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KAESER
Air Compressor
M122
KAESER M122 Service Manual
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➤
Do not allow operating materials to escape to the environment or into the sewage system.
➤
Store and dispose of operating materials and replaced parts in accordance with local environ‐
ment protection regulations.
➤
Observe national regulations.
This applies particularly to parts contaminated with fuel, oil, coolants and acids.
3
Safety and Responsibility
3.10
Environment protection
30
Service manual Portable compressor
M122
No.: 9_6974 20 E
RAMIRENT
41
43
Table of Contents
Default Chapter
3
Table of Contents
3
1 Regarding this Document Using this Document
13
Using this Document
13
Further Documents
13
Copyright
13
Symbols and Labels
13
Warnings
13
Tab. 1 Danger Levels and Their Definitions (Personal Injury)
13
Potential Damage Warnings
14
Other Alerts and Their Symbols
14
Tab. 2 Danger Levels and Their Definition (Damage to Property)
14
2 Technical Specifications Nameplate
16
Options Summary
16
Tab. 3 Nameplate
16
Compressed Air Distributor
17
Compressed Air Treatment Devices
17
Tab. 4 Combined Label for Coupling Load and Options Fitted
17
Tab. 5 Compressed Air Treatment Options
17
Tab. 6 Tool Lubricator Option
17
Tool Lubricator
17
Check Valve Function
18
Diesel Particulate Filter
18
Equipment for Fire Hazard Areas
18
Low Temperature Equipment
18
Proportional Controller
18
Tab. 10 Low Temperature Equipment Options
18
Tab. 11 Diesel Particulate Filter Option
18
Tab. 7 Compressed Air Distributor Option
18
Tab. 8 Non-Return Option
18
Tab. 9 Proportional Controller Option
18
Battery Isolating Switch
19
Chassis
19
Lighting
19
Sealed Floor Pan
19
Tab. 12 Optional Equipment for Fire Hazard Areas
19
Tab. 13 Optional Battery Isolating Switch
19
Tab. 14 Chassis Options
19
Tab. 15 Lighting Options
19
Tab. 16 Sealed Floor Pan
19
Anti-Theft Device
20
Instrument Panel Cover
20
Pedestrian Protection
20
Machine (Without Options)
20
Sound Emission
20
Tab. 19 Instrument Panel Cover Option
20
Tab. 20 Guaranteed Sound Power Level [Db(A)]
20
Tab. 21 Emission Sound Pressure Level [Db(A)]
20
Torques
21
Ambient Conditions
21
Additional Specifications According to the Machine's Operating Licence
21
Chassis
21
Mass
21
Tab. 22 Sound Pressure Level [Db(A)]
21
Tab. 23 Torques for Hex-Head Screws
21
Tab. 24 Ambient Conditions
21
Tyres
22
Wheel Nut/Bolt Tightening Torque
22
Towbar Tightening Torque
22
Compressor
22
Working Pressure and FAD
22
Tab. 25 Mass of the Machine
22
Tab. 26 Tyres
22
Tab. 27 Wheel Nut/Bolt Tightening Torque
22
Tab. 28 Towbar Tightening Torque
22
Tab. 29 Working Pressure and FAD
22
Compressed Air Outlet
23
Pressure Relief Valves
23
Temperature
23
Cooling Oil Recommendation
23
Tab. 30 Compressed Air Distributor
23
Tab. 31 Pressure Relief Valve Opening Pressure
23
Tab. 32 Machine Temperatures
23
Cooling Oil Charge
24
Engine
24
Engine Data
24
Oil Recommendation
25
Recommended Cooling Fluid
25
Tab. 35 Engine Data
25
Tab. 36 Engine Oil Recommendation
25
Tab. 37 Recommended Oil for Engines with Diesel Particulate Filters
25
Fluid Volumes
26
Batteries
26
Options
26
Tool Lubricator
26
Fresh Air Filter
26
Tab. 38 Fluid Volumes
26
Tab. 39 Batteries
26
Tab. 40 Road Breaker Lubricant Recommendation
26
Tab. 41 Fresh Air Filter Conditions
26
Low Temperature Equipment
27
Diesel Particulate Filter
27
Tab. 42 Environmental Conditions, Low Temperature Equipment
27
Tab. 43 Recommended Antifreeze
27
Tab. 44 Batteries, Low-Temperature Equipment
27
Tab. 45 Coolant Pre-Heater
27
Tab. 46 Diesel Particulate Filter Data
28
3 Safety and Responsibility Basic Instructions
29
Specified Use
29
Incorrect Use
29
User's Responsibilities
29
Observe Statutory and Universally Accepted Regulations
29
Determining Personnel
30
Adherence to Inspection Schedules and Accident Prevention Regulations
30
Complying with Inspection Intervals for Diesel Particulate Filters
31
Dangers
31
Safely Dealing with Sources of Danger
31
Tab. 47 Inspection Intervals According to Regulations
31
Safe Machine Operation
34
Organisational Measures
37
Danger Areas
37
Safety Devices
37
Tab. 48 Danger Areas
37
Safety Signs
38
Fig. 1 Location of Safety Signs
38
Emergencies
40
Correct Fire Fighting
40
Injury from Handling Operating Fluids/Materials
40
Tab. 49 Safety Signs
40
Warranty
41
Environment Protection
41
4 Design and Function Bodywork
43
Fig. 2 Bodywork
43
Machine Installation
44
Machine Function
44
Fig. 3 Right-Hand Door Opened
44
Fig. 4 Left-Hand Door Opened
44
Fig. 5 Machine Layout
45
Operating Modes and Control Modes
46
Operating Modes
46
PART LOAD Control
46
Safety Devices
47
Monitoring Functions with Shutdown
47
Fig. 6 Stepless Regulation of FAD (Standstill)
47
Further Safety Devices
48
Fuel Level Monitoring
48
Fig. 7 Fuel Level Monitoring
48
Fuel Pre-Filter Level Monitoring
49
Options
49
Compressed Air Treatment Options
49
Fig. 8 Compressed Air Options
49
Low Temperature Equipment Options
51
Fig. 9 Tool Lubricator
51
Fig. 10 Frost Protector
52
Optional Battery Isolating Switch
53
Fig. 11 Coolant Pre-Heating
53
Fig. 12 Battery Isolating Switch
53
Options for Operating in Fire Hazard Areas
54
Fig. 13 Pull Handle of Engine Air Shut-Off Valve
54
Diesel Particulate Filter Option
55
Transport Options
55
Fig. 14 General Design of the Diesel Particulate Filter System
55
Closed Floor Pan Option
56
Optional Anti-Theft Device
57
Pedestrian Protection Option
57
Fig. 15 Position of Service Openings in the Closed Floor Pan
57
Fig. 16 Drains for Oil and Coolant from Engine and Compressor
57
Tab. 17 Optional Anti-Theft Device
57
Tab. 18 Pedestrian Protection Option
57
5 Installation and Operating Conditions
58
Ensuring Safety
58
Installation Conditions
58
Fig. 17 Minimum Distance from Excavations/Slopes and Walls
58
6 Installation
60
Ensuring Safety
60
Reporting Transport Damage
60
Fitting the Towbar
60
Installation 6.1 Ensuring Safety
60
Fig. 18 Height Adjustable Towbar, Fitted
61
Fig. 19 Fitting the Height Adjustable Towbar
61
Fitting the Height Adjustable Towbar
61
Fig. 20 Non-Adjustable Towbar Fitted
62
Fitting a Non-Adjustable Towbar
62
Fig. 21 Fitting the Overrun Braking Mechanism of the Non-Adjustable Towbar
63
Adjusting the Chassis
64
Fig. 22 Fitting the Jockey Wheel of the Non-Adjustable Towbar
64
Adjusting the Towbar Height
65
Changing the Towing Eye
65
Fig. 23 Towbar Height Adjustment
65
Fig. 24 Changing the Towing Eye (Height-Adjustable Drawbar)
66
Fig. 25 Changing the Towing Eye (Fixed Height Towbar, GB Chassis Version)
67
Fig. 26 Changing the Towing Eye (Fixed Height Towbar, USA Chassis Version)
68
7 Initial Start-Up Ensuring Safety
69
Before Initial Start-Up (or Recommissioning)
69
Note When Commissioning
69
Special Measures for Re-Commissioning after Storage
70
Checking Installation and Operating Conditions
70
Tab. 50 Measures for Re-Commissioning the Compressor after a Long Period of Storage
70
Tab. 51 Positioning and Operating Conditions Checklist
70
Low-Temperature Operation (Winter)
71
Starting Assistance
71
Fig. 27 Jumper Cable Connection Diagram
72
Starting up Low-Temperature Equipment
73
Fig. 28 Coolant Pre-Heating
74
Tab. 52 Low-Temperature Equipment Checklist
74
8 Operation
75
Ensuring Safety
75
Starting and Stopping
75
Operation 8.1 Ensuring Safety
75
Commissioning the Machine
76
Fig. 29 Starting Instruments
76
Allow the Machine to Run up to Operating Temperature
77
Fig. 30 Label Referring to the Warm-Up Period When Ambient Temperatures Are below -10 °C
77
Starting the Machine
77
Fig. 31 Proportional Controller
78
Manual Pressure Setting
78
Switching to LOAD
78
Shutting down the Machine
79
Monitoring the Fuel Level
79
Operating the Tool Lubricator
80
Fig. 32 Setting the Tool Lubricator
80
Using the Low-Temperature Equipment
81
Using with the Frost Protector Switched on
81
Fig. 33 Frost Protector on and off
81
Coolant Pre-Heating
82
Operating the Battery Isolating Switch
82
Fig. 34 Battery Isolating Switch
82
Shut down the Machine if any Dangerous Situation Arises
83
Fig. 35 Handle for Manually Closing the Engine Air Intake Valve
83
9 Fault Recognition and Rectification
84
Basic Instructions
84
Evaluate Engine Faults and Alarms
84
Engine Refuses to Start or Does Not Turn over
84
Engine Does Not Reach Full Speed
85
Indicator Lamp Remains on
85
Tab. 53 Fault: Engine Refuses to Start or Comes to a Stop
85
Tab. 54 Fault: Engine Does Not Reach Full Speed
85
Evaluate Compressor Faults and Alarms
86
Working Pressure too High
86
Working Pressure too Low
86
Tab. 55 Indicator Lamp Remains on
86
Tab. 56 Fault: Working Pressure too High
86
Pressure Relief Valve Blowing off
87
Machine Overheating
87
Tab. 57 Fault: Working Pressure too Low
87
Tab. 58 Fault: Pressure Relief Valve Blowing off
87
Too Much Oil Residue in the Compressed Air
88
Oil Flows from the Compressor Air Filter after Shutdown
88
Tab. 59 Fault: Machine Overheating
88
Tab. 60 Fault: too Much Oil Residue in the Compressed Air
88
Tab. 61 Fault: Oil Flows from the Compressor Air Filter after Shutdown
88
High Moisture Content in the Compressed Air
89
Evaluate Faults in the Diesel Particulate Filter
89
Tab. 62 Fault: High Moisture Content in the Compressed Air
89
Tab. 63 Faults in the Diesel Particulate Filter
89
Tab. 64 Fault 'Blue Engine Exhaust
89
Tab. 65 Grey or Brownish Exhaust Gas
90
10 1 Maintenance
91
Ensuring Safety
91
Following the Maintenance Plans
92
Logging Maintenance Work
92
Maintenance Tasks after Commissioning
92
Regular Maintenance Tasks
93
Tab. 66 Maintenance Tasks after Commissioning
93
Tab. 67 Maintenance Intervals and Regular Maintenance Tasks
93
Tab. 68 Regular Machine Maintenance Tasks
96
Engine Maintenance
97
Tab. 69 Regular Maintenance Task Options
97
Water Cooler Maintenance
98
Fig. 36 Checking Coolant Level
99
Tab. 70 KAESER Coolant Mixture Table
100
Fig. 37 Draining the Coolant from the Radiator
101
Fig. 38 Draining the Coolant from the Radiator (Closed Floor Pan - Stationary Machine)
102
Engine Air Filter Maintenance
103
Fig. 39 Engine Air Filter Maintenance
103
Fig. 40 Cleaning the Filter Element
104
Fuel System Maintenance
105
Fig. 41 Fuel System Maintenance
105
Fig. 42 Bleeding the Fuel System
106
Fig. 43 Emptying the Fuel Pre-Filter Water Trap
107
Fig. 44 Changing the Fuel Pre-Filter Cartridge
108
Checking the Engine Oil Level
109
Fig. 45 Fuel Filter Maintenance
109
Engine Oil Filling and Topping up
110
Fig. 46 Checking the Engine Oil Level
110
Changing the Engine Oil
111
Fig. 47 Draining the Engine Oil
112
Fig. 48 Draining the Engine Oil (Closed Floor Pan - Stationary Machine)
113
Replace the Engine Oil Filter
114
Fig. 49 Changing the Oil Filter
114
Drive Belt Maintenance
115
Fig. 50 Belt Guard Attachment
116
Fig. 51 Belt Tension Checking by Hand
117
Fig. 52 Changing/Tensioning the Drive Belt
118
Battery Maintenance
119
Fig. 53 Safety Signs - Warning Stickers on the Battery
119
Compressor Maintenance
122
Checking Cooling Oil Level
122
Fig. 54 Checking Cooling Oil Level
122
Cooling Oil Filling and Topping up
123
Changing the Cooling Oil
124
Fig. 55 Draining Cooling Oil
125
Fig. 56 Draining the Cooling Oil (Closed Floor Pan - Stationary Machine)
126
Replace the Compressor Oil Filter
127
Fig. 57 Changing the Oil Filter
127
Oil Separator Tank Dirt Trap Maintenance
128
Fig. 58 Oil Separator Tank Dirt Trap Maintenance
129
Changing the Oil Separator Cartridge
130
Fig. 59 Changing the Oil Separator Cartridge
131
Fig. 60 Changing the Oil Separator Cartridge (Option Ba)
133
Compressor Air Filter Maintenance
134
Fig. 61 Compressor Air Filter Maintenance
135
Fig. 62 Cleaning the Filter Element
136
Checking Pressure Relief Valves
137
Clean Cooler/Radiator
137
Cleaning the Cooler/ Radiator
137
Cleaning the Compressed Air Aftercooler
138
Fig. 63 Cleaning the Cooler/ Radiator
138
Maintenance of Rubber Sealing Strips
139
Fig. 64 Cleaning the Compressed Air Aftercooler
139
Chassis Maintenance
140
Wheel Checks
140
Towbar Maintenance
140
Fig. 65 Towbar Maintenance
141
Brake System Maintenance
142
Fig. 66 Ball Coupling (EC Version)
142
Fig. 67 Ball Coupling (USA Version)
142
Fig. 68 Checking the Brake Lining Thickness
143
Fig. 69 Brake System Adjustment
144
Maintenance of Optional Items
145
Fig. 70 Brake Rod Adjustment
145
Fig. 71 Tool Lubricator Maintenance
146
Tool Lubricator Maintenance
146
Cyclone Separator Maintenance
147
Fig. 72 Cleaning the Dirt Trap
148
Combination Filter Maintenance
149
Fig. 73 Combination Filter Maintenance
149
Fig. 74 Fresh Air Filter Maintenance
152
Fresh Air Filter Maintenance
152
Fig. 75 Filling the Frost Protector
155
Frost Protector Maintenance
155
Fig. 76 Cleaning the Spark Arrestor (Standard)
156
Spark Arrestor Cleaning
156
Fig. 77 Cleaning the Spark Arrestor (Closed Floor Pan)
157
Engine Air Intake Shut-Off Valve Maintenance
158
Fig. 78 Engine Air Intake Shut-Off Valve Maintenance
158
Fig. 79 Checking Manual Operation of the Engine Air Intake Valve
159
Documenting Maintenance and Service Work
160
Tab. 71 Maintenance Log
160
11 Spares, Operating Materials, Service
161
Note the Nameplate
161
Ordering Consumable Parts and Operating Fluids/Materials
161
Tab. 72 Compressor Consumables
161
Tab. 73 Consumable Engine Parts
161
Kaeser Air Service
162
Service Addresses
162
Spares for Service and Repair
162
12 Decommissioning, Storage and Transport
236
De-Commissioning
236
Temporary De-Commissioning
236
Tab. 74 "Temporarily Decommissioned" Information Notice
236
Long-Term De-Commissioning and Storage
237
Transport
238
Safety
238
Road Transport of the Machine as a Trailer
238
Tab. 75 "Long-Term Decommissioning and Storage" Checklist
238
Tab. 76 Text for the "Long-Term Decommissioned and Storage" Information Notice
238
Fig. 80 Towing Alignment
240
Fig. 81 Ball Coupling (ALKO-EU)
240
Fig. 82 Ball Coupling Wear Indicator ALKO-EU
241
Fig. 83 Ball Coupling (ALKO-USA)
242
Tab. 77 Ball Coupling Wear Indicator
242
Fig. 84 Release the Parking Brake
243
Fig. 85 Safety Sign - Secure the Chocks
244
Parking the Compressor
245
Fig. 86 Breakaway Cable Attachment
245
Fig. 87 Warning "Risk of Injury Due to Falling Towbar
246
Fig. 88 Actuating the Parking Brake
246
Transport with a Crane
247
Fig. 89 Safety Sign - Secure the Chocks
247
Transporting with a Forklift Truck
248
Fig. 90 Transport Using a Forklift Truck
248
Transporting as a Load
249
Fig. 91 Load Secured by Strapping
249
Storage
250
Disposal
250
13 Annex
252
Identification
252
Pipeline and Instrument Flow Diagram (P+I Diagram)
252
Fig. 92 Identification
252
Dimensional Drawings
257
Dimensional Drawing - Chassis with Height-Adjustable Tow Bar
257
Dimensional Drawing, Chassis with Fixed Height Tow Bar
259
Dimensional Drawing, Chassis Without Parking Brake
261
Dimensional Drawings of Stationary Machine (Skids)
263
Dimensional Drawings of Stationary Machine (Base Frame)
265
Wiring Diagrams
267
Electrical Diagram
267
Connection Adapter for the Diesel Particulate Filter
292
Lighting and Signalling System Connection
297
Lighting and Signalling System Connection
305
Fuel Circulation Diagram
310
Operating Instructions for Compressed Air Filter (Combination Filter)
312
Instruction Manual
313
Safety Rules
321
Technical Data
322
Technische Daten
322
Description of Operation
323
Condensate Drain
325
Operating Instructions for Compressed Air Filter (Fresh Air Filter)
333
Service Tasks on the Diesel Particulate Filter
347
5
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KAESER M122 Specifications
General
Brand
KAESER
Model
M122
Category
Air Compressor
Language
English
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