KAESER KOMPRESSOREN MOBILAIR M125 SIGMA CONTROL MOBIL pV Manuals

Manuals and User Guides for KAESER KOMPRESSOREN MOBILAIR M125 SIGMA CONTROL MOBIL pV. We have 1 KAESER KOMPRESSOREN MOBILAIR M125 SIGMA CONTROL MOBIL pV manual available for free PDF download: Operator's Manual

KAESER KOMPRESSOREN MOBILAIR M125 SIGMA CONTROL MOBIL pV Operator's Manual (456 pages)

Portable Rotary Screw Compressor

Brand: KAESER KOMPRESSOREN | Category: Air Compressor | Size: 22 MB

Table of Contents
3
List of Tables
13
Regarding this Document Using this Document
15
Further Documents
15
Copyright
15
Symbols and Labels
15
Warnings
15
Potential Damage Warnings
16
Tab. 1 Danger Levels and Their Definition (Personal Injury)
16
Tab. 2 Danger Levels and Their Definition (Damage to Property)
16
Other Alert Notes and Their Symbols
17
Technical Data Nameplate
18
Vehicle Identification Number
18
Options - Options Label
18
Tab. 3 Nameplate
18
Air Treatment
19
Compressed Air Distributor
19
Low Temperature Equipment
19
Tab. 4 Extract from the Options Label
19
Tab. 5 Air Treatment Options
19
Tab. 6 Compressed Air Distributor Option
19
Equipment for Fire Hazard Areas
20
Automatic Engine Start/Stop
20
GSM/GPS Unit
20
Lighting
20
Generator
20
Tab. 7 Low Temperature Equipment Options
20
Tab. 8 Optional Equipment for Fire Hazard Areas
20
Tab. 9 Automatic Engine Start/Stop
20
Tab. 10 GSM/GPS Unit
20
Tab. 11 Lighting Options
20
Closed Floor Pan
21
Pedestrian Protection
21
Machine (Without Options)
21
Sound Pressure Level
21
Tightening Torque
21
Tab. 13 Closed Floor Pan Option
21
Tab. 14 Pedestrian Protection Option
21
Tab. 15 Sound Pressure Level
21
Tab. 16 Torques for M4-M8 Screws
21
Ambient Conditions
22
Additional Specifications
22
Tab. 17 Torques for M10-M24 Screws
22
Tab. 18 Torques for Lifting Eye Screws
22
Tab. 19 Tightening Torques for Oil Separator Tank Cover Fixing Screws
22
Tab. 20 Ambient Conditions
22
Chassis
23
Chassis Options
23
Machines with Stationary Frame Design
23
Weight of Machines with Stationary Frame Design
23
Compressor
23
Variable Pressure Flow Rate Control (Pv Control)
23
Tab. 21 Weight of the Machine
23
Tab. 22 Maximum Working Pressure
23
Fig. 1 Engine Speed/Flow Rate Depending on the Nominal System Pressure
24
Tab. 23 Flow Rate Depending on the Nominal System Pressure
24
Tab. 24 Engine Speed Depending on the Nominal System Pressure
24
Compressed Air Outlet
25
Safety Relief Valve
25
Temperature
25
Fig. 2 Engine Speed Depending on the Nominal System Pressure
25
Tab. 25 Compressed Air Distributor
25
Tab. 26 Safety Relief Valve Activating Pressure
25
Tab. 27 Required Temperatures Readiness to Switch to LOAD Mode
25
Cooling Oil Recommendation
26
Tab. 28 Airend Discharge Temperature
26
Tab. 29 Cooling Oil Recommendation
26
Cooling Oil Charge
27
Engine
27
Engine Specifications
27
Tab. 30 Cooling Oil Recommendation (Food Processing)
27
Tab. 31 Cooling Oil Charge
27
Oil Recommendation
28
Tab. 32 Deutz / TCD 4.1 L04 Engine Specifications
28
Tab. 33 Engine Specifications
28
Tab. 37 Reduction Agent
28
Fuel Recommendation
29
Tab. 34 Engine Oil Recommendation
29
Tab. 35 Initial Engine Oil Quantity
29
Engine Coolant Recommendation
30
Reduction Agent
30
Tab. 36
30
Fluid Volumes
31
Batteries
31
Options
31
Air Treatment Options
31
Tab. 38 Fluid Volumes
31
Tab. 39 Batteries
31
Tab. 40 Fresh Air Filter Conditions
31
Tab. 41 Interrelation between Compressed Air Treatment and Compressed Air Quality
31
Low Temperature Equipment
32
Tab. 42 Ambient Conditions, Low Temperature Equipment
32
Tab. 43 Batteries, Low-Temperature Equipment
32
Generator
33
Tab. 44 Power Supply Details
33
Tab. 45 Technical Data - Cooling Water Pre-Heating Device
33
Tab. 46 Battery Charger Specification
33
Tab. 47 Generator Specification
34
Tab. 48 Flow Rate in Generator Mode
34
Tab. 49 Connection Sockets
34
Tab. 50 Circuit Breaker
35
Tab. 51 Generator Operating Limits
35
Tab. 52 Maximum Three-Phase Mains Load
35
GSM/GPS Unit
36
Tab. 53 Maximum AC Mains Load
36
Tab. 54 GSM/GPS Unit
36
Safety and Responsibility Basic Instructions
37
Specified Use
37
Incorrect Use
37
User's Responsibilities
37
Observe Statutory and Universally Accepted Regulations
37
Determining Personnel
38
Complying with Inspection Schedules and Accident Prevention Regulations
38
Taking the Machine for General Inspection
39
Documenting the Mileage of the Machine as Trailer
40
Dangers
40
Safely Dealing with Sources of Danger
40
Save Handling of the DEF Reduction Agent
43
Safe Machine Operation
43
Organizational Measures
47
Danger Areas
47
Safety Devices
48
Safety Signs
48
Fig. 3 Location of Safety Signs (Outside)
48
Fig. 4 Location of Safety Signs (Inside)
52
Noise Control Requirements
53
Generator Operation
54
Comply with the Protective Measures against Dangerous Electric Current
54
Safe Generator Operation
54
Connecting Extension Cables
54
Do Not Exceed the Maximum Supply System Load
55
Perform Regular Generator Inspections
55
Emergencies
55
Correct Actions in the Event of a Fire
55
Treating Injuries from Handling Operating Fluids/Materials
56
Warranty
56
Noise Emissions Warranty
57
Identifying the Effects of Improper Modifications
57
Environmental Protection
57
Design and Function Bodywork
59
Fig. 5 Overview of Bodywork
59
Machine Layout
60
Fig. 6 Right-Hand Door Opened
60
Fig. 7 Left-Hand Door Opened
61
Fig. 8 Machine from Above, Roof Removed
62
Machine Function
63
Fig. 9 View from Beneath
63
Fig. 10 Machine Overview
64
Operating Modes and Control Mode
65
Machine Operating Modes
65
MODULATING Control
65
Safety Devices
66
Monitoring Functions with Shutdown
66
Further Safety Devices
66
Fig. 11 Continuous Regulation of FAD (Standstill)
66
SIGMA CONTROL MOBIL Control Panel
67
Fig. 12 SIGMA CONTROL MOBIL Main Display - Overview
67
Variable Pressure Speed Control
68
Exhaust Gas After-Treatment
69
Engine Optimisation
69
Reduction of Particle Emissions
70
Fig. 13 Exhaust Gas Treatment - Reduction of Particle Emissions
70
Diesel Particulate Filter Regeneration
71
Reduction of Nitrogen Oxide Emissions
72
Fig. 14 Exhaust Gas Treatment - Reduction of Nitrogen Oxide Emissions
73
Options
74
Air Treatment Options
74
Fig. 15 Compressed Air Options
75
Auxiliary Electrical Systems
77
Low Temperature Equipment Options
77
Options for Operating in Fire Hazard Areas
77
Generator Option
78
Fig. 16 Engine Air Shut-Off Valve
78
Fig. 17 Operator Panel of the Generator Control Cabinet, 400/230 VAC
80
Fig. 18 Instrument Panel - Generator Control Box, 230 V Three Phase
80
Automatic Start/Stop Options
81
GSM/GPS Unit
82
Fig. 19 Automatic Start/Stop, External Connections
82
Transport Options
83
Frame Design Options for Stationary Machines
83
Sealed Floor Pan Option
83
Pedestrian Protection Option
84
Fig. 20 Position of Service Openings in the Closed Floor Pan
84
Fig. 21 Drain Points for Oil and Coolant from Engine and Compressor
84
Installation and Operating Conditions
85
Ensuring Safety
85
Installation Conditions
85
Fig. 22 Minimum Distance from Excavations/Slopes and Walls
85
Machine with Stationary Frame Structure
86
Installation
87
Ensuring Safety
87
Reporting Transport Damage
87
Perform Regular Maintenance on the Chassis
87
Installing a Machine with Stationary Frame Superstructure on a Truck Platform
87
Connect Automatic Start/Stop Externally
88
Fig. 23 Connect Automatic Start/Stop Externally
88
Electrical Connection of the Battery Charger
89
Initial Start-Up Ensuring Safety
90
Before Initial Start-Up (or Recommissioning)
90
Instructions to be Observed before Commissioning or Recommissioning
90
Special Measures for Recommissioning after Storage
91
Checking Installation and Operating Conditions
91
Low-Temperature Operation (Winter)
92
Jump Starting the Machine
92
Fig. 24 Jumper Cable Connection Diagram
93
Starting up Low-Temperature Equipment
94
Commissioning Electrical Equipment
95
Activating the Generator
95
Checking the Generator
95
Fig. 25 Connect Auxiliary Electrical Systems
95
Fig. 26 Insulation Monitoring - 400 V Three-Phase Generator
96
Fig. 27 Insulation Monitoring - 230 V Three-Phase Generator
96
Operation
98
Ensuring Safety
98
Starting and Stopping
99
Follow the Brief Instructions
99
Fig. 28 Starting Instruments
99
Starting the Machine
100
Fig. 29 Brief Instructions on Starting Procedure
100
Fig. 30 Brief Instructions on Stopping Procedure
100
Starting the Machine
101
Setting the Compressed Air Discharge Pressure
102
Fig. 31 Select Menu Option "Set Pressure in the Oil Separator Tank
103
Fig. 32 Setting the Output Pressure
103
Switching the Machine to the Run-On Phase
104
Shutting down the Machine
104
Shutting down in an Emergency
105
Acknowledging Alarm, Warning and Maintenance Messages
105
Confirming Alarm Messages
105
Acknowledging Warning and Maintenance Messages
106
Operating the Options
106
Operating the Machine with the "Automatic Start/Stop" Option
106
Fig. 33 Preparing Readiness to Start of the "Automatic Start/Stop
107
Fig. 34 Waiting for Start Command
107
Using the Low-Temperature Equipment
108
Bypassing and Activating the Heat Exchanger
109
Fig. 35 Heat Exchanger Without Bypass Operation (with Compressed Air Heating)
110
Fig. 36 Heat Exchanger with Bypass Operation (no Compressed Air Heating)
111
Generator Operation
112
Cleaning the Machine after Operation
113
Refuelling the Machine
114
Use the Correct Type of Fuel
114
Fig. 37 Filling the Tank with the Correct Fuel Type
115
Filling the Fuel Tank at a Pump with a Refuelling Nozzle
116
Filling the Fuel Tank on a Construction Site with a Canister
117
Fault Recognition and Rectification
118
Basic Instructions
118
Analyzing SIGMA CONTROL MOBIL Messages
118
Alarm Messages on the Controller (Machine Off)
118
Warning Messages on the Controller
123
Evaluating Engine Faults and Alarms
125
Engine Refuses to Start or Does Not Turn over
125
Engine Does Not Reach Full Speed
126
Analyzing Compressor Faults and Alarms
127
Working Pressure too High
127
Working Pressure too Low
127
Safety Relief Valve Blowing off
128
Machine Overheating
128
Too Much Oil Residue in the Compressed Air
129
Oil Flows from the Compressor Air Filter after Shutdown
129
High Moisture Content in the Compressed Air
130
Generator Faults and Alarms
130
No Voltage or too Low a Voltage from the Generator
130
Generator Voltage too High
130
10 Maintenance
132
Ensuring Safety
132
Note the Maintenance Messages on the Controller
133
Evaluating the Maintenance Message
133
Concluding the Maintenance
134
Maintenance Schedules
134
Logging Maintenance Work
134
Maintenance Tasks after Commissioning
134
Preventive Maintenance
135
Regular Maintenance Tasks
135
Engine Maintenance
140
Coolant Cooler Maintenance
141
Fig. 38 Checking Coolant Level
142
Fig. 39 Checking Coolant Level
142
Fig. 40 Recommended Mixture Ratio for Coolant
144
Fig. 41 Draining the Coolant from the Engine Coolant Cooler
146
Fig. 42 Draining the Coolant from the Engine Coolant Cooler (Closed Floor Pan/Stationary Machine)
147
Engine Air Filter Maintenance
148
Fig. 43 Warning Messages: Air Filter Engine Intake Maintenance
149
Fig. 44 Engine Air Filter Maintenance
149
Fig. 45 Clean the Filter Element (Air Filter)
149
Fuel System Maintenance
150
Fig. 46 Service Fuel System
151
Fig. 47 Bleeding the Fuel System
152
Fig. 48 Warning Message: Fuel Filter Water Level
153
Fig. 49 Emptying the Fuel Pre-Filter and Water Separator
153
Fig. 50 Change the Fuel Prefilter Cartridge
154
Fig. 51 Fuel Filter Maintenance
155
Checking the Engine Oil Level
156
Fig. 52 Checking the Engine Oil Level
156
Engine Oil Filling and Topping off
157
Changing the Engine Oil
157
Fig. 53 Draining the Engine Oil
158
Fig. 54 Draining the Engine Oil (Sealed Floor Pan - Stationary Machine)
159
Replacing the Engine Oil Filter
160
Drive Belt Maintenance
161
Fig. 55 Change the Oil Filter
161
Fig. 56 Belt Guard Attachment
162
Fig. 57 Manually Checking the Belt Tension
163
Fig. 58 Changing/Tensioning the Drive Belt
164
Battery Maintenance
165
Fig. 59 Safety Signs - Warning Labels on the Battery
165
Checking the Fastening of the Fuel Tank
168
Replace the Filter Insert for the Reduction Agent Pump
169
Fig. 60 Reduction Agent Pump
170
Fig. 61 Remove Reduction Agent Pump
170
Fig. 62 Changing the Filter Insert for the Reduction Agent Pump
171
Compressor Maintenance
172
Checking the Cooling Oil Level
172
Fig. 63 Checking the Cooling Oil Level
172
Cooling Oil Filling and Topping off
173
Changing the Cooling Oil
174
Fig. 64 Draining the Compressor Cooling Oil
175
Fig. 65 Draining the Cooling Oil (Sealed Floor Pan - Stationary Machine)
177
Replacing the Compressor Oil Filter
178
Fig. 66 Change the Oil Filter
179
Oil Separator Tank Dirt Trap Maintenance
180
Fig. 67 Oil Separator Tank Dirt Trap Maintenance
180
Changing the Oil Separator Cartridge
181
Fig. 68 Changing the Oil Separator Cartridge
182
Compressor Air Filter Maintenance
183
Fig. 69 Warning Messages: Compressor Air Filter Maintenance
184
Fig. 70 Compressor Air Filter Maintenance
185
Fig. 71 Clean the Filter Element (Air Filter)
185
Fit the Flexible Pipe Connection
186
Cleaning the Cooler
187
Fig. 72 Fit the Flexible Pipe Connection
187
Cleaning the Compressor Cooler and Engine Radiator
188
Fig. 73 Cleaning the Compressor Cooler and Engine Radiator
188
Cleaning the Compressed Air After-Cooler
189
Fig. 74 Cleaning the Compressed Air After-Cooler
189
Checking Screw Connections
190
Check Wing Doors
191
Check Sound Proofing Material
192
Maintenance of Rubber Sealing Strips
192
Check/Replace Hose Lines
192
Replace the Fuel Lines of the Drive Engine
193
Replace the Pressure Hoses of the Drive Engine
193
Replace the Pressure Hoses of the Compressor
193
Check Safety Functions
193
Check the EMERGENCY STOP Push Button
193
Have the Activating Pressure of the Relief Valve Checked
194
Having Excessive Temperature Shut-Down Function Checked
195
Maintenance for Optional Items
195
Centrifugal Separator Maintenance
195
Fig. 75 Cleaning the Condensate Drain
196
Combination Filter Maintenance
197
Fig. 76 Filter Combination
197
Fig. 77 Combination Filter Maintenance
198
Fresh Air Filter Maintenance
200
Fig. 78 Fresh Air Filter Maintenance
201
Engine Air Shut-Off Valve Maintenance
203
Fig. 79 Engine Air Shut-Off Valve Maintenance
204
Maintaining the Generator Drive Belt
205
Fig. 80 Tighten the Generator Drive Belt
206
Draining Liquid Accumulation Within the Machine
207
Documenting Maintenance and Service Work
209
11 Spares, Operating Materials, Service
210
Note the Nameplate
210
Ordering Consumable Parts and Operating Fluids/Materials
210
Kaeser Air Service
211
Replacement Parts for Service and Repair
211
12 Decommissioning, Storage and Transport
286
Decommissioning
286
Temporary Decommissioning
286
Long-Term Decommissioning and Storage
287
Transport
288
Safety
288
Transporting the Machine as Trailer
288
Transporting the Machine by Crane
288
Transporting the Machine by Forklift
290
Transporting the Machine as a Load
290
Fig. 81 Transporting Using a Forklift Truck
290
Fig. 82 Bracing to Secure the Load
291
Storage
292
Disposal
293
Removing the Batteries
293
Draining Operating Fluids
294
Draining Condensate
294
Fig. 83 Battery Labelling
294
Removing Filters/Filter Elements
295
Disposing of the Machine
295
13 Annex
296
Marking
296
Pipeline and Instrument Flow Diagram (P+I Diagram)
296
Fig. 84 Marking
296
Pipeline and Instrument Flow Diagram (Exhaust Treatment)
302
Dimensional Drawings
304
Dimensional Drawing - Chassis
304
Dimensional Drawing - Chassis
306
Dimensional Drawing - Chassis
308
Dimensional Drawing, Chassis Options
310
Dimensional Drawing - Chassis
312
Dimensional Drawing - Chassis
314
Dimensional Drawing, Stationary Version
316
Dimensional Drawing, Stationary Version
318
Wiring Diagrams
320
Electrical Diagram
320
Lighting and Signaling System Connection
363
Lighting and Signaling System Connection
371
Generator Electrical Diagram 400/230 V/3
376
Generator Electrical Diagram, 230V, 3-Ph
385
Battery Charger Electrical Diagram
394
Fuel Circulation Diagram
400
Pipeline and Instrument Flow Diagram (Exhaust Treatment)
403
Compressed Air Flow Rate in Generator Mode
405
Operating Instructions for Compressed Air Filter (Combination Filter)
407
Operating Instructions for Compressed Air Filter (Fresh Air Filter)
435
Maintenance Tasks for the Generator
449
Oil-Injected MOBILAIR Service Intervals
449

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KAESER KOMPRESSOREN MOBILAIR M125 SIGMA CONTROL MOBIL pV Operator's Manual (456 pages)

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