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KAESER KOMPRESSOREN
Air Compressor
M250
KAESER KOMPRESSOREN M250 - User Manual
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Operator Manual
Screw Compressor
M250
SIGMA CONTROL MOBIL
No.: 9_9570 07 USE
Manufacturer:
KAESER KOMPRESSOREN SE
96410 Coburg • PO Box 2143 • GERMANY • Tel. +49-(0)9561-6400 • Fax +49-(0)9561-640130
http://www.kaeser.com
2
Table of Contents
Main Page
Table of Contents
3
List of Tables
13
Copyright
15
Further Documents
15
Regarding this Document Using this Document
15
Symbols and Labels
15
Tab. 1 Danger Levels and Their Definitions (Personal Injury)
15
Warnings
15
Other Alerts and Their Symbols
16
Potential Damage Warnings
16
Tab. 2 Danger Levels and Their Definition (Damage to Property)
16
Options - Options Label
18
Tab. 3 Nameplate
18
Technical Data Nameplate
18
Check Valve Function
19
Compressed Air Treatment Devices
19
Emission After-Treatment
19
Tab. 4 Extract from the Options Label
19
Tab. 5 Compressed Air Treatment Options
19
Tab. 6 Check Valve Option
19
Tab. 7 Options for Emission Treatment
19
Automatic Engine Start/Stop
20
Chassis
20
Equipment for Fire Hazard Areas
20
GSM/GPS Modem
20
Low Temperature Equipment
20
Tab. 10 Automatic Engine Start/Stop
20
Tab. 11 GSM/GPS Modem
20
Tab. 8 Low Temperature Equipment Options
20
Tab. 9 Optional Equipment for Fire Hazard Areas
20
Lighting
21
Sealed Floor Pan
21
Tab. 12 Chassis Options
21
Tab. 13 Options: Stationary Frame
21
Tab. 14 Lighting Options
21
Tab. 15 Sealed Floor Pan Option
21
Additional Specifications
22
Ambient Conditions
22
Machine (Without Options)
22
Sound Pressure Level
22
Tab. 16 Sound Pressure Level
22
Tab. 17 Tightening Torques for Screws (Property Class 8.8, Coefficient of Friction Μ = 0.12)
22
Tab. 18 Ambient Conditions
22
Tightening Torques for Screws
22
Chassis
23
Fig. 1 Example of Tire Information on the Side Wall
23
Mass
23
Tab. 19 Mass of the Machine
23
Tab. 20 Tires
23
Tires
23
Compressed Air Outlet
24
Compressor
24
Safety Valves
24
Tab. 21 Wheel Nut/Bolt Tightening Torque
24
Tab. 22 Towbar Tightening Torque
24
Tab. 23 Working Gauge Pressure and Volumetric Flow Rate
24
Tab. 24 Compressed Air Distributor
24
Towbar Tightening Torque
24
Wheel Nut/Bolt Tightening Torque
24
Working Gauge Pressure and Volumetric Flow Rate
24
Cooling Oil Recommendation
25
Tab. 25 Relief Valve Activating Pressure
25
Tab. 26 Required Temperatures Readiness to Switch to LOAD Mode
25
Tab. 27 Airend Discharge Temperature
25
Temperature
25
Cooling Oil Charge
26
Engine
27
Engine Specification
27
Oil Recommendation
27
Tab. 30 Cooling Oil Charge
27
Tab. 31 Engine Data (Engine with SCR Catalytic Converter)
27
Tab. 32 Engine Data (Engine Without Exhaust Treatment)
27
Tab. 33 Engine Oil Recommendation
28
Engine Coolant Recommendation
29
Fuel Recommendation
29
Tab. 34 Initial Engine Oil Quantity
29
Fluid Volumes
30
Reduction Agent
30
Tab. 35 Water Quality Parameters for Cooling Water
30
Tab. 36 Reduction Agent
30
Air Treatment Options
31
Batteries
31
Options
31
Low Temperature Equipment
32
Trickle Charging for Starter Batteries
32
Tab. 44 Battery Charger Specification
33
Tab. 45 Power Supply Details
33
Incorrect Use
34
Observe Statutory and Universally Accepted Regulations
34
Safety and Responsibility Basic Instructions
34
Specified Use
34
User's Responsibilities
34
Adherence to Inspection Schedules and Accident Prevention Regulations
35
Determining Personnel
35
Taking the Machine for General Inspection
35
Dangers
36
Documenting the Mileage of the Machine as Trailer
36
Safely Dealing with Sources of Danger
36
Tab. 46 General Inspection Intervals
36
Save Handling of the DEF Reduction Agent
39
Safe Machine Operation
40
Danger Areas
43
Organizational Measures
43
Fig. 2 Location of Safety Signs
44
Safety Devices
44
Safety Signs
44
Tab. 47 Danger Areas
44
Correct Fire Fighting
47
Emergency Situations
47
Noise Control Requirements
47
Tab. 48 Safety Signs
47
Treating Injuries from Handling Operating Fluids/Materials
48
Identifying the Effects of Improper Modifications
49
Noise Emissions Warranty
49
Warranty
49
Environmental Protection
50
Design and Function Bodywork
51
Fig. 3 Bodywork
51
Fig. 4 Left-Hand Doors, Opened
52
Machine Structure
52
Fig. 5 Right-Hand Doors, Opened
53
Fig. 6 Rear Side, Air Inlet Grille Removed
53
Fig. 7 View from Above, Machine Roof Removed
54
Machine Function
54
Fig. 8 Machine Overview
55
Machine Operating Modes
56
MODULATING Control
56
Operating Modes and Control Mode
56
Fig. 9 Stepless Regulation of Volumetric Flow (Standstill)
57
Further Safety Devices
57
Monitoring Functions with Shutdown
57
Safety Devices
57
Battery Isolating Switch
58
Fig. 10 Battery Isolating Switch
58
Fig. 11 SIGMA CONTROL MOBIL Main Display - Overview
58
SIGMA CONTROL MOBIL Control Panel
58
Compressed Air Treatment Options
60
Fig. 12 Compressed Air Options
60
Options
60
Tab. 49 Instrument Panel Keys and Displays
60
Options for Emission Treatment
62
Fig. 13 General Design of the SCR System
63
Fig. 14 Coolant Pre-Heating
64
Low Temperature Equipment Options
64
Options for Operating in Fire Hazard Areas
64
Fig. 15 Access Engine Air Shut-Off Valve
65
GSM/GPS Modem" Option
66
Start/Stop/Automatic Options
66
Transport Options
66
Fig. 16 Locations of Service Openings in the Sealed Floor Pan
69
Location of Draining Points for the Machine's Fluids
69
Sealed Floor Pan Option
69
Fig. 17 Drain Points for Oil and Coolant from Engine and Compressor
70
Ensuring Safety
71
Fig. 18 Minimum Distance from Excavations/Slopes and Walls
71
Installation and Operating Conditions
71
Installation Conditions
71
Fig. 19 Parking the Machine in Slanted Position
72
Machine with Stationary Frame Structure
73
Ensuring Safety
74
Fitting the Towbar
74
Installation
74
Reporting Transport Damage
74
Fig. 20 Height Adjustable Towbar, Fitted
75
Fig. 21 Fitting the Height Adjustable Towbar
75
Fitting the Height-Adjustable Towbar (Chassis 7716 Lb)
75
Fig. 22 Non-Adjustable Tow Bar Fitted
76
Fitting the Fixed Height Towbar (Chassis 7716 Lb)
76
Fig. 23 Fitting the Overrun Braking Mechanism of the Non-Adjustable Tow Bar
77
Adjusting the Chassis
78
Fig. 24 Fitting the Jockey Wheel of the Non-Adjustable Tow Bar
78
Adjusting the Tow Bar (Chassis 7716 Lb)
79
Fig. 25 Towbar Height Adjustment
79
Adjusting the Tow Bar (Chassis 7716 Lb)
80
Fig. 26 Towbar Height Adjustment
80
Changing the Towing Eye/Ball Hitch
81
Fig. 27 Changing the Towing Eye/Ball Hitch (Height-Adjustable Drawbar)
82
Fig. 28 Changing the Towing Eye/Ball Hitch (Fixed Height Towbar)
83
Fig. 29 Changing the Towing Eye
84
Fig. 30 Changing the Towing Eye (Fixed Height Towbar)
85
Connecting the Battery Trickle Charger
86
Installing a Machine with Stationary Frame Superstructure on a Truck Platform
86
Before Initial Start-Up (or Recommissioning)
88
Initial Start-Up Ensuring Safety
88
Instructions to be Observed before Commissioning or Recommissioning
88
Checking Installation and Operating Conditions
89
Special Measures for Recommissioning after Storage
89
Tab. 50 Measures for Recommissioning the Compressor after a Long Period of Storage
89
Tab. 51 Installation Conditions Checklist
89
Low-Temperature Operation (Winter)
90
Starting Assistance
90
Fig. 31 Jumper Cable Connection Diagram
91
Starting up Low-Temperature Equipment
92
Activating the Battery Trickle Charging
93
Fig. 32 Coolant Pre-Heating
93
Fig. 33 Battery Charger
94
Tab. 52 Battery Charger Control
94
Ensuring Safety
95
Operation
95
Fig. 34 Starting Instruments
96
Follow the Brief Instructions
96
Starting and Stopping
96
Fig. 35 Brief Instructions on Starting and Stopping
97
Starting the Machine
97
Fig. 36 "Battery Isolating Switch
98
Starting the Machine
98
Fig. 37 Control Line Shut-Off Valve
99
Regulating the Shut-Off Valve
99
Setting the Compressed Air Discharge Pressure
99
Fig. 38 Select Menu Option "Set Pressure in the Oil Separator Tank
100
Fig. 39 Setting the Output Pressure
101
Shutting down the Machine
101
Shutting down in an Emergency
102
Acknowledging Alarm Messages
103
Acknowledging Alarm, Warning and Maintenance Messages
103
Acknowledging Warning and Maintenance Messages
103
Coolant Pre-Heating
104
Fig. 40 Handle for Manually Closing the Engine Air Intake Valve
104
Shutting down if any Dangerous Situation Arises
104
Cleaning the Machine after Operation
105
Alarm Messages on the Controller (Machine Off)
106
Basic Instructions
106
Fault Recognition and Rectification
106
SIGMA CONTROL MOBIL Messages
106
Tab. 53 Alarm Messages and Actions Concerning the Engine
108
Tab. 54 Alarm Messages and Actions Concerning the Compressor Unit
109
Tab. 55 Alarm Messages and Actions Concerning the Controller
109
Tab. 56 General Alarm Messages and Measures
110
Warning Message on the Controller
111
Engine Refuses to Start or Does Not Turn over
113
Evaluating Engine Faults and Alarms
113
Tab. 57 Warning Messages and Measures Relating to the Engine
113
Tab. 58 Warning Messages and Measures Relating to the Compressor
113
Engine Does Not Reach Full Speed
114
Tab. 59 Fault: Engine Refuses to Start or Comes to a Stop
114
Tab. 60 Alarm: "Engine Does Not Reach Full Speed
114
Analysing Compressor Faults and Alarms
115
Tab. 61 Fault: Working Pressure too High
115
Tab. 62 Fault: Working Pressure too Low
115
Working Pressure too High
115
Working Pressure too Low
115
Machine Overheating
116
Pressure Relief Valve Blowing off
116
Tab. 63 Fault: Pressure Relief Valve Blowing off
116
Tab. 64 Fault: Machine Overheating
116
High Moisture Content in the Compressed Air
117
Oil Flows from the Compressor Air Filter after Shutdown
117
Tab. 65 Alarm: "Too Much Oil Residue in the Compressed Air
117
Tab. 66 Alarm: "Oil Flows from the Compressor Air Filter after Shutdown
117
Tab. 67 Fault: High Moisture Content in the Compressed Air
117
Too Much Oil Residue in the Compressed Air
117
10 Maintenance
118
Ensuring Safety
118
Tab. 68 Advise Others that the Machine Is Being Serviced
118
Evaluating the Maintenance Message
119
Note the Maintenance Messages on the Controller
119
Concluding the Maintenance
120
Logging Maintenance Work
120
Maintenance Schedules
120
Maintenance Tasks after Commissioning
120
Tab. 69 Maintenance Messages and Required Actions
120
Regular Maintenance Tasks
121
Tab. 70 Maintenance Tasks on the Chassis after Commissioning
121
Tab. 71 Maintenance Intervals
121
Tab. 72 Regular Machine Maintenance Tasks
124
Tab. 73 Regular Maintenance Task Options
125
Tab. 74 Chassis Maintenance Intervals and Regular Maintenance Tasks
125
Engine Maintenance
127
Tab. 75 Regular Chassis Maintenance Tasks
127
Water Cooler Maintenance
127
Fig. 41 Checking Coolant Level
128
Tab. 76 KAESER Coolant Mixture Table
130
Fig. 42 Draining the Coolant from the Radiator
131
Fig. 43 Draining the Coolant from the Radiator (Sealed Floor Pan)
132
Engine Air Filter Maintenance
133
Fig. 44 Warning Messages: Air Filter Engine Intake Maintenance
134
Fig. 45 Engine Air Filter Maintenance
134
Fig. 46 Clean the Filter Element (Air Filter)
134
Fuel System Maintenance
135
Fig. 47 Fuel System Maintenance
136
Fig. 48 Bleeding the Fuel System
137
Fig. 49 Emptying the Fuel Pre-Filter and Water Trap
138
Fig. 50 Changing the Fuel Pre-Filter Cartridge
139
Fig. 51 Maintain the Engine Fuel Filter
140
Checking the Engine Oil Level
141
Engine Oil Filling and Topping up
142
Fig. 52 Checking the Engine Oil Level
142
Changing the Engine Oil
143
Fig. 53 Draining the Engine Oil
144
Fig. 54 Draining the Engine Oil (Closed Floor Pan)
145
Fig. 55 Change the Oil Filter
146
Replace the Engine Oil Filter
146
Battery Maintenance
147
Fig. 56 Safety Signs - Warning Stickers on the Battery
147
Engine Belt Maintenance
150
Fig. 57 Replacing the Engine Belt
151
Checking the Fastening of the Lashed Fluid Containers
152
Compressor Maintenance
152
Check the Cooling Oil Level
153
Fig. 58 Check the Cooling Oil Level
153
Cooling Oil Filling and Topping up
154
Changing the Cooling Oil
155
Fig. 59 Drain the Oil from the Oil Separator Tank and the Airend
156
Fig. 60 Draining the Oil from the Cooler
157
Fig. 61 Draining the Compressor's Cooling Oil (Closed Floor Pan)
158
Fig. 62 Change the Oil Filter
160
Replacing the Compressor Oil Filter
160
Oil Separator Tank Dirt Trap Maintenance
161
Fig. 63 Oil Separator Tank Dirt Trap Maintenance
162
Changing the Oil Separator Cartridge
163
Fig. 64 Changing the Oil Separator Cartridge
164
Compressor Air Filter Maintenance
165
Fig. 65 Warning Messages: Compressor Air Filter Maintenance
166
Fig. 66 Compressor Air Filter Maintenance
167
Fig. 67 Clean the Filter Element (Air Filter)
167
Checking Safety Relief Valves
168
Fit the Flexible Pipe Connection
168
Cleaning the Cooler
169
Fig. 68 Fit the Flexible Pipe Connection
169
Tab. 77 Dimensions of the Flexible Pipe Connection
169
Cleaning the Compressor Cooler and Engine Radiator
170
Fig. 69 Cleaning the Compressor Cooler and Engine Radiator
170
Cleaning the Compressed Air Aftercooler
171
Fig. 70 Cleaning the Compressed Air Aftercooler
171
Drive Belt Maintenance
172
Carry out Visual Check
173
Checking Belt Tension
173
Fig. 71 Drive Belt Maintenance
173
Changing/Tensioning the Drive Belt
174
Fig. 72 Tension the Belt
174
Fig. 73 Replace the Drive Belt
175
Fig. 74 Maintain the Fan Shaft Bearing
176
Maintain the Fan Shaft Bearing
176
Chassis Maintenance
177
Maintenance of Rubber Sealing Strips
177
Wheel Checks
177
Fig. 75 Maintaining the Height-Adjustable Towbar (Chassis 7716 Lb)
178
Towbar Maintenance
178
Fig. 76 Maintaining the Fixed Height Towbar (Chassis 7716 Lb)
179
Fig. 77 Maintaining the Height-Adjustable Towbar (Chassis 8818 Lb)
179
Fig. 78 Ball Coupling
180
Brake Maintenance
181
Fig. 79 Checking the Brake Lining Thickness
181
Fig. 80 Brake System Adjustment
182
Fig. 81 Brake Rod Adjustment
183
Fig. 82 Maintaining the Parking Brake
184
Pressure Brake System Maintenance
184
Fig. 83 Drain the Brake Air Receiver
185
Fig. 84 Lubricate the Brake Lever Guide
186
Fig. 85 Lubrication of the Catch Mechanism
186
Lubrication of the Catch Mechanism
186
Cyclone Separator Maintenance
187
Fig. 86 Cleaning the Condensate Drain
187
Maintenance for Optional Items
187
Combination Filter Maintenance
188
Fig. 87 Filter Combination
189
Fig. 88 Combination Filter Maintenance
189
Fig. 89 Fresh Air Filter Maintenance
192
Fresh Air Filter Maintenance
192
Spark Arrestor Maintenance
195
Engine Air Shut-Off Valve Maintenance
196
Fig. 90 Cleaning the Spark Arrester (Sealed Floor Pan with Service Openings)
196
Fig. 91 Maintain the Engine Air Shut-Off Valve
197
Draining Liquid Accumulation Within the Machine
198
Fig. 92 Checking Manual Operation of the Engine Air Intake Valve
198
Fig. 93 Alarm Message: "Liquid in the Floor Pan too High
199
Documenting Maintenance and Service Work
201
Tab. 78 Maintenance Log
201
11 Spares, Operating Materials, Service
202
Note the Nameplate
202
Ordering Consumable Parts and Operating Fluids/Materials
202
Tab. 79 Compressor Consumable Parts/Spares
202
Kaeser Air Service
203
Replacement Parts for Service and Repair
203
Service Addresses
203
Tab. 80 Engine Consumable Parts/Spares
203
Tab. 81 Replacement Parts: Combination Filter
203
Tab. 82 Replacement Parts: Fresh Air Filter
203
12 Decommissioning, Storage and Transport
273
Commissioning
273
Tab. 83 "Temporarily Decommissioned" Information Notice
273
Temporary De-Commissioning
273
Long-Term Decommissioning and Storage
274
Tab. 84 Long-Term Decommissioning and Storage Checklist
274
Safety
275
Tab. 85 Text for the Long-Term Decommissioned and Storage Information Notice
275
Towing the Compressor on the Road
275
Transport
275
Fig. 94 Transport Position
277
Fig. 95 Ball Coupling (ALKO)
278
Fig. 96 Wear Indication, ALKO Ball Coupling
279
Tab. 86 Ball Coupling Wear Indicator
279
Fig. 97 Function of the Semi-Automatic Jockey Wheel
280
Fig. 98 Supply Lines Compressed Air Brake and ABS
281
Fig. 100 Automatic Jockey Wheel in Transport Position
282
Fig. 99 Release the Parking Brake
282
Fig. 101 Safety Signs: Secure the Chocks
283
Fig. 102 Breakaway Cable Attachment
284
Fig. 103 Attach Safety Chains
285
Parking the Machine
285
Fig. 104 Warning "Injury Can Occur if the Towbar Is Allowed to Fall
287
Fig. 105 Risk of Injury Due to Incorrect Operation of the Automatic Jockey Wheel
287
Fig. 106 Actuating the Parking Brake
287
Fig. 107 Safety Sign - Secure the Chocks
289
Transport with a Crane
289
Fig. 108 Transport with a Forklift Truck
290
Transport with a Forklift Truck
290
Transporting the Machine as Load
291
Disposal
292
Storage
292
13 Annex
294
Marking
294
Pipeline and Instrument Flow Diagram (P+I Diagram)
294
Pipeline and Instrument Flow Diagram (Exhaust Treatment)
300
Chassis Drawing
302
Dimensional Drawings
302
Dimensional Drawing, Chassis Options
304
Dimensional Drawing, Chassis Options
306
Dimensional Drawing, Chassis Options
308
Dimensional Drawing, Chassis Options
310
Dimensional Drawing, Stationary Version
312
Dimensional Drawing, Stationary Version
314
Electrical Diagram
316
Wiring Diagrams
316
Lighting and Signaling System Connection
352
Lighting and Signaling System Connection
356
Battery Charger Electrical Diagram
361
Fuel Circulation Diagram
371
Air Brake Diagram
374
Assembly Diagrams - Chassis
376
Assembly Diagrams - EU Chassis
376
Assembly Diagrams - GB/US Chassis
379
Assembly Diagram Brake Rod
382
Operating Instructions for Compressed Air Filter (Combination Filter)
384
Operating Instructions for Compressed Air Filter (Fresh Air Filter)
412
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KAESER KOMPRESSOREN M250 Specifications
General
Brand
KAESER KOMPRESSOREN
Model
M250
Category
Air Compressor
Language
English
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