KAESER M27 User manual

Operator Manual
Screw Compressor
M27
No.: 9_9548 05 USE
Manufacturer:
KAESER KOMPRESSOREN SE
96410 Coburg • PO Box 2143 • GERMANY • Tel. [phone] • Fax [phone]
http://www.kaeser.com

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
2 Technical Data
2.1 Nameplate ........................................................................................................................ 4
2.2 Options ............................................................................................................................. 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 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 Sealed floor pan .................................................................................................. 8
2.2.13 Hose reels ........................................................................................................... 8
2.2.14 Anti-theft device .................................................................................................. 8
2.3 Machine (without options) ................................................................................................ 8
2.3.1 Sound pressure level .......................................................................................... 8
2.3.2 Tightening torques for screws ............................................................................. 8
2.3.3 Ambient conditions ............................................................................................. 9
2.3.4 Additional specifications ..................................................................................... 9
2.4 Chassis ........................................................................................................................... 9
2.4.1 Weight of machines approved for towing on public roads .................................. 9
2.4.2 Tires .................................................................................................................... 10
2.4.3 Wheel nut/bolt tightening torque ......................................................................... 11
2.4.4 Towbar tightening torque .................................................................................... 11
2.5 Compressor ..................................................................................................................... 11
2.5.1 Working pressure and FAD ................................................................................ 11
2.5.2 Compressed air outlet ......................................................................................... 11
2.5.3 Air quality at the compressed air outlets ............................................................. 11
2.5.4 Safety relief valve ............................................................................................... 12
2.5.5 Temperature ....................................................................................................... 12
2.5.6 Cooling oil recommendation ............................................................................... 12
2.5.7 Cooling oil charge ............................................................................................... 13
2.6 Engine ............................................................................................................................. 13
2.6.1 Engine data ......................................................................................................... 13
2.6.2 Oil recommendation ............................................................................................ 14
2.6.3 Fuel recommendation ......................................................................................... 14
2.6.4 Engine coolant recommendation ........................................................................ 14
2.6.5 Fluid volumes ...................................................................................................... 15
2.6.6 Batteries .............................................................................................................. 15
2.7 Options ............................................................................................................................ 15
2.7.1 Tool lubricator ..................................................................................................... 15
2.7.2 Low temperature equipment ............................................................................... 15
2.7.3 Generator ............................................................................................................ 16
Contents
No.: 9_9548 05 USE
Operator Manual Screw Compressor
M27 i

2.7.4 Air hose with hose reel ....................................................................................... 20
3 Safety and Responsibility
3.1 Basic instructions ............................................................................................................. 21
3.2 Specified use .................................................................................................................... 21
3.3 Incorrect Use .................................................................................................................... 21
3.4 User's Responsibilities ..................................................................................................... 21
3.4.1 Observe statutory and universally accepted regulations .................................... 21
3.4.2 Determining personnel ........................................................................................ 22
3.4.3 Adherence to inspection schedules and accident prevention regulations .......... 22
3.5 Dangers ............................................................................................................................ 22
3.5.1 Safely dealing with sources of danger ................................................................ 23
3.5.2 Safe machine operation ...................................................................................... 25
3.5.3 Organizational Measures .................................................................................... 29
3.5.4 Danger areas ...................................................................................................... 29
3.6 Safety devices .................................................................................................................. 29
3.7 Safety signs ...................................................................................................................... 29
3.8 Generator operation ......................................................................................................... 32
3.8.1 Comply with the protective measures against dangerous electric current ......... 32
3.8.2 Instructions for safe generator operation ............................................................ 33
3.8.3 Connecting extension cables .............................................................................. 33
3.8.4 Do not exceed the maximum supply system load .............................................. 33
3.8.5 Perform regular generator inspections ............................................................... 33
3.9 Emergency situations ....................................................................................................... 34
3.9.1 Correct fire fighting ............................................................................................. 34
3.9.2 Injury from handling operating fluids/materials ................................................... 34
3.10 Warranty ........................................................................................................................... 35
3.11 Environmental protection ................................................................................................. 35
4 Design and Function
4.1 Bodywork ......................................................................................................................... 37
4.2 Component identification .................................................................................................. 38
4.3 Machine function .............................................................................................................. 39
4.4 Operating modes and control modes ............................................................................... 40
4.4.1 Operating modes ................................................................................................ 40
4.4.2 MODULATING control ........................................................................................ 40
4.5 Safety devices .................................................................................................................. 41
4.5.1 Monitoring functions with shutdown .................................................................... 41
4.5.2 Further safety devices ........................................................................................ 41
4.6 Options ............................................................................................................................. 41
4.6.1 Compressed air treatment options ...................................................................... 41
4.6.2 Generator option ................................................................................................. 43
4.6.3 Low temperature equipment options .................................................................. 45
4.6.4 Options for operating in fire hazard areas .......................................................... 47
4.6.5 Fuel de-watering filter option .............................................................................. 48
4.6.6 Sealed floor pan option ....................................................................................... 48
4.6.7 Battery isolating switch ...................................................................................... 48
4.6.8 Hose reel option .................................................................................................. 49
4.6.9 Optional anti-theft device ................................................................................... 49
4.6.10 Transportation options ........................................................................................ 50
5 Installation and Operating Conditions
5.1 Ensuring safety ................................................................................................................ 52
5.2 Installation conditions ....................................................................................................... 52
Contents
ii
Operator Manual Screw Compressor
M27 No.: 9_9548 05 USE

6 Installation
6.1 Ensuring safety ................................................................................................................ 55
6.2 Reporting Transport Damage ........................................................................................... 55
6.3 Fitting the towbar .............................................................................................................. 55
6.3.1 Fitting the height-adjustable towbar .................................................................... 56
6.3.2 Fitting the fixed height towbar ............................................................................. 58
6.3.3 Installing the fixed height towbar (US towbar) .................................................... 59
6.4 Adjusting the chassis ....................................................................................................... 59
6.4.1 Adjusting the towbar height ................................................................................ 60
6.4.2 Adjusting the towbar height ................................................................................ 61
6.4.3 Replacing the ball coupling with a towing eye .................................................... 63
7 Initial Start-up
7.1 Ensuring safety ................................................................................................................ 75
7.2 Before initial start-up (or recommissioning) ...................................................................... 75
7.2.1 Instructions to be observed before commissioning or recommissioning ............ 75
7.2.2 Special measures for recommissioning after storage ......................................... 76
7.3 Checking installation and operating conditions ................................................................ 76
7.4 Low-temperature operation (winter) ................................................................................. 77
7.4.1 Starting assistance ............................................................................................. 77
7.4.2 Starting up low-temperature equipment .............................................................. 79
7.5 Activating the generator ................................................................................................... 80
7.5.1 Generator control box 400V with insulation monitoring ...................................... 80
7.5.2 Generator control box 115V with insulation monitoring ...................................... 81
7.5.3 Testing the insulation monitor ............................................................................. 81
8 Operation
8.1 Ensuring safety ................................................................................................................ 83
8.2 Starting and stopping ....................................................................................................... 84
8.2.1 Running the machine .......................................................................................... 85
8.2.2 Starting the machine ........................................................................................... 85
8.2.3 Allow the machine to run up to operating temperature ....................................... 85
8.2.4 The machine is running under load .................................................................... 86
8.2.5 Shutting down the machine ................................................................................ 86
8.3 Operating the tool lubricator ............................................................................................. 86
8.4 Using the low-temperature equipment ............................................................................. 88
8.4.1 Coolant pre-heating ............................................................................................ 88
8.4.2 Operating the machine with frost protector ......................................................... 88
8.5 Generator operation ......................................................................................................... 89
8.5.1 Before you operate the generator ....................................................................... 89
8.5.2 Switching on the generator ................................................................................. 90
8.5.3 Disconnect electric consumers ........................................................................... 90
8.5.4 Switching off the generator ................................................................................. 91
8.6 Operating the battery isolating switch .............................................................................. 91
8.7 Using the hose reel .......................................................................................................... 92
8.7.1 Operating the machine with an extension air hose ............................................. 92
8.7.2 Operating the machine without an extension air hose ........................................ 93
8.7.3 Securing the hose reel for transport ................................................................... 93
8.8 Cleaning the machine after operation .............................................................................. 93
9 Fault Recognition and Rectification
9.1 Basic instructions ............................................................................................................. 95
9.2 Engine faults and alarms .................................................................................................. 95
9.2.1 Engine refuses to start or comes to a stop ......................................................... 95
9.2.2 Engine does not reach full speed ....................................................................... 96
9.2.3 Indicator lamp remains on .................................................................................. 96
Contents
No.: 9_9548 05 USE
Operator Manual Screw Compressor
M27 iii

9.3 Compressor faults and alarms ......................................................................................... 97
9.3.1 Working pressure too high .................................................................................. 97
9.3.2 Working pressure too low ................................................................................... 97
9.3.3 Safety relief valve blowing off ............................................................................. 98
9.3.4 Machine overheating .......................................................................................... 98
9.3.5 Too much oil residue in the compressed air ....................................................... 99
9.3.6 Oil flows from the compressor air filter after shutdown ....................................... 99
9.3.7 High moisture content in the compressed air ..................................................... 100
9.4 Generator faults and alarms ............................................................................................. 100
9.4.1 No voltage or too low a voltage from the generator ............................................ 100
9.4.2 Generator voltage too high ................................................................................. 100
10 Maintenance
10.1 Ensuring safety ................................................................................................................ 102
10.2 Maintenance schedules ................................................................................................... 103
10.2.1 Logging maintenance work ................................................................................. 103
10.2.2 Maintenance tasks after commissioning ............................................................. 103
10.2.3 Regular maintenance tasks ................................................................................ 104
10.3 Engine maintenance ........................................................................................................ 108
10.3.1 Water cooler maintenance .................................................................................. 109
10.3.2 Engine air filter maintenance .............................................................................. 113
10.3.3 Fuel system maintenance ................................................................................... 116
10.3.4 Changing the engine oil ...................................................................................... 120
10.3.5 Changing the engine oil filter .............................................................................. 123
10.3.6 Drive belt maintenance ....................................................................................... 124
10.3.7 Battery maintenance ........................................................................................... 126
10.3.8 Checking the fastening of the fuel tank .............................................................. 129
10.4 Compressor Maintenance ................................................................................................ 129
10.4.1 Checking cooling oil level ................................................................................... 129
10.4.2 Filling or topping off the cooling oil ..................................................................... 130
10.4.3 Changing the cooling oil ..................................................................................... 131
10.4.4 Replace the compressor oil filter ........................................................................ 133
10.4.5 Oil separator tank dirt trap maintenance ............................................................. 135
10.4.6 Changing the oil separator cartridge ................................................................... 136
10.4.7 Compressor air filter maintenance ...................................................................... 139
10.4.8 Checking safety relief valves .............................................................................. 141
10.5 Cleaning the cooler .......................................................................................................... 141
10.5.1 Cleaning the compressor cooler and engine radiator ......................................... 142
10.5.2 Cleaning the compressed air aftercooler ............................................................ 143
10.6 Maintenance of rubber sealing strips ............................................................................... 144
10.7 Chassis maintenance ....................................................................................................... 144
10.7.1 Wheel checks ..................................................................................................... 144
10.7.2 Checking wheel bearings .................................................................................... 145
10.7.3 Towbar maintenance .......................................................................................... 150
10.7.4 Brake system maintenance ................................................................................ 152
10.8 Maintenance for Optional Items ....................................................................................... 155
10.8.1 Tool lubricator maintenance ............................................................................... 156
10.8.2 Compressed air water separator maintenance ................................................... 157
10.8.3 Frost protector maintenance ............................................................................... 158
10.8.4 Engine air intake shut-off valve maintenance ..................................................... 159
10.8.5 Draining liquid accumulation within the machine ................................................ 161
10.8.6 Generator drive belt maintenance ...................................................................... 162
10.9 Documenting maintenance and service work .................................................................. 164
Contents
iv
Operator Manual Screw Compressor
M27 No.: 9_9548 05 USE

11 Spares, Operating Materials, Service
11.1 Note the nameplate .......................................................................................................... 165
11.2 Ordering consumable parts and operating fluids/materials .............................................. 165
11.3 KAESER AIR SERVICE .................................................................................................. 166
11.4 Service Addresses ........................................................................................................... 166
11.5 Replacement parts for service and repair ........................................................................ 166
12 Decommissioning, Storage and Transport
12.1 De-commissioning ............................................................................................................ 216
12.1.1 Temporary de-commissioning ............................................................................ 216
12.1.2 Long-term decommissioning and storage ........................................................... 217
12.2 Transport .......................................................................................................................... 218
12.2.1 Safety .................................................................................................................. 218
12.2.2 Towing the compressor on the road ................................................................... 218
12.2.3 Parking the machine ........................................................................................... 226
12.2.4 Transporting with a crane ................................................................................... 229
12.2.5 Transporting as a load ........................................................................................ 230
12.3 Storage ............................................................................................................................. 231
12.4 Disposal ........................................................................................................................... 232
13 Annex
13.1 Identification ..................................................................................................................... 233
13.2 Pipeline and instrument flow diagram (P+I diagram) ....................................................... 233
13.3 Dimensional drawing ........................................................................................................ 237
13.3.1 Dimensional drawing, chassis options ................................................................ 237
13.3.2 Dimensional drawing, chassis options ................................................................ 239
13.3.3 Dimensional drawing, chassis options ................................................................ 241
13.3.4 Dimensional drawing – chassis options .............................................................. 243
13.3.5 Dimensional drawing, chassis options ................................................................ 245
13.3.6 Dimensional drawing, chassis options ................................................................ 247
13.4 Wiring diagrams .............................................................................................................. 249
13.4.1 Electrical Diagram ............................................................................................... 249
13.4.2 Generator electrical diagram, 400V, 3-ph ........................................................... 259
13.4.3 Generator electrical diagram, 115 V, 2-ph .......................................................... 265
13.4.4 Lighting and signaling system connection .......................................................... 270
13.4.5 Lighting and signaling system connection .......................................................... 275
13.5 Fuel circulation diagram ................................................................................................... 280
13.6 Assambly diagrams chassis ............................................................................................. 283
13.7 Maintenance tasks for the generator ................................................................................ 285
Contents
No.: 9_9548 05 USE
Operator Manual Screw Compressor
M27 v

Fig. 1 Example for tire information on the side wall ............................................................................. 10
Fig. 2 Locations of safety signs ............................................................................................................ 30
Fig. 3 Bodywork .................................................................................................................................... 37
Fig. 4 Side view (canopy removed) ...................................................................................................... 38
Fig. 5 General design ........................................................................................................................... 39
Fig. 6 Compressed air treatment options ............................................................................................. 42
Fig. 7 Tool lubricator ............................................................................................................................. 43
Fig. 8 Instrument panel, generator control box 400 V/3~/N/PE, 50 Hz ................................................ 45
Fig. 9 Instrument panel, generator control box 115 V/1~/N/PE, 50 Hz, 32 A ....................................... 45
Fig. 10 Coolant pre-heating .................................................................................................................... 46
Fig. 11 Frost protector ............................................................................................................................ 47
Fig. 12 Battery isolating switch ............................................................................................................... 49
Fig. 13 Container for safety chain .......................................................................................................... 49
Fig. 14 Minimum distance from excavations/slopes and walls ............................................................... 53
Fig. 15 Fitting the height-adjustable towbar ........................................................................................... 56
Fig. 16 Fitting the fixed height towbar .................................................................................................... 58
Fig. 17 Fixed height towbar .................................................................................................................... 59
Fig. 18 Towbar height adjustment rb/rm/rr ............................................................................................. 60
Fig. 19 Towbar height adjustment rb/rm/rs ............................................................................................. 62
Fig. 20 Replacing the ball coupling (height-adjustable towing system) .................................................. 64
Fig. 21 Replacing the ball coupling (towing device with overrun brake) ................................................. 66
Fig. 22 Distance elements, towing adapter ............................................................................................ 67
Fig. 23 Changing the towing eye ............................................................................................................ 69
Fig. 24 Replacing the towing eye with a ball coupling ............................................................................ 71
Fig. 25 Distance elements ...................................................................................................................... 72
Fig. 26 Changing the towing eye (towbar - US version) ......................................................................... 73
Fig. 27 Jumper cable connection diagram ............................................................................................. 78
Fig. 28 Coolant pre-heating .................................................................................................................... 79
Fig. 29 Insulation monitoring – 400V, 3-phase generator ....................................................................... 80
Fig. 30 Insulation monitoring - 115V, single-phase generator ................................................................ 81
Fig. 31 Starting instruments ................................................................................................................... 84
Fig. 32 Label referring to the warm-up period when ambient temperatures are below 14 °F ................ 85
Fig. 33 Setting the tool lubricator ............................................................................................................ 87
Fig. 34 Frost protector on and off ........................................................................................................... 88
Fig. 35 Generator cut-in pictogram ......................................................................................................... 90
Fig. 36 Battery isolating switch ............................................................................................................... 91
Fig. 37 Hose reel .................................................................................................................................... 92
Fig. 38 Checking coolant level ............................................................................................................... 110
Fig. 39 Draining the coolant from the radiator ........................................................................................ 112
Fig. 40 Maintenance indicator ................................................................................................................ 114
Fig. 41 Engine air filter maintenance ...................................................................................................... 114
Fig. 42 Cleaning the filter element .......................................................................................................... 115
Fig. 43 Bleeding the fuel system ............................................................................................................ 117
Fig. 44 Fuel filter with water trap ............................................................................................................ 119
Fig. 45 Changing the engine oil .............................................................................................................. 121
Fig. 46 Detail oil drain valve ................................................................................................................... 121
Fig. 47 Changing the engine oil filter ...................................................................................................... 123
Fig. 48 Belt tension checking by hand .................................................................................................... 125
Fig. 49 Safety signs - warning stickers on the battery. ........................................................................... 126
Fig. 50 Checking cooling oil level ........................................................................................................... 130
Fig. 51 Draining the compressor cooling oil ........................................................................................... 132
Fig. 52 Changing the oil filter .................................................................................................................. 134
Fig. 53 Oil separator tank dirt trap maintenance .................................................................................... 135
Fig. 54 Changing the oil separator cartridge .......................................................................................... 137
List of Illustrations
No.: 9_9548 05 USE
Operator Manual Screw Compressor
M27 vii

Fig. 55 Maintenance indicator ................................................................................................................ 140
Fig. 56 Compressor air filter maintenance ............................................................................................. 140
Fig. 57 Cleaning the compressed air aftercooler .................................................................................... 143
Fig. 58 Adjusting the bearing play .......................................................................................................... 147
Fig. 59 Remove the wheel hub with tapered roller bearing .................................................................... 148
Fig. 60 Install the wheel hub with tapered roller bearing. ....................................................................... 149
Fig. 61 Securing the collar of the locknut ............................................................................................... 149
Fig. 62 Ball coupling (EU version) .......................................................................................................... 152
Fig. 63 Ball coupling (US version) .......................................................................................................... 152
Fig. 64 Checking the brake lining thickness ........................................................................................... 153
Fig. 65 Brake system adjustment ........................................................................................................... 154
Fig. 66 Brake rod adjustment ................................................................................................................. 155
Fig. 67 Tool lubricator maintenance ....................................................................................................... 156
Fig. 68 Cleaning the dirt trap .................................................................................................................. 157
Fig. 69 Filling the frost protector ............................................................................................................. 159
Fig. 70 Engine air intake shut-off valve maintenance ............................................................................. 160
Fig. 71 Replacing the generator belt ...................................................................................................... 162
Fig. 72 Transport position ....................................................................................................................... 219
Fig. 73 Ball coupling (EU version) .......................................................................................................... 220
Fig. 74 Wear alert, ball coupling (EU version) ........................................................................................ 221
Fig. 75 Ball coupling (US version) .......................................................................................................... 222
Fig. 76 Release the parking brake with gas spring assistance .............................................................. 223
Fig. 77 Automatic jockey wheel in transport position ............................................................................. 223
Fig. 78 Safety signs: Secure the chocks ................................................................................................ 224
Fig. 79 Installing the safety chains ......................................................................................................... 225
Fig. 80 Breakaway cable attachment ..................................................................................................... 225
Fig. 81 Actuating the parking brake with gas spring assistance ............................................................. 226
Fig. 82 Warning: Risk of injury due to falling towing device! .................................................................. 227
Fig. 83 Safety signs: Secure with chocks ............................................................................................... 228
Fig. 84 Container for safety chain .......................................................................................................... 229
Fig. 85 Load secured by strapping ......................................................................................................... 231
Fig. 86 Identification ............................................................................................................................... 233
List of Illustrations
viii
Operator Manual Screw Compressor
M27 No.: 9_9548 05 USE

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 Options label .............................................................................................................................. 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 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 Sealed floor pan option .............................................................................................................. 8
Tab. 17 Hose reel option ......................................................................................................................... 8
Tab. 18 Anti-theft device option ............................................................................................................... 8
Tab. 19 Sound pressure level ................................................................................................................. 8
Tab. 20 Tightening torques for screws (property class 8.8, coefficient of friction µ = 0.12) .................... 8
Tab. 21 Torque cover fixing screws oil separator tank ............................................................................ 9
Tab. 22 Torques for lifting eye screws ..................................................................................................... 9
Tab. 23 Ambient conditions ..................................................................................................................... 9
Tab. 24 Weight of the machine ................................................................................................................ 10
Tab. 25 Technical data – tires and wheel bolts ....................................................................................... 10
Tab. 26 Wheel nut/bolt tightening torque ................................................................................................. 11
Tab. 27 Towbar tightening torque ............................................................................................................ 11
Tab. 28 Working pressure and FAD ........................................................................................................ 11
Tab. 29 Compressed air distributor ......................................................................................................... 11
Tab. 30 Interrelation between compressed air treatment and compressed air quality ............................ 12
Tab. 31 Relief valve activating pressure .................................................................................................. 12
Tab. 32 Machine temperatures ................................................................................................................ 12
Tab. 33 Cooling oil recommendation ....................................................................................................... 12
Tab. 34 Cooling oil charge ....................................................................................................................... 13
Tab. 35 Engine data ................................................................................................................................ 13
Tab. 36 Engine oil recommendation ........................................................................................................ 14
Tab. 37 Fluid volumes ............................................................................................................................. 15
Tab. 38 Batteries ..................................................................................................................................... 15
Tab. 39 Road breaker lubricant recommendation ................................................................................... 15
Tab. 40 Ambient conditions, low temperature equipment ....................................................................... 15
Tab. 41 Coolant pre-heater ..................................................................................................................... 16
Tab. 42 Recommended anti-freeze ......................................................................................................... 16
Tab. 43 Generator data, 400V ................................................................................................................. 16
Tab. 44 Compressed air delivery in generator mode .............................................................................. 17
Tab. 45 Connection sockets .................................................................................................................... 17
Tab. 46 Circuit breaker ............................................................................................................................ 17
Tab. 47 Maximum 3-phase power supply ................................................................................................ 18
Tab. 48 Maximum single phase power supply ........................................................................................ 18
Tab. 49 Generator data 115V .................................................................................................................. 18
Tab. 50 Compressed air delivery in generator mode .............................................................................. 19
Tab. 51 Connection sockets .................................................................................................................... 19
Tab. 52 Circuit breaker ............................................................................................................................ 19
Tab. 53 Maximum single-phase power supply loading ............................................................................ 19
Tab. 54 Generator operating limits .......................................................................................................... 20
List of Tables
No.: 9_9548 05 USE
Operator Manual Screw Compressor
M27 ix

Tab. 55 Output power reduction .............................................................................................................. 20
Tab. 56 Additional discharge valve for the air hose ................................................................................. 20
Tab. 57 Danger areas .............................................................................................................................. 29
Tab. 58 Safety signs ................................................................................................................................ 30
Tab. 59 Generator mode selector switch ................................................................................................. 44
Tab. 60 Generator operating modes ....................................................................................................... 44
Tab. 61 Chassis - overview ..................................................................................................................... 50
Tab. 62 Height-adjustable towbar ............................................................................................................ 59
Tab. 63 Distance elements ...................................................................................................................... 67
Tab. 64 Measures for recommissioning the compressor after a long period of storage .......................... 76
Tab. 65 Installation conditions checklist .................................................................................................. 76
Tab. 66 Low-temperature equipment checklist ........................................................................................ 80
Tab. 67 Test instructions for a generator with a ground short detection device ...................................... 81
Tab. 68 Alarm: Engine refuses to start or comes to a stop. .................................................................... 95
Tab. 69 Alarm: Engine does not reach full speed. ................................................................................... 96
Tab. 70 Indicator lamp remains on .......................................................................................................... 96
Tab. 71 Alarm: Working pressure too high .............................................................................................. 97
Tab. 72 Alarm: Working pressure too low ............................................................................................... 97
Tab. 73 Alarm: Safety relief valve blowing off ......................................................................................... 98
Tab. 74 Alarm: Machine overheating ....................................................................................................... 98
Tab. 75 Fault: Too much oil residue in the compressed air ..................................................................... 99
Tab. 76 Fault: Oil flows from the compressor air filter after shutdown .................................................... 99
Tab. 77 Fault: High moisture content in the compressed air ................................................................... 100
Tab. 78 Fault: No voltage or too low a voltage from the generator ......................................................... 100
Tab. 79 Fault: Generator voltage too high ............................................................................................... 100
Tab. 80 Advise others that the machine is being serviced. ..................................................................... 102
Tab. 81 Maintenance tasks after commissioning .................................................................................... 103
Tab. 82 Maintenance intervals and regular maintenance tasks .............................................................. 104
Tab. 83 Regular machine maintenance tasks ......................................................................................... 105
Tab. 84 Regular maintenance task options ............................................................................................. 107
Tab. 85 KAESER coolant mixture table ................................................................................................... 111
Tab. 86 Oil drain valve ............................................................................................................................. 121
Tab. 87 Oil drain valve ............................................................................................................................. 133
Tab. 88 Connecting elements .................................................................................................................. 142
Tab. 89 Maintenance according to mileage ............................................................................................. 145
Tab. 90 Maintenance according to time interval ...................................................................................... 145
Tab. 91 Lubricating points of the towbar ................................................................................................. 150
Tab. 92 Maintenance log ......................................................................................................................... 164
Tab. 93 Compressor spare parts ............................................................................................................. 165
Tab. 94 Engine spare parts ..................................................................................................................... 165
Tab. 95 "Temporarily decommissioned" information notice .................................................................... 216
Tab. 96 "Long-term decommissioning and storage" checklist ................................................................. 217
Tab. 97 “Long-term decommissioning and storage” information notice .................................................. 218
Tab. 98 Ball coupling, wear indicator ....................................................................................................... 221
List of Tables
x
Operator Manual Screw Compressor
M27 No.: 9_9548 05 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
■ Manufacturer’s declaration / declaration of conformity in accordance with applicable directives
■ Engine documentation (compressors driven by internal combustion engine)
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 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_9548 05 USE
Operator Manual Screw Compressor
M27 1

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.
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 death 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
Unlike the warnings shown above, damage warnings do not indicate a potential personal injury.
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,
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 placed by lists of actions comprising one stage of a task.
1. For instructions with several steps ...
2. ... the sequence of actions is numbered.
1 Regarding this Document
1.4 Symbols and labels
2
Operator Manual Screw Compressor
M27 No.: 9_9548 05 USE

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
cyclone moisture separator"). Option codes used in this service manual are explained in chap‐
ter 2.2.
Information referring to potential problems are 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_9548 05 USE
Operator Manual Screw Compressor
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.
A list of the options fitted is given as code letters on the right side of the options label.
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 appear on the nameplate.
2 Technical Data
2.1 Nameplate
4
Operator Manual Screw Compressor
M27 No.: 9_9548 05 USE

M27 Material No. Serial number
Options fitted
02-M0277-PE
r1= rb; rc; rd; rg
r3= rm; ro
r4= rr; rs; rt
*
tctb
r4r3r1
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 the fitted options from the options label and enter them here for reference.
2.2.1 Option da
Compressed air treatment devices
Option Option code Available?
Aftercooler and water separator da
Heat exchanger db
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
Separated compressed air distribution lines, down‐
stream of the option
fc
Tab. 7 Compressed air distributor option
2 Technical Data
2.2 Options
No.: 9_9548 05 USE
Operator Manual Screw Compressor
M27 5

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
M27 No.: 9_9548 05 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/Service brake
Example: rb/rm/rs means
EU chassis with height-adjustable towbar and overrun brake
Chassis
Chassis Option code Available?
Model (rb, rc, rd):
EU chassis rb
GB chassis rc
GB chassis rg
US chassis rd
Height adjustment options (rm, rn, ro):
Height-adjustable towbar rm
Adjustable coupling height rn
Fixed height towbar ro
Anti-twist protection towbar (rp):
Adapter, mounted rotatable rp
Service brake (rr, rs):
Without service brake rr
With overrun brake rs
EU = Europe, GB = Great Britain, US = United States of America
Tab. 14 Chassis options
2.2.11 Option tb, tc, te
Lighting
Option Option code Available?
Reflective warning triangle tb
EG 12 V tc
2 Technical Data
2.2 Options
No.: 9_9548 05 USE
Operator Manual Screw Compressor
M27 7

Option Option code Available?
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 option
2.2.13 Option ua
Hose reels
Option Option code Available?
Hose reels ua
Tab. 17 Hose reel option
2.2.14 Option sf
Anti-theft device
Option Option code Available?
Anti-theft device sf
Tab. 18 Anti-theft device option
2.3 Machine (without options)
2.3.1 Sound pressure level
Sound pressure levels comply with the American EPA Standard.
Measurement distance: 23 ft
M27
Guaranteed sound pressure level [dB(A)] 76
Tab. 19 Sound pressure level
2.3.2 Tightening torques for screws
Recommended values for screws of property class 8.8
Thread M4 M5 M6 M8 M10 M12 M14 M16 M18 M20
Torque [lbf-in] 26.6 52.2 88.5 216.8 424.8 743.5 1177 1823 2611 3673
Tab. 20 Tightening torques for screws (property class 8.8, coefficient of friction µ = 0.12)
2 Technical Data
2.3 Machine (without options)
8
Operator Manual Screw Compressor
M27 No.: 9_9548 05 USE

2.3.2.1 Torque cover fixing screws oil separator tank
Recommended values for screws corresponding to the strength category:
Screws Strength category Thread Torque [lbf in]
Hex-head screw 5.6 M12 332
Tab. 21 Torque cover fixing screws oil separator tank
2.3.2.2 Torques for lifting eye
Recommended values for screws corresponding to the strength category:
Screws Strength category Thread Torque [lbf in]
Hex-head screw 8.8 M12 708
Stud 8.8 M12 708
Tab. 22 Torques for lifting eye screws
2.3.3 Ambient conditions
Positioning Limit value
Maximum altitude amsl* [ft] 3000
Minimum ambient temperature [°F] 14
Maximum ambient temperature [°F] 113
* Higher altitudes are permissible only after consultation with the manufacturer.
Tab. 23 Ambient conditions
2.3.4 Additional specifications
For specifications, according to the machine's operating license, such as:
■dimensions,
■ track width,
■ footprint,
can be found in the dimensioned drawings in Chapter 13.3.
The dimensional drawings also show the position of the following inlets and outlets:
■Cooling air inlet
■ Cooling air outlet
■ Compressed air outlet
■ Exhaust
2.4 Chassis
2.4.1 Option rb/rm/rr, rb/rm/rs, rc/ro/rr, rg/rp/rr, rc/ro/rs, rd/ro/rr
Weight of machines approved for towing on public roads
Actual weight of individual machines is dependent on equipment fitted (see machine nameplate).
2 Technical Data
2.4 Chassis
No.: 9_9548 05 USE
Operator Manual Screw Compressor
M27 9

➤ Enter the actual overall weight* from the nameplate into the table for reference.
Option rb/rm/rr rb/rm/rs rc/ro/rr rg/rp/rr rc/ro/rs rd/ro/rr
Chassis type EU
chassis
EU
chassis
GB
chassis
GB
chassis
GB
chassis
US
chassis
Height-adjustable towbar x x − − − −
Fixed height towbar − − x x x x
Adapter, mounted rotata‐
ble
− − − x − −
Parking brake − x x x x −
Overrun brake − x − − x −
Actual total weight [lb]*
Permissible axle load [lb] 1653 1653 1653 1653 1653 1653
x = fitted, − = not fitted
EU = Europe, GB = Great Britain, US = United States of America
Tab. 24 Weight of the machine
2.4.2 Tires
The tire's dimensions are shown on the side wall, see also Fig. 1.
Fig. 1 Example for tire information on the side wall
1Section, tire side wall
2Tire width [in]
3Ratio cross-section height to cross-section
width [%]
4Radial design
5Rim diameter [in]
6Cross-section height
7Cross-section width
Use the following table for detailed information regarding the tires of your machine:
Characteristic/marking Value
Market Europe USA
Unit of pressure bar psi
Tire size 145/80 R 13 145/80 R 13
Minimum and recommen‐
ded tire pressure
2.7 39
2 Technical Data
2.4 Chassis
10
Operator Manual Screw Compressor
M27 No.: 9_9548 05 USE