Name: KAESER KOMPRESSOREN MOBILAIR M58utility
Brand: KAESER KOMPRESSOREN
Rating: 4 (1 reviews)

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Operator Manual

Portable Rotary Screw Compressor

MOBILAIR M58utility SIGMA CONTROL SMART

No.: 901779 08 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
Tab. 1 Danger Levels and Their Definitions (Personal Injury)13
Potential Damage Warnings14
Other Alerts and Their Symbols14
Tab. 2 Danger Levels and Their Definition (Damage to Property)14
Technical Data Nameplate16
Vehicle Identification Number16
Options16
Tab. 3 Nameplate16
Air Treatment17
Tool Lubricator17
Air Distributor17
Low Temperature Equipment17
Tab. 4 Extract from the Options Label17
Tab. 5 Optional Air Treatment Equipment17
Tab. 6 Tool Lubricator Option17
Tab. 7 Compressed Air Distributor Option17
Equipment for Fire Hazard Areas18
Automatic Engine Start/Stop18
GSM/GPS Unit18
Machine (Without Options)18
Sound Pressure Level18
Tab. 8 Low Temperature Equipment Options18
Tab. 9 Optional Equipment for Fire Hazard Areas18
Tab. 10 Automatic Engine Start/Stop18
Tab. 11 GSM/GPS Unit18
Tab. 12 Sound Pressure Level18
Tightening Torque19
Ambient Conditions19
Tab. 13 Torques for M4-M8 Screws19
Tab. 14 Torques for M10-M24 Screws19
Tab. 15 Torque Cover Fixing Screws Oil Separator Tank19
Tab. 16 Ambient Conditions19
Additional Information According to the Machine's Operating Licence20
Compressor20
Working Gauge Pressure and Volumetric Flow Rate20
Compressed Air Outlet20
Safety Valves20
Tab. 17 Working Pressure an Volumetric Flow (Installation of the Machine Within the EU)20
Tab. 18 Working Pressure an Volumetric Flow (Installation of the Machine Outside of the EU)20
Tab. 19 Compressed Air Distributor20
Temperature21
Cooling Oil Recommendation21
Tab. 20 Safety Valve Opening Pressure21
Tab. 21 Required Temperatures Readiness to Switch to LOAD Mode21
Tab. 22 Airend Discharge Temperature21
Tab. 23 Cooling Oil Recommendations21
Cooling Oil Charge Quantity22
Tab. 24 Cooling Oil Recommendation (Food Processing)22
Tab. 25 Cooling Oil Charge Quantity22
Engine23
Engine Specification23
Tab. 26 Kubota V 2403-CR Engine Specifications23
Tab. 27 Engine Specifications23
Oil Recommendation24
Fuel Recommendation24
Tab. 28 Engine Oil Recommendation24
Tab. 29 Initial Engine Oil Quantity24
Engine Coolant Recommendation25
Tab. 30 Water Quality Parameters for Cooling Water25
Fluid Volumes26
Tab. 31 Initial Filling of Engine Water Cooler26
Tab. 32 Fluid Volumes26
Battery27
Options27
Air Treatment Options27
Low Temperature Equipment27
Tab. 33 Battery27
Tab. 34 Road Breaker Lubricant Recommendation27
Tab. 35 Interrelation between Compressed Air Treatment and Compressed Air Quality27
Auxiliary Electrical Systems28
GSM/GPS Unit28
Tab. 36 Environmental Conditions, Low Temperature Equipment28
Tab. 37 Power Supply Details28
Tab. 38 Technical Data - Cooling Water Pre-Heating Device28
Tab. 39 Battery Charger Specification28
Tab. 40 GSM/GPS Unit29
Safety and Responsibility Basic Instructions30
Specified Use30
Incorrect Use30
User's Responsibilities30
Observe Statutory and Universally Accepted Regulations30
Determining Personnel31
Complying with Inspection Schedules and Accident Prevention Regulations31
Dangers32
Safely Dealing with Sources of Danger32
Tab. 41 Inspection Intervals According to Ordinance on Industrial Health and Safety32
Safe Machine Operation35
Organizational Measures38
Danger Areas38
Safety Devices38
Tab. 42 Danger Areas38
Safety Signs39
Fig. 1 Location of Safety Signs (Outside)39
Tab. 43 Safety Signs40
Fig. 2 Location of Safety Signs (Inside)41
Noise Control Requirements42
Emergencies42
Correct Actions in the Event of a Fire42
Tab. 44 Safety Signs42
Treating Injuries from Handling Operating Fluids/Materials43
Warranty43
Noise Emissions Warranty44
Identifying the Effects of Improper Modifications44
Environmental Protection45
Design and Function Bodywork46
Fig. 3 Overview of Bodywork46
Machine Structure47
Fig. 4 Left Side (Access Side), Panel Removed47
Fig. 5 Right Side, Panels Removed47
Fig. 6 Access Door (Operating Side), Open48
Fig. 7 View from Above, Machine Roof Removed49
Fig. 8 Underside of the Machine49
Machine Function50
Fig. 9 Machine Overview50
Operating Modes and Control Mode51
Machine Operating Modes51
MODULATING Control51
Safety Devices52
Monitoring Functions with Shut-Down52
Fig. 10 Stepless Regulation of Volumetric Flow (Standstill)52
Further Safety Devices53
Battery Isolating Switch53
Fig. 11 Battery Isolating Switch53
SIGMA CONTROL SMART Operator Panel54
Fig. 12 SIGMA CONTROL SMART Operator Panel - Overview54
Exhaust Gas After-Treatment55
Engine Optimisation55
Tab. 45 Instrument Panel Keys and Displays55
Exhaust Gas Treatment System56
Fig. 13 Principle of Treatment Devices56
Regeneration of the Diesel Particulate Filter57
Sealed Floor Pan58
Options58
Fig. 14 Position of Service Openings in the Closed Floor Pan58
Air Treatment Options59
Fig. 15 Compressed Air Options59
Fig. 16 Tool Lubricator60
Auxiliary Electrical Systems61
Fig. 17 Principle Tool Lubricator61
Low Temperature Equipment Options62
Options for Operating in Fire Hazard Areas62
Fig. 18 Service Work on the Machine Roof62
Start/Stop/Automatic Options63
GSM/GPS Unit63
Installation and Operating Conditions64
Ensuring Safety64
Installation Conditions64
Complying with Installation Conditions When Installing on a Truck Load Platform65
Observing the Conditions of Stationary Installation65
Fig. 19 Installation on a Truck Load Platform65
Fig. 20 Minimum Distance from Excavations/Slopes and Walls66
Installation67
Ensuring Safety67
Reporting Transport Damage67
Mounting the Machine on the Truck Platform67
Mounting the Machine Mounts/Rubber Pads on the Machine67
Mounting the Machine on the Truck Platform68
Have the "Remote on Contact" of the Automatic Start/Stop System Connected68
Fig. 21 Mounting the Machine Mount/Rubber Pad68
Electrical Connection of the Battery Charger69
Initial Start-Up Ensuring Safety70
Before Initial Start-Up (or Recommissioning)70
Instructions to be Observed before Commissioning or Recommissioning70
Special Measures for Re-Commissioning after Storage or De-Commissioning71
Checking Installation and Operating Conditions71
Tab. 46 Measures for Re-Commissioning the Compressor after a Long Period of Storage or De-Commissioning71
Tab. 47 Installation Conditions Checklist71
Low-Temperature Operation (Winter)72
Starting Assistance72
Fig. 22 Jumper Cable Connection Diagram73
Starting up Low-Temperature Equipment74
Commissioning Electrical Equipment75
Fig. 23 Connect Auxiliary Electrical Systems75
Operation76
Ensuring Safety76
Starting and Stopping77
Fig. 24 Starting Instruments77
Follow the Brief Operating Instructions78
Fig. 25 Instrument Panel Keys and Indicators78
Fig. 26 Brief Instructions on Starting Procedure78
Commissioning the Machine79
Fig. 27 Brief Instructions on Stopping Procedure79
Starting the Machine80
Fig. 28 "Battery Isolating Switch80
Regulating the Shut-Off Valve81
Setting the Compressed Air Discharge Pressure82
Fig. 29 Control Line Shut-Off Valve82
Fig. 30 Quick Access Adjustment Compressed Air Output Pressure83
Fig. 31 Setting the Compressed Air Discharge Pressure83
Shutting down the Machine84
Shutting down in an Emergency85
Refueling the Machine86
Use the Specified Fuel Type86
Fig. 32 Filling the Tank with the Correct Fuel Type87
Tab. 48 Measures Required Should the Fuel Tank be Filled with the Incorrect Fuel Type87
Filling the Fuel Tank at a Pump by Means of a Refueling Nozzle88
Tab. 49 Fuel / Fuel Specification88
Filling the Fuel Tank on a Construction Site by Means of a Canister89
Confirming Alarm and Warning Messages89
Confirming Alarm Messages89
Confirming Warning Messages90
Cleaning the Machine after Operation90
Cleaning the Exterior of the Machine91
Cleaning the Interior of the Machine92
Tab. 50 Plug Sockets on the Exterior of the Machine92
Tab. 51 High-Pressure Washer Setting93
Operating the Options94
Operating the Machine with the "Start-Stop Automatic" Option94
Fig. 33 Make the "Start-Stop Automatic" Ready to Start95
Operating the Tool Lubricator96
Fig. 34 Setting the Tool Lubricator96
Using the Low-Temperature Equipment97
Fault Recognition and Rectification98
Basic Instructions98
Analysing SIGMA CONTROL SMART Messages98
Alarm Messages on the Controller (Machine Off)98
Tab. 52 Alarm Messages and Actions Concerning the Engine99
Tab. 53 Alarm Messages and Actions Concerning the Compressor Unit100
Tab. 54 Alarm Messages and Actions Concerning the Controller100
Warning Messages on the Controller101
Tab. 55 Alarm Messages and Troubleshooting in "General Faults101
Tab. 56 Warning Messages and Measures Relating to the Engine102
Tab. 57 Warning Messages and Measures Relating to the Compressor102
Evaluating Engine Faults and Alarms103
Engine Stops or Fails to Start103
Tab. 58 General Warning Messages and Measures103
Drive Engine Does Not Reach Full Speed104
Drive Engine Knocking or Fails to Start104
Tab. 59 Fault: "Engine Does Not Start or Stops104
Tab. 60 Fault: "Engine Not Reaching Full Speed104
Tab. 61 Fault: "Drive Engine Knocking or Fails to Start104
Analysing Compressor Faults and Alarms105
Working Pressure too High105
Working Pressure too Low105
Tab. 62 Fault: Working Pressure too High105
Tab. 63 Fault: Working Pressure too Low105
Pressure Relief Valve Blowing off106
Machine Overheating106
Tab. 64 Fault: Pressure Relief Valve Blowing off106
Tab. 65 Fault: Machine Overheating106
Too Much Oil Residue in the Compressed Air107
Oil Flows from the Compressor Air Filter after Shutdown107
High Moisture Content in the Compressed Air107
Tab. 66 Alarm: "Too Much Oil Residue in the Compressed Air107
Tab. 67 Alarm: "Oil Flows from the Compressor Air Filter after Shutdown107
Tab. 68 Fault: High Moisture Content in the Compressed Air107
10 Maintenance108
Ensuring Safety108
Tab. 69 Advise Others that the Machine Is Being Serviced108
Note the Maintenance Messages on the Controller109
Evaluating the Maintenance Message109
Concluding the Maintenance110
Maintenance Schedules110
Logging Maintenance Work110
Preventive Maintenance110
Tab. 70 Maintenance Messages and Required Actions110
Maintenance Tasks after Commissioning111
Regular Maintenance Tasks111
Tab. 71 Maintenace Tasks on the Machine after Commissioning111
Tab. 72 Maintenance Intervals and Regular Maintenance Tasks111
Tab. 73 Regular Machine Maintenance Tasks115
Drive Engine Maintenance116
Coolant Cooler Maintenance116
Tab. 74 Regular Maintenance Task Options116
Fig. 35 Checking the Coolant Level117
Fig. 36 Recommended Mixture Ratio for Coolant119
Tab. 75 Coolant Mixture Table119
Fig. 37 Draining the Coolant from the Engine Coolant Cooler120
Engine Air Filter Maintenance121
Fig. 38 Cleaning the Dust Evacuator Valve122
Fig. 39 Engine Air Filter Maintenance122
Fig. 40 Service Cover Engine Air Filter123
Fig. 41 Cleaning the Filter Element123
Fuel System Maintenance124
Fig. 42 Fuel System Maintenance125
Fig. 43 Bleeding the Fuel System125
Fig. 44 Warning Messages: Fuel Filter Water Level126
Fig. 45 Emptying the Fuel Pre-Filter and Water Trap127
Fig. 46 Changing the Fuel Pre-Filter Cartridge128
Checking the Engine Oil Level129
Fig. 47 Fuel Fine Filter Maintenance129
Engine Oil Filling and Topping up130
Fig. 48 Checking the Engine Oil Level130
Changing the Engine Oil131
Fig. 49 Draining the Engine Oil132
Replace the Engine Oil Filter133
Fig. 50 Change the Oil Filter133
Drive Belt Maintenance134
Fig. 51 Belt Guard Attachment134
Fig. 52 Checking the Drive Belt Seating135
Fig. 53 Manually Checking the Belt Tension135
Fig. 54 Tension the Belt136
Fig. 55 Replace the Drive Belt137
Battery Maintenance138
Fig. 56 Safety Signs - Warning Stickers on the Battery138
Tab. 76 Starter Battery Charge Level139
Change the Oil Separator Element141
Checking the Fastening of the Fuel Tank142
Fig. 57 Change the Oil Separator Element142
Servicing the Components of the Emission After-Treatment System143
Compressor Maintenance143
Check the Cooling Oil Level143
Cooling Oil Filling and Topping up144
Fig. 58 Check the Cooling Oil Level144
Changing the Cooling Oil145
Fig. 59 Draining the Compressor Cooling Oil146
Replacing the Compressor Oil Filter147
Fig. 60 Change the Oil Filter148
Oil Separator Tank Dirt Trap Maintenance149
Fig. 61 Oil Separator Tank Dirt Trap Maintenance149
Changing the Oil Separator Cartridge150
Fig. 62 Changing the Oil Separator Cartridge151
Compressor Air Filter Maintenance152
Fig. 63 Compressor Air Filter Maintenance153
Fig. 64 Cleaning the Filter Element154
Fit the Flexible Pipe Connection155
Fig. 65 Fit the Flexible Pipe Connection155
Tab. 77 Dimensions of the Flexible Pipe Connection155
Cleaning the Cooler156
Cleaning the Compressor Cooler and Engine Radiator156
Cleaning the Compressed Air After-Cooler157
Fig. 66 Cleaning the Compressor Cooler and Engine Radiator157
Checking Screw Connections158
Fig. 67 Cleaning the Compressed Air After-Cooler158
Maintenance of Rubber Sealing Strips159
Check/Replace Hose Lines160
Replace the Fuel Lines of the Drive Engine160
Replace the Pressure Hoses of the Engine160
Replace the Pressure Hoses of the Compressor160
Draining Liquid Accumulation Within the Machine161
Check Safety Functions161
Check the EMERGENCY STOP Push Button161
Have the Activating Pressure of the Safety Relief Valve Checked162
Tab. 78 Relief Valve Activating Pressure162
Having Excessive Temperature Shut-Down Function Checked163
Maintenance for Optional Items163
Tool Lubricator Maintenance163
Tab. 79 Safety Shut-Down at Excessive Airend Discharge Temperature163
Fig. 68 Tool Lubricator Maintenance164
Centrifugal Separator Maintenance165
Fig. 69 Cleaning the Condensate Drain165
Spark Arrestor Cleaning166
Fig. 70 Spark Arrestor Cleaning167
Documenting Maintenance and Service Work168
Tab. 80 Maintenance Log168
11 Spares, Operating Materials, Service169
Note the Nameplate169
Ordering Consumable Parts and Operating Fluids/Materials169
Tab. 81 Compressor Consumables169
Kaeser Air Service170
Service Addresses170
Replacement Parts for Service and Repair170
Tab. 82 Consumable Engine Parts170
12 Decommissioning, Storage and Transport205
Decommissioning205
Temporary Decommissioning205
Tab. 83 "Temporarily Decommissioned" Information Notice205
Long-Term De-Commissioning and Storage206
Tab. 84 "Long-Term Decommissioning and Storage" Checklist206
Transport207
Safety207
Transport with a Crane207
Tab. 85 Notice Text: "Long-Term Decommissioned and Storage207
Transport with a Forklift Truck208
Transporting the Machine as Load209
Fig. 71 Transporting Using a Forklift Truck209
Storage210
Fig. 72 Guys to Secure the Freight210
Disposal211
Removing the Batteries211
Draining Operating Fluids212
Draining Condensate212
Fig. 73 Battery Labelling212
Tab. 86 Machine Fluids212
Removing Filters/Filter Elements213
Disposing of the Machine213
Tab. 87 Machine Filters/Filter Elements213
13 Annex214
Identification214
Identification of the Machine214
Identification of the Drive Engine214
Fig. 74 Identification of the Machine214
Fig. 75 Identification of the Drive Engine214
Identification of the Exhaust Gas After-Treatment System215
Pipeline and Instrument Flow Diagram (P+I Diagram)215
Fig. 76 Identification of the Exhaust Gas After-Treatment System215
Dimensional Drawing219
Electrical Diagram221
Battery Charger Electrical Diagram248
Fuel Circulation Diagram252

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KAESER KOMPRESSOREN MOBILAIR M58utility Specifications

General

Brand	KAESER KOMPRESSOREN
Model	MOBILAIR M58utility
Category	Air Compressor
Language	English

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Table of Contents

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KAESER KOMPRESSOREN MOBILAIR M58utility Specifications

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