KAESER M135 SIGMA CONTROL MOBIL User manual

Service Manual
Screw Compressor
M135 SIGMA CONTROL MOBIL
No.: 9_6975 00 E
Manufacturer:
KAESER KOMPRESSOREN GmbH
96410 Coburg • PO Box 2143 • GERMANY • Tel. [phone] • Fax [phone]
http://www.kaeser.com

Original instructions
/KKW/M135 1.00 en SBA-MOBILAIR

1 Regarding this document
1.1 Using the Document ......................................................................................................... 1
1.2 Further documents ........................................................................................................... 1
1.3 Copyright .......................................................................................................................... 1
1.4 Symbols and markings ..................................................................................................... 1
1.4.1 Warning notices .................................................................................................. 1
1.4.2 Other notices and symbols ................................................................................. 2
2Technical Specification
2.1 Nameplate ........................................................................................................................ 3
2.2 List of Options .................................................................................................................. 3
2.2.1 Compressed air treatment plant ......................................................................... 4
2.2.2 Compressed air distributor .................................................................................. 4
2.2.3 Check valve function ........................................................................................... 5
2.2.4 Low temperature equipment ............................................................................... 5
2.2.5 Chassis ............................................................................................................... 5
2.2.6 Lighting ............................................................................................................... 5
2.2.7 Pedestrian protection .......................................................................................... 6
2.3 Machine (without options) ................................................................................................ 6
2.3.1 Sound emission ................................................................................................. 6
2.3.2 Torques ............................................................................................................... 7
2.3.3 Ambient conditions ............................................................................................. 7
2.3.4 Additional specifications ..................................................................................... 7
2.4 Chassis ........................................................................................................................... 7
2.4.1 Weights ............................................................................................................... 7
2.4.2 Tyres ................................................................................................................... 8
2.4.3 Wheel nut/bolt tightening torque ......................................................................... 8
2.4.4 Towbar tightening torque .................................................................................... 8
2.5 Compressor ..................................................................................................................... 8
2.5.1 Working pressure and FAD ................................................................................ 8
2.5.2 Compressed air outlet ......................................................................................... 9
2.5.3 Pressure relief valve ........................................................................................... 9
2.5.4 Temperature ....................................................................................................... 9
2.5.5 Cooling oil recommendation ............................................................................... 9
2.5.6 Cooling oil charge ............................................................................................... 10
2.6 Engine ............................................................................................................................. 10
2.6.1 Engine specification ............................................................................................ 10
2.6.2 Oil recommendation ............................................................................................ 11
2.6.3 Engine coolant recommendation ........................................................................ 11
2.6.4 Fluid volumes ...................................................................................................... 11
2.6.5 Batteries .............................................................................................................. 11
2.7 Options ............................................................................................................................ 12
2.7.1 Low temperature equipment ............................................................................... 12
2.7.2 Generator ............................................................................................................ 13
3 Safety and Responsibility
3.1 Basic Information ............................................................................................................. 16
3.2 Specified use .................................................................................................................... 16
3.3 Improper Use ................................................................................................................... 16
3.4 User's Responsibilities ..................................................................................................... 16
3.4.1 Observe statutory and universally accepted regulations. ................................... 16
3.4.2 Defining personnel .............................................................................................. 17
3.4.3 Adherence to inspection schedules and accident prevention regulations .......... 17
3.5 Dangers ............................................................................................................................ 18
3.5.1 Safely dealing with sources of danger ................................................................ 18
Contents
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3.5.2 Safe machine operation ...................................................................................... 20
3.5.3 Organisational Measures .................................................................................... 22
3.5.4 Danger areas ...................................................................................................... 23
3.6 Safety Devices ................................................................................................................. 23
3.7 Safety signs ...................................................................................................................... 23
3.8 Generator operation ......................................................................................................... 25
3.8.1 Protection against dangerous electric current .................................................... 25
3.8.2 Instructions for safe generator operation ............................................................ 25
3.8.3 Connection of extension cables .......................................................................... 25
3.8.4 Maximum power supply loading ......................................................................... 25
3.8.5 Regular generator inspections ............................................................................ 26
3.9 Emergencies .................................................................................................................... 26
3.9.1 Correct fire fighting ............................................................................................. 26
3.9.2 Contact with operating fluids/materials ............................................................... 26
3.10 Warranty ........................................................................................................................... 27
3.11 Environmental Protection ................................................................................................. 27
4 Design and Function
4.1 Bodywork ......................................................................................................................... 28
4.2 Component identification .................................................................................................. 29
4.3 Machine function .............................................................................................................. 29
4.4 Operating modes and control modes ............................................................................... 31
4.4.1 Operating modes ................................................................................................ 31
4.4.2 MODULATING control mode .............................................................................. 31
4.5 Safety devices .................................................................................................................. 32
4.5.1 Monitoring functions with shutdown .................................................................... 32
4.5.2 Further safety devices ........................................................................................ 32
4.6 SIGMA CONTROL MOBIL keys and displays ................................................................. 33
4.7 SIGMA CONTROL MOBIL function ................................................................................. 34
4.7.1 Display ................................................................................................................ 34
4.7.2 SIGMA CONTROL MOBIL operating sequence ................................................. 37
4.7.3 Menu structure of the SIGMA CONTROL MOBIL ............................................. 38
4.8 List of menus .................................................................................................................... 39
4.8.1 SIGMA CONTROL MOBIL main menu ............................................................... 41
4.8.2 SIGMA CONTROL MOBIL settings menu .......................................................... 42
4.8.3 SIGMA CONTROL MOBIL event memory .......................................................... 45
4.9 Air treatment options ........................................................................................................ 48
4.9.1 Air cooler ............................................................................................................. 49
4.9.2 Cyclone separator ............................................................................................... 49
4.9.3 Heat exchanger .................................................................................................. 49
4.9.4 Filter combination ............................................................................................... 49
4.9.5 Breathing air filter ................................................................................................ 50
4.10 Low temperature equipment option .................................................................................. 50
4.11 Generator option .............................................................................................................. 51
4.11.1 Operating modes ................................................................................................ 51
4.11.2 Operating controls .............................................................................................. 51
4.11.3 Note when operating the generator .................................................................... 52
4.12 Transport options ............................................................................................................. 53
4.12.1 Chassis ............................................................................................................... 53
4.12.2 Chassis ............................................................................................................... 53
4.12.3 Chassis ............................................................................................................... 53
4.12.4 Stationary frame ................................................................................................. 54
4.12.5 Stationary frame ................................................................................................. 54
4.13 Pedestrian protection option ............................................................................................ 54
Contents
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Service Manual Screw Compressor
M135 SIGMA CONTROL MOBIL No.: 9_6975 00 E

5 Installation and Operating Conditions
5.1 Safety ............................................................................................................................... 55
5.2 Positioning conditions ...................................................................................................... 55
6 Installation
6.1 Safety ............................................................................................................................... 57
6.2 Reporting Transport Damage ........................................................................................... 57
6.3 Fitting the towbar .............................................................................................................. 57
6.4 Adjusting the chassis ....................................................................................................... 58
6.4.1 Adjusting the towbar height ................................................................................ 59
6.4.2 Changing the towing eye .................................................................................... 59
7 Initial Start-up
7.1 Safety ............................................................................................................................... 63
7.2 Instructions to be observed before commissioning or recommissioning .......................... 63
7.3 Checking installation and operating conditions ................................................................ 63
7.4 Setting the displayed units ............................................................................................... 64
7.5 Entering a password ........................................................................................................ 65
7.6 Engine settings ................................................................................................................. 66
7.7 Changing the parameters of the start/stop/automatic option ........................................... 68
7.8 After storing the machine for a long period ...................................................................... 70
7.9 Low-temperature operation (winter) ................................................................................. 70
7.9.1 Starting assistance ............................................................................................. 70
7.9.2 Starting up low-temperature equipment .............................................................. 72
7.10 Putting the generator into operation ................................................................................. 73
8 Operation
8.1 Safety ............................................................................................................................... 75
8.2 Starting and stopping ....................................................................................................... 75
8.2.1 Follow the brief instructions ................................................................................ 75
8.2.2 Commissioning the machine ............................................................................... 76
8.2.3 Starting the engine .............................................................................................. 77
8.2.4 Setting the output pressure ................................................................................. 77
8.2.5 Shutting down the machine ................................................................................ 79
8.2.6 Shutting down in an emergency ......................................................................... 80
8.3 Setting parameters ........................................................................................................... 80
8.4 Acknowledging alarm, warning and maintenance messages .......................................... 80
8.5 Displaying machine operating data .................................................................................. 81
8.6 Using the external fuel pump option ................................................................................. 82
8.7 Using the low-temperature equipment ............................................................................. 83
8.8 Generator operation ......................................................................................................... 83
8.8.1 Switching in the generator .................................................................................. 84
8.8.2 Switching off the generator ................................................................................. 84
9 Fault Recognition and Rectification
9.1 Basic instructions ............................................................................................................. 85
9.2 SIGMA CONTROL MOBIL messages ............................................................................. 85
9.2.1 Alarm messages on the controller (machine off) ................................................ 85
9.2.2 Warning message on the controller .................................................................... 88
9.3 Engine faults and alarms .................................................................................................. 90
9.3.1 Engine refuses to start or does not turn over ...................................................... 90
9.3.2 Engine does not reach full speed ....................................................................... 91
9.4 Compressor faults and alarms ......................................................................................... 91
9.4.1 Working pressure too high .................................................................................. 91
9.4.2 Working pressure too low ................................................................................... 92
9.4.3 Pressure relief valve blowing off ......................................................................... 92
Contents
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9.4.4 Machine overheating .......................................................................................... 93
9.4.5 Too much oil residue in the compressed air ....................................................... 93
9.4.6 Oil flows from the compressor air filter after shutdown ....................................... 94
9.4.7 High moisture content in the compressed air ..................................................... 94
9.5 Generator faults and alarms ............................................................................................. 94
9.5.1 There is no voltage or too low a voltage from the generator .............................. 94
9.5.2 Generator voltage too high ................................................................................. 95
10 Maintenance
10.1 Safety ............................................................................................................................... 96
10.2 Maintenance message on the controller .......................................................................... 96
10.3 Maintenance schedules ................................................................................................... 97
10.3.1 Logging maintenance work ................................................................................. 97
10.3.2 Maintenance tasks after commissioning ............................................................. 97
10.3.3 Regular maintenance tasks ................................................................................ 98
10.4 Engine .............................................................................................................................. 102
10.4.1 Radiator maintenance ......................................................................................... 103
10.4.2 Air filter maintenance .......................................................................................... 108
10.4.3 Fuel system maintenance ................................................................................... 110
10.4.4 Checking the engine oil level .............................................................................. 114
10.4.5 Engine oil filling and topping up .......................................................................... 114
10.4.6 Changing the engine oil ...................................................................................... 115
10.4.7 Changing the oil filter .......................................................................................... 117
10.4.8 Checking the drive belts ..................................................................................... 118
10.4.9 Battery maintenance ........................................................................................... 120
10.5 Compressor ...................................................................................................................... 123
10.5.1 Checking cooling oil level ................................................................................... 123
10.5.2 Cooling oil filling and topping up ......................................................................... 124
10.5.3 Changing the cooling oil ..................................................................................... 124
10.5.4 Changing the oil filter .......................................................................................... 127
10.5.5 Oil separator tank dirt trap maintenance ............................................................. 129
10.5.6 Changing the oil separator cartridge ................................................................... 130
10.5.7 Air filter maintenance .......................................................................................... 131
10.5.8 Checking pressure relief valves ......................................................................... 133
10.6 Cleaning the coolers and radiator .................................................................................... 133
10.6.1 Cleaning the compressed air aftercooler ............................................................ 135
10.7 Rubber sealing strip maintenance .................................................................................... 136
10.8 Chassis ............................................................................................................................ 136
10.8.1 Wheel checks ..................................................................................................... 136
10.8.2 Towbar maintenance .......................................................................................... 136
10.8.3 Brake maintenance ............................................................................................. 138
10.9 Options ............................................................................................................................. 141
10.9.1 Cyclone separator maintenance ......................................................................... 141
10.9.2 Combination filter maintenance .......................................................................... 142
10.9.3 Breathing air filter maintenance .......................................................................... 145
10.9.4 Generator drive belt maintenance ...................................................................... 147
10.10 Document maintenance and service work. ...................................................................... 150
11 Spares, Operating Materials, Service
11.1 Note the Nameplate ......................................................................................................... 151
11.2 Ordering consumable parts and operating materials ....................................................... 151
11.3 KAESER AIR SERVICE .................................................................................................. 152
11.4 Service Addresses ........................................................................................................... 152
12 Decommissioning, Storage and Transport
12.1 De-commissioning ............................................................................................................ 153
Contents
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Service Manual Screw Compressor
M135 SIGMA CONTROL MOBIL No.: 9_6975 00 E

12.1.1 Temporary decommissioning .............................................................................. 153
12.1.2 Long-term decommissioning ............................................................................... 154
12.2 Transporting ..................................................................................................................... 155
12.2.1 Towing the compressor on the road ................................................................... 155
12.2.2 Parking the compressor ...................................................................................... 160
12.2.3 Transporting with a crane ................................................................................... 162
12.2.4 Transporting with a forklift truck .......................................................................... 162
12.2.5 Transporting as a load ........................................................................................ 163
12.3 Storage ............................................................................................................................. 164
12.4 Disposal ........................................................................................................................... 165
13 Annex
13.1 Marking ............................................................................................................................ 166
13.2 Pipeline and instrument flow diagram (P+I diagram) ....................................................... 166
13.3 Dimensional drawing, chassis with height-adjustable tow bar ......................................... 171
13.4 Dimensional drawing, chassis with fixed height tow bar .................................................. 173
13.5 Dimensional drawing, chassis without parking brake ...................................................... 175
13.6 Dimensional drawings of stationary machine (skids) ....................................................... 177
13.7 Dimensional drawings of stationary machine (base frame) ............................................. 179
13.8 Electrical Diagram ............................................................................................................ 181
13.9 Lighting and signalling system connection ....................................................................... 205
13.10 Lighting and signalling system connection ....................................................................... 210
13.11 Generator electrical diagram, 400 V, 3-ph ....................................................................... 213
13.12 Generator electrical diagram, 230 V, 3-ph ....................................................................... 225
13.13 Fuel circulation diagram ................................................................................................... 235
13.14 SIGMA CONTROL MOBIL message codes ..................................................................... 238
13.15 Operating instructions for compressed air filter (combination filter) ................................. 241
13.16 Operating instructions for compressed air filter (breathing air filter) ................................ 262
Contents
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Service Manual Screw Compressor
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Contents
vi
Service Manual Screw Compressor
M135 SIGMA CONTROL MOBIL No.: 9_6975 00 E

Fig. 1 Location of safety signs .............................................................................................................. 23
Fig. 2 Bodywork .................................................................................................................................... 28
Fig. 3 Right-hand door opened ............................................................................................................. 29
Fig. 4 Left-hand door opened ............................................................................................................... 29
Fig. 5 General design ........................................................................................................................... 30
Fig. 6 Stepless regulation of FAD (standstill) ....................................................................................... 32
Fig. 7 Instrument panel keys and displays ........................................................................................... 33
Fig. 8 Opening page ............................................................................................................................. 34
Fig. 9 Engine preheating ...................................................................................................................... 35
Fig. 10 Display of operating mode (example) ......................................................................................... 35
Fig. 11 Menu structure of the SIGMA CONTROL MOBIL ..................................................................... 39
Fig. 12 Machine data symbol ................................................................................................................. 41
Fig. 13 Symbolic settings menu ............................................................................................................. 44
Fig. 14 Event memory ............................................................................................................................ 45
Fig. 15 Event memory example: Alarm message ................................................................................... 47
Fig. 16 Event memory example: Warning message ............................................................................... 47
Fig. 17 Event memory example: Maintenance message ....................................................................... 47
Fig. 18 Message code structure ............................................................................................................. 48
Fig. 19 Air treatment options .................................................................................................................. 49
Fig. 20 Coolant pre-heating .................................................................................................................... 50
Fig. 21 Generator instrument panel - control box, 400 V, 3-phase ........................................................ 52
Fig. 22 Generator instrument panel - control box, 230 V, 3-phase ........................................................ 52
Fig. 23 Minimum distance from excavations/slopes and walls ............................................................... 55
Fig. 24 Fitting the towbar ........................................................................................................................ 58
Fig. 25 Fitting the towbar ........................................................................................................................ 58
Fig. 26 Towbar height adjustment .......................................................................................................... 59
Fig. 27 Changing the towing eye (height-adjustable towbar) ................................................................. 60
Fig. 28 Changing the towing eye (fixed height towbar, GB chassis version) ......................................... 61
Fig. 29 Changing the towing eye (fixed height towbar, USA chassis version) ....................................... 61
Fig. 30 Temperature display setting ....................................................................................................... 64
Fig. 31 Unit of pressure setting .............................................................................................................. 65
Fig. 32 Waiting for password entry ......................................................................................................... 65
Fig. 33 Password level 1 activated. ........................................................................................................ 66
Fig. 34 Engine settings menu ................................................................................................................. 67
Fig. 35 Settings in start/stop/automatic .................................................................................................. 69
Fig. 36 Jumper cable connection diagram ............................................................................................. 71
Fig. 37 Coolant pre-heating .................................................................................................................... 73
Fig. 38 Insulation monitoring - 400 V, 3-phase generator ...................................................................... 73
Fig. 39 Insulation monitoring - 230 V, 3-phase generator ...................................................................... 74
Fig. 40 Starting instruments ................................................................................................................... 75
Fig. 41 Brief instructions on starting and stopping ................................................................................. 76
Fig. 42 «Battery isolating switch» .......................................................................................................... 76
Fig. 43 Select menu option "set pressure in the oil separator tank" ....................................................... 78
Fig. 44 Setting the output pressure ........................................................................................................ 78
Fig. 45 Operating data menu .................................................................................................................. 82
Fig. 46 External fuel pump switch-on symbol ......................................................................................... 83
Fig. 47 Checking coolant level ............................................................................................................... 104
Fig. 48 Draining the coolant from the radiator ........................................................................................ 106
Fig. 49 Radiator with centralised drainage ............................................................................................. 107
Fig. 50 Engine air filter maintenance ...................................................................................................... 108
Fig. 51 Cleaning the filter element .......................................................................................................... 109
Fig. 52 Fuel system maintenance .......................................................................................................... 110
Fig. 53 Warning indication: Fuel filter water level ................................................................................... 111
Fig. 54 Emptying the fuel prefilter water trap .......................................................................................... 112
List of Illustrations
No.: 9_6975 00 E
Service Manual Screw Compressor
M135 SIGMA CONTROL MOBIL vii

Fig. 55 Changing the fuel prefilter cartridge ........................................................................................... 112
Fig. 56 Fuel filter maintenance ............................................................................................................... 113
Fig. 57 Checking the engine oil level ...................................................................................................... 114
Fig. 58 Draining the engine oil ................................................................................................................ 116
Fig. 59 Draining the engine oil, central drain point ................................................................................. 117
Fig. 60 Changing the oil filter .................................................................................................................. 118
Fig. 61 Belt tension checking by hand .................................................................................................... 119
Fig. 62 Safety signs - warning stickers on the battery. ........................................................................... 120
Fig. 63 Checking cooling oil level ........................................................................................................... 123
Fig. 64 Changing the cooling oil ............................................................................................................. 125
Fig. 65 Central compressor oil drainage ................................................................................................ 126
Fig. 66 Changing the oil filter .................................................................................................................. 128
Fig. 67 Cleaning the dirt trap .................................................................................................................. 129
Fig. 68 Changing the oil separator cartridge .......................................................................................... 130
Fig. 69 Compressor air filter maintenance ............................................................................................. 132
Fig. 70 Cleaning the filter element .......................................................................................................... 132
Fig. 71 Cooler/radiator cleaning ............................................................................................................. 134
Fig. 72 Cleaning the compressed air aftercooler .................................................................................... 135
Fig. 73 Overrun braking mechanism maintenance ................................................................................. 137
Fig. 74 Ball coupling maintenance ......................................................................................................... 138
Fig. 75 Ball coupling maintenance (USA version) .................................................................................. 138
Fig. 76 Checking the brake lining thickness ........................................................................................... 139
Fig. 77 Brake adjustment ....................................................................................................................... 140
Fig. 78 Cleaning the dirt trap .................................................................................................................. 141
Fig. 79 Combination filter maintenance .................................................................................................. 143
Fig. 80 Breathing air filter maintenance .................................................................................................. 145
Fig. 81 Generator belt tensioning ........................................................................................................... 147
Fig. 82 Towing alignment ....................................................................................................................... 156
Fig. 83 Ball coupling (ALKO-EU) ............................................................................................................ 157
Fig. 84 Ball coupling (ALKO-USA) ......................................................................................................... 158
Fig. 85 Safety sign - secure the chocks ................................................................................................. 159
Fig. 86 Breakaway cable attachment ..................................................................................................... 160
Fig. 87 Injury can occur if the towbar is unsupported and allowed to fall. .............................................. 160
Fig. 88 Safety sign - secure the chocks ................................................................................................. 161
Fig. 89 Transporting using a forklift truck ............................................................................................... 163
Fig. 90 Load secured by strapping ......................................................................................................... 164
Fig. 91 Marking ....................................................................................................................................... 166
List of Illustrations
viii
Service Manual Screw Compressor
M135 SIGMA CONTROL MOBIL No.: 9_6975 00 E