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KAESER KOMPRESSOREN
Air Compressor
M170
KAESER KOMPRESSOREN M170 User Manual
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Service Manual
Screw Compressor
M170
SIGMA CONTROL MOBIL
No.: 9_9425 01 E
Manufacturer:
KAESER KOMPRESSOREN GmbH
96410 Coburg • PO Box 2143 • GERMANY • Tel. +49-(0)9561-6400 • Fax +49-(0)9561-640130
http://www.kaeser.com
2
Table of Contents
Default Chapter
3
Table of Contents
3
1 Regarding this Document Using the Document
13
Further Documents
13
Copyright
13
Symbols and Markings
13
Warning Notices
13
Other Notices and Symbols
14
Tab. 1 the Levels of Danger and Their Meaning
14
2 Technical Specification Nameplate
15
List of Options
15
Tab. 2 Nameplate
15
Air Treatment
16
Compressed Air Distributor
16
Tab. 3 Combined Label for Coupling Load and Options Fitted
16
Tab. 4 Air Treatment
16
Tab. 5 Compressed Air Distributor
16
Automatic Engine Start/Stop
17
Chassis
17
Check Valve Function
17
External Fuel Pump
17
Low Temperature Equipment
17
Tab. 6 Check Valve Function
17
Tab. 7 Low Temperature Equipment
17
Tab. 8 Automatic Engine Start/Stop
17
Tab. 9 External Fuel Pump
17
Lighting
18
Pedestrian Protection
18
Machine (Without Options)
18
Sound Emission
18
Tab. 10 Chassis
18
Tab. 11 Lighting
18
Tab. 12 Pedestrian Protection
18
Tab. 13 Guaranteed Sound Power Level
18
Torques
19
Ambient Conditions
19
Additional Specifications
19
Tab. 14 Emission Sound Pressure Level
19
Tab. 15 Guaranteed Sound Pressure Level
19
Tab. 16 Torques for Hex-Head Screws
19
Tab. 17 Ambient Conditions
19
Chassis
20
Weights
20
Tyres
20
Wheel Nut/Bolt Tightening Torque
20
Towbar Tightening Torque
20
Tab. 18 Machine Weights
20
Tab. 19 Tyres
20
Tab. 20 Wheel Nut/Bolt Tightening Torque
20
Compressor
21
Working Pressure and FAD
21
Compressed Air Outlet
21
Pressure Relief Valve
21
Temperature
21
Tab. 21 Towbar Tightening Torque
21
Tab. 22 Working Pressure and FAD
21
Tab. 23 Compressed Air Distributor
21
Tab. 24 Relief Valve Activating Pressure
21
Tab. 25 Machine Temperatures
21
Cooling Oil Recommendation
22
Cooling Oil Charge
22
Engine
22
Engine Data
22
Tab. 26 Cooling Oil Recommendation
22
Tab. 27 Cooling Oil Charge
22
Oil Recommendation
23
Engine Coolant Recommendation
23
Tab. 28 Engine Data
23
Tab. 29 Engine Oil Recommendation
23
Fluid Volumes
24
Batteries
24
Options
24
Fresh Air Filter
24
Low Temperature Equipment
24
Tab. 30 Engine Fluid Volumes
24
Tab. 31 Batteries
24
Tab. 32 Fresh Air Filter Conditions
24
Tab. 33 Ambient Conditions
24
Trickle Charging Starter Batteries
25
Tab. 34 Batteries
25
Tab. 35 Coolant Pre-Heater
25
Tab. 36 Battery Charger
25
Tab. 37 Mains Supply
25
3 Safety and Responsibility Basic Information
26
Specified Use
26
Improper Use
26
User's Responsibilities
26
Observe Statutory and Universally Accepted Regulations
26
Defining Personnel
27
Adherence to Inspection Schedules and Accident Prevention Regulations
27
Dangers
28
Safely Dealing with Sources of Danger
28
Tab. 38 the Following Questions Must be Answered in Preparation for an ISO 14001 Certification/Monitoring (See WI-210001-Preparation for an ISO 14001 Audit)
28
Safe Machine Operation
31
Organisational Measures
33
Danger Areas
34
Safety Devices
34
Safety Signs
34
Tab. 39 Danger Areas
34
Fig. 1 Location of Safety Signs
35
Tab. 40 Safety Signs
36
Emergency Situations
37
Correct Fire Fighting
37
Contact with Operating Fluids/Materials
37
Warranty
37
Environmental Protection
38
4 Design and Function Bodywork
39
Fig. 2 Overview Bodywork
39
Component Identification
40
Machine Function
40
Fig. 3 Right-Hand Door Opened
40
Fig. 4 Left-Hand Door Opened
40
Fig. 5 General Design
41
Operating Modes and Control Modes
42
Operating Modes
42
PART LOAD Control
42
Safety Devices
43
Monitoring Functions with Shutdown
43
Further Safety Devices
43
Fig. 6 Stepless Regulation of FAD (Standstill)
43
Battery Isolating Switch
44
Fig. 7 Battery Isolating Switch
44
SIGMA CONTROL MOBIL Keys and Displays
45
Fig. 8 Instrument Panel Keys and Displays
45
SIGMA CONTROL MOBIL Function
46
Display
46
Fig. 9 Opening Page
46
Fig. 10 Engine Preheating
46
Tab. 41 Instrument Panel Keys and Displays
46
Fig. 11 Display of Operating Mode (Example)
47
Tab. 42 Display of Messages Prior to Starting
47
Tab. 43 Operating Mode Display
47
SIGMA CONTROL MOBIL Operating Sequence
48
Tab. 44 Display of Operational State
48
Menu Structure of the SIGMA CONTROL MOBIL
50
Tab. 45 SIGMA CONTROL MOBIL Operating Sequence
50
Tab. 46 Menu Structure of the SIGMA CONTROL MOBIL
50
List of Menus
51
Fig. 12 Menu Structure of the SIGMA CONTROL MOBIL
51
Tab. 47 Settings Menu
51
Tab. 48 Menu Selection
52
Tab. 49 Menu Option List
52
Tab. 50 Navigation (Menu)
52
Fig. 13 Machine Data Symbol
53
SIGMA CONTROL MOBIL Main Menu
53
Tab. 51 Symbolic Display of Engine Oil Pressure
53
SIGMA CONTROL MOBIL Settings Menu
54
Tab. 52 Engine Data Display
54
Tab. 53 Display of Compressor Operating Data
54
Tab. 54 Password Level
55
Tab. 55 Menu Guidance
55
Fig. 14 Symbolic Settings Menu
56
Fig. 15 Event Memory
57
SIGMA CONTROL MOBIL Event Memory
57
Tab. 56 Event Memory Outline
58
Fig. 16 Event Memory Example: Alarm Message
59
Fig. 17 Event Memory Example: Warning Message
59
Fig. 18 Event Memory Example: Maintenance Message
59
Air Treatment Options
60
Fig. 19 Message Code Structure
60
Tab. 57 Message Code Structure
60
Compressed-Air Aftercooler
61
Cyclone Separator
61
Fig. 20 Air Treatment Options
61
Filter Combination
61
Heat Exchanger
61
Fresh Air Filter
62
Low Temperature Equipment Option
62
Start/Stop/Automatic Option
63
External Fuel Pump" Option
63
Fig. 21 Coolant Pre-Heating
63
Transport Options
64
Chassis
64
Stationary Frame
64
Pedestrian Protection Option
65
5 Installation and Operating Conditions
66
Safety
66
Installation Conditions
66
Fig. 22 Minimum Distance from Excavations/Slopes and Walls
66
6 Installation Safety
68
Reporting Transport Damage
68
Fitting the Towbar
68
Fitting the Height Adjustable Towbar
69
Fig. 23 Height Adjustable Towbar, Fitted
69
Fig. 24 Fitting the Height Adjustable Towbar
69
Fitting a Non-Adjustable Towbar
70
Fig. 25 Non-Adjustable Towbar Fitted
70
Fig. 26 Fitting the Overrun Braking Mechanism of the Non-Adjustable Towbar
71
Adjusting the Chassis
72
Fig. 27 Fitting the Jockey Wheel of the Non-Adjustable Towbar
72
Adjusting the Towbar Height
73
Changing the Towing Eye
73
Fig. 28 Towbar Height Adjustment
73
Fig. 29 Changing the Towing Eye (Height-Adjustable Towbar)
74
Fig. 30 Changing the Towing Eye (Fixed Height Towbar, GB Chassis Version)
75
Fig. 31 Changing the Towing Eye (Fixed Height Towbar, USA Chassis Version)
76
7 Initial Start-Up Safety
77
Instructions to be Observed before Commissioning or Recommissioning
77
Checking Installation and Operating Conditions
77
Tab. 58 Installation and Operating Conditions Checklist
77
Setting the Displayed Units
78
Fig. 32 Temperature Display Setting
78
Entering a Password
79
Fig. 33 Unit of Pressure Setting
79
Fig. 34 Waiting for Password Entry
79
Engine Settings
80
Fig. 35 Password Level 1 Activated
80
Fig. 36 Engine Settings Menu
81
Changing the Parameters of the Start/Stop/Automatic Option
82
Fig. 37 Settings in Start/Stop/Automatic
83
After Storing the Machine for a Long Period
84
Low-Temperature Operation (Winter)
84
Starting Assistance
84
Tab. 59 Measures for Re-Commissioning the Compressor after a Long Period of Storage
84
Fig. 38 Jumper Cable Connection Diagram
85
Starting up Low-Temperature Equipment
86
Activating the Battery Trickle Charging
87
Fig. 39 Coolant Pre-Heating
87
Fig. 40 Battery Charger
88
Tab. 60 Battery Charger Control
88
8 Operation Safety
89
Starting and Stopping
89
Follow the Brief Instructions
89
Fig. 41 Starting Instruments
89
Running the Machine
90
Fig. 42 Brief Instructions on Starting and Stopping
90
Fig. 43 "Battery Isolating Switch
90
Starting the Engine
91
Setting the Output Pressure
92
Fig. 44 Select Menu Option "Set Pressure in the Oil Separator Tank
92
Shutting down the Machine
93
Fig. 45 Setting the Output Pressure
93
Shutting down in an Emergency
94
Setting Parameters
94
Acknowledging Alarm, Warning and Maintenance Messages
95
Acknowledge Alarm Message
95
Acknowledging Warning and Maintenance Messages
95
Resetting Maintenance Interval Counters
95
Displaying Machine Operating Data
96
Fig. 46 Operating Data Menu
96
Using the External Fuel Pump Option
97
Using the Low-Temperature Equipment
97
Fig. 47 External Fuel Pump Switch-On Symbol
97
9 Fault Recognition and Rectification
98
Basic Instructions
98
SIGMA CONTROL MOBIL Messages
98
Alarm Messages on the Controller (Machine Off)
98
Tab. 61 Fault Messages and Actions Concerning the Engine
99
Tab. 62 Fault Messages and Actions Concerning the Compressor Unit
100
Tab. 63 Fault Messages and Actions Concerning the Controller
100
Warning Message on the Controller
101
Tab. 64 General Fault Messages and Measures
101
Tab. 65 Warning Messages and Measures Relating to the Engine
102
Engine Faults and Alarms
103
Engine Refuses to Start or Does Not Turn over
103
Tab. 66 Warning Messages and Measures Relating to the Compressor
103
Tab. 67 General Warning Messages and Measures
103
Engine Does Not Reach Full Speed
104
Compressor Faults and Alarms
104
Working Pressure too High
104
Tab. 68 Fault: Engine Refuses to Start or Comes to a Stop
104
Tab. 69 Fault: Engine Does Not Reach Full Speed
104
Working Pressure too Low
105
Pressure Relief Valve Blowing off
105
Tab. 70 Fault: Working Pressure too High
105
Tab. 71 Fault: Working Pressure too Low
105
Machine Overheating
106
Too Much Oil Residue in the Compressed Air
106
Tab. 72 Fault: Pressure Relief Valve Blowing off
106
Tab. 73 Fault: Machine Overheating
106
Oil Flows from the Compressor Air Filter after Shutdown
107
High Moisture Content in the Compressed Air
107
Tab. 74 Fault: too Much Oil Residue in the Compressed Air
107
Tab. 75 Fault: Oil Flows from the Compressor Air Filter after Shutdown
107
Tab. 76 Fault: High Moisture Content in the Compressed Air
107
10 1 Maintenance
108
Safety
108
Maintenance Message on the Controller
108
Maintenance Schedules
109
Logging Maintenance Work
109
Tab. 77 Maintenance Messages and Measures Connected with Engine Maintenance
109
Tab. 78 Maintenance Messages and Measures Connected with Compressor Maintenance
109
Maintenance Tasks after Commissioning
110
Regular Maintenance Tasks
110
Tab. 79 Maintenance Tasks after Commissioning
110
Tab. 80 Maintenance Intervals and Regular Maintenance Tasks
110
Tab. 81 Regular Maintenance Tasks
113
Engine
114
Cooler Maintenance
114
Tab. 82 Regular Maintenance Task Options
114
Fig. 48 Checking Coolant Level
115
Tab. 83 KAESER Coolant Mixture Table
117
Fig. 49 Draining the Coolant from the Radiator
118
Air Filter Maintenance
119
Fig. 50 Radiator with Centralised Drainage
119
Fig. 51 Engine Air Filter Maintenance
120
Fig. 52 Cleaning the Filter Element
120
Fuel System Maintenance
121
Fig. 53 Fuel System Maintenance
122
Fig. 54 Warning Messages: Fuel Filter Water Level
123
Fig. 55 Emptying the Fuel Pre-Filter Water Trap
123
Fig. 56 Changing the Fuel Pre-Filter Cartridge
124
Checking the Engine Oil Level
125
Fig. 57 Fuel Filter Maintenance
125
Engine Oil Filling and Topping up
126
Fig. 58 Checking the Engine Oil Level
126
Changing the Engine Oil
127
Fig. 59 Draining the Engine Oil
128
Changing the Oil Filter
129
Fig. 60 Draining the Engine Oil, Central Drain Point
129
Maintaining the Drive Belt
130
Fig. 61 Changing the Oil Filter
130
Fig. 62 Belt Guard Attachment
131
Fig. 63 Manual Checking of the Belt Tension
132
Fig. 64 Changing/Tensioning the Drive Belt
133
Battery Maintenance
134
Fig. 65 Safety Signs - Warning Stickers on the Battery
134
Compressor
137
Checking Cooling Oil Level
137
Fig. 66 Checking Cooling Oil Level
137
Cooling Oil Filling and Topping up
138
Changing the Cooling Oil
139
Fig. 67 Changing the Cooling Oil
139
Fig. 68 Central Compressor Oil Drainage
141
Changing the Oil Filter
142
Fig. 69 Changing the Oil Filter
142
Oil Separator Tank Dirt Trap Maintenance
143
Fig. 70 Oil Separator Tank Dirt Trap Maintenance
144
Changing the Oil Separator Cartridge
145
Fig. 71 Changing the Oil Separator Cartridge
146
Air Filter Maintenance
147
Fig. 72 Compressor Air Filter Maintenance
148
Fig. 73 Cleaning the Filter Element
148
Checking Pressure Relief Valves
149
Cleaning the Coolers and Radiator
149
Cleaning the Compressed Air Aftercooler
150
Fig. 74 Cooler/Radiator Cleaning
150
Maintenance of Rubber Sealing Strips
151
Fig. 75 Cleaning the Compressed Air Aftercooler
151
Chassis
152
Wheel Checks
152
Towbar Maintenance
152
Fig. 76 Towbar Maintenance
153
Brake System Maintenance
154
Fig. 77 Ball Coupling (EC Version)
154
Fig. 78 Ball Coupling (USA Version)
154
Fig. 79 Checking the Brake Lining Thickness
155
Fig. 80 Brake System Adjustment
156
Options
157
Cyclone Separator Maintenance
157
Fig. 81 Cleaning the Dirt Trap
158
Combination Filter Maintenance
159
Fig. 82 Combination Filter Maintenance
159
Fresh Air Filter Maintenance
162
Fig. 83 Fresh Air Filter Maintenance
162
Document Maintenance and Service Work
165
Tab. 84 Logged Maintenance Tasks
165
11 Spares, Operating Materials, Service
166
Note the Nameplate
166
Ordering Consumable Parts and Operating Materials
166
Tab. 85 Compressor Consumables
166
Tab. 86 Consumable Engine Parts
166
Kaeser Air Service
167
Service Addresses
167
12 Decommissioning, Storage and Transport
168
Commissioning
168
Temporary Decommissioning
168
Tab. 87 "Temporarily Decommissioned" Information Notice
168
Long-Term Decommissioning
169
Tab. 88 Long-Term Decommissioning Checklist
169
Transport
170
Towing the Compressor on the Road
170
Tab. 89 Text for the Long-Term Decommissioned Information Notice
170
Fig. 84 Towing Alignment
171
Fig. 85 Ball Coupling (ALKO-EU)
172
Fig. 86 Ball Coupling Wear Indicator
173
Fig. 87 Ball Coupling (ALKO-USA)
174
Tab. 90 Ball Coupling Wear Indicator
174
Fig. 88 Release the Parking Brake
175
Fig. 89 Safety Sign - Secure the Chocks
176
Parking the Compressor
177
Fig. 90 Breakaway Cable Attachment
177
Fig. 91 Injury Can Occur if the Towbar Is Unsupported and Allowed to Fall
177
Fig. 92 Actuating the Parking Brake
178
Transport with a Crane
179
Fig. 93 Safety Sign - Secure the Chocks
179
Transporting with a Forklift Truck
180
Transporting as a Load
180
Fig. 94 Transporting Using a Forklift Truck
180
Fig. 95 Load Secured by Strapping
181
Storage
182
Disposal
182
13 Annex
183
Marking
183
Pipeline and Instrument Flow Diagram (P+I Diagram)
183
Fig. 96 Marking
183
Dimensional Drawings
188
Dimensional Drawing, Chassis with Height-Adjustable Tow Bar
188
Dimensional Drawing, Chassis with Fixed Height Tow Bar
190
Dimensional Drawing, Chassis Without Parking Brake
192
Dimensional Drawings of Stationary Machine (Skids)
194
Dimensional Drawings of Stationary Machine (Base Frame)
196
Wiring Diagrams
198
Electrical Diagram
198
Lighting and Signalling System Connection
222
Lighting and Signalling System Connection
227
Battery Charger Electrical Diagrams
230
Fuel Circulation Diagram
240
SIGMA CONTROL MOBIL Message Codes
243
Tab. 91 Message Code Range 1100 - 1199: Engine Faults
243
Tab. 92 Message Code Range 1200 - 1299: Compressor Unit Faults
244
Tab. 93 Message Code Range 1300 - 1399: Controller Faults
244
Tab. 94 Message Code Range 1400 - 1499: General Faults
245
Tab. 95 Message Code Range 2100 - 2199: Engine Maintenance
245
Tab. 96 Message Code Range 2200 - 2299: Compressor Unit Maintenance
245
Tab. 97 Message Code Range 3100 - 3199: Engine Warnings
245
Tab. 98 Message Code Range 3200 - 3299: Compressor Unit Warnings
245
Tab. 99 Message Code Range 3400 - 3499: General Warnings
245
Operating Instructions for Compressed Air Filter (Combination Filter)
246
Operating Instructions for Compressed Air Filter (Fresh Air Filter)
267
4
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KAESER KOMPRESSOREN M170 Specifications
General
Brand
KAESER KOMPRESSOREN
Model
M170
Category
Air Compressor
Language
English
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