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SERVICE MANUAL

1. saun BunjieJqJaA Japo Gunyraquova Bungaunads 5 aBrjsuos sapo uaidoy NZ JnDJ J8AUD nz p i eis sayIng nyassno sasun 441319 7 eif 104 SERVICE MANUAL Screw Compressor M 13 15 17 No 9 6983 01 USE 13 Annex Mel 13 Electrical Diagram 13 5 Electrical Diagram SERVICE MANUAL Screw Compressor No 9 6983 01 USE M 13 15 17 105 Wess EEGI ELA enpwes abed voy US IV 3 aorsrn wies 2 saljued 1915 22 apeu Jo papJe Joj snw sou sjeuibiJo sayay asodund uey4 Aue Joy apeu aq jou 5 21u0J423 8 Jo asn q uoijeuiuassip pue juawyeasy abesoys suoijanpoJdaJ Jaujo Aue Jo 9140 asodund ayy pajsnyjua ase auj KjJado id aAIsnjoxa Jno uwas sBuimesp 241 Binqo 01796 ELS 4504 Hquij uasossaidwoy Jasaey JaJnj2ejnue J J040A VONOH A SIW ELW al 1800 13 5 Electrical Diagram 13 Annex suleJbeip e31J128 3 N 9 m
2. 38 Alarm Too much residue the compressed 39 Alarm Oil flows from the compressor air filter after shutdown 40 Alarm Air temperature too high 40 Alarm Outflow of condensate 40 Regular compressor maintenance tasks sese enne 42 Regular engine maintenance tasks 42 Regular fuel system maintenance tasks nennen 43 Regular battery maintenance tasks nennen nnne 44 Regular chassis maintenance tasks nnne 44 Lifting eye check 2 2 ees 44 Lifting uou Ee eB EB S 44 Regular canopy maintenance tasks 45 Other maintenance tasks one e aa e hee hc tete 45 Cyclone separator maintenance schedule 45 Logged maintenance tasks nnne nnn nnn nnn a A a nnn rnnt nnn 67 Compressor consumables 68 Consumable engine 68 Temporarily decommissioned information notice 92 Long term decommissioni
3. nennen 34 8 2 Operating the external air treatment unit sesssssssssssseseeneen 35 Fault Recognition and Rectification 9 1 Basic instructions A E EE 36 9 2 Engine faults and alarms nennen nnne nnne nnns 36 9 2 1 Engine refuses to start or comes to a stop 36 9 22 Engine does not reach full speed 37 9 3 Compressor faults and alarms 4 37 9 3 1 Working pressure too 37 9 3 2 Working pressure too low svrsi birisi 38 9 3 3 Safety relief valve blowing eene 38 9 3 4 Machine overheating ene m ener nnne nennen 38 9 3 5 Too much oil residue the compressed air 39 9 3 6 Oil flows from the compressor air filter after shutdown 40 9 4 Faults and alarms on external air treatment units 40 9 4 1 temperature of the treated air is too high 40 9 4 2 Outflow of condensate cccccccceeeeeeeeeeeeeeeeeeeeeaeeeeeeaeceeeeeeeeeeeseeeseeeteneeeetees 40 Maintenance TOS
4. 20 General arrangement 01 21 General arrangement 02 E Ee 21 Air treatment Oplioris RIIRDRUERPICEGERUIMERUiIDPIRMEIMRIGRINGIRICIN AEREA EEEIEE 23 Minimum distance from excavations slopes and walls 25 Connecting the air treatment unit 27 Starting elemehts 5 ec e tei petalis cadi 33 Instruments RE EDRHCBR EB DRCBRSNERPIM EPA 33 Engine air filter maintenance 46 Changing the engine 44 49 Belt tension checkirig by e e e d etel C 50 Belt terisioninig o eR PERIERE eae eee nase aka Hane RING 51 Warning stickers on the battery 52 Checking cooling oil level 55 Changing the cooling oil nnn nnn enne nennen 57 Changing the oil filter r a e E a a a ar 59 Changing the oil separator cartridge 60 Compressor air filter maintenance 62 Cleaning Coolers uh ee eot e ern EHE eee tu 64 Cleaning c sss A at re
5. enne tenen enne nen 6 Safety relief blow off setting nnne 7 Machine temperatures eite e EE E EEG eec CR eR Re RR RU EORR RE 7 Cooling oil recommendation nennen rentre nnn nene nennen nnn 7 Cooling oll charge ADI 8 Engirie specifiCatlon EE 8 Engine oil recommendation essseseseessssessseeseeeeennne nennen innt 9 Fl id vol mmes sn pee Eee ete eut ode eee uites ds 9 Battery 9 DanGer ucc cc 15 Safety Signs eo e eei I DRE 16 Positioning and operating conditions checklist 29 Measures for re commissioning the compressor after a long period of storage 30 Alarm Engine refuses to start or comes to a stop 36 Alarm Engine does not reach full speed nnne 37 Alarm Working pressure too high nennen nnn nnne nnn 37 Alarm Working pressure too low enhn nn nennen sensn enhn n nnne 38 Alarm Safety relief valve blowing off ccceceececeeeeeeeeeeeeeeeeeeeeaeaeeeeeecaeeeseseeeeeseeneeeeeseaees 38 Alarm Machine overheating
6. eed eee eB ete ee MD 41 10 2 Maintenance schedules 2 etu Epp 41 10 2 1 Logging maintenance work 41 SERVICE MANUAL Screw Compressor M 13 15 17 No 9 6983 01 USE COMPRESSORS No 9 6983 01 USE 11 12 13 Contents 10 2 2 Compressor maintenance schedule 42 10 2 3 Engine maintenance schedule ssseseeeenennnn 42 10 2 4 Chassis maintenance schedule 44 10 2 5 Other maintenance tasks ener eene nennen 45 10 2 6 Maintenance schedules for options essssssssseseeeneeeeees 45 10 3 SENQING n URDU A Be oe as esate eect ee ee eee 45 10 3 1 Air filter maintenance ccccceeeecceceeeeeeeceeeeeeceeceeeeeaeeeeesaeeesesesaeeesssneeeeeetneaees 46 10 3 2 Changing the engine oil sssssssseeeemeeenee enne 48 10 3 3 Checking the drive ennt 49 10 3 4 Battery maintenance nennen nmn nnn nnne 52 10 4 Compressor nt unis pU USUS hr qs Par rus 1 55 10 4 1 Checking cooling oil level sssssssssneemeennnnenen nennen 55 10 4 2 Topping up the cooling enn 56 10 4 3 Changing the cooling enne 56 10 4 4 Changing the sss 58 10 4 5 Changing the oil separator cart
7. No 9 6983 01 USE SERVICE MANUAL Screw Compressor M 13 15 17 106 FS eg LO ELOLO IH EL V JS 104440 tuner Amp 24543 2 1 8d3S3V emus 5 l 104440 25 yo bnid yseds 241 aJnssaJd 10 aJnjeJadus sxuejsig IMEA BurjuaA uoj4nqusnd dojs xoinb Joe Jauab 1uorjunj 1102 JosiAJadng BALA JjO jnus jany 4914245 uorpung pe q 7 42819 9119 2219 anig7ayiym 11 314 Em a M 3 m 2 19 13 Annex 13 5 Electrical Diagram 4 anjg pelq 749214 cc o o cc 07 1 SERVICE MANUAL Screw Compressor M 13 15 17 No 9 6983 01 USE fusum mae ee nens wen ann FN LO ELOLO WH ELW4S Jg LLW SLW ELW TISON Pi uawd nba je21423 3 83S 3V5 emu l 1 ZA IAEA 4 0 4N S jan LA 1102 vol yu LI ZL1 uoj4nqusnd dojs 5inb 175 187 15 10 4015 u24IMs LS ZN 1010J4 8 e 1S LW NO ejed SJ JojeJauab aseud ajbuis zD 4D xgjeds amp i3 7i3 Jnop 88 Jossaudwojyabneb a
8. 23S JV mess B JBUIE LYS 3 ZZou des 1110 aul uJnjaJ 110 1040 jaued 1044405 aJnssaJg BAJEA aunssald yms aunyevadway Bnjd 2 Jap 110 ajzzou aJnssaJd unuiuly 1ojeJedaes 95 110 JojeJedas 110 19 JossaJduio SERVICE MANUAL Screw Compressor M 13 15 17 No 9 6983 01 USE 100 TENUTI 13 Annex 133 Dimensional drawing version with chassis 13 3 Option sa Dimensional drawing version with chassis SERVICE MANUAL Screw Compressor No 9 6983 01 USE M 13 15 17 101 COMPRESSORS 13 Annex 13 3 Dimensional drawing version with chassis Folding handlebar Engine exhaust T 10937 USE 10125055_00 KOMPRESSOREN Portable compressor M 15 M 17 Ersatz f r 3007 Gisela F sel Ma stab 1 10 auf Compressed air outlet pv 4990 snu j p Dunuure7 ueBunJapuy ajDuipeqsbunpprju3 HL Z EN uxnBugBnz asia 4 6 0 ui sapo ua iu usjJnp vaun pya aou Pubi Japan uapJam nz JNU uejJnp auia ss
9. i imm mmm mm mw ATA 1925 SERVICE MANUAL Screw Compressor 78 M 13 15 17 No 9 6983 01 USE 14 Y 3 13 4 11 Spares Operating Materials Service ezo l EEES 115 Spare parts for service and repair Legend KAESER Airend engine SEL 1789 01E _ Sigma HD sas ease tnt Drive belt Engine oiy Fgh a mr Inlet valve Mamtemancekinetvave _____________ ______ Overhaulkit inlet valve su i ane ade ea pd as aac Rec ad E tenets ot Please quote the part number and serial number of the machine together with the item number and the description of the part when ordering Before and during all work be sure to read and follow the safety and service instructions in the machine s service manual see cooling oil engine oil recommendations SERVICE MANUAL Screw Compressor No 9 6983 01 USE M 13 15 17 Spares Operating Materials Service 11 5 Spare parts for service and repair 11 o cc 9 m SERVICE MANUAL Screw Compressor M 13 15 17 No 9 6983 01 USE 80 11 Spares Operating Materials Service KAESER COMPRESSORS 11 5 Spare parts for service and repair i Alternator
10. 10 M0391 Cleaning the dirt trap Cyclone separator Sealing ring Dirt trap 6 Strainer Condensate drain hose Condensate drain hose union nut Screw plug Nozzle Cleaning the dirt trap 1 Unscrew the plug 4 and remove the strainer 6 from the dirt trap 2 2 Loosen the union nut 7 and detach the condensate drain hose 3 from the dirt trap 3 Unscrew the nozzle 8 from the dirt trap housing and clean 4 Check the nozzle for function and wear Renew if non functional 5 Clean the dirt trap housing plug and sealing ring 5 SERVICE MANUAL Screw Compressor M 13 15 17 65 MAESER 10 Maintenance exol 106 Options 6 Clean the strainer 7 Check the strainer and sealing ring for function and wear Renew if non functional 8 Replace the strainer in the dirt trap and screw in the plug 9 Screw in the nozzle and re attach the condensate drain hose Function and leakage check 1 Start the machine and run for approximately 5 minutes 2 Check the cyclone separator housing and hose line for leaks SERVICE MANUAL Screw Compressor 66 M 13 15 17 No 9 6983 01 USE 10 Maintenance 107 Document maintenance and service work No 9 6983 01 USE 10 7 Document maintenance and service work Machine number gt Enter maintenance and service work carried out in the list Date Maintenance task carried out Operating hours Tab 47 Logged maintenance tasks SERVICE M
11. Jejun BunjiaJqJ8A Japo Gunyraquova Bunsayiads uarsjanuisurs sapo uaidoy NZ JnDJ J8AUD nz JNU p i eis sayIng nyassno sasun 441319 7 eif 102 SERVICE MANUAL Screw Compressor M 13 15 17 No 9 6983 01 USE TENUTI 13 Annex 13 Dimensional drawing stationary version 13 4 Option sc Dimensional drawing stationary version SERVICE MANUAL Screw Compressor No 9 6983 01 USE M 13 15 17 103 COMPRESSORS 13 Annex 13 4 Dimensional drawing stationary version 10125087 00 KOMPRESSOREN T 10938 USE KAESER Engine exhaust Stationary compressor Ersatz f r Gisela Fosel Ma stab 1 20 auf 3007 Gisela machine mounts 642770 M 15 Compressed air outlet pv 4990 snu j p Dunuurez ajDuipeqsbunpprju3 Available with rubber mounts or machine mounts Bolt down the compressor with machine mounts only asia 4 6 0 ui sapo ua iu uafiun6i og eiJaA aou Pub Japan uapJam 151148aBuD nz JNU uejJnp auia s s
12. plug Fuel cut off TDI TT _ Oil pressure swith 0000000000000 ML I MM vei Engine oil fiter SEL 1791_01E machine s service manual Please quote the part number and serial number of the machine together with the item number and the description of the part when ordering Before and during all work be sure to read and follow the safety and service instructions in the SERVICE MANUAL Screw Compressor No 9_6983 01 USE M 13 15 17 81 19 4539 3 2 11 Spares Operating Materials Service 115 Spare parts for service and repair SEG 1962 01 4461 SERVICE MANUAL Screw Compressor 82 M 13 15 17 No 9 6983 01 USE 45343 4 11 Spares Operating Materials Service Ide 5 3 21255 115 Spare parts for service and repair Legend KAESER Engine SEL 1793 01E X Alternator regulator pressure swith MACC ENIM Please quote the part number and serial number of the machine together with the item number and the description of the part when ordering Before and during all work be sure to read and follow the safety and service instructions in the machine s service manual SERVICE MANUAL Screw Compressor No 9 6983 01 USE M 13 15 17 14 Y 3 13 4 11 Spares Operating Materials Service 115 Spare parts for service and re
13. Copyright This service manual is copyright protected Queries regarding use or duplication of the documentation should be referred to KAESER Correct use of information will be fully supported Symbols and Identification Warnings Warning notices indicate three levels of danger signified by the signal word DANGER WARNING CAUTION DANGER These show the kind of danger and its source The possible consequences of ignoring a warning are shown here The word Danger indicates that death or severe injury can result from ignoring the instruction gt measures required to protect yourself from danger are shown here SERVICE MANUAL Screw Compressor M 13 15 17 1 KAESER 1 Regarding this Document 14 Symbols and Identification gt Always read and comply with warning instructions Signal word Meaning Consequences of non observance DANGER Warns of an imminent threat of danger Death or serious injury may result WARNING Warns of possible danger Death or serious injury are possible CAUTION Warns of a possibly dangerous situa Light injuries or material damage are possible tion Tab 1 Thelevels of danger and their meaning 1 4 2 Other instructions and symbols This symbol refers to particularly 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 t
14. Cil circuit Comprsd air outlet SEL 1783 01E Maintenance kit combi valve Compressor cooler scavenge line Din ep ol scavenge line s dad wat Prepared hose _ Pipec connection seal oe CAM __ Claw coupling adapter Clawcoupling Please quote the part number and serial number of the machine together with the item number and the description of the part when ordering Before and during all work be sure to read and follow the safety and service instructions in the machine s service manual Overhaul k kit combination valve i M Compressor o oil cooler drain x ETT ee Prepared h hose d SERVICE MANUAL Screw Compressor No 9 6983 01 USE M 13 15 17 73 Spares Operating Materials Service 11 o cc 9 m 11 5 Spare parts for service and repair LO 8661 2938 SERVICE MANUAL Screw Compressor M 13 15 17 9 6983 01 USE No 74 45343 4 11 Spares Operating Materials Service ezo l EEEE 115 Spare parts for service and repair Legend KAESER Electrics Instruments SEL 1785 O1E ML i se sed can wash esas ls ee pl Dean tee ah st a ate dell NEM Battery bracket 0d ecd Mains supply cable set JU instrument panel Please quote the part number and serial number of the machine together with the item number and the description of the part when ordering Before and
15. SERVICE MANUAL Screw Compressor M 13 15 17 97 13 Annex 13 1 Marking 13 13 4 Marking 13 M0150 Fig 23 Marking VIN number vehicle identification number Machine nameplate with serial number Engine nameplate with serial number 13 2 Pipeline and instrument flow diagram diagram SERVICE MANUAL Screw Compressor 98 M 13 15 17 No 9 6983 01 USE 13 Annex COMPRESSORS 13 2 Pipeline and instrument flow diagram P l diagram 1060010 LSZLELWW44 ue se ajqejleAe 4 passaJduoj lt 84 00 60010 LSHIEIMHd Bunudsuq N3H0S S 43S 31V SERVICE MANUAL Screw Compressor M 13 15 17 99 No 9 6983 01 USE 13 Annex 13 2 Pipeline and instrument flow diagram P diagram o cc o 9 m L0 600L0 LSZLELWW44 pu es JIE GOW eren ue se ajqejleAe J8 044u02 pua ajzzoN 1l8q A 4994 JaJua s Jsneux3 ue Jeq lt saJnssaJd Bulysom saulyzew uo Ja3uallS uojsid paads JofoW gt 10 491002 110 4911044402 aJnjeJaduiaj 110 p N3H0S S
16. Secure all retaining clips 4 DECOX Ur dy NA Cleaning the paper filter element Release all retaining clips 4 Take off the filter cap 1 Withdraw the paper element 3 from the housing 5 Clean all sealing faces with a damp cloth UE CP Dislodge dirt from the element 3 by tapping against a firm surface or by blowing out with com pressed air max 30 psig do not attempt to brush the dirt out Insert the paper element 3 in the housing 5 Replace the filter cap 1 on the housing 5 8 Secure all retaining clips 4 2579 Changing the engine oil The engine oil should be changed according to the maintenance schedule according to the degree of contamination of the intake air atleast once a year Engine oil Receptacle Cleaning rags Funnel The machine is shut down The machine is standing level The machine is fully vented the pressure gauge reads 0 psig Engine at operating temperature All compressed air consumers are disconnected and the air outlet valve is open Rear panel removed The negative cable to the battery is disconnected CAUTION Danger of burns from hot components and escaping engine oil gt Wear long sleeved clothing and gloves SERVICE MANUAL Screw Compressor M 13 15 17 No 9_6983 01 USE KAESER COMPRESSORS Fig 12 x Further information 10 3 3 No 9 6983 01 USE 10 Maintenance 10 3 Engine 10 0165 NO
17. The machine is fully vented the pressure gauge reads 0 psig Machine cooled down All compressed air consumers are disconnected and the air outlet valve is open Canopy open SERVICE MANUAL Screw Compressor M 13 15 17 61 KAESER COMPRESSORS 62 Fig 20 10 Maintenance 10 4 Compressor 10 M0342 Compressor air filter maintenance Retaining clip Air filter element Air filter housing Filter cap Direction of air blast Checking contamination of the filter element The filter element should be checked visually for contamination Checking should be carried out according to the compressor maintenance schedule in chap ter 10 2 2 gt Check the filter element Release both retaining clips 1 Take off the filter cap 5 Withdraw the element 4 from the housing 2 Check the filter element 4 Visually check for RON gt Damage The element 4 must be replaced if it is damaged see section on replacing the air filter element Excessive dirt contamination Large dirt particles If it can be seen that the element 4 can be reused after cleaning it should be cleaned according to the given instructions 5 If cleaning is not necessary the element should be correctly re installed Insert the element 4 in the housing 2 Replace the filter cap 5 m Secure the cap 5 with the two retaining clips 1 Renewing the filter element 1 Release both retaining clips 1 2 Take of
18. 5 The starter switch is in the O position 4 Pull out the choke 1 to position 3 mixture enrichment for every start 5 Turn the starter switch 5 to the I position The starter switch is in the run position 6 Turn the starter key 5 to the II position and release it as soon as the engine starts The starter switch 4 springs back to the I run position 7 When the engine is running smoothly push in the choke 1 slowly to the 2 position Allow the machine to run up to operating temperature To avoid unnecessary wear the engine should be run in idle until the airend discharge temperature reaches 86 F The airend discharge temperature is shown by the temperature gauge switch 7 gt Allow the machine to warm up in idle Shutting down For minimum wear shut down Allow the machine to run in idle before shutting down Run the machine in slow speed idle Turn the starter key 5 to the 0 position Wait until the machine has automatically vented pressure gauge 8 reads 0 bar Close the compressed air outlet valve Withdraw the starter key 5 from the starter switch 4 and secure in a safe place Qu o oo a Emergency shutdown Press the QUICK STOP 6 button to bring the machine to a stop as quickly as possible in an emergency The QUICK STOP button is located immediately above the starter switch 4 see Fig 9 After the QUICK STOP button has been pressed All rotating machine parts
19. COMPRESSORS 60 10 4 5 Material Precondition 10 Maintenance 10 4 Compressor Changing the oil separator cartridge If the safety relief valve blows off during operation of the machine the pressure drop over the oil separator cartridge is too high see chapter 9 3 gt The oil separator cartridge must be changed immediately The oil separator cartridge cannot be cleaned The life of the oil separator cartridge is influenced by Contamination in the air drawn into the compressor Adherence to the changing intervals for Cooling oil Oil filter Air filter Spares Cleaning cloths The machine is shut down The machine is fully vented the pressure gauge reads 0 psig Machine cooled down All compressed air consumers are disconnected and the air outlet valve is open Rear panel removed The negative cable to the battery is disconnected 10 M0155 Fig 19 Changing the oil separator cartridge Control air line union nut O ring Dirt trap Strainer Oil scavenge pipe 9 Cover Compressed air hose fitting O ring Compressed air hose Oil separator cartridge 6 Fixing screws SERVICE MANUAL Screw Compressor M 13 15 17 No 9_6983 01 USE KAESER COMPRESSORS 10 4 6 Material Precondition No 9 6983 01 USE 10 Maintenance 10 4 Compressor Changing the oil separator cartridge 1 Unscrew the union nut 1 and carefully put the parts
20. Carry out maintenance tasks according to the following schedule Interval Maintenance task See chapter Weekly Check the battery fluid level 10 3 4 every 40 h connections operating hours Regular battery maintenance tasks Chassis maintenance schedule Chassis maintenance gt Carry out maintenance tasks according to the following schedule Interval Maintenance task See chapter Weekly Check the tire pressures Annually Check the condition of the lock ing rings Regular chassis maintenance tasks Checking the lifting eye gt Carry out maintenance tasks according to the following schedule Interval Maintenance task See chapter Annually Have checked Specialized workshop every 400 500 h h operating hours Lifting eye check Checking lifting handles gt Carry out maintenance tasks according to the following schedule Interval Maintenance task See chapter Annually Check secure attachment every 400 500 h h operating hours Lifting handle check SERVICE MANUAL Screw Compressor M 13 15 17 No 9 6983 01 USE KAESER COMPRESSORS Tab 44 10 2 5 Tab 45 10 2 6 Option da Tab 46 10 3 No 9 6983 01 USE 10 Maintenance 10 3 Engine Canopy maintenance gt Carry out maintenance tasks according to the following schedule Interval Maintenance task See chapter Every 6 months Check all screw connections every 200 250 h hinges locks catches and h
21. Contact with operating materials The following operating materials are in the machine fuel battery electrolyte lubricating oil m compressor cooling oil SERVICE MANUAL Screw Compressor M 13 15 17 Shut down the machine from the instrument panel if possible 17 KAESER COMPRESSORS 18 3 9 3 10 62 3 Safety and Responsibility 3 9 Warranty If necessary request a copy of the safety data sheet for KAESER SIGMA FLUID gt Eye contact rinse thoroughly with lukewarm water and seek medical assistance gt Skin contact wash off immediately Warranty This service manual contains no independent warranty commitment Our general terms and condi tions of business apply with regard to warranty A condition of our warranty is that the machine is used for the purpose for which it is intended under the conditions specified Due to the multitude applications for which the machine is suitable the obligation lies with the user to determine its suitability for his specific application In addition we accept no warranty obligation for m use of unsuitable parts or operating materials m unauthorized modifications m incorrect maintenance incorrect repair Correct maintenance and repair includes the use of original spare parts and operating materials gt Obtain confirmation from KAESER that your specific operating conditions are suitable Environmental Protection Store and dis
22. gt Strictly forbid fire open flame and smoking gt f welding is carried out on or near the machine take adequate measures to prevent sparks or heat from igniting fuel or oil vapors or parts of the machine machine is not explosion proof Do not operate in areas in which specific requirements regarding explosion protection are in force For instance the requirements of ATEX directive 94 9 EC Equipment and Protective Systems intended for use in Potentially Explosive Atmospheres gt Ensure that required ambient conditions are maintained with regard to m ambient temperature clean inlet air with no damaging contaminants inlet air free of explosive or chemically unstable gases or vapors inlet air free of acid alkaline forming substances particularly ammonia chlorine or hydrogen sulfide Keep suitable fire extinguishing agents ready for use Machine placement The ground at the machine s location must be level firm and able to take the machine s weight not more than 15 inclination in any direction L Lx 1 5 15m 15m 05 0141 Minimum distance from excavations slopes and walls Distance from excavations slopes Required wall distance Side exhaust outlet see also chapter 13 3 1 Keep sufficient distance at least 5 feet from the edges of exc
23. 3 gt Fill the engine and oil separator tank with preserving oil Engine SM 10 4 2 gt Run the machine for about 10 minutes to coat all parts with protec tive oil film gt Disconnect the battery batteries the negative terminal first and then the positive terminal and store in a frost free room gt Check the battery fluid level gt Check the battery charge monthly and recharge if necessary to pre vent the battery freezing gt Clean the battery terminals and coat with acid resistant grease gt Close the air outlet valves Use plastic sheeting and moisture resistant adhesive tape to seal off the following openings Engine air intake Compressor air intake Exhaust outlet gt Clean the bodywork and treat with a preservative gt a notice on the instrument panel informing of the decommis sioning measurements taken Engine SM engine manufacturer s service manual Tab 51 Long term decommissioning checklist SERVICE MANUAL Screw Compressor No 9 6983 01 USE M 13 15 17 93 19 4539 12 Decommissioning Storage and Transport 12 2 Transporting gt Place the following notice on the instrument panel informing of the decommissioning measure ments taken Attention 1 The machine is decommissioned 2 It is filled with preserving oil 3 For recommissioning Take measures for recommissioning after a long period of storage m Recommission acco
24. Any dangerous materials contained within the machine must be removed before transport gt Remove all dangerous materials These include m Residues of fuel or fuel vapors Lubricating and cooling oils in the engine and compressor unit Battery electrolyte Storage Moisture can lead to corrosion particularly in the engine airend and oil separator tank Frozen moisture can damage components valve diaphragms and gaskets Advice can be obtained from KAESER on storage and commissioning CAUTION Moisture and frost can damage the machine gt Prevent ingress of moisture and formation of condensation gt Maintain a storage temperature of gt 32 F gt Store the machine in a dry place free from frost if possible Disposal When disposing of a machine drain out all liquids and remove old filters The machine is decommissioned Completely drain the fuel from the machine Completely drain the cooling oil and engine oil from the machine Remove used filters and the oil separator cartridge Drain the coolant from water cooled engines and systems Hand the machine over to an authorized disposal expert SERVICE MANUAL Screw Compressor M 13 15 17 No 9 6983 01 USE KAESER COMPRESSORS x No 9 6983 01 USE 12 Decommissioning Storage and Transport 12 4 Disposal gt Parts contaminated with cooling oil or engine oil must be disposed of in accordance with local environment protection regulations
25. Belt tensioning between pulleys 1 Check belt tension by hand see Fig 13 RON Replace the belt guard Tighten loose belts see chapter 10 3 3 3 Reconnect the negative cable to the battery For simple belt tensioning the airend 5 is mounted on an adjustable tensioning device see Fig 14 The nuts 2 clamp the airend to the tensioning device and allow adjustment of the distance between the engine and airend pulleys The nuts 2 are accessible from above Belt tensioning Belt tensioning device more tension 2 less tension Clamping nut Adjusting nut Tension is adjusted by turning the adjusting nut 3 Clockwise more tension Anticlockwise less tension It is not necessary to secure the bolts while loosening the nuts 2 SERVICE MANUAL Screw Compressor M 13 15 17 4 Locknut 5 Airend 6 Engine 7 Engine pulley 8 Airend pulley 10 M 0367 51 KAESER COMPRESSORS 52 10 3 4 10 3 4 1 A Fig 15 10 Maintenance 10 3 Engine 1 Use a socket wrench to loosen all nuts 2 2 Loosen the locknut 4 3 Turn the adjusting nut 3 to increase or decrease belt tension as required 4 Check belt tension D o Repeat steps 3 and 4 if tension is still not correct Hold the adjusting nut 3 in position with a wrench while tightening the locknut 4 Tighten all clamping nuts 2 The machine is ready for further operation Battery mainte
26. Chassis Stationary Load capacity of the lifting frame Ib Enter here for reference the load capacity of the lifting frame taken from the nameplate Machine weights SERVICE MANUAL Screw Compressor M 13 15 17 19 439 53 24 2 Technical Data GEELEN 25 Compressor 2 4 2 Tires M 13 M 15 M 17 Tire size 10 1 4 x 3 3 8 10 1 4 x 3 3 8 10 1 4 x 3 3 8 Recommended tire pres 36 36 36 sure psig Tab 11 Tires 2 4 3 Wheel fixing Dimensions Quantity Spacer 33x 25 x 1 0 2 Circlip 25 x 1 2 1 Tab 12 Wheel fixing 2 5 Compressor 2 5 1 Free air delivery Free air delivery cfm Maximum working pres M13 M15 M17 sure psig 100 42 50 60 145 35 175 32 190 30 217 35 Tab 13 Free air delivery 2 5 2 Compressed air outlet Model M 13 M 15 M 17 Working pressure psig 100 145 175 190 100 100 217 Number of outlet valves 1 1 1 1 1 1 1 Outlet valve G 1 2 X X X X X Outlet valve 1 2 NPT X X x fitted not fitted Tab 14 Compressed air distributor 2 5 3 Safety relief valve Further information Maximum working pressure see nameplate SERVICE MANUAL Screw Compressor 6 M 13 15 17 No 9 6983 01 USE Technical Data 17 13 3 2 25 Compressor Maximum working pres sure psig 100 145 175 190 217 on the oil separator tank Relief valve blow off setting psig 130 175 217 217 232 Tab 15 Safety relief blow off set
27. RP RDUM BB 11 3 5 1 Safely dealing with sources of danger 12 3 5 2 Safe machine operation 4 14 3 5 8 Organizational Measures ccccccceeeeeeceeeenceeeeeeeeceeeeecaeeeseceaeeeeseeeeeeeeeseeeeeees 15 354 du ee ae et eee 15 3 6 Safety Devices usb ee Beles UE s S 15 9 7 Safety SIGHS on Ua 15 3 9 ettet eee ere eene On tute geteilt eed onte 17 3 8 4 Correct fire fighting 17 3 8 2 Contact with operating materials sssssssssssssssseeeneeeeeeenne 17 3 9 Warranty ai cunei AE Sele 18 3 10 Environmental Protection 18 SERVICE MANUAL Screw Compressor M 13 15 17 i COMPRESSORS 10 Contents Design and Function 4 1 BOdyWOIK ea eal 19 4 2 Component identification 20 4 3 Machine function 21 4 4 Operating modes and control modes cccceeeeeceeeeeeeeceeeeeeeeaeeeeeeneeeeeseesaeeeteeeeeneeeetees 22 4 4 1 Operating modes nenne nennen nnn 22 4 5 Safety devices SURE UE Ee CERE S 23 4 5 1 Monitoring functions with shutdown
28. Service service work manual shop X X X Where can get help KAESER Service Specialized workshop X 37 38 ESER ICA COMPRESSORS 9 3 2 Tab 30 9 3 3 Tab 31 9 3 4 Fault Recognition and Rectification 9 3 Compressor faults and alarms Working pressure too low Possible cause Proportional controller malad justed or defective Inlet valve not opening or only opening partially Pressure gauge giving false reading Pressure relief valve maladjusted and or leaking Venting valve does not close Engine not running at full speed Engine air filter and or compres Action Where can get help Specialized KAESER Servi workshop ce Check the diaphragm and clean X the nozzle or replace proportional controller if necessary Repair or replace if necessary X Change X Replace if necessary X Check the connections and func X tion and repair or replace as nec essary See chapter 9 2 Clean or change see chap ters 10 3 1 and 10 4 6 Change see chapter 10 4 5 Sor air filter clogged Oil separator cartridge heavily clogged Alarm Working pressure too low Safety relief valve blowing off Possible cause Action separator cartridge heavily clogged Change see chapter 10 4 5 Inlet valve not closing Check the controller the control air line and the inlet valve and re place if necessar
29. The frequency is mainly dependent on local operating conditions Heavily clogged coolers cause oil circuit overheating Check coolers regularly for clogging Avoid dust Wear breathing protection if necessary Do not clean the coolers with a sharp instrument otherwise they could be damaged A severely contaminated cooler should be cleaned by KAESER Service SERVICE MANUAL Screw Compressor M 13 15 17 63 KAESER COMPRESSORS Material Precondition A Fig 21 x 64 10 Maintenance 10 4 Compressor Compressed air Water or steam jet blaster Machine placed over a washing point equipped with an oil separator The machine is shut down Machine cooled down The machine is fully vented the pressure gauge reads 0 psig All compressed air consumers are disconnected and the air outlet valve is open Rear panel removed The negative cable to the battery is disconnected CAUTION Damage to the machine can be caused by water or steam jets Direct water or steam jets can damage or destroy electrical components and indicating instruments gt Cover up electrical components such as the alternator starter and instruments gt not direct water or steam jets at sensitive components such as the starter or instruments 3 10 M0157 Cleaning coolers Side view canopy removed Battery Rear panel locks Direction of impacting water or steam jet from Rear panel outside to inside 6 Cooler Seal off the air intake
30. assess the work to be done and recognize the possible dangers involved Authorized operators possess the following qualifications are of legal age familiar with and adhere to the safety instructions and sections of the service manual relevant to operation have received adequate training and authorization to operate vehicles and electrical and com pressed air devices Authorized maintenance personnel possess the following qualifications of legal age have read are familiar with and adhere to the safety instructions and sections of the service manual applicable to installation and maintenance are fully conversant with the safety concepts and regulations of motor vehicle electrical and compressed air engineering able to recognize the possible dangers of motor vehicle electrical and compressed air devices and take appropriate measures to safeguard persons and property have received adequate training in and authorization for the safe installation and maintenance of this machine Authorized transport personnel possess the following qualifications are of legal age familiar with and adhere to the safety instructions and sections of the service manual relevant to transporting m are trained and authorized in safe vehicle transporting m conversant with the safety regulations relating to handling motor vehicles and transport goods are able to recognize the possible da
31. cae 65 La EMI 98 SERVICE MANUAL Screw Compressor M 13 15 17 V 74 4 3 14 4 List of Illustrations COMPRESSORS SERVICE MANUAL Screw Compressor VI M 13 15 17 No 9 6983 01 USE COMPRESSORS No 9 6983 01 USE Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab List of Tables The levels of danger and their meaning 2 RIED Pn 3 Compressed air treatment plant enne nennen nennen 3 Chassis eicit Boece ects tbe ote ee 4 Model classificatilon iot 4 Emission sound pressure level 4 Guaranteed sound power level 4 Torques for hex head screws eene en nnns nn nnne nenne 5 AMIDIGMt conditions 5 Machine Weights t tto 5 EE 6 Wheel tat emot ee teet MS 6 Free air dellvetry i eet P Ea ed eet de Fees ert Fe cH Eo Ehe 6 Compressed air distributor
32. come to rest The QUICK STOP button remains latched in machine cannot be started SERVICE MANUAL Screw Compressor M 13 15 17 No 9 6983 01 USE 045 4 9 Operation COMPRESSORS 8 2 Precondition No 9 6983 01 USE Result 8 2 X Operating the external air treatment unit gt Press the QUICK STOP button The machine is stopped and cannot be restarted gt When the machine can be safely restarted turn the QUICK STOP button to unlatch it and turn the starter key to the 0 position Option da Operating the external air treatment unit The machine is warmed up see chapter 8 1 2 The installation tasks described in chapter 6 3 have been carried out 1 Start the machine see chapter 8 1 2 Open the compressed air outlet valve on the compressor 3 Open the compressed air outlet valve on the external air treatment unit Consumers are supplied with treated compressed air SERVICE MANUAL Screw Compressor M 13 15 17 35 36 ESER ICA COMPRESSORS Further information 9 2 Further information 9 2 1 Fault Recognition and Rectification 9 1 Basic instructions Fault Recognition Basic instructions and Rectification The following tables are intended to assist in fault finding and rectification 1 Do not attempt fault rectification measures other than those given in this manual 2 Inform KAESER Service if the fault cannot be removed by the action su
33. during all work be sure to read and follow the safety and service instructions in the machine s service manual SERVICE MANUAL Screw Compressor No 9 6983 01 USE M 13 15 17 75 Spares Operating Materials Service 11 o cc 9 m 11 5 Spare parts for service and repair LO 6861 0985 086 SERVICE MANUAL Screw Compressor M 13 15 17 9 6983 01 USE No 76 19 43 3 4 11 Spares Operating Materials Service erol EEEE 115 Spare parts for service and repair Legend KAESER Instrument panel SEL 1787_01E Operating hours counter Please quote the part number and serial number of the machine together with the item number and the description of the part when ordering Before and during all work be sure to read and follow the safety and service instructions in the machine s service manual SERVICE MANUAL Screw Compressor No 9_6983 01 USE M 13 15 17 77 19 4539 3 2 11 Spares Operating Materials Service 115 Spare parts for service and repair SEG 1960 01 6 iem m m m m m m m m jum mim m m m jm m m m Y wm mw iw mim m m m m m n iim m m
34. if no oil is visible 3 Replace the filler plug 3 SERVICE MANUAL Screw Compressor M 13 15 17 55 KAESER COMPRESSORS 56 10 4 2 Material Precondition 10 4 3 10 Maintenance 10 4 Compressor Topping up the cooling oil Cooling oil Funnel Wrench Cleaning rags The machine is shut down The machine is standing level The machine is fully vented the pressure gauge reads 0 psig Machine cooled down All compressed air consumers are disconnected and the air outlet valve is open The negative cable to the battery is disconnected Filling with cooling oil A sticker on the oil separator tank specifies the type of oil used CAUTION The machine could be damaged by unsuitable oil gt Never mix incompatible types of oil gt Never top up with a different type of oil to that already used in the machine Slowly unscrew and withdraw the plug from the oil filler port Top up the cooling oil to the maximum level with the help of a funnel Check the oil level moe IPC Check the filler plug gasket for damage Change a damaged gasket immediately Replace the plug in the filler port om Reconnect the negative cable to the battery Starting the machine and carrying out a trial run Start the machine and run in idle up to operating temperature Close the compressed air outlet valve Shut down the machine ESOS Wait until the machine has automatically vented Pressure gauge reads psig Open th
35. or even severing of extremities fingers from rotating components gt Operate the machine only with closed safety guards access doors and pan els gt Shut down the machine before opening a door or canopy Loca tion with in the machine SERVICE MANUAL Screw Compressor 16 M 13 15 17 No 9 6983 01 USE 54 4 14 3 Safety and Responsibility COMPRESSORS No 9 6983 01 USE Tab 24 3 8 3 8 1 3 8 2 3 8 n Emergency Item Sign Meaning 600 Risk of fatal injury caused by dismantling valves spring loaded or under pres sure gt not open or dismantle valves gt Call an authorized Service Technician if a fault occurs 160 Incorrect oil levels can cause damage to the machine or excessive oil content in the compressed air gt Check the oil level regularly and correct as necessary 320 Loud noise and oil mist Hearing damage and burning by relief valve blowoff gt Wear hearing protectors and protective clothing gt Close the canopy or doors gt Work with caution Loca tion with in the machine Safety Signs In Emergency Correct fire fighting Suitable extinguishing agents Foam m Carbon dioxide m Sand or dirt Unsuitable extinguishing agents Strong jet of water Keep calm Give the alarm Move to safety Warn persons in danger Help incapacitated persons 5 Try to extinguish the fire if you have the skill to do so
36. ssssssssseeen ene 23 4 5 2 Further safety devices nnn 23 4 6 Air treatment Oplloris REESE RD REED 23 4 6 1 External compressed air treatment seessssssssssssssseeeen 23 Installation and Operating Conditions uM REPE 25 5 2 Machine placement Vae eno a ete oe ea 25 Installation 6 1 elu ta e tan tot ep Loto toit ofer cote od 27 6 2 Reporting Transport Damage 27 6 3 Connecting an external air treatment unit essssssssssssssseeeeeeene 27 Initial Start up 74 Safety usus EAR eed eee ER e eed reed Eee E eee 29 7 2 Instructions to be observed before commissioning or recommissioning 29 7 3 Checking positioning and operating conditions 29 7 4 After storing the machine for a long period sss 30 7 5 Low temperature operation winter eene 30 TSA Starting ASSiStanCe a e t echte tede ecc 31 Operation 8 1 Starting and stopplng e oHG GNI ELA ce 33 Bidet 33 8 1 2 Allow the machine to run up to operating temperature 34 813 Shutting GOWN tee RI 34 8 1 4 Emergency shutdown
37. temperature too high See conditions given in chap ter 5 2 Tab 32 Alarm Machine overheating 9 3 5 Too much oil residue in the compressed air Possible cause Action Where can get help Specialized KAESER Servi workshop ce Oil separator cartridge scavenge Clean the strainer in the separa X line clogged tor cartridge dirt trap or change if necessary see chapter 10 4 5 Fractured oil separator cartridge Change see chapter 10 4 5 Compressor oil level too high Reduce to maximum level see chapters 10 4 1 and 10 4 3 Tab 33 Alarm Too much oil residue in the compressed air SERVICE MANUAL Screw Compressor No 9 6983 01 USE M 13 15 17 39 ICA COMPRESSORS 40 3 13d 4 9 Fault Recognition and Rectification 9 3 6 Tab 34 9 4 9 4 1 Tab 35 9 4 2 Tab 36 9 4 Faults and alarms on external air treatment units Oil flows from the compressor air filter after shutdown Possible cause Action Where can get help Specialized KAESER Servi workshop ce Defective non return function of Repair or replace if necessary X the inlet valve Alarm Oil flows from the compressor air filter after shutdown Faults and alarms on external air treatment units The temperature of the treated air is too high Possible cause Action Where can get help Specialized KAESER workshop Service The air treatment unit fan is faul Check connecting cables and ty change if necessary Ch
38. the description of the part when ordering Before and during all work be sure to read and follow the safety and service instructions in the machine s service manual Dc cr E SERVICE MANUAL Screw Compressor No 9 6983 01 USE M 13 15 17 87 19 4539 3 2 11 Spares Operating Materials Service 115 Spare parts for service and repair SEG 1965 01 8630 SERVICE MANUAL Screw Compressor 88 M 13 15 17 No 9 6983 01 USE 19 43 3 4 11 Spares Operating Materials Service ezo l EEES 115 Spare parts for service and repair Legend KAESER Bodywork SEL 1799_01E 8468 Push bar 8470 Exhaust air grill MTM 8600 Sealing mu 8820 1 Please quote the part number and serial number of the machine together with the item number and the description of the part when ordering Before and during all work be sure to read and follow the safety and service instructions in the machine s service manual SERVICE MANUAL Screw Compressor No 9 6983 01 USE M 13 15 17 19 4539 3 2 11 Spares Operating Materials Service 115 Spare parts for service and repair SEG 1966 01 8470 8630 8500 8555 SERVICE MANUAL Screw Compressor 90 M 13 15 17 No 9 6983 01 USE 45343 4 11 Spares Operating Materials Service ozo l EEES 115 Spare parts for se
39. 10 4 Compressor Unscrew the drain plug and allow the oil to drain into the receptacle Fit a new gasket on the drain plug 4 and screw it back in again Place the receptacle beneath the oil cooler 1 Fit a new gasket on the drain plug 3 and screw it back in again Fill up the cooling oil using a funnel Check the cooling oil level 000 EN OD Oe 0 Check the filler plug 6 gasket for damage Change a damaged gasket immediately 11 Replace the plug in the filler port 5 12 Reconnect the negative cable to the battery Unscrew the drain plug 3 and allow the cooling oil to drain into the receptacle Dispose of used oil and oil contaminated working materials according to environment protection regulations Starting the machine and carrying out a trial run Start the machine and run in idle up to operating temperature Close the compressed air outlet valve Shut down the machine T Wait until the machine has automatically vented Pressure gauge reads 0 psig Open the outlet valve Check the level after about 5 minutes Top up if necessary 7 Carry out a visual check for leaks Changing the oil filter Spares Receptacle Cleaning rags The machine is shut down The machine is fully vented the pressure gauge reads 0 psig Machine cooled down All compressed air consumers are disconnected and the air outlet valve is open Rear panel removed Negative cable to the batteries disconne
40. 7 5 SERVICE MANUAL Screw Compressor 26 M 13 15 17 No 9 6983 01 USE 6 Installation ICA COMPRESSORS Further information 6 2 6 3 Precondition No 9 6983 01 USE Fig 8 6 1 Safety Installation Safety Follow the instructions below for safe installation Warning instructions are located before a potentially dangerous task Basic safety instructions 1 Follow the instructions in chapter Safety and Responsibility 2 Installation work may only be carried out by authorized personnel Information on authorized personnel are found in chapter 3 4 2 Information on dangers and their avoidance are found in chapter 3 5 Reporting Transport Damage 1 Checkthe machine for visible and hidden transport damage 2 Inform the carrier and the manufacturer in writing of any damage found Option da Connecting an external air treatment unit The machine may be connected to an external compressed air cooler and cyclone separator to treat the air The machine is switched off The machine is fully vented the pressure gauge reads 0 psig oo 10 Jl 4 3 06 M0437 Connecting the air treatment unit Machine 6 Hose coupling compressed air inlet Claw coupling machine Hose coupling for condensate drainage Male hose coupling for condensate drainage Plug for fan Socket for the fan 9 Claw coupling treated air Externa
41. ANUAL Screw Compressor M 13 15 17 Signature 67 COMPRESSORS 68 11 11 1 11 2 Tab 48 Tab 49 11 Spares Operating Materials Service 11 1 Note the nameplate Spares Operating Materials Service Note the nameplate The nameplate contains all information to identify your machine This information is essential to us in order to provide you with optimal service Please give the information from the nameplate with every inquiry and order for spares Ordering consumable parts and operating materials KAESER consumable parts and operating materials are all genuine KAESER parts They are selected for use in KAESER machines WARNING There is risk of personal injury or damage to the machine resulting from the use of unsuitable spare parts or operating materials Unsuitable or poor quality consumable parts and operating materials may damage the machine or impair its proper function In the event of damage personal injury may result gt Use only genuine KAESER parts and operating materials gt Have an authorized KAESER Service Technician carry out regular maintenance Compressor Name Quantity Number Air filter element 1 1260 Oil filter 1 1200 Oil separator cartridge set 1 1450 Cooling oil 1 1600 Compressor consumables Engine parts HONDA Name Quantity Number Foam air filter element 1 1275 Paper air filter element 1 1280 Fuel filter 1 1910 Oil filter 1 1905 Oil drain plug sealing ring 1 4496 Spark
42. E Tab 27 9 2 2 Tab 28 9 3 9 3 1 Tab 29 Fault Recognition and Rectification 9 3 Possible cause Oil pressure switch sensing in sufficient oil pressure Compressor faults and alarms Action Check the engine oil pressure Have the engine repaired or ex changed Alarm Engine refuses to start or comes to a stop Engine does not reach full speed Possible cause Airlock in the fuel line between fuel tank and carburetor Fuel filter clogged Fuel line broken Speed adjustment cylinder mal adjusted or defective Action Bleed the fuel line Clean or change Change Repair or replace if necessary Alarm Engine does not reach full speed Compressor faults and alarms Working pressure too high Possible cause Proportional controller malad justed or defective Inlet valve not closing Pressure gauge giving false reading Venting valve does not blow off Action Check the diaphragm and clean the nozzle or replace proportional controller if necessary Check the controller the control air line and the inlet valve and re place if necessary Change Check the connections and func tion and repair or replace as nec essary Alarm Working pressure too high SERVICE MANUAL Screw Compressor M 13 15 17 Where can get help Special KAESER Engine ized Service service work manual shop X X Where can get help Special KAESER Engine ized
43. JnjeJadums a uejsi 1040 2 aJnssaud 110 YI4IMS aunssaJd 110 JosiAJadng 13 5 Electrical Diagram 13 Annex COMPRESSORS No 9_6983 01 USE SERVICE MANUAL Screw Compressor M 13 15 17 108 13 136 Fuel circulation diagram 13 6 Fuel circulation diagram SERVICE MANUAL Screw Compressor No 9 6983 01 USE M 13 15 17 109 zjesJ3 Ee neg 00 S7000 O4LELWW4 SL 7 ELM 433055344 40 voyeo pn _ _ 5 JV uoijsnquioj E 40 43 Inq Je S Jaj a id yang 5 Jany c T lt N cc 9 m 9 6983 01 USE SERVICE MANUAL Screw Compressor M 13 15 17 110
44. L Screw Compressor M 13 15 17 No 9 6983 01 USE Operation 8 1 Starting and stopping 8 Operation 8 1 Starting and stopping Precondition No personnel are working on the machine The QUICK STOP button is unlatched 08 M0340 Fig 9 Starting elements Choke Starter key Choke open 0 position OFF Choke closed I position RUN Il position START Starter key QUICK STOP button o 60 gt 80 ww 15077 120 bes 08 M0001 Fig 10 Instruments Temperature gauge switch Compressed air outlet pressure gauge 9 Operating hours counter 811 Starting CAUTION Serious damage to engine from the use of cold starting sprays The use of ether or other cold start sprays can cause serious damage to the engine gt Do not use cold start sprays SERVICE MANUAL Screw Compressor No 9 6983 01 USE M 13 15 17 33 KAESER COMPRESSORS 34 A 8 1 3 8 Operation 8 4 Starting and stopping CAUTION Destruction of the starter Improper operation could destroy the starter gt starter must not operate while the engine is running gt starter key must not be held in the start position longer than 5 seconds gt Wait 10 seconds between starting attempts gt Turn the starter key back to the 0 position between each starting attempt repeat start inhibit Disconnect air consumers Open air outlet valve Insert the starter key
45. O 3016 Demulsibility at 129 F 40 40 0 10 min D 1401 ASTM test Cooling oil recommendation Cooling oil charge M 13 M 15 M 17 Total charge at 4 8 4 8 4 8 Cooling oil charge Engine Engine specification M 13 M 15 M 17 Engine Honda GX 620 Honda GX 670 Engine power hp 18 18 20 5 at maximum speed Maximum speed rpm 3600 3600 3600 Speed under full load 2500 3000 3300 2300 rpm Idling speed 2200 2200 2200 2000 rpm Fuel consumption under 4 0 5 0 6 3 5 9 full load qt h Type of fuel Lead free petrol Lead free petrol Lead free petrol Lead free petrol Required octane rating 286 Oil consumption related to 0 2 fuel consumption 96 ap prox The performance data of the engine given in this document is according to SAE J1349 taken from a production series engine at a specified speed Data of individual engines may vary slightly The performance of an engine in a finished machine may vary according to factors such as engine speed environmental influences the quality of maintenance etc Engine specification SERVICE MANUAL Screw Compressor M 13 15 17 No 9 6983 01 USE KAESE COMPRESSORS No 9 6983 01 USE 2 2 Technical Data 2 6 2 Tab 20 2 6 3 Tab 21 2 6 4 Tab 22 2 6 Engine Oil recommendation The engine is filled initially with engine oil of viscosity class SAE 10 W Ambient temperature F 68 122 32 68 5 32 Engine oil recommendation Fluid volumes Name Engi
46. S Changing the engine oil Filler cap Oil dipstick Drain screw Drain hole Gasket Changing the engine oil The engine manufacturer s handbook gives instructions on oil changing Place the receptacle below the drain hole 5 Change the engine oil in accordance with the manufacturer s handbook Reconnect the negative cable to the battery again Replace the machine rear panel QU OO ap Engage locks Dispose of old oil and oil soaked working materials according to environmental protection reg ulations See engine manual for oil change under dusty conditions Starting the machine and carrying out a trial run 1 Start the machine and allow it to idle for at least 5 minutes 2 Checkthe engine oil level in accordance with the manufacturer s handbook Top up as necessary 3 Carry out a visual check for leaks Shut down the machine Checking the drive belts The life of the drive belts is influenced by belt tension Slack belts can slip and become damaged m Over tight belts stretch and fatigue quicker Furthermore over tight belts place unnecessary stress on bearings and shorten their life SERVICE MANUAL Screw Compressor M 13 15 17 49 KAESER COMPRESSORS 50 Material Precondition A 10 3 3 1 10 3 3 2 Precondition Fig 13 10 Maintenance 10 3 Engine Belt tension measuring device Spares The machine is shut down The machine is fully vented the pressure gauge reads 0 psig Machin
47. SERVICE MANUAL Screw Compressor M 13 15 17 No 9 6983 01 USE KKW MCO 1 01 en 01 SBA MOBILAIR COMPRESSORS No 9 6983 01 USE 1 Contents Regarding this Document 1 4 Using the Document rennen nnns 1 1 2 1 1 3 Copyright 1 1 4 Symbols and Identification enne 1 144 WaMINGS isse E aU ee 1 1 4 2 Other instructions and symbols sssssssssseeeeenemnnnen 2 Technical Data 2 1 Nameplate aede epe eese ee 3 2 2 Eistof Options siot tpe p ote dde e te Mabel ata dep 3 2 2 1 Compressed air treatment plant nne 3 223 Chassis ottiene DRE dete Oe ett Mes Ret 4 2 3 Machine without options nne 4 2 31 oS ournid emissi n eaat a tte ettet Ett eee a a eee s 4 2 3 2 TOQUES uode eG REP IRURE De ERE La Ee E DUIS ETE Hr qud 5 2 3 3 Ambient conditions ccccccceeeececceeeeeeceeeeeeeeeeaeeeeeeeeaeeeseseeceeeesseeeseeeesneeeeers 5 2 3 4 Dimensions and locations cccccccceeeecceeeeeeeeeceeeeeeeeeeeeeeeeeeeaeeeeeeneeaeeeeesnaeees 5 24 CHASSIS eee p Mte nte ts taped detta cett eedem mto Med dem 5 2 4 4 Weights b
48. achine gt Donotoperate in areas in which specific requirements regarding explosion protection are in force gt Ensure adequate ventilation gt Ensure that required ambient conditions are maintained with regard to ambient temperature m clean inlet air with no damaging contaminants inlet air free of explosive or chemically unstable gases or vapors inlet air free of exhaust gasses from internal combustion engines inlet air free of acid alkaline forming substances particularly ammonia chlorine or hydrogen sulfide gt Do not position the machine in warm exhaust air from other machines gt Ensure accessibility so that all work on the machine can be carried out without danger or hin drance gt Chock the wheels to prevent unwanted movement Operation Keep the canopy closed for safety and to ensure correct cooling function gt Carry out regular inspections m for visible damage and leakage of safety devices of components needing to be monitored gt Never operate machines without an air filter when drawing in air from the surroundings Maintenance sure the machine is shut down cooled down and pressure free before starting any main tenance work gt Wear close fitting flame resistant clothing Wear protective clothing as necessary gt Do leave any loose components tools or cleaning rags on or in the machine gt Components removed from the machine can still be dangerous Do no
49. an dles for wear and secure fixing Annually Grease the canopy hinges every 400 500 h operating hours Regular canopy maintenance tasks Other maintenance tasks Carry out maintenance tasks according to the following schedule Interval Maintenance task See chapter Annually Check all accessible fittings every 400 500 h Screw connections pipes and clamps for wear and tightness Check hoses for leaks and wear Check that all electrical connec tions are tight operating hours Other maintenance tasks Maintenance schedules for options Cyclone separator maintenance schedule Carry out maintenance tasks according to the following schedule Interval Maintenance task See chapter Annually Clean the dirt trap 10 6 1 Cyclone separator maintenance schedule Engine Carry out maintenance tasks in accordance with the schedules in chapter 10 2 3 SERVICE MANUAL Screw Compressor M 13 15 17 45 KAESER COMPRESSORS 46 10 3 1 Material Precondition Fig 11 10 Maintenance 10 3 Engine Air filter maintenance Damp cloths Warm soapy water Non flammable solvent Compressed air for blowing out Spare parts as required The machine is shut down The machine is fully vented the pressure gauge reads 0 psig Machine cooled down All compressed air consumers are disconnected and the air outlet valve is open 1 Engine air filter maintenance Filter cap Retai
50. ation Battery checking and care Even so called maintenance free batteries need a degree of care to obtain their maximum opera tional life The outside of the battery and the terminals should be cleaned regularly with a soft cloth This avoids current leaks and minimizes the discharge rate Terminal grease Distilled water Cleaning rags Protective gloves The machine is shut down The machine is standing level The machine is fully vented the pressure gauge reads 0 bar Machine cooled down 1 Clean the casing and terminals 2 Lightly grease the terminals to prevent corrosion 3 Check that connections are tight and tighten if necessary Check the battery electrolyte level The electrolyte level must be checked weekly The level should be up to the mark 0 4 in above the plates If a battery casing leaks fluid the battery must be replaced immediately WARNING Battery destruction Topping up with pure acid will increase the electrolyte concentration and can destroy the battery gt only with distilled water gt Check the electrolyte level If the level does not reach the mark gt top up with distilled water Winter operation Batteries are particularly stressed in winter Only a fraction of the normal starting energy is available at low temperatures SERVICE MANUAL Screw Compressor M 13 15 17 53 54 COMPRESSORS A O i 10 3 4 3 Precondition A 10 Maintenance 10 3 En
51. avations and slopes see Fig 7 item 1 2 Ensure accessibility so that all work on the machine can be carried out without danger or hin drance SERVICE MANUAL Screw Compressor M 13 15 17 25 049 439 3 2 5 Installation and Operating Conditions EEIehEE 52 Machine placement CAUTION Danger of burning from build up of heat and hot exhaust Insufficient distance from a wall may well cause heat build up that could damage the machine gt Do not position the machine directly against a wall gt Ensure always sufficient ventilation space around the machine 3 Locate the machine with maximum possible distance from any wall see Fig 7 item 2 4 Ensure there is enough free space around and above the machine 5 Keeproom ventilation openings free of obstructions so that the cooling air can flow freely through the room 6 Donotallow wind to blow into the cooling air outlet not allow exhaust gases and heated cooling air to be drawn into the compressor 8 Ensure accessibility so that all work on the machine can be carried out without danger or hin drance CAUTION Ambient temperature too low Frozen condensate and highly viscous engine or compressor oil can cause damage when starting the machine Use winter grade engine oil gt Use low viscosity compressor oil gt Allow the machine to warm up in idle see chapter 8 1 2 9 Atambient temperatures below 32 F follow instructions in chapter
52. between the rotors themselves and between them and the airend casing This direct cooling in the compression chamber ensures a very low airend discharge temperature Cooling oil recovered from the compressed air in the oil separator tank 5 gives up its heat in the oil cooler 20 The oil then flows through the oil filter 21 and back to the point of injection Pressure within the machine keeps the oil circulating A separate pump is not necessary The combination valve maintains optimum cooling oil temperature Compressed air freed of cooling oil in the oil separator tank 5 flows through the minimum pressure nozzle 8 into the air distributor 10 The minimum pressure nozzle ensures that there is always a minimum internal air pressure sufficient to maintain cooling oil circulation in the machine The cooling fan ensures optimum cooling of all components within the enclosure Operating modes and control modes Pipe and Instrument Diagram P amp Diagram see chapter 13 2 Operating modes The machine operates in the following modes LOAD inlet valve is open The engine speed control cylinder is at maximum speed The airend provides compressed air for connected consumers The minimum pressure nozzle ensures that the pressure in the oil separator tank cannot fall below the set minimum The minimum pressure ensures continuous circulation of cooling oil through the machine MODULATING With the he
53. cessive pressure It is preset at the factory EMERGENCY STOP button The EMERGENCY STOP button stops the machine immediately without run on m Enclosures and covers over moving parts and electrical connections These protect against accidental contact Air treatment options The following is a description of the possible air treatment options that may be fitted to the machine Option da External compressed air treatment 2 X 04 M0010 Air treatment options Frame Fan Compressed air cooler option da Cyclone separator option da SERVICE MANUAL Screw Compressor M 13 15 17 23 KAESER COMPRESSORS Further information 24 4 _ Design and Function 4 6 Air treatment options Compressed air cooler The cooler brings down the compressed air temperature to only 9 F to 18 Fabove ambient Most of the moisture carried in the air is removed during this cooling process Cyclone separator Condensate accumulating during the air cooling process is separated fed to the exhaust gas silencer and evaporated there See chapter 6 3 for installation of external air treatment units SERVICE MANUAL Screw Compressor M 13 15 17 No 9_6983 01 USE 5374 3 14 5 Installation and Operating Conditions COMPRESSORS 5 2 Precondition No 9 6983 01 USE Fig 7 5 1 Safety Installation and Operating Conditions Safety
54. chedules The maintenance schedules provide an overview of the maintenance instructions for the machine Read the relative section before undertaking maintenance 10 2 1 Logging maintenance work The maintenance intervals given are those recommended for average applications and oper I ating conditions Maintenance schedules may be modified to take into account the application the environment and the quality of maintenance WARNING Wear and machine damage through unusual applications or operating conditions gt Maintenance tasks must be carried out more frequently when operating conditions are unfav orable e g dusty atmosphere or when the equipment is in constant use gt Adjust the maintenance intervals with regard to local installation and operating conditions SERVICE MANUAL Screw Compressor No 9 6983 01 USE M 13 15 17 41 19 4539 10 Maintenance Ide V iE EE 102 Maintenance schedules gt Keep a log of all properly carried out maintenance and service work This enables the frequency of individual maintenance tasks and deviations from our recommen dations to be determined Further information A prepared list is provided in chapter 10 7 10 2 2 Compressor maintenance schedule Carry out maintenance tasks according to the following schedule Interval Maintenance task See chapter Daily before the first compressor Check the oil level 10 4 1 use Check the air filter 10 4 6 50 h after initial start up Change th
55. combustion of fuel can result in serious injury or death Allow no open flames or sparks at the place of use Do not smoke while refuelling Never refuel the machine when it is running Do not allow fuel to overflow Wipe up spilled fuel immediately Keep fuel away from hot machine parts Y YY Y Make sure that the ambient temperature at the machine s place of use is within permissible limits Forces of compression Escaping compressed air can cause serious injury The following information concerns work on com ponents that could be under pressure gt Wait until the machine has automatically vented check that the pressure gauge indicates 0 psig gt carry out welding heat treatment or mechanical modifications to pressurized components e g pipes and vessels as this influences the component s resistance to pressure The safety of the machine is then no longer ensured Spring force Sudden release of spring force can cause serious energy Check valves pressure relief valves and inlet valves are powerfully spring loaded gt not open or dismantle any valves Compressed air quality gt Never directly inhale compressed air Use appropriate systems for air treatment before using the compressed air from this machine as breathing air and or for the processing of foodstuffs Use food grade cooling oil whenever compressed air is to come into contact with food products SERVICE MANUAL Screw Co
56. cted CAUTION There is risk of burns from hot components and escaping oil gt Wear long sleeved clothing and gloves SERVICE MANUAL Screw Compressor M 13 15 17 No 9 6983 01 USE 17 1932 10 COMPRESSORS No 9 6983 01 USE Maintenance 10 4 Compressor 10 0154 Fig 18 Changing the oil filter Combination valve oil filter Direction of rotation to unscrew the oil filter Changing the oil filter Ox guide coo dot Prepare a receptacle Loosen the filter 2 by turning counter clockwise 3 and catch any escaping oil Carefully clean sealing surfaces using lint free cloth Lightly oil the new filter s 2 gasket Turn the oil filter 2 clockwise by hand to tighten Check the oil level in the oil separator tank Top up if necessary Reconnect the negative cable to the battery Replace the machine rear panel Lock the rear panel closed Dispose of old cooling oil and any materials or parts contaminated with oil according to envi ronment protection regulations Starting the machine and carrying out a trial run PONS e Start the machine and run in idle up to operating temperature Close the outlet valves Shut down the machine Wait until the machine has automatically vented Pressure gauge reads 0 psig Open the outlet valve Check the oil level after about 5 minutes Top up if necessary Carry out a visual check for leaks SERVICE MANUAL Screw Compressor M 13 15 17 59
57. e D IPS 5 LE PANI c EE 6 243 MWheelfixing epe Rp eee ge tede ovd 6 2 5 Compressor edite se p Mee tao etn cete td a 6 2 5 Free air delivery edet eee die icles 6 2 5 2 Compressed air 223 2 3 6 2 5 3 Safety relief valve ennt nennen nennen 6 2 5 4 Temperature diet eter veda eue etate cd dte c redeas 7 2 5 5 Cooling oil recommendation sse 7 2 5 6 Cooling oil charge nenne 8 2 6 Engines Ere de e E atta eere 8 2 00 1 tet p oto dca 8 2 6 2 Oil recommendation 9 2 6 3 Fluid vol rmi s e peret D 9 2 04 Battery medela pede n ete 9 Safety and Responsibility 3 1 Basic Information 10 3 2 Specified Use osten etsi tete ettet etie 10 3 3 Improper ss soot er Educ uec iE DELL ue 10 3 4 User s Responsibilities 4 10 3 4 1 Observe statutory and universally accepted regulations 10 342 Defining personnel 3 shi nemen tene editiert 11 3 5 Dangers usse vA
58. e compressor oil filter 10 4 4 Every 6 months Clean or change the air filter 10 4 6 every 200 250 h Clean the oil cooler 10 4 8 Annually in addition Have the pressure relief valve s 10 4 7 every 400 500 h checked Change the oil 10 4 3 Change the compressor oil filter 10 4 4 Every 2 years Change the air filter 10 4 6 Change the oil separator car 10 4 5 tridge in the oil separator tank h operating hours Tab 37 Regular compressor maintenance tasks 10 2 3 Engine maintenance schedule Engine maintenance gt Carry out maintenance tasks according to the following schedule Interval Maintenance task See chapter Daily before the first compressor Check the oil level Engine SM dus Check the air filter 10 3 1 20 hours after initial start up Change the engine oil 10 3 2 Engine SM 50 hours after initial start up Check belt tension and re ten 10 3 3 sion if necessary Engine SM Every 6 months Clean or change the air filter 10 3 1 every 200 250 h If fitted Engine SM Clean the engine oil cooler Check belt tension and re ten 10 3 3 sion if necessary Engine SM h 5 operating hours Engine SM 2 engine manufacturer s service manual SERVICE MANUAL Screw Compressor 42 M 13 15 17 No 9 6983 01 USE KAESER COMPRESSORS Tab 38 10 Maintenance 10 2 Maintenance schedules Interval Annually in addition every 400 500 h Every 1000 h Every 1500 h Every 2 years h operating hours Maintenance ta
59. e cooled down All compressed air consumers are disconnected and the air outlet valve is open Rear panel removed The negative cable to the battery is disconnected WARNING Beware of rotating pulleys and moving belts There is danger of serious injury from pinching gt Never check the drive belts unless the engine is at standstill gt Never run the machine without a belt guard gt Heed the safety instructions in chapter 3 5 Visual check 1 Remove the belt guard if fitted 2 Check the belts thoroughly for cracks fraying or stretching Change damaged belts immediately 3 Reconnect the negative cable to the battery Checking belt tension Belt tension can be checked with a measuring device or by hand Check belt tension when the belts are warm but not hot temperature variations cause variations in length 10 M0174 Belt tension checking by hand Permissible movement Approximate pressure exerted 16 5 Ib Permissible movement 0 4 0 5 in SERVICE MANUAL Screw Compressor M 13 15 17 No 9 6983 01 USE KAESER COMPRESSORS No 9 6983 01 USE 10 3 3 3 Fig 14 10 Maintenance 10 3 Engine Checking belt tension with a measuring device tension checking by hand 1 Check belt tension with the tension measur Press the belts in with the thumb at the mid point ing device Tighten loose belts see chapter 10 3 3 3 Replace the belt guard Reconnect the negative cable to the battery
60. e outlet valve om Check the oil level after about 5 minutes Top up if necessary 7 Carry out a visual check for leaks Changing the cooling oil Drain all cooling oil from the oil separator tank SERVICE MANUAL Screw Compressor M 13 15 17 No 9 6983 01 USE KAESER COMPRESSORS Material Precondition No 9 6983 01 USE A Fig 17 10 Maintenance 10 4 Compressor the oil cooler m the oil pipes Cooling oil Receptacle New gasket for the drain plug Funnel Cleaning rags The machine is shut down The machine is standing level The machine is fully vented the pressure gauge reads 0 psig The machine is at operating temperature All compressed air consumers are disconnected and the air outlet valve is open The negative cable to the battery is disconnected CAUTION There is risk of burns from hot components and escaping oil gt Wear long sleeved clothing and gloves Changing the cooling oil the oil cooler 6 Oil filler plug the oil separator tank Combination valve Oil cooler drain plug Oil filter Oil separator tank drain plug 9 Airend Oil filler port Changing the cooling oil 1 Remove the plug 6 from the oil separator tank 2 filling port 2 Position the receptacle below the separator tank drain plug 4 SERVICE MANUAL Screw Compressor M 13 15 17 10 0153 57 KAESER COMPRESSORS 10 4 4 Material Precondition A 58 10 Maintenance
61. e resistant adhesive tape Engine air inlet Compressor air inlet Exhaust 3 Place the following notice on the instrument panel informing of the decommissioning measure ments taken Attention 1 The machine is temporarily decommissioned 2 The following machine openings have been covered Engine air inlet Compressor air inlet Exhaust 3 Recommission according to service manual Date signature Temporarily decommissioned information notice Decommissioning of the compressor for several weeks during severe frost CAUTION Danger of batteries freezing Discharged batteries are subject to frost damage and can freeze at 14 F gt Store the battery in a frost free place gt Store the battery preferably fully charged SERVICE MANUAL Screw Compressor M 13 15 17 No 9_6983 01 USE 4 Y3 13 4 12 Decommissioning Storage and Transport 12 1 De commissioning 1 Remove the battery and store in a frost free room 2 Make sure the battery is fully charged 12 1 2 Long term decommissioning Decommissioning the machine for 5 months or longer Material Receptacle Preserving oil Preservative Desiccant Plastic sheeting Moisture resistant adhesive tape gt The following measures must be taken for long term decommissioning Long term decommissioning tasks See chapter Confirmed gt Drain the engine oil Engine SM gt Drain the cooling oil from the separator tank and oil cooler 10 4
62. e working with the machine gt not change bypass or disable safety devices gt Check safety devices for correct function regularly gt Do not remove or obliterate labels and notices gt Ensure that labels and notices are clearly legible More information on safety devices is contained in chapter 4 section 4 5 Safety Signs The diagram shows the positions of safety signs on the machine The table lists the various safety signs used and their meanings SERVICE MANUAL Screw Compressor M 13 15 17 15 4534 3 24 3 Safety and Responsibility 37 Safety Signs 620 331 330 320 160 03 M0029 Fig 1 Location of safety signs Item Sign Meaning 310 311 It is forbidden to run the machine with open access doors or panels Personal injury or machine damage can result from an open machine enclosure gt Operate only with the enclosure fully closed gt Transport only with the enclosure fully closed 332 Hot surfaces and dangerous gases Burning from contact with hot components or gases gt Do not touch the surface gt Wear long sleeved garments not synthetics such as polyester and protec tive gloves gt Noxious gases do not inhale 330 fh Hot surface 331 Risk of burns caused by contact with hot components gt Do not touch the surface gt Wear long sleeved garments not synthetics such as polyester and protec tive gloves 620 621 Risk of serious lacerations
63. eck plug connections Alarm Air temperature too high Outflow of condensate Possible cause Action Where can get help Specialized KAESER workshop Service Condensate drain is faulty or in Check condensate feed hoses correctly connected and connections for leaks and tightness Alarm Outflow of condensate SERVICE MANUAL Screw Compressor M 13 15 17 No 9 6983 01 USE 19 459 3 2 10 Maintenance TULELE 101 Safety 10 Maintenance 10 4 Safety Follow the instructions below to ensure safe machine maintenance Warning instructions are located before a potentially dangerous task Basic safety instructions 1 Follow the instructions in chapter Safety and Responsibility Maintenance work may only be carried out by authorized personnel 3 Before restarting the machine make sure that personnel are working on the machine all protective guards and cover panels are screwed back tools have been removed from the machine Working on pressure systems 1 Disconnect all air consumers 2 Wait until the machine is automatically vented check that the pressure gauge indicates O psig 3 Do not open or dismantle any valves Working on the drive system 1 The negative cable to the battery is disconnected 2 The machine has cooled down Further information Details of authorized personnel are found in chapter 3 4 2 Details of dangers and their avoidance are found in chapter 3 5 10 2 Maintenance s
64. el 9 Compressor air filter 2 Battery 10 Airend 3 Oil cooler 11 Engine 4 Oil separator tank 12 Compressed air outlet valve 5 Oil filler port with plug 13 Engine air filter 6 Combination valve 14 Lifting eye 7 Pressure relief valve 15 Proportional controller 8 Fuel tank SERVICE MANUAL Screw Compressor 20 M 13 15 17 No 9 6983 01 USE KAESE COMPRESSORS No 9 6983 01 USE 4 Design and Function 4 3 Fig 4 Fig 5 4 3 Machine function Machine function Machine function without options Item numbers correspond to the pipe and instrument flow diagram in chapter 13 2 04 0013 General arrangement 01 Compressor air filter Oil separator cartridge Inlet valve Pressure relief valve Airend Dirt trap Oil separator tank Proportional controller 04 M04 16 General arrangement 02 Compressed air distributor Oil filter Engine Engine air filter Combination valve oil temperature thermo Engine speed control cylinder stat Fan Oil cooler Ambient air is cleaned as it is drawn in through the filter 4 SERVICE MANUAL Screw Compressor M 13 15 17 21 KAESER COMPRESSORS 4 4 Further information 4 4 1 22 4 _ Design and Function 4 4 Operating modes and control modes The air is then compressed in the airend 4 The airend is driven by an internal combustion engine Cooling oil is injected into the airend It lubricates moving parts and forms a seal
65. f the filter cap 5 3 Withdraw the filter insert 4 SERVICE MANUAL Screw Compressor M 13 15 17 No 9 6983 01 USE KAESER COMPRESSORS 10 4 7 10 4 8 No 9 6983 01 USE 10 Maintenance 10 4 Compressor Clean the air filter cap 5 and housing 2 Clean all sealing faces Insert the new element 4 in the housing 2 Replace the filter cap 5 Secure the cap 5 with the two retaining clips 1 Qo UM SOS OY oem Cleaning the filter element by gently tapping Gently tapping the element will remove coarse dirt 1 Carry out element renewal steps 1 to 5 2 Tap the inlet side of the filter element a number of times against the palm of the hand Coarse dirt particles are freed from the element Insert the cleaned element in the housing Carry out element renewal steps 7 and 8 Blowing the filter element clean Use compressed air at less than 73 psig direction of air blast 3 through the element is always contra to the intake direction Contamination in the filter element can be blown out with compressed air 1 Carry out element renewal steps 1 to 5 2 Blow out the filter element with compressed air Dirt particles are freed from the element 3 Insert the cleaned element in the housing 4 Carry out element renewal steps 7 and 8 Checking the safety relief valve gt Have pressure relief valves checked by KAESER Service in accordance with the maintenance schedule Cleaning coolers
66. for any risks incurred Keep to the specifications listed in this service manual Operate the machine only within its performance limits and under the permitted ambient condi tions gt not use compressed air for breathing purposes unless it is specifically treated gt Do not use compressed for any application that will bring it into direct contact with food products unless it is specifically treated Improper Use Never direct compressed air at persons or animals Do not use untreated compressed air for breathing purposes Do not allow the machine to breathe in toxic acidic flammable or explosive gases or vapors Y Do not operate the machine in areas in which specific requirements with regard to explosion protection are in force User s Responsibilities Observe statutory and universally accepted regulations These are for example nationally applied European directives and or valid national legislation safety and accident prevention regulations gt Observe relevant statutory and accepted regulations during operation transporting and mainte nance of the machine SERVICE MANUAL Screw Compressor M 13 15 17 No 9 6983 01 USE 54 4 14 3 Safety and Responsibility COMPRESSORS No 9 6983 01 USE 3 4 2 3 5 3 5 Dangers Defining personnel Suitable personnel are experts who by virtue of their training knowledge and experience as well as their knowledge of relevant regulations can
67. fter a long period of storage Storage period Action longer than 5 months gt Remove the desiccant from the openings in the air intake filters of the engine and compressor Check the air and oil filters Drain the preserving oil from the separator tank Fill with compressor oil Drain the preserving oil from the engine Fill up with engine oil Check the battery charge Re connect the battery Y Y Y Check all fuel lines engine oil lines and compressor oil lines for leaks loose connections wear and damage Clean the bodywork with a grease and dirt cleansing agent gt Check the tire pressure 36 months gt Have the overall technical condition checked by an authorized KAESER Service Technician Measures for re commissioning the compressor after a long period of storage Low temperature operation winter The machine s electrical equipment is designed for starting at ambient temperatures as low as 14 F gt At temperatures below 0 F use m winter grade engine oil low viscosity compressor oil stronger battery Use air hoses that are as short as possible under extremely cold conditions Machine operational state CAUTION Problems with pneumatic control at low temperatures Damage to the machine may be caused by ice particles in the pneumatic control and feedback systems gt Let the machine warm up in idle to ensure trouble free regulation gt Allow the machine to warm up in
68. ggested Observe the instructions in chapter Safety and prevailing local safety regulations when rectifying faults and malfunctions Engine faults and alarms See also the engine service manual Engine refuses to start or comes to a stop Possible cause Defective starter The fuel cut off device has not opened Fuel tank empty Airlock in the fuel line between fuel tank and carburetor Fuel filter clogged Fuel line broken Defective control fuse or relay Airend discharge temperature too high Defective temperature gauge Switch giving no enable signal Defective starter switch Defective spark plug connector Defective spark plug Electrical connections and or ca bles loose or broken Defective battery or low charge Defective alternator Defective alternator regulator SERVICE MANUAL Screw Compressor M 13 15 17 Action Exchange Check the coil and electrical components and exchange if necessary Fill up the fuel tank Bleed the fuel line Clean or change Change Change Have adjusted Change Change Change Check and adjust gap or change Tighten connection or replace ca ble Maintain battery see chapter Change Change Where can get help Special ized work shop X X KAESER Engine Service service manual X X X X X X X X No 9 6983 01 USE ESER 3 COMPRESSORS No 9 6983 01 US
69. gine CAUTION Danger of batteries freezing Discharged batteries are subject to frost damage and can freeze at 14 F gt Check battery charge with a specific gravity tester gt Recharge the battery gt Clean the battery terminals and wipe with grease 1 Check the battery charge weekly Recharge as necessary 2 If the machine is to be unused for a number of weeks remove the battery and store in a frost proof room In extreme cases the use of heavy duty cold start batteries to DIN 75311 and or additional batteries is recommended Battery removal and installation The machine is shut down The machine is standing level The machine is fully vented the pressure gauge reads 0 psig Machine cooled down Removing the battery WARNING There is danger of batteries bursting If a battery is short circuited it will overheat and can burst Battery electrolyte will be sprayed out in such an event gt Never short circuit a battery e g with a hand tool gt Always wear protective gloves CAUTION Excessive voltage produced by the alternator Voltage peaks can destroy the alternator regulator and diodes gt The battery serves as a buffer and must not be disconnected while the engine is running Remove the machine rear panel Disconnect the negative cable first then the positive cable Unscrew the battery fixing clamp Remove the battery from the machine m o IS S Battery replacement If the battery is t
70. he task Here conditions relevant to safety are named that will help you to avoid dangerous situations Option H1 This bullet is is placed by lists of actions comprising one stage of a task In lists of actions with several stages the sequence of actions is numbered Information that refers to only one option is marked with an indicator e g H1 means that this section is only valid for machines with adjustable machine mountings Option indicators used in this service manual are explained in chapter 2 2 2 Information referring to potential problems are identified by a question mark The cause is named in the help text gt remedy given e This symbol refers to important information or measures concerning environmental protection Further information Here your attention is drawn to further topics SERVICE MANUAL Screw Compressor M 13 15 17 No 9 6983 01 USE KAESER 2 Technical Data 2 1 Nameplate 2 Technical Data 2 1 Nameplate The model designation and important technical information are given on the machine s nameplate The nameplate is located on the outside of the machine see illustration in chapter 13 1 gt Enter the data from the nameplate here as a reference Attribute Value Options Vehicle identity no Compressor model Material number Serial number Year of manufacture Lifting point load capacity Engine power Engine speed Maximum working pressure Tab 2 Name
71. ial start up of every machine takes place at the factory Every machine is also given a trial run and passes a careful check Incorrect or improper commissioning can cause injury to persons and damage to the machine gt Commissioning may only be carried out by authorized installation and service personnel who have been trained on this machine gt Remove all packing materials and tools on and in the machine gt Observe the machine during the first few hours of operation to ensure that it is operating correctly Checking positioning and operating conditions gt Check and confirm all the items in the checklist before starting the machine Task See chapter Confirmed gt Are the operators fully familiar with safety regulations gt Have all the positioning conditions been fulfilled 5 gt Is there sufficient cooling oil in the separator tank 10 4 1 gt ls there sufficient oil in the engine Engine SM gt 5 there sufficient fuel in the fuel tank Engine SM Canopy closed and all panels in place gt Are the tire pressures OK Engine SM engine manufacturer s service manual Positioning and operating conditions checklist SERVICE MANUAL Screw Compressor M 13 15 17 29 KAESER COMPRESSORS 30 7 4 Tab 26 7 5 A initial Start up 7 4 After storing the machine for a long period After storing the machine for a long period gt Carry out the following before every re commissioning a
72. idle with open air outlet valves until an airend discharge tem perature of 86 F is reached The airend discharge temperature is shown by the temperature gauge switch SERVICE MANUAL Screw Compressor M 13 15 17 No 9_6983 01 USE KAESER COMPRESSORS 7 5 1 Material Precondition A No 9_6983 01 USE 7 initial Start up 7 5 Low temperature operation winter Starting assistance If the machine s starter batteries are discharged it can be started by jump starting from the battery of another engine driven machine or vehicle Jumper cables The machine is standing firm and level DANGER Fire and explosion hazard High currents caused by short circuited battery Shorted batteries can catch fire or explode Battery casing may crack and allow acidic fluid to spray out gt Observe the instructions provided with the battery jumper cables gt Do not connect the battery jumper cables to the negative pole of the discharged battery or to the bodywork of the machine gt Follow the safety rules when dealing with batteries Connect batteries of the same voltage only starting machine and machine to be started must not touch not bend over the battery when attaching jumper cables use battery jumper cables of sufficient cross sectional area and with insulated terminal clamps Observe the instructions provided with the battery jumper cables Keep jumper cables away from rotating pa
73. ive 2000 14 EC sound emission basic Standard ISO 3744 Measuring distance d 1 Logerithmic surface ratio Q2 14 7 dB A Emission sound pressure level Model M 13 M 15 M 17 Guaranteed sound power 97 97 level according to Directive 2000 14 EC Guaranteed sound power level SERVICE MANUAL Screw Compressor M 13 15 17 No 9 6983 01 USE KAESER COMPRESSORS No 9 6983 01 USE 2 3 2 Tab 8 2 3 3 Tab 9 2 3 4 24 2 4 1 10 2 Technical Data 24 Chassis Torques Recommended values for hexagonal bolts of strength category 8 8 Hex head screws Thread M6 M8 M10 M12 M14 M16 M18 Torque Nm 9 5 23 46 80 127 195 280 Torques for hex head screws Ambient conditions Positioning Limit value Maximum altitude AMSL 3000 ft Minimum ambient temper 14 ature F Maximum ambient tem 104 perature F Higher altitudes are permissible only after consultation with the manufacturer Ambient conditions Dimensions and locations Dimensions and function relevant locations are found in the dimensional drawing in chapter 13 3 Examples of function relevant locations are m compressed air outlet exhaust instrument panel Chassis Weights The loading capacity of the lifting frame see machine nameplate corresponds to the total weight of the machine The weight of the machine is also given on a label to the right of the operating hours counter Characteristic
74. l air treatment unit Compressed air outlet valve SERVICE MANUAL Screw Compressor M 13 15 17 27 4 6 Installation eol vld IEE EE 6 3 3 Connecting an external air treatment unit Making necessary connections Connect the hose 6 to the point 2 on the machine 1 Connect the hose 7 to the point 3 on the machine 1 Connect the plug 8 to the point 4 on the machine 1 Connect the consumer hose to the claw coupling 9 gv orm cx Check if the following components are correctly connected Compressed air hose m Condensate drainage Electrical power cable for the fan Result The external air treatment unit is completely connected SERVICE MANUAL Screw Compressor 28 M 13 15 17 No 9 6983 01 USE KAESER COMPRESSORS Further information No 9 6983 01 USE 7 2 7 3 Tab 25 7 initial Start up 7 14 Safety Initial Start up Safety Here you will find instructions for safe commissioning of the machine Warning instructions are located before a potentially dangerous task Basic safety instructions 1 Follow the instructions in chapter Safety and Responsibility 2 Commissioning work may only be carried out by authorized operating and maintenance person nel Information on authorized personnel are found in chapter 3 4 2 Information on dangers and their avoidance are found in chapter 3 5 Instructions to be observed before commissioning or recommission ing The init
75. larly loud Operating materials Strictly forbid fire open flame and smoking Follow safety regulations when dealing with fuel lubricants and chemical substances Avoid contact with skin and eyes Do not inhale fumes or aerosols from fuel or oil Do not eat or drink while handling fuel cooling and lubricating fluids Keep suitable fire extinguishing agents ready for use Y Y Use only KAESER approved operating materials Unsuitable spare parts gt Use only spare parts approved by the manufacturer for use in this machine Unsuitable spare parts compromise the safety of the machine Use only genuine KAESER pressure components Conversion or modification of the machine gt Do not permit conversion or modification of the machine as this can compromise function and safe working SERVICE MANUAL Screw Compressor M 13 15 17 13 ICA COMPRESSORS 14 39 2 3 Safety and Responsibility 3 5 2 3 5 Dangers Safe machine operation Information on conduct that will help in handling the machine safely is listed here Transport gt Shut down and fully disconnect the machine before transporting it gt Allow transport only by personnel trained in safely dealing with motor vehicles and the transport of goods gt Ensure that no persons are on the machine when transporting Positioning gt Do not position the compressor directly against a wall A build up of heat from the exhaust can damage the m
76. lp of a control valve the proportional controller the opening and closing of the inlet valve is continuously varied in relation to the actual air demand Engine speed is also varied accordingly by the control cylinder The airend provides compressed air for connected consumers This MODULATING control ensures minimum fuel consumption during times of low demand The load and fuel consumption of the engine rises and falls with the air demand The control valve is factory set The setting should not be changed without consultation with KAESER Service NO LOAD IDLE The engine speed control cylinder is at minimum speed The inlet valve is closed The minimum pressure nozzle maintains minimum internal pressure SERVICE MANUAL Screw Compressor M 13 15 17 No 9 6983 01 USE KAESER COMPRESSORS No 9 6983 01 USE 4 5 4 5 1 4 5 2 4 6 4 6 1 Fig 6 4 _ Design and Function 4 5 Safety devices Safety devices Monitoring functions with shutdown The following functions are monitored automatically Engine oil pressure Coolant temperature Airend discharge temperature Engine alternator Ignition is cut when a fault occurs The engine comes to a stop and the venting valve releases pressure from the machine Further safety devices The following safety devices are provided and may not be modified in any way Pressure relief valve This valve protects the system from ex
77. mpressor M 13 15 17 No 9 6983 01 USE KAESER COMPRESSORS No 9 6983 01 USE 3 Safety and Responsibility 3 5 Dangers Rotating components Touching the fan wheel the coupling or the belt drive while the machine is running can result in serious injury gt Operate the machine only with closed safety guards access doors and panels gt Shut down the machine before opening a door or canopy gt Wear close fitting clothes and a hair net if necessary gt Fit all safety devices and panels before starting the engine Electricity gt Allow only qualified and authorized electricians or trained personnel under the supervision of a qualified and authorized electrician to carry out work on electrical equipment according to elec trical engineering regulations gt Check regularly that all electrical connections are tight and in order High temperature gt Avoid contact with hot components These include for example engine compressor airend oil and compressed air lines coolers and oil separator tank gt Wear protective clothing gt f welding is carried out on or near the machine take adequate measures to prevent sparks or heat from igniting fuel or oil vapors or parts of the machine Noise gt Operate the machine only with intact soundproofing Y Open canopy for checks for a short period only gt Wear hearing protection if necessary The safety relief valve blowing off for example can be particu
78. nance gt Check the charging system if the battery discharges without reason Safety WARNING Danger of acid burns from escaping electrolyte gt gt gt gt Wear appropriate protective clothing including acid proof rubber gloves Always wear eye and face protection Do not tip the battery Electrolyte may run out of the vent holes Work with caution Observe the following points when working on the batteries 0 s A Q 10 M0167 Warning stickers on the battery 1 2 3 Fire sparks open flame and smoking are for Batteries are filled with caustic electrolyte bidden Observe the battery manufacturer s instruc Wear eye and face protection Danger of acid tions burn 6 Explosion hazard Keep children well away from batteries and acid Take heed of any safety symbols on the battery labels Further instructions on working with batteries 1 Do not remove battery terminal covers unnecessarily SERVICE MANUAL Screw Compressor M 13 15 17 No 9_6983 01 USE KAESER COMPRESSORS 10 3 4 2 Material Precondition No 9 6983 01 USE gt 10 Maintenance 10 3 Engine 2 Donotlay tools on the battery These can lead to short circuiting overheating and battery burst ing 3 Take particular care when the battery has been in service for a long time or has just been charged as highly explosive gas is emitted Ensure adequate ventil
79. ne oil Engine oil with additional filter change Fuel Fluid volumes Battery Characteristic Voltage V Capacity Ah PTC testing current A according to EN 50342 Battery SERVICE MANUAL Screw Compressor M 13 15 17 Viscosity class SAE 40 SAE 20W SAE 10W Fluid volume qt 1 2 1 5 21 1 Value 12 18 90 ICA COMPRESSORS 10 39 2 3 Safety and Responsibility 3 2 3 3 3 4 3 4 1 3 1 Basic Information Safety and Responsibility Basic Information The machine is manufactured to the latest engineering standards and acknowledged safety regula tions Nevertheless dangers can arise through its operation danger to life and limb of the operator or third parties m impairments to the machine and other material assets DANGER Disregard of these instructions can result in serious injury gt Read the service manual carefully and take note of the contents for safe machine operation Use this machine only if it is in a technically perfect condition and only for the purpose for which it is intended observe all safety measures and the instructions in the service manual gt Immediately rectify have rectified any faults that could be detrimental to safety Specified Use The machine is intended solely for generating compressed air for industrial use Any other use is considered incorrect The manufacturer is not liable for any damages that may result there from The user alone is liable
80. ng checklist 93 Text for the long term decommissioned information notice 94 SERVICE MANUAL Screw Compressor M 13 15 17 vii 77 4 3 14 List of Tables COMPRESSORS SERVICE MANUAL Screw Compressor VIII M 13 15 17 No 9 6983 01 USE COMPRESSORS No 9 6983 01 USE 1 2 1 3 1 4 1 4 1 1 Regarding this Document 1 1 Using the Document Regarding this Document Using the Document The service manual is part of the machine gt Keep the service manual in a safe place throughout the life of the machine gt Pass the manual on to the next owner user of the machine gt Ensure that all amendments received are entered in the manual gt Enter details from the machine nameplate and individual items of equipment in the table in chap ter 2 Further Documents Included with this service manual are additional documents intended to assist in the safe operation of the machine Certificate of acceptance operating instructions for the pressure vessel Manufacturer s declaration declaration of conformity in accordance with applicable directives Engine documentation not electric motor driven machines Missing documents can be requested from KAESER gt sure all documents are complete and observe the instructions contained in them gt sure you give the data from the nameplate when ordering documents
81. ngers of motor vehicles and take appropriate measures to safeguard persons and property DANGER There is danger of fatal injury caused by contact with live components gt Only qualified electricians may work on the installation maintenance and repair of the machine s electrical assemblies This includes work on current carrying components gt Ensure that personnel entrusted with operation maintenance and transporting are qualified and authorized to carry out their tasks Dangers Basic Information Information concerning the various forms of danger that can arise during machine operation are found here Basic safety instructions are found in this service manual at the beginning of each chapter in the section entitled Safety SERVICE MANUAL Screw Compressor M 13 15 17 11 ICA COMPRESSORS 12 39 2 3 Safety and Responsibility 3 5 1 3 5 Dangers Warning instructions are found before a potentially dangerous task Safely dealing with sources of danger Information is found here concerning how to counter the various forms of danger that can arise during machine operation Exhaust fumes Exhaust fumes from combustion engines contain carbon monoxide this gas is odorless and can cause death gt Never use the machine in enclosed spaces only in the open gt Do not inhale exhaust fumes gt Direct the exhaust fumes to the open air with a pipe gt than 4 in Fire and explosion Spontaneous ignition and
82. ning clip Foam element Filter housing Paper element 6 Engine Checking contamination of the air filter Both filter elements should be checked daily before first use of the compressor gt Check the degree of contamination of the filter elements 1 Release all retaining clips 4 2 Take off the filter cap 1 3 Withdraw the foam element 2 from the housing 1 SERVICE MANUAL Screw Compressor M 13 15 17 10 M0158 No 9 6983 01 USE KAESER COMPRESSORS No 9 6983 01 USE 10 Maintenance 10 3 Engine 4 Check the foam element 2 Visually check for 5 6 Damage The foam filter element 2 must be replaced if it is damaged see section on replacing the foam filter element Excessive dirt contamination Large dirt particles If it can be seen that the foam element 2 can be reused after cleaning it should be cleaned according to the instructions Cleaning the foam filter element Withdraw the paper element 3 from the housing 5 Check the paper element 3 Visually check for Damage The paper filter element 3 must be renewed if it is damaged see Renewing the paper filter element m Excessive dust clogging If it can be seen that the paper filter element 3 can be reused after cleaning it should be cleaned according to the instructions Cleaning the paper filter element If cleaning of the elements is not necessary they should be correctly re installed m Inser
83. o be replaced the new battery should have the same capacity current rating and shape as the original battery gt Always replace a battery with one of the same type Installing the battery 1 Place the battery in the machine SERVICE MANUAL Screw Compressor M 13 15 17 No 9 6983 01 USE KAESER COMPRESSORS 10 4 10 4 1 Material Precondition No 9 6983 01 USE Fig 16 10 Maintenance 10 4 Compressor Tighten the battery fixing clamp Connect first the positive cable then the negative cable Replace the machine rear panel 200 Engage locks The old battery is special waste and must be disposed of correctly in accordance with local environment protection regulations Compressor Carry out maintenance tasks in accordance with the schedule in chapter 10 2 2 Checking cooling oil level The oil level is checked at the oil separator tank filling port Oil must be visible in the port when the filler plug is removed Wrench Cleaning rags The machine is shut down The machine is standing level The machine is fully vented the pressure gauge reads 0 psig All compressed air consumers are disconnected and the air outlet valve is open 10 M0152 Checking cooling oil level Oil separator tank Mark for minimum oil level Oil filler port Mark for maximum level Screw plug 1 Slowly unscrew and withdraw the plug 3 from the oil filler port 2 Check that oil is visible Top up
84. pair g S T lt SERVICE MANUAL Screw Compressor No 9 6983 01 USE 84 M 13 15 17 19 43 3 4 11 Spares Operating Materials Service erol EEEE 115 Spare parts for service and repair Legend KAESER Oil separation control air SEL 1795_01E 228 e EM 2300 Solenoid valve 6050 dei pe tanc ze rc RD Ik 2412 Check valve overhaul kit ee a Lr NM r pee aa E ETA f A aa rm 7195 MU MM AM el Please quote the part number and serial number of the machine together with the item number and the description of the part when ordering Before and during all work be sure to read and follow the safety and service instructions in the machine s service manual SERVICE MANUAL Screw Compressor No 9 6983 01 USE M 13 15 17 85 Spares Operating Materials Service 11 5 Spare parts for service and repair 11 o cc 9 m LO v961 O3S SERVICE MANUAL Screw Compressor M 13 15 17 No 9 6983 01 USE 86 45343 4 11 Spares Operating Materials Service ezo l EEES 115 Spare parts for service and repair Legend KAESER Fuel supply SEL 1797 01E M Fuel pump Please quote the part number and serial number of the machine together with the item number and
85. per handling the goods arrive in perfect condition at the destination Consult KAESER Service for advice concerning sea or air transport Chocks Restraints or timber balks Straps tie downs Load securing devices Use chocks restrainers or wooden blocks for securing the load If necessary use straps across the chassis and the tow bar CAUTION Straps can damage the bodywork Movement during transport can damage the bodywork gt Do not use straps over the bodywork gt Use straps only over the chassis 1 Always observe valid accident and safety regulations when transporting 2 The loads must be secured against rolling tipping slipping and falling SERVICE MANUAL Screw Compressor M 13 15 17 95 KAESER COMPRESSORS 96 12 3 li A 12 4 Precondition 12 Decommissioning Storage and Transport 12 3 Storage Contact KAESER Service with any questions regarding transporting or load securing KAESER accepts no liability for damages arising through incorrect transport methods or insuf ficient or wrong securing of loads On rented hired or exhibition machines the transport securing devices should be re used for the return journey Before shipment as air freight The machine is designated as dangerous goods for air freight purposes any disregard can result in a heavy fine DANGER Danger of fire or explosion from operating materials The machine incorporates an internal combustion engine gt
86. plate 2 2 List of Options A list of the options fitted to your machine helps to relate the information in this service manual Options fitted to the machine are listed on the nameplate code letters The nameplate is to be found m the outside of the machine on the front see chapter 13 1 Only the codes for those options fitted appear on the label Read off the options fitted from the nameplate 2 2 1 Option da Compressed air treatment plant gt Enter the fitted options as reference Option Option code Exists Aftercooler and cyclone da separator Tab Compressed air treatment plant SERVICE MANUAL Screw Compressor No 9_6983 01 USE M 13 15 17 3 KAESER COMPRESSORS 2 2 2 Tab 4 2 3 2 3 1 2 3 1 1 Tab 5 2 3 1 2 Tab 6 Tab 7 2 Technical Data 2 3 Machine without options Option sa sc Chassis gt Enter the fitted option as reference Option Option code Exists Chassis sa Stationary SC Chassis Machine without options Sound emission Model classification Model M 13 M 15 M 17 Working pressure psig 100 145 175 190 100 100 217 Sound power level ac X X X X X cording to Directive 2000 14 EC x 5 yes no Model classification Sound emission Model M 13 M 15 M 17 Emission sound pressure 82 5 82 5 level according to EN ISO 11203 1995 num ber 6 2 3 d Calculated from the guaranteed sound power level Direct
87. plug 2 4467 Multi ribbed belts 1 1801 Engine oil 1 1925 Consumable engine parts SERVICE MANUAL Screw Compressor M 13 15 17 No 9 6983 01 USE KAESER COMPRESSORS No 9 6983 01 USE 11 3 11 4 11 5 11 Spares Operating Materials Service 11 3 SIGMA AIR SERVICE SIGMA AIR SERVICE SIGMA AIR SERVICE offers Authorized service technicians with KAESER factory training operational reliability ensured by preventive maintenance Energy savings achieved by avoidance of pressure losses security of genuine KAESER spare parts Increased legal certainty as all regulations are kept to gt Why not sign a SIGMA AIR SERVICE maintenance agreement The advantages Lower costs and higher compressed air availability Service Addresses Addresses of KAESER representatives are given at the end of this manual Spare parts for service and repair With the help of this parts list you can plan your material requirement according to operating conditions and order the spare parts you need WARNING Personal injury or machine damage due to correct working on the machine Incorrect inspection service or repair can damage the machine or severely impair its function In the event of damage personal injury may result gt Inspections preventive maintenance or repair tasks not described in this manual must not be carried out by unqualified personnel gt Have further tasks not described in thi
88. pose of operating materials and replaced parts in accordance with local environ mental protection regulations gt Observe relevant national regulations This applies particularly to parts contaminated with fuel oil coolants and acids gt Do not allow operating materials to escape to the environment or into the sewage system SERVICE MANUAL Screw Compressor M 13 15 17 No 9 6983 01 USE Design and Function 17 14 24 COMPRESSORS 1 Bodywork 4 Design and Function 4 1 Bodywork Bodywork is understood to be the exterior of the machine mounted on the chassis 2 3 1 Fig 2 Bodywork 04 M0009 Canopy Lower body Lifting eye cover 6 Lifting handle Rear panel Maneuvering handle Rear panel locks Safe and reliable operation is only ensured when the bodywork is closed The bodywork has several functions when it is closed weather protection sound insulation guarding against touching cooling air flow control The canopy 1 can be opened The maneuvering handle 7 is folding When the locks 4 are opened the rear panel 3 can be removed The lifting handles 6 allow the machine to be carried by at least 4 people SERVICE MANUAL Screw Compressor No 9 6983 01 USE M 13 15 17 19 4 Design and Function 42 Component identification 4 2 Component identification 1 04 M0364 Fig 3 Side view canopy removed 1 Instrument pan
89. rding to service manual Date signature Tab 52 Textfor the long term decommissioned information notice gt Store in a dry place with even temperature 12 2 Transporting Precondition Machine switched off and locked off All connecting lines and hoses disconnected and removed Any loose or movable parts that may fall when transporting removed or secured gt sure the danger area is clear 12 2 1 Positioning on site Maneuvering handles are provided for positioning the machine on an even location Pull down the maneuvering handles to the horizontal position for use Grasp the maneuvering handles Use the handles to maneuver the machine on site Move the machine to the new operating location Fold up the handles D OT um E Chock the wheels if necessary to prevent unwanted movement 12 2 2 Transporting with a crane Additional precautions for conditions of snow and ice Considerable snow or ice may build up on the machine under low temperature conditions This may adversely effect the machine s centre of gravity It is possible that the permissible loading on the crane or lifting eye is exceeded gt Additional measures should be taken under conditions of snow or ice m Remove any snow and ice from the machine before lifting by a crane sure the lifting eye cover plate is freely accessible and can be opened Carry out the following tasks before transporting the machine A lifting eye is p
90. ridge sssssssssssseeeeeee 60 10 4 6 Air filter maintenance nnne nnne tnt 61 10 4 7 Checking the safety relief valve 63 10 4 8 Coolers E E 63 10 5 Wheel ch ckS bein usc urbi eei 65 10 6 Options e ete b T Pe Heber ess rebus Le deco 65 10 6 1 Cyclone separator maintenance ssssssssssssssseeeneeeennen 65 10 7 Document maintenance and service work nenne 67 Spares Operating Materials Service 11 1 Note the nameplate n entren nnne nn nnne nennen 68 11 2 Ordering consumable parts and operating materials neeese eenree serne nerrnnn ee 68 11 3 SIGMA AIR SERVICE dede eddie e Ee c dO Hedge 69 11 4 Service Addresses 69 11 5 Spare parts for service and repair 69 Decommissioning Storage and Transport 12 1 De commissioning 4 92 12 1 1 Temporary decommissioning 44 enne 92 12 1 2 Long term decommissioning cc sccceeeeeeeceeeeeeeeeeeeeeeeeeeeceeeeeseceeeeeeeneeeeessaees 93 12 2 Transportirig oi eite Bd Le bte edi
91. rovided for transporting with a crane The lifting eye is located beneath a lift up cover in the centre of the canopy SERVICE MANUAL Screw Compressor 94 M 13 15 17 No 9 6983 01 USE KAESER COMPRESSORS 12 2 3 Precondition No 9 6983 01 USE A 12 2 4 Material A 12 Decommissioning Storage and Transport 12 2 Transporting Open the lifting eye cover Position the crane hook vertically over the lifting eye Engage the hook in the eye SON Lift the machine carefully Transporting a stationary version with a forklift truck The machine is shut down All connecting lines and hoses disconnected and removed CAUTION Damage to the machine by incorrect lifting with a fork truck The machine may fall or be damaged by the forks gt Do not use a fork truck to lift towable machines gt Only stationary machines without chassis and wheels may be lifted with a fork truck gt Lift the machine only from the side 1 Close the canopy 2 careful of protruding components within the canopy e g the oil separator tank 3 Drive the forks under the machine from the side and observe point 2 above regarding their po sitioning 4 Drive the forks in as far as possible beneath the frame The forks are fully under the machine 5 Liftthe machine carefully Transporting as a load The method of transport determines the type of packing and securing Packing and securing methods must be such that assuming pro
92. rts not attempt to start the machine if its battery is frozen Allow the battery to thaw first Do not try to start the machine with a boost charger Connecting the battery jumper cables 1 Stop the engine of the assisting vehicle 2 Switch off all power consumers 3 Connect positive battery poles DANGER Explosion hazard Danger of sparks igniting an explosive gas mixture gt Do not under any circumstances connect the negative pole of the assisting machine to the negative pole of the battery in the machine to be started connecting or disconnecting may cause sparking 4 Connect the negative pole of the assisting battery to a bare metal point on the compressor engine to be started as far away from the battery as possible Starting the engine 1 Start the engine of the assisting vehicle and operate at high speed 2 Startthe compressor engine Let both engines run for approximately 3 minutes SERVICE MANUAL Screw Compressor M 13 15 17 31 KAESER COMPRESSORS 32 7 initial Start up 7 5 Low temperature operation winter Disconnecting the battery jumper cables 1 Stop the engine of the assisting vehicle 2 Disconnect the jumper cables in the reverse order first negative then positive If the compressor engine stops as soon as the cables are disconnected it can mean serious damage to the alternator or battery and it should be handed over to a specialized workshop SERVICE MANUA
93. rvice and repair Legend KAESER Bodywork SEL 1801_01E _ Canopy Please quote the part number and serial number the machine together with the item number and the description of the part when ordering Before and during all work be sure to read and follow the safety and service instructions in the machine s service manual RM VOI MCI De MM EE ME _ Sound damping louver kit fee SERVICE MANUAL Screw Compressor No 9_6983 01 USE M 13 15 17 91 KAESER COMPRESSORS 12 12 1 Precondition 12 1 1 Material Tab 50 A 92 12 Decommissioning Storage and Transport 12 1 De commissioning Decommissioning Storage and Transport De commissioning De commissioning is necessary for example under the following circumstances m machine is temporarily not needed m machine will not be needed for a considerable time The machine is to be scrapped The machine is shut down Machine dry and cool 1 Carry out the following de commissioning procedures 2 Place a notice on the instrument panel describing the de commissioning procedures carried out Temporary decommissioning Decommissioning for about 4 months Plastic foil Moisture resistant adhesive tape 1 Disconnect the battery the negative terminal first and then the positive terminal 2 Close off the following openings with plastic foil and moistur
94. s of the engine and compressor air filters before starting cleaning N Clean the cooler with compressed air water or steam jet in the opposite direction to the cooling air flow Remove the protective coverings from the air filters Reconnect the battery 4 Replace the machine rear panel 3 Engage locks 2 Start the machine and run up to operating temperature so that excess water is evaporated Quo es 00 Clean the coolers only in a washing area equipped with an oil separator SERVICE MANUAL Screw Compressor M 13 15 17 No 9 6983 01 USE KAESER COMPRESSORS 10 5 Material Precondition 10 6 10 6 1 Material Precondition No 9 6983 01 USE Fig 22 10 Maintenance 10 5 Wheel checks Wheel checks Tire pressure gauge The machine is switched off 1 Check that the wheel fixings are tight visual check of locking ring 2 Check tires for wear and damage and change as necessary 3 Check the tire pressures Options Carry out maintenance tasks in accordance with the schedules in chapter 10 2 6 Option da Cyclone separator maintenance Clean the cyclone separator dirt trap if the moisture content in the compressed air is too high Cleaning cloths Dirt trap maintenance kit The machine is shut down Machine cooled down The machine is fully vented the pressure gauge reads 0 psig All compressed air consumers are disconnected and the air outlet valve is open J N
95. s service manual carried out by specialist workshops or KAESER Service SERVICE MANUAL Screw Compressor M 13 15 17 69 Spares Operating Materials Service 11 5 Spare parts for service and repair 11 o cc 9 m L0 9961 9985 SERVICE MANUAL Screw Compressor M 13 15 17 No 9 6983 01 USE 70 19 43 3 4 11 Spares Operating Materials Service ezo l EEEE 115 Spare parts for service and repair Legend KAESER Inlet air Cooling air Exhaust SEL 1781_01E Wi cos _ Compressor air intake filter element sedes Compressor air filter complt _ Filter mat __ Engine air filter elemen ______________ _______ Compressorintakehose Please quote the part number and serial number of the machine together with the item number and the description of the part when ordering Before and during all work be sure to read and follow the safety and service instructions in the machine s service manual SERVICE MANUAL Screw Compressor No 9 6983 01 USE M 13 15 17 Spares Operating Materials Service 11 o cc 9 m 11 5 Spare parts for service and repair LO 961 095 uondo SERVICE MANUAL Screw Compressor M 13 15 17 No 9 6983 01 USE 72 14 Y 3 13 4 11 Spares Operating Materials Service 115 Spare parts for service and repair Legend KAESER
96. sk Adjust the valve clearance Change the engine oil Change the engine oil filter See chapter Engine SM Specialist workshop 10 3 2 Engine SM Engine SM Grease the regulating rods gine speed Change the spark plugs Change the drive belts Adjust the valve clearance Replace the air filter Engine SM engine manufacturer s service manual Regular engine maintenance tasks Engine SM 10 3 3 Engine SM Engine SM Specialist workshop 10 3 1 The most important information on engine maintenance is contained in the maintenance sched ule Full information on engine maintenance is found in the engine manufacturer s service manual Fuel system maintenance Carry out maintenance tasks according to the following schedule Interval Daily Every 50h Annually every 400 500 h Maintenance task Fill up the fuel tank Check fuel pipes and replace if necessary Clean or change the fuel filter Clean the tank fuel strainer Clean the fuel tank Check fuel pipes and replace if necessary See chapter Engine SM Engine SM Engine SM h 4 operating hours Engine SM engine manufacturer s service manual Tab 39 Regular fuel system maintenance tasks No 9 6983 01 USE SERVICE MANUAL Screw Compressor M 13 15 17 43 KAESER COMPRESSORS Tab 40 10 2 4 Tab 41 Tab 42 Tab 43 44 10 Maintenance 10 2 Maintenance schedules Battery maintenance
97. t open or destroy removed components as some inlet valves for instance are powerfully spring loaded SERVICE MANUAL Screw Compressor M 13 15 17 No 9_6983 01 USE KAESER COMPRESSORS 3 5 3 3 5 4 Tab 23 3 6 Further information 3 7 No 9 6983 01 USE 3 Safety and Responsibility 3 6 Safety Devices Decommissioning storage disposal gt Drain out fluids and dispose of according to environmental regulations These include for example fuel engine and compressor oil and coolant Dispose of the machine in accordance with local environmental regulations Organizational Measures gt Designate personnel and their responsibilities Give clear instructions on reporting faults and damage to the machine Give instructions on fire reporting and fire fighting measures Danger areas The table gives information on areas dangerous to personnel Only authorized personnel may enter these areas Task Danger area Authorized personnel Transport Within a 10 ft radius of the machine Operating personnel to prepare for transport No personnel during transport Beneath the lifted machine No personnel Commissioning Within the machine Maintenance personnel Within a 3 5 ft radius of the machine Operation Within a 3 5 ftradius of the machine Operating personnel Maintenance Within the machine Maintenance personnel Within a 3 5 ft radius of the machine Danger areas Safety Devices Safety devices ensure saf
98. t the paper element 3 in the housing 5 Insert the foam element 2 in the housing 1 Replace the filter cap 1 on the housing 5 Secure all retaining clips 4 Renewing the foam filter element NSO ir aS Release all retaining clips 4 Take off the filter cap 1 Withdraw the foam element 2 from the housing 1 Clean all sealing faces with a damp cloth Insert the new foam element 2 in the housing 1 Replace the filter cap 1 on the housing 5 Secure all retaining clips 4 Cleaning the foam filter element O 109 Tc SONS OT Release all retaining clips 4 Take off the filter cap 1 Withdraw the foam element 2 from the housing 1 Clean the foam element 2 in warm soapy water or non flammable solvent Allow the foam element 2 to dry out do not apply oil Clean all sealing faces with a damp cloth Insert the foam element 2 in the housing 1 Replace the filter cap 1 on the housing 5 Secure all retaining clips 4 SERVICE MANUAL Screw Compressor M 13 15 17 47 KAESER COMPRESSORS 10 3 2 Material Precondition A 48 10 Maintenance 10 3 Engine Renewing the paper filter element Release all retaining clips 4 Take off the filter cap 1 Withdraw the paper element 3 from the housing 5 Clean all sealing faces with a damp cloth Insert the new paper element 3 in the housing 5 Replace the filter cap 1 on the housing 5
99. ting 2 5 4 Temperature Machine temperatures Values Recommended airend 86 discharge temperature for switching to load F Typical airend discharge 167 212 temperature during opera tion F Maximum airend dis charge temperature auto matic safety shut down F 230 Tab 16 Machine temperatures 2 5 5 Cooling oil recommendation A sticker showing the type of oil used is located near the oil separator tank filler Information on ordering cooling oil is found in chapter 11 No 9 6983 01 USE Characteristic SIGMA FLUID Oil grade 5 460 MOL Classification Silicone free Mineral oil synthetic oil Application Standard oil for all applications except in Standard oil for all applications connection with food products except in connection with food Particularly suitable for machines with Products high duty cycle Particularly suitable for ma chines with a low duty cycle Approval Viscosity at 40 Viscosity at 100 C 46 cSt D 445 ASTM test 7 2 cSt D 445 ASTM test SERVICE MANUAL Screw Compressor M 13 15 17 44 cSt D 445 ASTM test 6 8 cSt D 445 ASTM test KAESER COMPRESSORS Tab 17 2 5 6 Tab 18 2 6 2 6 1 Tab 19 2 Technical Data 2 6 Engine Characteristic SIGMA FLUID Oil grade 5 460 MOL Flash point 470 F 428 F D 92 ASTM test ISO 2592 Density at 60 F 7 1 Ib gal ISO 12185 Pour point 60 F 27 D 97 ASTM test IS
100. to one side then pull out the copper pipe 3 at item 2 Unscrew the fitting 4 at 5 and take off the compressed air hose Remove the cover fixing screws 6 and carefully place the cover 9 to one side Take out the old cartridge 11 and gaskets 10 Clean all sealing surfaces taking care that no foreign bodies dirt particles fall into the oil sep arator tank 6 Insert the new oil separator cartridge with new gaskets O rings and screw down the cover 7 Renew the strainer 8 and O ring 7 of the dirt trap 2 Replace and tighten all fittings ec Check the oil level in the oil separator tank Top up if necessary 10 Reconnect the negative cable to the battery 11 Replace the machine rear panel 12 Engage locks Dispose of the old separator cartridge and gaskets along with any working materials contami nated with cooling oil in accordance with environment protection regulations Starting the machine and carrying out a trial run 1 Start the machine and run in idle up to operating temperature 2 Close the compressed air outlet valve 3 Shut down the machine 4 Wait until the machine has automatically vented Pressure gauge reads 0 psig 5 Open the outlet valve 6 Check the oil level after about 5 minutes Top up if necessary 7 Carry out a visual check for leaks Air filter maintenance Cleaning cloths Compressed air for blowing out Spare parts as required The machine is shut down
101. tus IRR 94 12 21 Positioning onsite inte e eee ag 94 12 2 2 Transporting with a crane nennen 94 12 2 3 Transporting a stationary version with a forklift truck 95 12 2 4 Transporting as a load 44 enne 95 12 3 Storage orb CEREREM WU 96 12 4 Disposal intet e iE pe Ee erede Re 96 Annex 13 1 Marking nn e a a HUE dee OG E ERR ee dc TORRE tise 98 13 2 Pipeline and instrument flow diagram P diagram 98 13 3 Dimensional drawing version with chassis 101 13 4 Dimensional drawing stationary version 4 eene 103 13 5 Electrical Diagrari edet eer eene tec tee edie deeded 105 13 6 Fuel circulation diagram 4 ener enn nnne nennen nennen 109 SERVICE MANUAL Screw Compressor M 13 15 17 Contents COMPRESSORS SERVICE MANUAL Screw Compressor IV M 13 15 17 No 9 6983 01 USE 14 NX 3 9 3 2 List of Illustrations COMPRESSORS No 9 6983 01 USE Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Location of satety SIGNS oi it etie ERE ede et 16 BOGVWOIK SIRE 19 Side view canopy removed
102. y Safety relief valve maladjusted and or leaking Replace if necessary Alarm Safety relief valve blowing off Machine overheating Possible cause Action Defective cooling fan Replace blades or the complete fan wheel SERVICE MANUAL Screw Compressor M 13 15 17 Where can get help Specialized KAESER Servi workshop ce X X Where can get help Specialized KAESER Servi workshop ce X No 9 6983 01 USE KAESER COMPRESSORS 9 Fault Recognition and Rectification 9 3 Compressor faults and alarms Possible cause Action Where can get help Specialized KAESER Servi workshop ce Oil cooler clogged Clean surface see chap ter 10 4 8 Defective working element in the Change X combination valve Working pressure too high pro Reset to the permissible value or X portional controller maladjusted replace Oil separator cartridge heavily Measure the pressure differential X clogged and change the cartridge if great er than 1 bar see chap ter 10 4 5 Oil filter cartridge heavily conta Measure the pressure differential X minated and change the cartridge if great at 217 psig working pressure er than 11 psig see chap ter 10 4 5 Compressor oil filter clogged Change see chapter 10 4 4 Compressor oil level too low Top up see chapter 10 4 2 Oil pipes leaking Seal leaks or change pipes X X Defective engine cooling fan Repair X X Ambient

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