LGCY10-10 Instruction Manual

Kaishan LGCY-10/10 Series Rotary Screw Compressor Manual
PARTS & INSTRUCTION

MANUAL
Model LGCY 10/10 Diesel Engine Driven Air Compressor
PN: 97002023000079
Release August 2023, Version: A

This manual provides detailed Operation and Maintenance procedures for the Model
LGCY 10/10 Mobile Air Compressor Unit.
Prior to operation and maintenance of this compressor, it is important that the manual is
circulated and read by all relevant personnel and that all safety features of this compres-
sor are fully understood.
When operating this unit, the owner must employ safe working practices and observe all
related local work safety requirements.
The owner is responsible for maintaining the unit in a safe operating condition. Genuine
parts and accessories are available and must be replaced in accordance with Manufac-
turers recommendations.
Only Genuine Lubricants provided by Kaishan must be used. Never mix Lubricants of
different types as serious damage will occur to mechanical components.
Installation, operation, maintenance and repair shall only be performed by Kaishan au-
thorized, trained and competent personnel.
Kaishan reserves the right to research and improve any of its Products and is not liable
for the update, modification or retrofit of any existing units. Contents in this manual there-
fore may vary. Please be aware of such possibilities and always refer to the unit Serial
Number as the reference.
If you encounter any problem during operation of this Rotary Screw Air Compressor
please contact your local Kaishan Authorized Distributor.
If any statement in this manual, especially with regard to safety, does not comply
with local legislation, the stricter of the two shall apply.
Contents;
Chapter 1 Safety of Operation
Chapter 2 Compressor Specifications and Design
Chapter 3 Operating Principle of Air Compressor
Chapter 4 Engine Overview
Chapter 5 Compressor Weights and Dimensions
Chapter 6 Wiring Drawing
Chapter 7 Parts Identification
Chapter 8 Service Parts
Chapter 9 Maintenance
Chapter 1; Safety of Operation
Overview
Kaishan designs and manufactures its products with Safety as the primary feature.
However, the responsibility for safe operation rests with those who use and maintain
these products once the product is installed. The following safety precautions are offered
as a guide, which if conscientiously followed, will minimize the possibility of accidents
throughout the useful life of this machine.
The compressor should be operated only by those who have been trained, authorized to
do so and have read and understood this manual. Failure to follow the instructions, pro-
cedures and safety precautions can result in accidents and even injuries or death.
It is the responsibility of the owner or hirer of such products to ensure that operators are
provided with the manual and are suitably instructed regarding the purpose of the Manual
and its Safety Instructions. In addition operators should be suitably and adequately
trained in the use of the product.
THIS IS AN IMPORTANT NOTIFICATION AND IN THEIR OWN INTEREST OWNERS

AND HIRERS MUST COMPLY.
Control of Hazardous Substances
Your attention is drawn to the following list of substances used in a Diesel Engine
Driven Air Compressor which may expose personnel to risk if swallowed or if skin
or facial contact is allowed;
Diesel Oil Fuel

Compressor and Engine lubricating oils and greases
Anti-Freeze Agents and mixes
Corrosion Inhibitors and Conditioners
Battery Acid
Safety of Equipment
This manual has been prepared to assist the user in caring for this machine and every
effort has been made to provide sufficiently detailed information for a competent person
to be able to do this correctly and safely.
We cannot see circumstances in which this equipment will present health or safety haz-
ards providing operators observe normal safe practices when working on the machine
such as; safe handling of compressed air, engine exhaust, fuels, oils, cleaning fluids, lift-
ing and towing, working inside the machine and security of the unit if working under-
neath.
Fire and Explosion Protection
Clean up spills of fluid or inflammable substances immediately.

Avoid spark, flame or inflammable substances. Never smoke near the machine when
observing or filling fluid. Service shall be carried out when the machine is stopped and
compressor completely cools down.
An explosive atmosphere is a mixture with air, under atmospheric conditions, of flamma-

ble gases, vapors, hazes or dusts in which, after ignition has occurred, combustion prop-
agates to the entire unburned mixture and may cause a hazard.
A potentially explosive atmosphere is an atmosphere which could be explosive due to
local site conditions.
Do not permit fluid to splash on acoustic material or accumulate on the compressor lower
surfaces and inside of cabinet. Wipe down using an aqueous industrial cleaner or steam
– clean as required. If necessary, replace acoustic material and clean all surfaces. Any
acoustic material with a protective covering that has been damaged should be replaced
immediately to prevent accumulation of fluid within the material. Do not use inflammable
detergents.
In case welding is necessary when repairs, clear acoustic materials and other inflamma-
bles or heat sensitive articles out of site;
Sufficient fire extinguishers shall be provided when servicing or operating the compres-
sor;
Clear away inflammable materials such as oil cloth or paper near the compressor;
If the cooling system or lubrication system is not working correctly (poor circulation of
cooling air or fluid), do not start the machine;
Do not operate the compressor in a dangerous condition.
The Use of Compressed Air.
Use only Certified pressure vessels of adequate working pressure, others could explode.
Fit a non-return valve or a shut off valve in the delivery line if the compressor is to be
coupled in parallel with another compressor connected to the same air system.
Distribution pipework and hoses must be the correct size and suitable for the working
pressure involved.
If working pressures are above 7bar it is recommended that hoses incorporating safety
wires are used.
Do not use frayed, damaged or deteriorated hoses. Always store hoses properly and
away from heat sources. A hose failure will cause injury.
Use only the correct size hoses and hose end fittings. Use clamps made specifically for
compressed air application.
If using compressed air to clean down equipment take care not to blow debris onto your-
self or other persons and wear eye protection.
When blowing through a hose or airline ensure the open end is held securely. A free end
will cause whip and can cause injury.
Open the air valve slowly and ensure any ejected particles are restrained.
Never apply compressed air directly onto skin, do not use compressed air to blow dust
from clothing or overalls.
NEVER use compressed air for breathing purposes e.g. charging air cylinders unless the
compressor is specifically designed for this purpose.
Do not operate a compressed air system above the pressure rating which it has been
designed to operate.
Shut off appropriate air valves at the compressor before disconnecting a hose or airline.
Keep hands, arms and other parts of the body away from couplings, fans and other mov-
ing parts;
Do not attempt to start or operate the compressor with the fan, coupling or other guards
removed;
Wear tight-fitting clothing and confine long hair when working around this compressor,
especially when exposed to hot surface or moving parts;
Keep access doors closed except when making repairs or adjustments;
Make sure all personnel are out of and/or clear of the compressor prior to attempting to
start or operate it.
Lifting and Transportation.
The designated lifting point or points provided on a mobile compressor are designed pri-
marily for the vertical loading associated with the transfer of the compressor between the
ground and a transportation vehicle.
Transport by suspending from the lifting point or points over rough terrain is not recom-
mended, but if absolutely necessary, care must be taken to avoid lateral or shock loading
of the lifting points by suitably restraining any swinging motion of the compressor with
respect to the suspension device.
Check the tow bar, braking system and coupling. Check the wheels are secure and the
tyres are in good condition and inflated correctly.
Connect the lighting cable to the towing vehicle and ensure all lights and indicators are
working correctly.
Before towing the unit;
~ ascertain that the pressure vessel(s) is (are) depressurized,

~ check the tow bar, the brake system and the towing eye. Also check the coupling of the
towing vehicle,
~ check the towing and brake capability of the towing vehicle,
~ check that the tow bar, jockey wheel or stand leg is safely locked in the raised position,
~ ascertain that the towing eye can swivel freely on the hook,
~ check that the wheels are secure and that the tyres are in good condition and inflated
correctly,
~ connect the signalization cable, check all lights and connect the pneumatic brake
~ attach the safety break-away cable or safety chain to the towing vehicle,
~ remove wheel chocks, if applied, and disengage the parking brake.
To tow a unit use a towing vehicle of ample capacity. Refer to the documentation of the
towing vehicle.
If the unit is to be backed up by the towing vehicle, disengage the overrun brake mecha-
nism (if it is not an automatic mechanism).
Never exceed the maximum towing speed of the unit (mind the local regulations).
Place the unit on level ground and apply the parking brake before disconnecting the unit
from the towing vehicle. Unclip the safety break-away cable or safety chain. If the unit
has no parking brake or jockey wheel, immobilize the unit by placing chocks in front of
and/or behind the wheels. When the tow bar can be positioned vertically, the locking de-
vice must be applied and kept in good order.
Before Starting Compressor.
Make sure that the compressor is located on a level and secure ground, secure the
brakes and if possible point the engine exhaust downwind of operators.
Check all hoses are in good condition, secure by whip checks and not exposed to hot
surfaces.
Make a visual check of the entire compressor specifically looking for signs of fluid leaks.
If required, top up any fluid or lubricant to the correct level.
Check battery leads are secure.
Check nothing fallen on or leaning against the exhaust system, particularly combustible
materials.
Make sure start and stop procedures are clearly understood. Close all valves before
starting.
During Operation.
Keep enclosure doors closed.
Check all temperatures and pressures are correct.
Stop immediately if warning or alarms are displayed or if gauges register outside of nor-
mal working limits. Do not allow unauthorized personnel to make any adjustments.
Do not refill with fuel whilst the compressor is running.
Ensure the engine exhaust is always free to vent.
Do not carry out adjustments unless authorized and trained to do so.
Do not remove any guards when the plant is running; make sure all guards are always in
place.
Do not run the compressor in an area deemed as Fire Hazard, do not operate in the
presence of toxic fumes.
Be aware of the noise level and warn other people in the location also.
After Stopping.
Ensure that the blowdown system has operated correctly and the compressor has vented
on shutdown.
Allow the radiator to cool down before removing the filler cap.
Do not leave the ignition key in place when the compressor is unattended.
Secure and lock all enclosure doors at the end of each shift.
Maintenance and Service.
Ensure a “Work in Progress” or other similar sign is prominently displayed on the unit
whilst service or repairs are being carried out. Remove the ignition key.
If the compressor is to be left under repair and unattended remove the key and discon-
nect the battery.
Check all pressure is released internally before removing any plugs or hoses.
Apply the brakes and chock the wheels to prevent the unit moving whilst work is being
undertaken.
Always support the unit on axel stands if working underneath, do not rely on jacks alone
to support the weight of the unit.
Ensure that the doors are supported correctly when open. Doors can easily slam shut.
Always use correct tooling especially lifting gear, hoists and jacks.
Do not weld or perform any operation involving heat near fuel or oil systems.
Do not weld or make temporary repairs to any pressure vessel.
Check all safety switches are working by simulating fault conditions if possible. NEVER
bypass a safety switch.
NEVER use alternative spare parts or mix lubricants of different brands or grades.
Ensure all waste products and lubricants are disposed of in accordance to local sight
rules and conditions.
This specifically applies to oils, greases, anti-freeze, inhibitors and conditioners.
NEVER allow these products to enter the industrial or domestic waste water systems.
The unit has parts, which may be accidentally touched by personnel, of which the tem-
perature can be in excess of 80 °C (176 °F). The insulation or safety guard, protecting
these parts shall not be removed before the parts have cooled down to room tempera-
ture.
Noise Levels
Noise, even at reasonable levels, can cause irritation and disturbance which, over a long
period of time, may cause severe injuries to the nervous system of human beings. When
the sound pressure level, at any point where personnel normally has to attend, is;
~below 70 dB(A): no action needs to be taken
~ above 70 dB(A): noise-protective devices should be provided for people continuously

being present in the room
~ below 85 dB(A): no action needs to be taken for occasional visitors staying a limited
time only
~ above 85 dB(A): room to be classified as a noise-hazardous area and an obvious

warning shall be placed permanently at each entrance to alert people entering the room,
for even relatively short times, about the need to wear ear protectors.
~ above 95 dB(A): the warning(s) at the entrance(s) shall be completed with the
recommendation that also occasional visitors shall wear ear protectors
~ above 105 dB(A): special ear protectors that are adequate for this noise level and the
spectral composition of the noise shall be provided and a special warning to that effect
shall be placed at each entrance.
Permit to Work
All work must only be carried out when approved by the local Permit to Work System.
.
Chapter 2; Compressor Specification and Design
Engine
The engine’s power is transmitted to the compressor element through a heavy-duty cou-
pling.
Compressor
The compressor casing houses two screw-type rotors, mounted on ball and roller bear-
ings. The male rotor, driven by the engine, drives the female rotor. The compressor de-
livers pulsation-free air. Injected oil is used for sealing, cooling and lubricating purposes.
Compressor Lubrication
The oil is driven by air pressure. The circuit has no oil pump fitted.
The oil is removed from the air in the air/oil separator tank, first by centrifugal force, sec-
ondly through an air/oil separator element.
The separator tank is fitted with an oil level indicator for correct level filling.
Regulation
The compressor is provided with a continuous regulating system, blowdown valve and
load cylinder activated inlet valve assembly.
The separator tank pressure variation is sensed by the regulating valve which, by means
of control air to the unloader and and engine speed regulator, matches the air output to
the air consumption.
The air receiver pressure is maintained between the pre-selected working pressures
and the corresponding unloading pressure.
Cooling system
The engine is provided with a liquid-cooler and intercooler and the compressor is provid-
ed with an oil cooler.
The cooling air is generated by a fan, driven by the engine.
Safety Switches
An over temperature switch protects the compressor against overheating. The separator
tank is provided with a pressure relief valve.
Engines are equipped with low oil pressure and high coolant temperature shut-down
switches.
Frame and Running Gear
The compressor/engine unit is supported by anti-vibration mounts.

The standard compressors running gear is equipped with braking and lighting systems.
Panelwork
The compressor panel work has openings for the intake and outlet of cooling air and
hinged doors for maintenance and service operations. The bodywork is internally lined
with sound-absorbing material.
Doors should remain closed during transportation and when the compressor is in opera-
tion.
JCD 900 Controller
The compressors are fitted with a purpose built Model JCD900 Control unit. The control-
ler is programmed with all the information required to operate the unit safely and to speci-
fication.
Operators must be trained on the correct working and functionality of this system.
To keep the compressor in optimum condition, please read Chapter 6 (Maintenance)

thoroughly. For any questions not covered in this Manual, please contact your local
Kaishan Distributor.
Compressor Dataplate
Enter the details from your compressor nameplate onto this illustration below.
This will help to have all the important information to hand in the case of any discussions
with Kaishan Service department.
Refer to the Compressor nameplate for;
Unit Model Number

Unit Power
Air Capacity
Discharge Pressure
Rated Speed
Weight
Serial Number
Manufacturing Date
Always quote Model and Serial Number when ordering spareparts.

Chapter 3; Operating Principle of Air Compressor
Compressor Unit Prepare to Start;
Check Engine Oil Level is to “H” Mark on Dipstick
Check Compressor Lubrication Level is to Top Red Mark on Sight Tube
Check Engine Cooling System Coolant System if Full to Top
Check Fuel Level, Less than 20% will Alarm
Close both Air Discharge Outlet Valves
Check for Water in the Fuel Filter, Drain if Nessacary
Engage Electrical Isolater ON
Ready to Start; Start;
Key Switch On Press Start Button

3 Way Valve to Unload Compressor Idling
Compressor Unit Run and Load;
Load; Full Load;

Shift 3 Way Valve to Load Open Air Dis-
charge Valves
Engine rpm will Increase Engine at Full rpm
Alarm; Shutdown;
Alarm Light Illuminates Unload Compressor
Flashing Widow Indicates Alarm Status Stop and Investi-
gate
Principle of Operation.
Compressor;
On start up the 3 way control valve is set in the Unload position this prevents any air from
activating the Inlet Servo Valve fixed to the AIVM-120B Inlet Valve.
The inlet valve remains in a closed position allowing only a small amount of air to bypass
to maintain minimum pressure.
The blowdown valve is open and a minimum pressure of 4bar should be observed.
Activating the 3 way control valve to the Load position closes the blowdown valve and
energises the Inlet Valve Servo Valve to open.
The compressor is now On Load.

Engine;
On engaging Start, with the 3 Way Valve in Unload, the engine will revert to minium rpm
as set up by the mechanical control linkage linking the Engine Servo Cylinder to the En-
gine Governer.
The engine will idle at around 1500 rpm.
By engaging the 3 Way Valve to Load, Blowdown Valve now closed,Compressed Air In-
let Valve open, the air in the Separator tank quickly builds up feeding an air supply to the
Proportional Control Valve.
The Proportional Control Valve feeds air to the Engine Servo Cylinder pushing the Gov-
erner open and the Engine rpm increases to 1850 rpm.
The Compressor unit will continue to build up pressure in accordance to the Proportional
Control Valve setting.
At Maximum Set Point or if the Outlet Valves are closed the engine will start to reduce
speed and the compressor will unload.
Pressure Transducer;
The Pressure Transducer is installed into the Air Separator Tank and is preset to enure
the compressor can not run Overpressure. A Warning followed by Shutdown will occur if
the pressure exceeds the Preset Values.
Compressed Air Intake.
The Compressed Air inlet system is constructed of an air filter housing, filter element,
inlet elbow, flexible suction hose and air inlet valve.
When the machine is running on load, air is drawn into the air filter and is drawn into the
airend compression chamber through the suction inlet valve. Passing through the high
efficiency airend, volume reduction and compression occurs until the air is discharged at
the pressure rating of the compressor unit.
Air filter Assembly.
The air filter element is used to filter to provide clean air for the compressor. Impurities in
ambient air if not filtered may cause wear on the airend component parts and will certain-
ly degrade the compressor lubricant.
It is vital to change the air filter at its correct service interval or before in very dusty envi-
ronments. Periodically check the suction hose pipe to ensure it is tightly fastened and
there are no splits in the hose assembly.
Minimum pressure valve
The now clean air can make its way toward entry into the customer’s air distribution sys-
tem.
The minimum pressure valve located on the top of the separator tank allows the air to
pass when the compressor is running and in a load condition, on shutdown the spring
return and internal piston will close preventing line pressure to back feed the separator
tank.
It is important if oil levels are to be checked that no pressure is present in the separator
tank. Make sure the compressor has fully blown down before removing the filler cap.
The MPV has a dual function which prevents the compressor from delivering com-
pressed air lower than 4 bar. The internal spring and piston will start to close and restrict
the air flow at that pressure, this setting cannot be modified.
This minimum pressure of 4 bar is required to maintain good levels of lubrication and
prevent oil carryover which would occur below this threshold.
Please note that the condensate needs to be drain away freely to prevent moisture con-
taminating downstream tooling.
The condensate cannot be discharged directly into the foul drain as it contains a quantity
of oil. Use an oil/water separator to manage this process.
Blowdown valve
The automatic blowdown valve is an integrated part of the air inlet system. The valve is
N.C.until the air pressure reaches its upper limit. At that point the valve opens.
At complete shutdown, the blowdown valve reduces the internal pressure to 0bar.
Pressure Relief valve
The PRV is fitted to the separator vessel to prevent generated pressure exceeding safe
working limits of the compressor components.
This valve must not be altered and is subject to local Insurance Certification.
Oil Circuit Compressed Air System
The Lubrication system is composed of compressor lubricant, separator vessel, thermal

control valve, oil cooler, oil filter and connecting pipework.
This lubricant must not be mixed with any other; this will defiantly result in prema-
ture failure of bearings, separators, oil filters and coolers due to internal varnish-
ing.
The level of the lubricant can clearly be seen in the sight tube fitted to the separator tank.
The correct level is ¾ full when the compressor is stopped and settled.
Take care before removing the filler cap that all the pressure is at zero.
(1) Cooling - Oil injected into the airend will absorb a large amount of heat generated
during the compression cycle.
(2) Lubricating – The lubricant forms a film of oil between the rotors, ensuring there is
no direct contact between rotors and internally lubricates the airend bearings.
(3) Seals - Lubricant seals the clearances between the rotors and rotor housing for max-
imum airend efficiency.
As the lubricant warms up the thermo valve will start to open and allow the oil
through the oil cooler. The oil passing through the cooler and the bypass oil will mix
to create an optimum operating temperature.
Oil Filter
All lubricant oil must pass through the oil filter before injection into the airend. The oil filter
has a service life of 2,000 hours and must be changed
accordingly.
Oil Scavenge line
Any oil scavenged back from the separator element will be re-introduced back into oil
circuit through a scavenge line. The scavenge line must be kept clear and is a servicea-
ble item.
Failure to do this will result in oil carryover as the separator element will be unable to
drain.
Cooling system
Cooling of the oil as it passes through the cooler is achieved by engine driven cooling fan.
The fan engages on compressor start up and blasts air across the cooler matrix
as the oil passes through internally.
It is very important to keep the external matrix of the cooler(s) clean otherwise overheat-
ing will occur.
This should be checked prior to starting the compressor.
Air/Oil separator element
The separator element is the key part of the filtration system which separates the oil from
the compressed air generated by the airend.
A 0,5 micron multi layered or pleated element removes the oil content from outside to in
down to 3 ppm at final discharge.
The element has a maximum service life of 8,000 hours, 1 bar differential pressure or an-
nually, whichever comes first.
High separator differentials increase the absorbed power of the compressor and may
cause a motor overload if ignored.
Over Temperature Switch
Sensor monitors the running temperature of the compressor and should never be bypassed. If the
compressor temperature reaches 120℃ the machine will shut down in fail safe mode.
Chapter 4; Engine Overview
Engine Overview
The driving power for the air compressor unit is a direct drive multi cylinder diesel engine.
Just like the air compressor the engine requires regular checks and maintenance proce-
dures to be carried out.
Oil Level
The engine oil level should be checked prior to every start up. A crankcase dipstick is
provided and marked up at low, high and correct levels.
Never run the engine when low on oil. The Compressor controllers monitoring oil pres-
sure, engine speed and cooling water temperature.
Water Level
Cooling of the Engine is achieved via a water filled radiator cooled by a multi blade fan
assembly.
The water levels should be checked prior to start up, the level should be to the top of the
radiator.
NEVER open the radiator cap when the engine is running, leave the unit to cool down for
at least ½ hour before removing the cap.
Fuel
The engine runs off diesel oil and running out of fuel should be avoided. Check the fuel
level prior to start up, the Compressor controller displays the fuel level as a digital read
out.
Running out of fuel will create an air lock in the injectors and will require bleeding before
the engine can be restarted.
Fuel Filter
A fuel filter is installed to protect the injectors from contamination. This filter must be
changed during the service schedule. Fill the fuel filler with diesel when changing to pre-
vent air getting sucked into the circuit.
Poor grade or water contaminated diesel oil will cause engine starting difficulties.
Oil Filter
The oil filter is installed to protect the engine crankshaft and conn rod bearings.
Always change as per schedule and do not use cheap alternative filters which will not
have the correct micron rating / internal bypass.
Air Filters
Depending on the size of the engine one or multiple air filter assemblies will be installed.
The air filter ensures clean air without damaging particles are drawn into the engine for
combustion.
Dirty filters will facilitate incorrect fuel/air mix causing damage to the engine valves.
Do not use cheap alternative parts which will not have the correct micron rating.
Battery
A good healthy battery is important to ensure the compressor is able to start under all
ambient conditions, therefore keep the battery clean and dry.
Keep the electrolyte level above the plates or at the indicated level. Level above plates at
least 10 mm (0.4 in) to 15 mm (0.6 in). Top up with distilled water only.
Keep the terminals and clamps tight, clean, and lightly covered with petroleum jelly.
Protection
The JCD 900 Controller monitors and protects the following engine functions;
Oil Pressure
Engine Water Temperature
Engine Speed
Low Liquid Level
Chapter 5; Compressor Weights and Dimensions
Air discharge
G3/4*1
G1 1/4*1
1878
1703
49°
511
652
2330 1260
2900
1700
3544
3790
Unit Specifications;
Total Unit Height (inc exhaust) 1878mm
Total Unit Width (inc towbar) 1700mm
Total Unit Length 3790mm
Unit Weight 1400kgs

FU1
HL1 HL3 HL4 HL5 HL6 SB6 SB4 SB7 Power

switch
Speed sensor
charging Run Pressure Oil KA4 Start
Alarm KA2 KA1 KA1 KA2 Heating
indicator alarm filtor CD-ZS-30-00A
cogging 33
32 34 35 36
Discharge pressure sensor
16 17 18 19 24V+ CD-QY-20-08A
24V+
D1 Engine oil pressure sensor
CD-ZS-YY-08A
Discharge temperature sensor
37 38
Monitor mothor 24V- CD-QW-13-01A
board Engine water temperature sensor
CD-SW-35-01A
24V- 25 26 27 HL2 Liquid level sensor
D13 D4 D3 D6 D5 D7 D8
CD-YW-30-00A
Heating
SB5 instruction
Oil filter
detection P
SB1 SB2 SB3 Stop KA4
sensor
signal
Menu/ Displacement Modify/Timing
confirm /Restoration
Black
Block
Red Red
Air
Generator Off the oil preheater
Yellow
Start motor solenoid valve
B R
RED Block
01
Speed sensor D1
02
D2
03
Discharge pressure sensor D3
04
D4
Engine oil pressure sensor 05
D5
06
Discharge temperature sensor
D6
07
D7
Chapter 6; Wiring Schematic LGCY 10/10 Mobile Compressor
Engine water temperature sensor 08

D8
09
Liquid level sensor D15
10
D16
Chapter 7; Parts Identification
Airend, Inlet Valve and Air Filtration;

Airend, Inlet Valve and Air Filtration;
No. Name Qty. Part Number Remarks

1 Adaptor 1 150599002813
2 Airend 1 820101
3 Air filter hoop 2 120910000010
4 Flexible pipe 1 150599021396
5 Gasket 1 150599006208
6 Bolt 4 100000000427 M14*30
7 Washer 6 100004000019 14
8 T clamp 2 150599004208
9 Screw 2 100001000227 M20*35
10 Washer 2 100004000093 20
11 Washer 2 100004000025 20
12 Bolt 2 100000000428 M14*35
13 Washer 2 100004000089 14
14 Screw 4 100001000191 M16*45
15 Washer 6 100004000021 16
16 Stud 8 100002000018 M16*50
17 Washer 8 100004000091 16
18 Nut 8 100003000107 M16
19 Air filter indicator 1 150599022289
20 Inlet valve 1 120514000073
21 Airend support 1 150599021390
22 Joint 1 150599003086
23 Screw washer 1 150599005060
24 O ring 1 120000000108 45*3.55
25 O ring 1 120000000094 25.8*3.55
26 Gasket 1 150599002678
27 O ring 2 120000000114 51.5*3.55
28 Connecting pipe 1 150599021398
29 Oil/air pipe 1 150599021395
30 Screw washer 1 150599005061
31 O ring 1 120000000118 56*3.55
32 Joint 1 150599003070 G2-M64X2
33 Check valve 1 150599004064
34 Joint 2 120601000065
35 Oil return pipe 1 150599002066
36 Absorber 2 150599010659
37 Air filter element 1 120901000066
38 Safety element 1 120901000067
39 Air filter shell 1 120910000105
Sub Frame and Pivot Plate(LGCG);
Sub Frame and Pivot Plate(LGCG);

1 Base 1 150599021412
2 Hoisting part 1 150599021416
3 Maintenance plate 1 150599021402
4 Cooler bottom plate 1 150599021404
5 Support 2 150599021410
6 Washer 8 100004000091 16
7 Washer 8 100004000021 16
8 Bolt 8 100000000445 M16*50
9 Screw 16 100001000070 M8*20
10 Washer 16 100004000083 8
11 Washer 16 100004000011 8
Sub Frame and Pivot Plate(LGCY);

Sub Frame and Pivot Plate(LGCY);

1 Base 1 150599021412
2 Moving part 1 150599002098
3 Maintenance plate 1 150599021402
4 Cooler bottom 1 150599021403
5 Support 2 150599002099
6 Screw 16 100001000070 M8*20
7 Washer 16 100004000083 8
8 Washer 16 100004000011 8
9 Bolt 4 100000000372 M10*35
10 Washer 4 100004000085 10
11 Washer 4 100004000014 10
12 Support seat 2 150599002100
13 Support 2 150599002101
14 Bolt 6 150599002102
15 Nut 6 100003000096 M10
16 Bolt 8 100000000443 M16*45
17 Washer 16 100004000091 16
18 Washer 16 100004000021 16
19 Nut 8 100003000107 M16
20 Bolt 8 100000000445 M16*50
21 Hoisting part 1 150599021416
Separator Tank and Associated Fittings;
Separator Tank and Associated Fittings;

1 Air/oil separator tank 1 150599021420
2 Gasket 2 150599002092
3 Sight glass 1 150599002402
4 Hollow bolt 2 150599003249 M10X40
5 O ring 4 120000000011 10.6*1.8
6 O ring 1 120000000050 23.6*2.65
7 Plug 1 150599003289 M27X2
8 Combination washer 1 120012000010 27
9 Drain pipe 1 150599021418
10 Ball valve 1 120501000017
11 Safety valve 1 120500000086
12 Lid 1 150599021421
13 Air/oil separator element 1 120902000018
14 Washer 12 100004000021 16
15 Washer 12 100004000091 16
16 Screw 12 100001000197 M16*55
17 Plug 1 150599019947
18 Safety valve 1 120500000009
19 Joint 1 150599003454 G0.75-M30x2
20 Nut 1 120601000080 22
21 Cutting sleeve 1 120601000087 22
22 Discharge pipe 1 150599021419
23 Screw washer 1 150599005057
24 Scavenging pipe 1 150599002067
25 Washer 2 100004000095 24
26 Washer 2 100004000027 22
27 Screw 2 100001000265 M22*60
28 Nut 2 100003000118 M22
Coupling System;
Coupling System;

1 Connecting plate 1 150599002103
2 Shaft boss 1 150599021072
3 Coupling 1 120402000008
4 Bolt 4 150599002104
5 Screw 4 100001000197 M16*55
6 Bolt 12 100000000376 M10*45
7 Washer 24 100004000014 10
8 Motor adaptor 1 150599021424
9 Screw 12 100001000116 M10*35
10 Pin 1 100100000006 10*18
Cooling System;
Cooling System;

1 Oil/water cooler 1 150599021426
2 Water tank pressure cover 1 150599002459
3 Wind scooper 1 150599021428
4 Water filling pipe 1 150599002457
5 Baffle plate 2 150599021427
6 Safety shield 1 150599001947
9 Bolt 4 100000000365 M10*20
10 Washer 4 100004000014 10
11 Nut 14 100003000092 M8
12 Bolt 14 100000000340 M8*20
13 Washer 14 100004000011 8
14 Washer 14 100004000083 8
15 Joint 4 150599003065
16 Screw washer 4 150599005056
17 O ring 4 120000000045 18*2.65
18 O ring 4 120000000044 16*2.65
19 Oil cooler drain pipe 1 150599001951
20 Water cooler drain pipe 1 150599001950
21 Ball valve 2 120501000017
22 Joint 2 150599003129
23 Plug 2 150599019947
53
Cooling System Pipework and Filtration;
Cooling System Pipework and Filtration;

1 Oil filter head 1 120905000050
2 Screw washer 5 150599005058
3 Screw washer 4 150599005057
4 O ring 5 120000000097 30*3.55
5 O ring 1 120000000094 25.8*3.55
6 O ring 4 120000000050 23.6*2.65
7 O ring 6 120000000092 23.6*3.55
8 O ring 2 120000000095 26.5*3.55
9 O ring 1 120000000091 22.4*3.55
10 Thermal valve 1 120510000001
11 Joint 1 150599003060
12 Joint 3 150599003059
13 Connecting pipe 1 150599003058
14 Hollow bolt 1 150599003247
15 Connecting seat 1 150599003246
16 Joint 3 150599003057
17 Combination joint 1 150599019811 G1-M36x2
18 Oil filter support 1 150599021519
19 Tank to thermal valve pipe 1 150599021434 22
20 Oil filter to airend pipe 1 150599021433 25
21 Inlet cooler pipe 1 150599021432
22 Inlet cooler pipe 1 150599021431 22
23 Oil filter 1 120905000086
Air Control System;
Air Control System;

1 Joint 2 150599003374
2 O ring 12 120000000008 8*1.8
3 Joint 5 150599003133
4 Tee joint 3 150599003299 1/4
5 Joint 5 150599003375
6 Joint 4 150599003197
7 Joint 1 150599003336
8 Joint 1 150599003196
9 High pressure oil pipe 1 150599002063
15 Switching valve 2 150599002105 R1/4
16 Check valve 1 150599004056 2-RP1/4
17 Plug 2 150599003262
19 Joint 1 150599003791
21 Screw washer 1 150599005068
22 O ring 1 120000000009 9.5*1.8
23 Check valve 1 150599004070
24 Joint 1 120601000005
Enclosure Panelwork（LGCG）;
Enclosure Panelwork(LGCG);

Emergency stop button
1 1 150599021490
shield
2 Baffle plate 2 150599021427
3 Door 2 150599021478
4 Side plate 1 150599021476
5 Side plate 1 150599021475
6 Cover plate 1 150599021473
7 Baffle plate 1 150599021472
8 Baffle plate 1 150599021471
9 Baffle plate 1 150599021489
10 Wind-blinds 1 150599021488
11 Maintenance cover 1 150599021486
12 Hoisting port cover 1 150599021469
13 Water filling port cover 1 150599021485
14 Door 1 150599021484
15 Door 1 150599021483
16 Protective cover 1 150599021480
17 Silencer cover 1 150599021468
18 Top cover 1 150599021463
19 Door 1 150599001946
Enclosure Panelwork（LGCY）;
Enclosure Panelwork(LGCY);

Emergency stop button
1 1 150599021490
shield
2 Baffle 2 150599021427
3 Door 2 150599021478
4 Mudflat 2 150599021477
5 Side plate 1 150599021476
6 Side plate 1 150599021475
7 Cover plate 1 150599021473
8 Baffle plate 1 150599021472
9 Baffle plate 1 150599021471
10 Side plate 1 150599021489
11 Wind-blinds 1 150599021488
13 Hoisting port cover 1 150599021469
14 Water filling port cover 1 150599021485
15 Door 1 150599021484
16 Door 1 150599021483
18 Silencer cover 1 150599021468
19 Top cover 1 150599021463
20 Door 1 150599001946
Diesel Tank System;
Diesel Tank System;

1 Oil tank 1 150599021493
2 Oil pipe 1 150599021492
3 Oil pipe 1 150599021491
4 Plug 1 150599019947
5 Combination joint 6 120012000003 14
6 Hollow bolt 6 150599019803 M14X1.5
7 Air filter 1 150599002107
8 Oil/water separator 1 150599002108
9 Oil pipe 1 150599021492
Diesel Engine System;

Diesel Engine System;

1 Support 1 150599021512
2 Support 1 150599021513
3 Absorber 4 150599005130
4 Bolt 8 100000000427 M14*30
5 Washer 10 100004000019 14
6 Fan assembly 1 150599002113
7 Bolt 4 100000000428 M14*35
8 Supercharger clamp 1 150599021525
9 Silicone pipe 2 150599002275
10 T clamp 10 150599004201
11 T clamp 4 150599004198
12 Screw 14 100001000116 M10*35
13 Washer 14 100004000014 10
14 Air filter indicator 1 150599022289
15 Diesel engine drain pipe 1 150599021505
16 Joint 1 150599003065
17 Screw washer 1 150599005056
18 O ring 1 120000000045 18*2.65
19 O ring 2 120000000044 16*2.65
20 Ball valve 1 120501000017
21 Joint 1 150599003129
22 Plug 1 150599019947
23 Screw washer 1 150599005070
24 O ring 1 120000000277
25 Diesel engine 1 120200000001
26 Cooler air outlet pipe 1 150599021507
27 Cooler air inlet pipe 1 150599021508
28 Flexible pipe 1 150599021506
29 T clamp 4 150599004207
30 T clamp 1 150599004210
31 Silicone pipe 1 150599002269
32 Air inlet pipe 1 150599021511
33 Air discharge silencer 1 150599021521
34 Air filter 1 120900000059
35 Air filter element 1 120901000057
36 Discharge connecting pipe 1 150599021515
Diesel Engine System; (continued)

38 Joint 2 150599003814
39 Throttle adjusting nut 1 150599020974
40 Servo cylinder 1 150599002106
41 Pull rod 1 150599020959
42 Throttle pull seat 1 150599020973
43 Cylinder rotary pin 2 150599020977
44 Throttle swivel 1 150599021442
45 Silicone pipe 1 150599002273
46 Silicone pipe 1 150599002271
47 Joint 1 150599021062 M18x1.5-M30x1.5
48 Rain cover 1 150599021524
Diesel engine water outlet
49 1 150599002070
pipe
Diesel engine water inlet
50 1 150599002071
pipe
51 Air cylinder support 1 150599021452
Battery System;
Battery System;

1 Battery 2 150599021500
2 Cable 1 150599021497
3 Cable 1 150599021498
4 Cable 1 150599021496
5 Cable 1 150599021499
6 Battery pressing plate 2 150599021408
7 Joint 4 150599002110
Air discharge System;
61
Air discharge System;

1 Joint 1 150599003069
2 Screw washer 1 150599005059
3 O ring 2 120000000102 38.7*3.55
4 MPV 1 120511000004
5 Joint 2 150599003145
6 Air discharge pipe 1 150599021516
7 Air discharge seat 1 150599021517
8 Joint 1 150599003162
9 Ball valve 1 120501000018
10 Ball valve 1 120501000020
11 Ring 2 150599021518
12 O ring 1 120000000099 33.5*3.55
Chapter 8; Service Parts;
Compressor Service Parts and Kits;
No. Description Qty. Part Number Remarks

Every 2000h
1 Air Filter Element 1 120901000066 More is site
conditions poor
Every 2000h or
2 Oil Filter Elemnet 1 120905000086
Twice per annum
Every 4000h or
3 Separator Element 1 120902000018
Annually
Every 4000h or
4 Compressor Oil (litres) 25I 4K-Blue Coolant
Annually
Kits Description Qty. Part Number Remarks
Every 4000h or
5 Inlet Valve Kit 1 6650000182
Annually
Every 4000h or
6 MPV Kit 1 6650000112
Annually
Every 4000h or
7 Servo Load Valve Kit 1 6650000444
Annually
Every 4000h or
8 Thermo Valve Kit 1 6650000183
Annually
Diesel Engine Service Parts and Kits;
Cummins Type: 4B TAA3.9 Diesel
Item Description Quantity Part Number Remarks

Every 2000h
1 Engine Air Filter Element 1 6600001221 More if site
conditions poor
Every 2000h or
2 Engine Oil Filter 1 6600001458 Twice per
annum
Every 2000h or
3 Engine Fuel Filter Element 1 6600001462 Twice per
annum
Every 2000h or
4 Engine Oil (litres) 11l
Annually
Chapter 9; Maintenance Procedures;
Overview
Maintenance periods listed should be carried out according to hour meter readings or a
time based schedule. Failure to carryout regular maintenance will have a detrimental ef-
fect on the compressor performance and life.
Warning
Be aware of hot oil and potential spillages as hazards, cordon of working areas
prior to commencing work.
All maintenance spare parts must be genuine Kaishan and used in accordance
with the requirements specified in the Kaishan operating manual.
The use of non-genuine parts and lubricants will affect the unit Warranty Terms
and Conditions.
TO BE CARRIED OUT BY CUSTOMER
Daily maintenance
Open the separator tank drain valve and release any condensate present. Close when
the flow is oil only.
Check the fuel tank levels and engine oil and coolant levels.
Check compressor oil level, top up if required.
Check operation condition of compressor after the machine has warmed up, high tem-
peratures, oil leakages or abnormal sound.
General check for oil, water or fuel leakages.
TO BE CARRIED OUT BY SERVICE TECHNICIAN
Every 2000 Hours
Change compressor oil filter

Change compressor air filter
Top Up compressor lubricant
Change engine oil filter element
Change engine air filter element
Change fuel filter element
Top up engine lubricant
Top up engine coolant
Check all electrical connections are tight
Check settings for Engine Speed and Operating Pressures are correct
Check for oil and fuel leakages
Clean compressor oil cooler, remove and steam clean if badly contaminated
Check battery electrolyte level, remove any deposits on terminals.
Thoroughly examine and lubricate running gear.
Check engine / airend coupling insert is in good order.
Check airend / engine mounts are in good order.
Check Emergency Stop is operational.
Every 4000 Hours or 12 Months
As per 2000 hour schedule, plus:
Change compressor lubricant

Change engine lubricant
Change compressor separator element
Strip and overhaul MPV
Strip and overhaul Inlet Valve
Srtip and overhaul servo load cylinder
Change compressor thermostat valve
Check Engine throttle linkage is locked and secure
Check airend oil seal is dry and shows no sign of leakage
Power wash soundproof foam
Test Safety Switches are operational
Check all hydraulic oil hoses are in good condition, change if required
Check all nylon 6mm tubing is secure and ingood condition
Examine exhaust manifold for signs of leakages or damage
Every 4000 Hours /

Service Task Daily
2000 Hours Annually
Drain Condensate from Pressure Vessel

Check Fuel Level in Tank
Check Engine Oil Level
Check Compressor Oil Level
Check Coolant Level in Radiator
Check Plant for Leaks and Damage
Inspect Silencing Foam
Check Doors, Hinges and Gas Struts
Check Speed Control and Unloading System
Check Tyre Pressures
Examine Compressor PRV and Manually Lift
Change Compressor Lubricant
Change Engine Oil
Change Compressor Air and Oil Filters
Change Separator Element
Change Engine Air, Oil and Fuel Filters
Clean Oil Cooler and Radiator
Check Battery Level
Lubricate Running Gear
Test Protection Circuits
Strip and Overhaul MPV
Strip andOverhaul Air Intake Valve
Change Compressor Thermostat
Check and Overhaul Servo Load Cylinder
Take Compressor Oil Sample

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LGCY10-10 Instruction Manual

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Kaishan LGCY-10/10 Series Rotary Screw Compressor Manual

PARTS & INSTRUCTION

Release August 2023, Version: A

Chapter 1 Safety of Operation

Chapter 2 Compressor Specifications and Design

Chapter 3 Operating Principle of Air Compressor

Chapter 4 Engine Overview

Chapter 5 Compressor Weights and Dimensions

Chapter 6 Wiring Drawing

Chapter 7 Parts Identification

Chapter 8 Service Parts

Chapter 1; Safety of Operation

THIS IS AN IMPORTANT NOTIFICATION AND IN THEIR OWN INTEREST OWNERS

Control of Hazardous Substances

Diesel Oil Fuel

Fire and Explosion Protection

Clean up spills of fluid or inflammable substances immediately.

An explosive atmosphere is a mixture with air, under atmospheric conditions, of flamma-

The Use of Compressed Air.

Lifting and Transportation.

Before towing the unit;

~ ascertain that the pressure vessel(s) is (are) depressurized,

Before Starting Compressor.

If required, top up any fluid or lubricant to the correct level.

Check battery leads are secure.

Keep enclosure doors closed.

Check all temperatures and pressures are correct.

Do not refill with fuel whilst the compressor is running.

Ensure the engine exhaust is always free to vent.

Do not carry out adjustments unless authorized and trained to do so.

Maintenance and Service.

Do not weld or make temporary repairs to any pressure vessel.

~below 70 dB(A): no action needs to be taken

~ above 70 dB(A): noise-protective devices should be provided for people continuously

~ above 85 dB(A): room to be classified as a noise-hazardous area and an obvious

Chapter 2; Compressor Specification and Design

Frame and Running Gear

The compressor/engine unit is supported by anti-vibration mounts.

JCD 900 Controller

To keep the compressor in optimum condition, please read Chapter 6 (Maintenance)

Refer to the Compressor nameplate for;

Unit Model Number

Always quote Model and Serial Number when ordering spareparts.

Chapter 3; Operating Principle of Air Compressor

Compressor Unit Prepare to Start;

Check Engine Oil Level is to “H” Mark on Dipstick

Check Compressor Lubrication Level is to Top Red Mark on Sight Tube

Check Engine Cooling System Coolant System if Full to Top

Check Fuel Level, Less than 20% will Alarm

Close both Air Discharge Outlet Valves

Check for Water in the Fuel Filter, Drain if Nessacary

Engage Electrical Isolater ON

Ready to Start; Start;

Key Switch On Press Start Button

Compressor Unit Run and Load;

Load; Full Load;

The compressor is now On Load.

Compressed Air Intake.

Air filter Assembly.

Minimum pressure valve

Pressure Relief valve

Oil Circuit Compressed Air System

The Lubrication system is composed of compressor lubricant, separator vessel, thermal

Oil Scavenge line