Name: KAESER KOMPRESSOREN MOBILAIR M55 PE
Brand: KAESER KOMPRESSOREN
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Operator Manual

Portable Rotary Screw Compressor

MOBILAIR M55 PE SIGMA CONTROL SMART pV

No.: 902366 10 USE

Manufacturer:

KAESER KOMPRESSOREN SE

96410 Coburg • PO Box 2143 • GERMANY • Tel. +49-(0)9561-6400 • Fax +49-(0)9561-640130

www.kaeser.com

Table of Contents3
Regarding this Document Using this Document13
Further Documents13
Copyright13
Symbols and Labels13
Warnings13
Potential Damage Warnings14
Tab. 1 Danger Levels and Their Definition (Personal Injury)14
Tab. 2 Danger Levels and Their Definition (Damage to Property)14
Other Alert Notes and Their Symbols15
Technical Data Nameplate16
Vehicle Identification Number16
Options Overview16
Tab. 3 Nameplate16
Air Treatment17
Air Distributor17
Low Temperature Equipment17
Fig. 1 Option Label MOBILAIR M55PE with Options17
Tab. 4 Air Treatment Options17
Tab. 5 Air Distributor Option17
Exhaust Gas After-Treatment18
GSM/GPS Modem18
Lighting18
Frame Design for Stationary Machines18
Tab. 6 Low Temperature Equipment Options18
Tab. 7 Exhaust Gas After-Treatment Options18
Tab. 8 GSM/GPS Modem18
Tab. 9 Lighting Options18
Machine (Without Options)19
Sound Pressure Level [Db(A)]19
Tightening Torque19
Tab. 10 Options for Stationary Frame Design19
Tab. 11 Guaranteed Sound Pressure Level [Db(A)]19
Tab. 12 Torques for M4-M8 Screws19
Tab. 13 Torques for M10-M24 Screws19
Ambient Conditions20
Additional Specifications20
Chassis20
Chassis Options20
Machines with Stationary Frame Design20
Weight of Machines with Stationary Frame Design20
Tab. 14 Torques for Lifting Eye Screws20
Tab. 15 Ambient Conditions20
Compressor21
Variable Pressure Flow Rate Control (Pv Control)21
Tab. 16 Weight of the Machine21
Tab. 17 Maximum Working Pressure21
Fig. 2 Nominal System Pressure / Flow Rate Diagram22
Tab. 18 Flow Rate Depending on the Nominal System Pressure22
Fig. 3 Nominal System Pressure / Engine Speed Diagram23
Tab. 19 Flow Rate Depending on the Nominal System Pressure23
Tab. 20 Nominal System Pressure and Engine Speed23
Compressed Air Outlet24
Safety Relief Valves24
Temperature24
Cooling Oil Recommendation24
Tab. 21 Nominal System Pressure and Engine Speed24
Tab. 22 Compressed Air Distributor24
Tab. 23 Safety Relief Valve Activating Pressure24
Tab. 24 Required Temperatures Readiness to Switch to LOAD Mode24
Tab. 25 Airend Discharge Temperature24
Tab. 26 Cooling Oil Recommendation25
Cooling Oil Charge26
Engine26
Engine Specification26
Oil Recommendations26
Tab. 27 Cooling Oil Recommendation (Food Processing)26
Tab. 28 Cooling Oil Charge26
Tab. 29 Engine Specification26
Fuel Recommendation27
Tab. 30 Engine Oil Recommendation27
Tab. 31 Viscosity Class for First Fill27
Engine Coolant Recommendation28
Tab. 32 Water Quality Specification28
Fluid Volumes29
Batteries29
Tab. 33 Initial Fill of Coolant Cooler29
Tab. 34 Fluid Volumes29
Tab. 35 Batteries29
Options30
Air Treatment Options30
Low Temperature Equipment30
Tab. 36 Interrelation between Compressed Air Treatment and Compressed Air Quality30
Tab. 37 Ambient Conditions, Low Temperature Equipment30
Tab. 38 Insulated Pressure Hoses30
Safety and Responsibility Basic Instructions31
Specified Use31
Incorrect Use31
User's Responsibilities31
Observe Statutory and Universally Accepted Regulations31
Determining Personnel32
Complying with Inspection Schedules and Accident Prevention Regulations33
Dangers33
Safely Dealing with Sources of Danger33
Tab. 39 Inspection Intervals According to Ordinance on Industrial Health and Safety33
Safe Machine Operation36
Organizational Measures40
Danger Areas40
Safety Devices40
Safety Signs40
Tab. 40 Danger Areas40
Fig. 4 Location of Safety Signs (Outside)41
Tab. 41 Safety Signs42
Fig. 5 Location of Safety Signs (Inside)43
Noise Control Requirements44
Tab. 42 Safety Signs44
Emergencies45
Correct Actions in the Event of a Fire45
Treating Injuries from Handling Operating Fluids/Materials45
Warranty46
Noise Emissions Warranty46
Identifying the Effects of Improper Modifications46
Environmental Protection47
Design and Function Bodywork48
Fig. 6 Bodywork48
Machine Structure50
Fig. 7 Right-Hand Door Opened50
Machine Function51
Fig. 8 Machine Overview52
Operating Modes and Control Mode53
Machine Operating Modes53
MODULATING Control54
Safety Devices54
Monitoring Functions with Shut-Down54
Further Safety Devices54
SIGMA CONTROL SMART Control Panel55
Fig. 9 SIGMA CONTROL SMART Control Panel - Overview55
Variable Pressure Flow Rate Control (Pv Control)56
Exhaust Gas After-Treatment56
Engine Optimization56
Tab. 43 Instrument Panel Keys and Displays56
Exhaust Gas Treatment System57
Regeneration of the Diesel Particulate Filter58
Fig. 10 Principle of Treatment Devices58
Options59
Air Treatment Options59
Fig. 11 Compressed Air Options60
GSM/GPS Modem61
Document Bag61
Fig. 12 Location of the GSM/GPS Modem Inside the Machine61
Tab. 44 Compressed Air Quality With/Without Heat Exchanger61
Transport Options62
Frame Design Options for Stationary Machines62
Fig. 13 Document Bag Option62
Tab. 45 Stationary Machines63
Installation and Operating Conditions64
Ensuring Safety64
Installation Conditions64
Fig. 14 Minimum Distance from Excavations/Slopes and Walls65
Requirements for Positioning on a Lorry Platform66
Installation67
Ensuring Safety67
Reporting Transport Damage67
Perform Regular Maintenance on the Chassis67
Securing the Parked Machine67
Fitting the Machine Feet68
Fig. 15 Mounting Machine Foot/Rubber Pad68
Initial Start-Up Ensuring Safety69
Before Initial Start-Up (or Recommissioning)69
Instructions to be Observed before Commissioning or Recommissioning69
Special Measures for Recommissioning after Storage70
Checking Installation and Operating Conditions70
Tab. 46 Special Measures for Recommissioning after Storage70
Low-Temperature Operation71
Checking the Warm-Up Function in Low-Temperature Conditions71
Tab. 47 Checking Installation and Operating Conditions71
Starting Assistance72
Fig. 16 Jumper Cable Connection Diagram73
Operation75
Ensuring Safety75
Starting up and Shutting down76
Control Panel76
Fig. 17 Control Panel with Starting Instruments76
SIGMA CONTROL SMART Control Unit77
Controller ON/OFF Switch77
Fig. 18 Keys and Indicators, SIGMA CONTROL SMART Control Unit77
Observing the Quick Reference Guide78
Fig. 19 Location, "Controller ON/OFF" Switch78
Fig. 20 Quick Reference Guide for Start-Up Procedure78
Operating the Machine in Winter Conditions79
Fig. 21 Quick Reference Guide for Shutdown Procedure79
Starting the Machine80
Setting the Compressed Air Discharge Pressure80
Fig. 22 Quick Access Adjustment Compressed Air Output Pressure81
Shutting down the Machine82
Fig. 23 Setting the Compressed Air Discharge Pressure82
Shutting down in an Emergency83
Refueling the Machine84
Using the Correct Type of Fuel84
Tab. 48 Measures Required Should the Fuel Tank be Filled with the Incorrect Fuel Type85
Filling the Fuel Tank at a Pump by Means of a Refuelling Nozzle86
Fig. 24 Filling the Tank with the Correct Fuel Type86
Tab. 49 Fuel / Fuel Specification86
Filling the Fuel Tank on a Construction Site by Means of a Canister87
Confirming Alarm and Warning Messages88
Confirming Alarm Messages88
Confirming Warning Messages88
Cleaning the Machine after Operation89
Cleaning the Exterior of the Machine90
Clean the Interior of the Machine90
Operating the Options91
Bypassing/Switching on the Heat Exchanger91
Fig. 25 Bypassing/Switching on the Heat Exchanger92
Tab. 50 Directional Control Valve Position and Selected Compressed Air Quality92
Tab. 51 Directional Control Valve Position and Selected Compressed Air Quality93
Fault Recognition and Rectification94
Basic Instructions94
Analysing SIGMA CONTROL SMART Messages94
Fault Messages on the Controller (Machine Off)94
Tab. 52 Alarm Messages and Actions Relating to "Engine Fault96
Tab. 53 Fault Messages and Actions Relating to "Compressor Fault96
Warning Messages on the Controller97
Tab. 54 Fault Messages and Actions Relating to "Controller Fault97
Tab. 55 Fault Messages and Actions Relating to "General Faults97
Tab. 56 Warning Messages and Measures Relating to the Engine98
Evaluating Engine Faults and Alarms99
Engine Refuses to Start or Does Not Turn over99
Tab. 57 Warning Messages and Measures Relating to the Compressor99
Tab. 58 General Warning Messages and Measures99
Engine Does Not Reach Full Speed100
Tab. 59 Fault: Engine Refuses to Start or Comes to a Stop100
Tab. 60 Alarm: "Engine Does Not Reach Full Speed100
Analyzing Compressor Faults and Alarms101
Working Pressure too High101
Working Pressure too Low101
Tab. 61 Fault: Working Pressure too High101
Tab. 62 Fault: Working Pressure too Low101
Safety Relief Valve Blows off102
Machine Overheating102
Tab. 63 Fault: Safety Relief Valve Blowing off102
Tab. 64 Fault: Machine Overheating102
Too Much Oil Residue in the Compressed Air103
Oil Flows from the Compressor Air Filter after Shutdown103
High Moisture Content in the Compressed Air103
Tab. 65 Alarm: "Too Much Oil Residue in the Compressed Air103
Tab. 66 Alarm: "Oil Flows from the Compressor Air Filter after Shutdown103
Tab. 67 Fault: High Moisture Content in the Compressed Air103
10 Maintenance104
Ensuring Safety104
Tab. 68 Advise Others that the Machine Is Being Serviced104
Observing Maintenance Messages in the Controller105
Evaluating Maintenance Messages105
Tab. 69 Maintenance Messages and Required Measures105
Completing Maintenance106
Following the Maintenance Plans107
Logging Maintenance Work107
Maintenance Tasks after Commissioning107
Regular Maintenance Tasks107
Tab. 70 Maintenance Tasks on the Machine after Commissioning107
Tab. 71 Maintenance Intervals and Regular Maintenance Tasks108
Fig. 59 Maintenance Indicator110
Tab. 72 Regular Machine Maintenance Tasks111
Tab. 73 Regular Maintenance Tasks for Options111
Drive Engine Maintenance112
Coolant Cooler Maintenance112
Fig. 26 Checking the Coolant Level113
Fig. 27 Recommended Mixture Ratio for Coolant114
Tab. 74 Coolant Mixture Table115
Fig. 28 Draining the Coolant116
Engine Air Filter Maintenance117
Tab. 75 Specific Message Code for "Service Engine Air Filter117
Fig. 29 Maintenance Indicator118
Fig. 30 Cleaning the Dust Evacuator Valve118
Fig. 31 Engine Air Filter Maintenance119
Fig. 32 Removing both Filter Elements120
Fuel System Maintenance121
Fig. 33 Cleaning the Primary Filter Element121
Fig. 34 Servicing the Fuel System122
Fig. 35 Bleeding the Fuel System123
Fig. 36 Warning Message: Water Level, Fuel Prefilter124
Fig. 37 Empty the Fuel Prefilter and Water Separator124
Fig. 38 Changing the Fuel Prefilter Cartridge125
Fig. 39 Fuel Filter Maintenance126
Checking the Engine Oil Level127
Fig. 40 Checking the Engine Oil Level127
Engine Oil Filling and Topping off128
Changing the Engine Oil129
Tab. 76 Specific Message Code for "Change the Engine Oil129
Replacing the Engine Oil Filter130
Fig. 41 Draining the Engine Oil130
Tab. 77 Specific Message Code for "Change the Oil Filter131
Fig. 42 Changing the Oil Filter132
Replacing the Engine Oil Separator Catridge133
Fig. 43 Replacing the Oil Separator Element133
Drive Belt Maintenance134
Fig. 44 Belt Guard Attachment134
Fig. 45 Check the Drive Belt Seating135
Fig. 46 Manually Checking the Belt Tension136
Fig. 47 Changing/Tensioning the Drive Belt137
Having the Anti-Vibration Mount Checked138
Battery Maintenance138
Fig. 48 Example for Anti-Vibration Mount of Drive Engine138
Fig. 49 Safety Signs - Warning Labels on the Battery139
Tab. 78 Starter Batteries Charge Level140
Servicing Components in the Exhaust Gas After-Treatment System142
Fig. 50 Heat Shield, Exhaust Gas After-Treatment143
Fig. 51 Exhaust Gas After-Treatment with Diesel Particulate Filter144
Compressor Maintenance145
Checking the Cooling Oil Level145
Fig. 52 Checking the Cooling Oil Level145
Filling or Topping off the Cooling Oil146
Changing the Cooling Oil147
Tab. 79 Specific Message Code for "Change the Cooling Oil147
Fig. 53 Draining the Compressor Cooling Oil149
Fig. 54 Airend Screw Plug150
Tab. 80 Specific Cooling Oil Volumes151
Replacing the Compressor Oil Filter152
Tab. 81 Specific Message Code for "Change the Oil Filter152
Fig. 55 Changing the Oil Filter153
Oil Separator Tank Dirt Trap Maintenance154
Fig. 56 Oil Separator Tank Dirt Trap Maintenance155
Tab. 82 Dirt Trap Screw Plug Torque155
Fig. 57 Install the Male Stud Fitting156
Changing the Oil Separator Cartridge157
Fig. 58 Changing the Oil Separator Cartridge157
Compressor Air Filter Maintenance159
Tab. 83 Specific Message Code for "Service Air Filter159
Fig. 60 Cleaning the Dust Evacuator Valve160
Fig. 61 Compressor Air Filter Maintenance161
Fig. 62 Removing both Filter Elements162
Cleaning the Cooler163
Fig. 63 Cleaning the Filter Element163
Cleaning the Oil Cooler and Coolant Cooler164
Fig. 64 Cleaning the Cooler165
Checking the Screw Connections166
General Guideline Values for Tightening Torques166
Specific Guideline Values for Tightening Torques167
Sealed Screw Connections167
Check Wing Doors167
Maintain Rubber Sealing Strips168
Checking Function of Closed Enclosure168
Checking Connecting Elements of Enclosure168
Check/Replace Hose Lines169
Replace the Fuel Lines of the Drive Engine169
Fig. 65 Connecting Rod Alignment169
Replace the Pressure Hoses of the Engine170
Replace the Pressure Hoses of the Compressor170
Check Safety Functions170
Check the EMERGENCY STOP Push Button170
Have the Actuating Pressure of the Safety Relief Valve Checked171
Having Excessive Temperature Shut-Down Function Checked171
Tab. 84 Safety Relief Valve Actuating Pressure171
Maintenance for Optional Items172
Compressed Air Aftercooler Maintenance172
Tab. 85 Safety Shut-Down at Excessive Airend Discharge Temperature172
Fig. 66 Cleaning the Compressed Air After-Cooler173
Maintenance of the Water Separator Dirt Trap174
Fig. 67 Clean the Dirt Trap175
Filter Combination Maintenance176
Fig. 68 Combination Filter Maintenance177
Tab. 86 Replacing the Filter Elements179
Documenting Maintenance and Service Work181
Tab. 87 Maintenance Log181
11 Spares, Operating Materials, Service182
Note the Nameplate182
Ordering Maintenance Parts and Operating Fluids/Materials182
Tab. 88 Compressor Maintenance Parts182
Kaeser Air Service183
Replacement Parts for Service and Repair183
Spare Parts Overview183
Tab. 89 Engine Maintenance Parts183
12 Decommissioning, Storage and Transport239
Decommissioning239
Temporary Decommissioning239
Tab. 90 "Temporarily Decommissioned" Information Notice239
Long-Term De-Commissioning/Storage240
Tab. 91 "Long-Term Decommissioning/Storage" Checklist240
Transportation241
Safety241
Tab. 92 Notice Text: "Long-Term Decommissioned/Storage241
Transporting the Machine by Crane242
Fig. 69 Lifting Eye for Transportation by Crane242
Transporting by Forklift Truck243
Fig. 70 Prohibition Signs for Forklift Transport244
Fig. 71 Forklift Example: Lifting Accessory Components244
Fig. 72 Ensure both Fork Prongs Are Positioned under the Machine245
Fig. 73 Lifting the Machine with a Forklift246
Transporting as a Load247
Fig. 74 Example: Transporting a Machine by Forklift247
Fig. 75 Example: Improper Load Securing248
Fig. 76 Example: Proper Load Securing Via Lashing Points Provided249
Fig. 77 Bracing as Load Securing (Machine in Stationary Configuration)250
Storage251
Disposal251
Removing the Batteries251
Draining Operating Fluids252
Fig. 78 Battery Labelling252
Tab. 93 Machine Fluids252
Draining Condensate253
Removing Filters/Filter Elements253
Tab. 94 Machine Option Fluids253
Tab. 95 Machine Filters/Filter Elements253
Tab. 96 Machine Option Filters/Filter Elements253
Disposing of the Machine254
13 Annex255
Identification255
Identification of the Machine255
Identification of the Drive Engine255
Fig. 79 Identification of the Machine255
Fig. 80 Identification of the Drive Engine255
Identification of the Exhaust Gas After-Treatment System256
Pipeline and Instrument Flow Diagram (P+I Diagram)256
Fig. 81 Identification of the Exhaust Gas After-Treatment System256
Dimensional Drawings261
Dimensional Drawing - Chassis261
Dimensional Drawing, Stationary Version263
Dimensional Drawing, Stationary Version265
Wiring Diagrams267
Electrical Diagram267
Lighting and Signaling System Connection295
Fuel Circulation Diagram299
Operating Instructions for Compressed Air Filter (Combination Filter)302

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KAESER KOMPRESSOREN MOBILAIR M55 PE Specifications

General

Brand	KAESER KOMPRESSOREN
Model	MOBILAIR M55 PE
Category	Air Compressor
Language	English

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Table of Contents

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KAESER KOMPRESSOREN MOBILAIR M55 PE Specifications

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