Ball coupling wear indicator ........................................................................................................ 230
List of Tables
xService manual Portable compressor
M122 No.: 9_6974 20 E
RAMIRENT

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
■ Engine documentation (not electric-motor-driven machines)
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 service manual is copyright protected. Queries regarding use or duplication of the documenta‐
tion should be referred to KAESER. Correct use of information will be fully supported.
1.4 Symbols and labels
➤ Please note the symbols and labels used in this document.
1.4.1 Warnings
Warning notices indicate dangers that may result in injury when disregarded.
Warning notices indicate three levels of danger identified by the corresponding signal word:
Signal term Meaning Consequences of ignoring the warning
DANGER Warns of an imminent danger Will result in death or severe injury
WARNING Warns of a potentially imminent danger May result in death or severe injury
CAUTION Warns of a potentially dangerous situation May result in a moderate physical injury
Tab. 1 Danger levels and their definitions (personal injury)
Warning notices preceding a chapter apply to the entire chapter, including all sub-sections.
For example,
1 Regarding this document
1.1 Using this document
No.: 9_6974 20 E
Service manual Portable compressor
M122 1
RAMIRENT

DANGER
These show the kind of danger and its source.
The possible consequences of ignoring a warning are shown here.
If you ignore the warning notice, the "DANGER" signal word indicates a lethal or severe in‐
jury will occur.
➤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.
For example,
1. WARNING!
These show the kind of danger and its source.
The possible consequences of ignoring a warning are shown here.
If you ignore the warning notice, the "WARNING" signal word indicates that a lethal or severe
injury may occur.
➤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.
Warning notices for damages are identified by their signal term.
Signal term Meaning Consequences of ignoring the warning
NOTE Warns of a potentially dangerous situation Damage to property is possible
Tab. 2 Danger levels and their definition (damage to property)
For example,
NOTICE
These show the kind of danger and its source.
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 alerts 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.
➤ This symbol is is placed by lists of actions comprising one stage of a task.
1. In process instructions with several steps ...
2. ... the sequence of action steps is numbered.
1 Regarding this document
1.4 Symbols and labels
2Service manual Portable compressor
M122 No.: 9_6974 20 E
RAMIRENT

Result Shows the expected conclusion of the previous action.
➤ Information relating to one option only are 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
cyclone separator"). Option codes used in this service manual are explained in chapter 2.2.
Information referring to potential problems are 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_6974 20 E
Service manual Portable compressor
M122 3
Option da
RAMIRENT

2 Technical Specifications
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 here the nameplate data as a reference:
Feature Value
Vehicle identity no.
Permissible total weight
Permissible coupling load
Permissible axle load
Portable compressor
Material number
Serial number:
Year of manufacture
Total weight
Lifting point load capacity
Rated motor power
Engine speed
Maximum working pressure
Tab. 3 Nameplate
2.2 Options summary
A list of the options fitted to your machine helps to relate the information in this service manual.
A list of options fitted is given as code letters on the right side of the coupling load / options label.
The label is to be found
■on the outside of the machine
■ on the front (see chapter 13.1)
The following table lists all possible options.
Only the codes for those options fitted appear on the label.
2 Technical Specifications
2.1 Nameplate
4Service manual Portable compressor
M122 No.: 9_6974 20 E
RAMIRENT

M122 part number Serial number:
Options fitted
Here is given the specified coupling load.
02-M0277
pa
sg
sf
tc
tb
ta
sc sdsa
shsi
oa oe
lb lc
la
ba bb
fa
ec
te
dd
dc
db
da
ea
fc
hd
hc
cb
ca
Tab. 4 Combined label for coupling load and options fitted.
➤ Take a list of fitted options from the combined coupling load / options label and enter the fitted
options as reference.
2.2.1 Option da, db, dc, dd
Compressed air treatment devices
Option Option code Available?
Aftercooler and cyclone separator da
Heat exchanger db
Fresh air filter dc
Filter combination dd
Tab. 5 Compressed air treatment options
2.2.2 Option ea, ec
Tool lubricator
Option Option code Available?
Tool lubricator (with option fa) ea
Tool 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 Specifications
2.2 Options summary
No.: 9_6974 20 E
Service manual Portable compressor
M122 5
RAMIRENT

Option Option code Available?
Separated compressed air lines downstream of the
option
fc
Tab. 7 Compressed air distributor option
2.2.4 Option hc, hd
Check valve function
Option Option code Available?
Pressure/check valve (without option dd) hc
Pressure/check valve (with option dd) hd
Tab. 8 Non-return option
2.2.5 Option ca, cb
Proportional controller
Option Option code Available?
Without manual adjustment (7 bar) ca
With manual adjustment (≥10 bar) cb
Tab. 9 Proportional controller option
2.2.6 Option ba, bb
Low temperature equipment
Option Option code Available?
Low temperature equipment ba
Low temperature equipment + engine coolant pre-
heating
bb
Tab. 10 Low temperature equipment options
2.2.7 Option lc
Diesel particulate filter
Option Option code Available?
Diesel particulate filter lc
Tab. 11 Diesel particulate filter option
2.2.8 Option la, lb
Equipment for fire hazard areas
Option Option code Available?
Spark arrestor la
2 Technical Specifications
2.2 Options summary
6Service manual Portable compressor
M122 No.: 9_6974 20 E
RAMIRENT

Option Option code Available?
Spark arrestor and engine air intake shut-off valve
(automatic)
lb
Tab. 12 Optional equipment for fire hazard areas
2.2.9 Option oa
Battery isolating switch
Option Option code Available?
Battery isolating switch oa
Tab. 13 Optional battery isolating switch
2.2.10 Option sa, sc, sd, sh, si
Chassis
Option Permissible
axle load [kg]
Option code Available?
Height adjustable towbar 1900 sa
Fixed height towbar 1900 sd
Fixed height towbar
without parking brake
1900 sh
Stationary, on skids – sc
Stationary, on a base frame – si
Tab. 14 Chassis options
2.2.11 Option ta, tb, tc, te
Lighting
Option Option code Available?
None (stationary) ta
Reflective warning triangle tb
EG - 12 V tc
USA - 12 V (DOT conformity) te
Tab. 15 Lighting options
2.2.12 Option oe
Sealed floor pan
Option Option code Available?
Sealed floor pan oe
Tab. 16 Sealed floor pan
2 Technical Specifications
2.2 Options summary
No.: 9_6974 20 E
Service manual Portable compressor
M122 7
RAMIRENT

2.2.13 Option sf
Anti-theft device
Option Option code Available?
Anti-theft device sf
Tab. 17 Optional anti-theft device
2.2.14 Option sg
Pedestrian protection
Option Option code Available?
Pedestrian protection sg
Tab. 18 Pedestrian protection option
2.2.15 Option pa
Instrument panel cover
Option Option code Available?
Instrument panel cover pa
Tab. 19 Instrument panel cover option
2.3 Machine (without options)
2.3.1 Sound emission
2.3.1.1 Sound emission [dB(A)]
type M122
Guaranteed sound power level* [dB(A)] 99
* To Directive 2000/14/EC
Tab. 20 Guaranteed sound power level [dB(A)]
type M122
Emission sound pressure level* [dB(A)]
According to EN ISO 11203: 1995 number 6.2.3.d.
81.0
Measuring distance: d = 1 m
Logarithmic surface ratio: Q2 = 18 dB(A)
* Calculated from the guaranteed sound power level (2000/14/EC Directive, Sound Emission
Standard ISO 3744)
Tab. 21 Emission sound pressure level [dB(A)]
2.3.1.2 Sound pressure level [dB(A)]
The sound pressure level conforms to the US EPA Standard.
Measuring distance: 7 m
2 Technical Specifications
2.3 Machine (without options)
8Service manual Portable compressor
M122 No.: 9_6974 20 E
RAMIRENT