KAESER KOMPRESSOREN MOBILAIR M55 PE User manual

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. [phone] • Fax [phone]
www.kaeser.com

Original instructions
/KKW/M55PE 2.09 en Z1 SBA-MOBILAIR
20220325 111411

1 Regarding this Document
1.1 Using this document ......................................................................................................... 1
1.2 Further documents ........................................................................................................... 1
1.3 Copyright .......................................................................................................................... 1
1.4 Symbols and labels .......................................................................................................... 1
1.4.1 Warnings ............................................................................................................. 1
1.4.2 Potential damage warnings ................................................................................ 2
1.4.3 Other alert notes and their symbols .................................................................... 3
2 Technical Data
2.1 Nameplate ........................................................................................................................ 4
2.2 Vehicle identification number ........................................................................................... 4
2.3 Options overview .............................................................................................................. 4
2.3.1 Air treatment ....................................................................................................... 5
2.3.2 Air distributor ....................................................................................................... 5
2.3.3 Low temperature equipment ............................................................................... 5
2.3.4 Exhaust gas after-treatment ............................................................................... 6
2.3.5 GSM/GPS modem .............................................................................................. 6
2.3.6 Lighting ............................................................................................................... 6
2.3.7 Frame design for stationary machines ................................................................ 6
2.4 Machine (without options) ................................................................................................ 7
2.4.1 Sound pressure level [dB(A)] .............................................................................. 7
2.4.2 Tightening torque ................................................................................................ 7
2.4.3 Ambient conditions ............................................................................................. 8
2.4.4 Additional specifications ..................................................................................... 8
2.5 Chassis ............................................................................................................................ 8
2.5.1 Chassis options .................................................................................................. 8
2.6 Machines with stationary frame design ............................................................................ 8
2.6.1 Weight of machines with stationary frame design .............................................. 8
2.7 Compressor ...................................................................................................................... 9
2.7.1 Variable pressure flow rate control (pV control) .................................................. 9
2.7.2 Compressed air outlet ......................................................................................... 12
2.7.3 Safety relief valves .............................................................................................. 12
2.7.4 Temperature ....................................................................................................... 12
2.7.5 Cooling oil recommendation ............................................................................... 12
2.7.6 Cooling oil charge ............................................................................................... 14
2.8 Engine .............................................................................................................................. 14
2.8.1 Engine specification ............................................................................................ 14
2.8.2 Oil recommendations .......................................................................................... 14
2.8.3 Fuel recommendation ......................................................................................... 15
2.8.4 Engine coolant recommendation ........................................................................ 16
2.8.5 Fluid volumes ...................................................................................................... 17
2.8.6 Batteries .............................................................................................................. 17
2.9 Options ............................................................................................................................. 18
2.9.1 Air treatment options ........................................................................................... 18
2.9.2 Low temperature equipment ............................................................................... 18
3 Safety and Responsibility
3.1 Basic instructions ............................................................................................................. 19
3.2 Specified use .................................................................................................................... 19
3.3 Incorrect Use .................................................................................................................... 19
3.4 User’s responsibilities ...................................................................................................... 19
3.4.1 Observe statutory and universally accepted regulations .................................... 19
3.4.2 Determining personnel ........................................................................................ 20
3.4.3 Complying with inspection schedules and accident prevention regulations ....... 21
Contents
No.: 902366 10 USE
Operator Manual Portable Rotary Screw Compressor
MOBILAIR M55 PE SIGMA CONTROL SMART pV i

3.5 Dangers ............................................................................................................................ 21
3.5.1 Safely dealing with sources of danger ................................................................ 21
3.5.2 Safe machine operation ...................................................................................... 24
3.5.3 Organizational Measures .................................................................................... 28
3.5.4 Danger areas ...................................................................................................... 28
3.6 Safety devices .................................................................................................................. 28
3.7 Safety signs ...................................................................................................................... 28
3.8 Noise control requirements .............................................................................................. 32
3.9 Emergencies .................................................................................................................... 33
3.9.1 Correct actions in the event of a fire ................................................................... 33
3.9.2 Treating injuries from handling operating fluids/materials .................................. 33
3.10 Warranty ........................................................................................................................... 34
3.10.1 Noise emissions warranty ................................................................................... 34
3.11 Identifying the effects of improper modifications .............................................................. 34
3.12 Environmental protection ................................................................................................. 35
4 Design and Function
4.1 Bodywork ......................................................................................................................... 36
4.2 Machine structure ............................................................................................................. 38
4.3 Machine function .............................................................................................................. 39
4.4 Operating modes and control mode ................................................................................. 41
4.4.1 Machine operating modes .................................................................................. 41
4.4.2 MODULATING control ........................................................................................ 42
4.5 Safety devices .................................................................................................................. 42
4.5.1 Monitoring functions with shut-down ................................................................... 42
4.5.2 Further safety devices ........................................................................................ 42
4.6 SIGMA CONTROL SMART control panel ........................................................................ 43
4.7 Variable pressure flow rate control (pV control) ............................................................... 44
4.8 Exhaust gas after-treatment ............................................................................................. 44
4.8.1 Engine optimization ............................................................................................ 44
4.8.2 Exhaust gas treatment system ........................................................................... 45
4.8.3 Regeneration of the diesel particulate filter ........................................................ 46
4.9 Options ............................................................................................................................. 47
4.9.1 Air treatment options ........................................................................................... 47
4.9.2 GSM/GPS modem .............................................................................................. 49
4.9.3 Document bag .................................................................................................... 49
4.9.4 Transport options ................................................................................................ 50
4.9.5 Frame design options for stationary machines ................................................... 50
5 Installation and Operating Conditions
5.1 Ensuring safety ................................................................................................................ 52
5.2 Installation conditions ....................................................................................................... 52
5.3 Requirements for positioning on a lorry platform ............................................................. 54
6 Installation
6.1 Ensuring safety ................................................................................................................ 55
6.2 Reporting Transport Damage ........................................................................................... 55
6.3 Perform regular maintenance on the chassis ................................................................... 55
6.4 Securing the parked machine .......................................................................................... 55
6.4.1 Fitting the machine feet ...................................................................................... 56
7 Initial Start-up
7.1 Ensuring safety ................................................................................................................ 57
7.2 Before initial start-up (or recommissioning) ...................................................................... 57
7.2.1 Instructions to be observed before commissioning or recommissioning ............ 57
7.2.2 Special measures for recommissioning after storage ......................................... 58
Contents
ii
Operator Manual Portable Rotary Screw Compressor
MOBILAIR M55 PE SIGMA CONTROL SMART pV No.: 902366 10 USE

7.3 Checking installation and operating conditions ................................................................ 58
7.4 Low-temperature operation .............................................................................................. 59
7.4.1 Checking the warm-up function in low-temperature conditions .......................... 59
7.4.2 Starting assistance ............................................................................................. 60
8 Operation
8.1 Ensuring safety ................................................................................................................ 63
8.2 Starting up and shutting down .......................................................................................... 64
8.2.1 Control panel ...................................................................................................... 64
8.2.2 SIGMA CONTROL SMART control unit ............................................................. 65
8.2.3 Controller ON/OFF switch ................................................................................... 65
8.2.4 Observing the quick reference guide .................................................................. 66
8.2.5 Operating the machine in winter conditions ........................................................ 67
8.2.6 Starting the machine ........................................................................................... 68
8.2.7 Setting the compressed air discharge pressure ................................................. 68
8.2.8 Shutting down the machine ................................................................................ 70
8.2.9 Shutting down in an emergency ......................................................................... 71
8.3 Refueling the machine ..................................................................................................... 72
8.3.1 Using the correct type of fuel .............................................................................. 72
8.3.2 Filling the fuel tank at a pump by means of a refuelling nozzle .......................... 74
8.3.3 Filling the fuel tank on a construction site by means of a canister ..................... 75
8.4 Confirming alarm and warning messages ........................................................................ 76
8.4.1 Confirming alarm messages ............................................................................... 76
8.4.2 Confirming warning messages ........................................................................... 76
8.5 Cleaning the machine after operation .............................................................................. 77
8.5.1 Cleaning the exterior of the machine .................................................................. 78
8.5.2 Clean the interior of the machine ........................................................................ 78
8.6 Operating the options ....................................................................................................... 79
8.6.1 Bypassing/switching on the heat exchanger ...................................................... 79
9 Fault Recognition and Rectification
9.1 Basic instructions ............................................................................................................. 82
9.2 Analysing SIGMA CONTROL SMART messages ........................................................... 82
9.2.1 Fault messages on the controller (machine off) .................................................. 82
9.2.2 Warning messages on the controller .................................................................. 85
9.3 Evaluating engine faults and alarms ................................................................................ 87
9.3.1 Engine refuses to start or does not turn over ...................................................... 87
9.3.2 Engine does not reach full speed ....................................................................... 88
9.4 Analyzing compressor faults and alarms ......................................................................... 89
9.4.1 Working pressure too high .................................................................................. 89
9.4.2 Working pressure too low ................................................................................... 89
9.4.3 Safety relief valve blows off ................................................................................ 90
9.4.4 Machine overheating .......................................................................................... 90
9.4.5 Too much oil residue in the compressed air ....................................................... 91
9.4.6 Oil flows from the compressor air filter after shutdown ....................................... 91
9.4.7 High moisture content in the compressed air ..................................................... 91
10 Maintenance
10.1 Ensuring safety ................................................................................................................ 92
10.2 Observing maintenance messages in the controller ........................................................ 93
10.2.1 Evaluating maintenance messages .................................................................... 93
10.2.2 Completing maintenance .................................................................................... 94
10.3 Following the maintenance plans ..................................................................................... 95
10.3.1 Logging maintenance work ................................................................................. 95
10.3.2 Maintenance tasks after commissioning ............................................................. 95
10.3.3 Regular maintenance tasks ................................................................................ 95
Contents
No.: 902366 10 USE
Operator Manual Portable Rotary Screw Compressor
MOBILAIR M55 PE SIGMA CONTROL SMART pV iii

10.4 Drive engine maintenance ............................................................................................... 100
10.4.1 Coolant cooler maintenance ............................................................................... 100
10.4.2 Engine air filter maintenance .............................................................................. 105
10.4.3 Fuel system maintenance ................................................................................... 109
10.4.4 Checking the engine oil level .............................................................................. 115
10.4.5 Engine oil filling and topping off .......................................................................... 116
10.4.6 Changing the engine oil ...................................................................................... 117
10.4.7 Replacing the engine oil filter .............................................................................. 118
10.4.8 Replacing the engine oil separator catridge ....................................................... 121
10.4.9 Drive belt maintenance ....................................................................................... 122
10.4.10 Having the anti-vibration mount checked ............................................................ 126
10.4.11 Battery maintenance ........................................................................................... 126
10.5 Servicing components in the exhaust gas after-treatment system ................................... 130
10.6 Compressor Maintenance ................................................................................................ 133
10.6.1 Checking the cooling oil level ............................................................................. 133
10.6.2 Filling or topping off the cooling oil ..................................................................... 134
10.6.3 Changing the cooling oil ..................................................................................... 135
10.6.4 Replacing the compressor oil filter ...................................................................... 140
10.6.5 Oil separator tank dirt trap maintenance ............................................................. 142
10.6.6 Changing the oil separator cartridge ................................................................... 145
10.6.7 Compressor air filter maintenance ...................................................................... 147
10.7 Cleaning the cooler .......................................................................................................... 151
10.7.1 Cleaning the oil cooler and coolant cooler .......................................................... 152
10.8 Checking the screw connections ...................................................................................... 154
10.8.1 General guideline values for tightening torques ................................................. 154
10.8.2 Specific guideline values for tightening torques ................................................. 155
10.8.3 Sealed screw connections .................................................................................. 155
10.9 Check wing doors ............................................................................................................. 155
10.9.1 Maintain rubber sealing strips ............................................................................. 156
10.9.2 Checking function of closed enclosure ............................................................... 156
10.9.3 Checking connecting elements of enclosure ...................................................... 156
10.10 Check/replace hose lines ................................................................................................. 157
10.10.1 Replace the fuel lines of the drive engine ........................................................... 157
10.10.2 Replace the pressure hoses of the engine ......................................................... 158
10.10.3 Replace the pressure hoses of the compressor ................................................. 158
10.11 Check safety functions ..................................................................................................... 158
10.11.1 Check the EMERGENCY STOP push button ..................................................... 158
10.11.2 Have the actuating pressure of the safety relief valve checked ......................... 159
10.11.3 Having excessive temperature shut-down function checked .............................. 159
10.12 Maintenance for Optional Items ....................................................................................... 160
10.12.1 Compressed air aftercooler maintenance ........................................................... 160
10.12.2 Maintenance of the water separator dirt trap ...................................................... 162
10.12.3 Filter combination maintenance .......................................................................... 164
10.13 Documenting maintenance and service work .................................................................. 169
11 Spares, Operating Materials, Service
11.1 Note the nameplate .......................................................................................................... 170
11.2 Ordering maintenance parts and operating fluids/materials ............................................. 170
11.3 KAESER AIR SERVICE ................................................................................................... 171
11.4 Replacement parts for service and repair ........................................................................ 171
11.4.1 Spare parts overview .......................................................................................... 171
12 Decommissioning, Storage and Transport
12.1 Decommissioning ............................................................................................................. 227
12.1.1 Temporary decommissioning .............................................................................. 227
Contents
iv
Operator Manual Portable Rotary Screw Compressor
MOBILAIR M55 PE SIGMA CONTROL SMART pV No.: 902366 10 USE

12.1.2 Long-term de-commissioning/storage ................................................................ 228
12.2 Transportation .................................................................................................................. 229
12.2.1 Safety .................................................................................................................. 229
12.2.2 Transporting the machine by crane .................................................................... 230
12.2.3 Transporting by forklift truck ............................................................................... 231
12.2.4 Transporting as a load ........................................................................................ 235
12.3 Storage ............................................................................................................................. 239
12.4 Disposal ........................................................................................................................... 239
12.4.1 Removing the batteries ....................................................................................... 239
12.4.2 Draining operating fluids ..................................................................................... 240
12.4.3 Draining condensate ........................................................................................... 241
12.4.4 Removing filters/filter elements ........................................................................... 241
12.4.5 Disposing of the machine ................................................................................... 242
13 Annex
13.1 Identification ..................................................................................................................... 243
13.1.1 Identification of the machine ............................................................................... 243
13.1.2 Identification of the drive engine ......................................................................... 243
13.1.3 Identification of the exhaust gas after-treatment system .................................... 244
13.2 Pipeline and instrument flow diagram (P+I diagram) ....................................................... 244
13.3 Dimensional drawings ...................................................................................................... 249
13.3.1 Dimensional drawing – chassis ........................................................................... 249
13.3.2 Dimensional drawing, stationary version ............................................................ 251
13.3.3 Dimensional drawing, stationary version ............................................................ 253
13.4 Wiring diagrams ............................................................................................................... 255
13.4.1 Electrical Diagram ............................................................................................... 255
13.4.2 Lighting and signaling system connection .......................................................... 283
13.5 Fuel circulation diagram ................................................................................................... 287
13.6 Operating instructions for compressed air filter (combination filter) ................................. 290
Contents
No.: 902366 10 USE
Operator Manual Portable Rotary Screw Compressor
MOBILAIR M55 PE SIGMA CONTROL SMART pV v

Contents
vi
Operator Manual Portable Rotary Screw Compressor
MOBILAIR M55 PE SIGMA CONTROL SMART pV No.: 902366 10 USE

Fig. 1 Option label MOBILAIR M55PE with options ............................................................................. 5
Fig. 2 Nominal system pressure / flow rate diagram ............................................................................ 10
Fig. 3 Nominal system pressure / engine speed diagram .................................................................... 11
Fig. 4 Location of safety signs (outside) ............................................................................................... 29
Fig. 5 Location of safety signs (inside) ................................................................................................. 31
Fig. 6 Bodywork .................................................................................................................................... 36
Fig. 7 Right-hand door opened ............................................................................................................. 38
Fig. 8 Machine overview ....................................................................................................................... 40
Fig. 9 SIGMA CONTROL SMART control panel – overview ................................................................ 43
Fig. 10 Principle of treatment devices .................................................................................................... 46
Fig. 11 Compressed air options ............................................................................................................. 48
Fig. 12 Location of the GSM/GPS modem inside the machine .............................................................. 49
Fig. 13 Document bag option ................................................................................................................. 50
Fig. 14 Minimum distance from excavations/slopes and walls ............................................................... 53
Fig. 15 Mounting machine foot/rubber pad ............................................................................................. 56
Fig. 16 Jumper cable connection diagram ............................................................................................. 61
Fig. 17 Control panel with starting instruments ...................................................................................... 64
Fig. 18 Keys and indicators, SIGMA CONTROL SMART control unit .................................................... 65
Fig. 19 Location, «Controller ON/OFF» switch ....................................................................................... 66
Fig. 20 Quick reference guide for start-up procedure ............................................................................. 66
Fig. 21 Quick reference guide for shutdown procedure ......................................................................... 67
Fig. 22 Quick access adjustment compressed air output pressure ........................................................ 69
Fig. 23 Setting the compressed air discharge pressure ......................................................................... 70
Fig. 24 Filling the tank with the correct fuel type .................................................................................... 74
Fig. 25 Bypassing/switching on the heat exchanger .............................................................................. 80
Fig. 26 Checking the coolant level ......................................................................................................... 101
Fig. 27 Recommended mixture ratio for coolant .................................................................................... 102
Fig. 28 Draining the coolant ................................................................................................................... 104
Fig. 29 Maintenance indicator ................................................................................................................ 106
Fig. 30 Cleaning the dust evacuator valve ............................................................................................. 106
Fig. 31 Engine air filter maintenance ...................................................................................................... 107
Fig. 32 Removing both filter elements .................................................................................................... 108
Fig. 33 Cleaning the primary filter element ............................................................................................. 109
Fig. 34 Servicing the fuel system ........................................................................................................... 110
Fig. 35 Bleeding the fuel system ............................................................................................................ 111
Fig. 36 Warning message: Water level, fuel prefilter .............................................................................. 112
Fig. 37 Empty the fuel prefilter and water separator .............................................................................. 112
Fig. 38 Changing the fuel prefilter cartridge ........................................................................................... 113
Fig. 39 Fuel filter maintenance ............................................................................................................... 114
Fig. 40 Checking the engine oil level ...................................................................................................... 115
Fig. 41 Draining the engine oil ................................................................................................................ 118
Fig. 42 Changing the oil filter .................................................................................................................. 120
Fig. 43 Replacing the oil separator element ........................................................................................... 121
Fig. 44 Belt guard attachment ................................................................................................................ 122
Fig. 45 Check the drive belt seating ....................................................................................................... 123
Fig. 46 Manually checking the belt tension ............................................................................................ 124
Fig. 47 Changing/tensioning the drive belt ............................................................................................. 125
Fig. 48 Example for anti-vibration mount of drive engine ....................................................................... 126
Fig. 49 Safety signs - warning labels on the battery ............................................................................... 127
Fig. 50 Heat shield, exhaust gas after-treatment ................................................................................... 131
Fig. 51 Exhaust gas after-treatment with diesel particulate filter ............................................................ 132
Fig. 52 Checking the cooling oil level ..................................................................................................... 133
Fig. 53 Draining the compressor cooling oil ........................................................................................... 137
Fig. 54 Airend screw plug ....................................................................................................................... 138
List of Illustrations
No.: 902366 10 USE
Operator Manual Portable Rotary Screw Compressor
MOBILAIR M55 PE SIGMA CONTROL SMART pV vii

Fig. 55 Changing the oil filter .................................................................................................................. 141
Fig. 56 Oil separator tank dirt trap maintenance .................................................................................... 143
Fig. 57 Install the male stud fitting .......................................................................................................... 144
Fig. 58 Changing the oil separator cartridge .......................................................................................... 145
Fig. 59 Maintenance indicator ................................................................................................................ 148
Fig. 60 Cleaning the dust evacuator valve ............................................................................................. 148
Fig. 61 Compressor air filter maintenance ............................................................................................. 149
Fig. 62 Removing both filter elements .................................................................................................... 150
Fig. 63 Cleaning the filter element .......................................................................................................... 151
Fig. 64 Cleaning the cooler .................................................................................................................... 153
Fig. 65 Connecting rod alignment .......................................................................................................... 157
Fig. 66 Cleaning the compressed air after-cooler .................................................................................. 161
Fig. 67 Clean the dirt trap ....................................................................................................................... 163
Fig. 68 Combination filter maintenance .................................................................................................. 165
Fig. 69 Lifting eye for transportation by crane ........................................................................................ 230
Fig. 70 Prohibition signs for forklift transport .......................................................................................... 232
Fig. 71 Forklift example: Lifting accessory components ......................................................................... 232
Fig. 72 Ensure both fork prongs are positioned under the machine ....................................................... 233
Fig. 73 Lifting the machine with a forklift ................................................................................................ 234
Fig. 74 Example: Transporting a machine by forklift .............................................................................. 235
Fig. 75 Example: improper load securing ............................................................................................... 236
Fig. 76 Example: proper load securing via lashing points provided ....................................................... 237
Fig. 77 Bracing as load securing (machine in stationary configuration) ................................................. 238
Fig. 78 Battery labelling .......................................................................................................................... 240
Fig. 79 Identification of the machine ....................................................................................................... 243
Fig. 80 Identification of the drive engine ................................................................................................. 243
Fig. 81 Identification of the exhaust gas after-treatment system ............................................................ 244
List of Illustrations
viii
Operator Manual Portable Rotary Screw Compressor
MOBILAIR M55 PE SIGMA CONTROL SMART pV No.: 902366 10 USE

Tab. 1 Danger levels and their definition (personal injury) .................................................................... 1
Tab. 2 Danger levels and their definition (damage to property) ............................................................ 2
Tab. 3 Nameplate .................................................................................................................................. 4
Tab. 4 Air treatment options .................................................................................................................. 5
Tab. 5 Air distributor option ................................................................................................................... 5
Tab. 6 Low temperature equipment options .......................................................................................... 5
Tab. 7 Exhaust gas after-treatment options .......................................................................................... 6
Tab. 8 GSM/GPS modem ...................................................................................................................... 6
Tab. 9 Lighting options .......................................................................................................................... 6
Tab. 10 Options for stationary frame design ........................................................................................... 6
Tab. 11 Guaranteed sound pressure level [dB(A)] .................................................................................. 7
Tab. 12 Torques for M4–M8 screws ........................................................................................................ 7
Tab. 13 Torques for M10–M24 screws .................................................................................................... 7
Tab. 14 Torques for lifting eye screws ..................................................................................................... 8
Tab. 15 Ambient conditions ..................................................................................................................... 8
Tab. 16 Weight of the machine ................................................................................................................ 9
Tab. 17 Maximum working pressure ....................................................................................................... 9
Tab. 18 Flow rate depending on the nominal system pressure ............................................................... 10
Tab. 19 Flow rate depending on the nominal system pressure ............................................................... 10
Tab. 20 Nominal system pressure and engine speed ............................................................................. 11
Tab. 21 Nominal system pressure and engine speed ............................................................................. 11
Tab. 22 Compressed air distributor ......................................................................................................... 12
Tab. 23 Safety relief valve activating pressure ........................................................................................ 12
Tab. 24 Required temperatures readiness to switch to LOAD mode ...................................................... 12
Tab. 25 Airend discharge temperature .................................................................................................... 12
Tab. 26 Cooling oil recommendation ....................................................................................................... 13
Tab. 27 Cooling oil recommendation (food processing) .......................................................................... 13
Tab. 28 Cooling oil charge ....................................................................................................................... 14
Tab. 29 Engine specification ................................................................................................................... 14
Tab. 30 Engine oil recommendation ........................................................................................................ 15
Tab. 31 Viscosity class for first fill ............................................................................................................ 15
Tab. 32 Water quality specification .......................................................................................................... 16
Tab. 33 Initial fill of coolant cooler ........................................................................................................... 17
Tab. 34 Fluid volumes ............................................................................................................................. 17
Tab. 35 Batteries ..................................................................................................................................... 17
Tab. 36 Interrelation between compressed air treatment and compressed air quality ............................ 18
Tab. 37 Ambient conditions, low temperature equipment ....................................................................... 18
Tab. 38 Insulated pressure hoses ........................................................................................................... 18
Tab. 39 Inspection intervals according to Ordinance on Industrial Health and Safety ............................ 21
Tab. 40 Danger areas .............................................................................................................................. 28
Tab. 41 Safety signs ................................................................................................................................ 29
Tab. 42 Safety signs ................................................................................................................................ 31
Tab. 43 Instrument panel keys and displays ........................................................................................... 43
Tab. 44 Compressed air quality with/without heat exchanger ................................................................. 49
Tab. 45 Stationary machines ................................................................................................................... 50
Tab. 46 Special measures for recommissioning after storage ................................................................ 58
Tab. 47 Checking installation and operating conditions .......................................................................... 58
Tab. 48 Measures required should the fuel tank be filled with the incorrect fuel type ............................. 72
Tab. 49 Fuel / fuel specification ............................................................................................................... 74
Tab. 50 Directional control valve position and selected compressed air quality ..................................... 80
Tab. 51 Directional control valve position and selected compressed air quality ..................................... 81
Tab. 52 Alarm messages and actions relating to “engine fault” .............................................................. 82
Tab. 53 Fault messages and actions relating to “compressor fault” ........................................................ 84
Tab. 54 Fault messages and actions relating to “controller fault” ............................................................ 84
List of Tables
No.: 902366 10 USE
Operator Manual Portable Rotary Screw Compressor
MOBILAIR M55 PE SIGMA CONTROL SMART pV ix

Tab. 55 Fault messages and actions relating to “General faults” ............................................................ 85
Tab. 56 Warning messages and measures relating to the engine. ......................................................... 86
Tab. 57 Warning messages and measures relating to the compressor .................................................. 87
Tab. 58 General warning messages and measures ................................................................................ 87
Tab. 59 Fault: engine refuses to start or comes to a stop. ...................................................................... 87
Tab. 60 Alarm: "engine does not reach full speed". ................................................................................ 88
Tab. 61 Fault: working pressure too high ................................................................................................ 89
Tab. 62 Fault: working pressure too low .................................................................................................. 89
Tab. 63 Fault: safety relief valve blowing off ........................................................................................... 90
Tab. 64 Fault: machine overheating ........................................................................................................ 90
Tab. 65 Alarm: "Too much oil residue in the compressed air" ................................................................. 91
Tab. 66 Alarm: "Oil flows from the compressor air filter after shutdown" ................................................ 91
Tab. 67 Fault: high moisture content in the compressed air .................................................................... 91
Tab. 68 Advise others that the machine is being serviced. ..................................................................... 92
Tab. 69 Maintenance messages and required measures ....................................................................... 93
Tab. 70 Maintenance tasks on the machine after commissioning ........................................................... 95
Tab. 71 Maintenance intervals and regular maintenance tasks .............................................................. 95
Tab. 72 Regular machine maintenance tasks ......................................................................................... 96
Tab. 73 Regular maintenance tasks for options ...................................................................................... 99
Tab. 74 Coolant mixture table ................................................................................................................. 103
Tab. 75 Specific message code for “Service engine air filter” ................................................................. 105
Tab. 76 Specific message code for “Change the engine oil” ................................................................... 117
Tab. 77 Specific message code for “Change the oil filter” ....................................................................... 119
Tab. 78 Starter batteries charge level ..................................................................................................... 128
Tab. 79 Specific message code for “Change the cooling oil” .................................................................. 135
Tab. 80 Specific cooling oil volumes ....................................................................................................... 139
Tab. 81 Specific message code for “Change the oil filter” ....................................................................... 140
Tab. 82 Dirt trap screw plug torque ......................................................................................................... 143
Tab. 83 Specific message code for “Service air filter” ............................................................................. 147
Tab. 84 Safety relief valve actuating pressure ........................................................................................ 159
Tab. 85 Safety shut-down at excessive airend discharge temperature ................................................... 160
Tab. 86 Replacing the filter elements ...................................................................................................... 167
Tab. 87 Maintenance log ......................................................................................................................... 169
Tab. 88 Compressor maintenance parts ................................................................................................. 170
Tab. 89 Engine maintenance parts .......................................................................................................... 170
Tab. 90 “Temporarily decommissioned” information notice ..................................................................... 227
Tab. 91 "Long-term decommissioning/storage" checklist ........................................................................ 228
Tab. 92 Notice text: "Long-term decommissioned/storage" .................................................................... 229
Tab. 93 Machine fluids ............................................................................................................................ 240
Tab. 94 Machine option fluids .................................................................................................................. 241
Tab. 95 Machine filters/filter elements ..................................................................................................... 241
Tab. 96 Machine option filters/filter elements .......................................................................................... 241
List of Tables
x
Operator Manual Portable Rotary Screw Compressor
MOBILAIR M55 PE SIGMA CONTROL SMART pV No.: 902366 10 USE

1 Regarding this Document
1.1 Using this document
The operating manual is a component of the product. It describes the machine as it was at the time
of first delivery after manufacture.
➤ Keep the operating manual in a safe place throughout the life of the machine.
➤ Supply any successive owner or user with this operating manual.
➤ Please insert any amendment or revision of the operating manual sent to you.
➤ Enter details from the machine nameplate and individual items of equipment in the table in
chapter 2.
1.2 Further documents
Further documents included with this operating manual are:
■ Certificate of acceptance / operating instructions for the pressure vessel
■ Declaration of Conformity in accordance with the applicable directive
■ Engine documentation (where applicable)
■ SIGMA CONTROL SMART operating manual
Missing documents can be requested from KAESER.
➤ Make sure all documents are complete and observe the instructions contained in them.
➤ Make sure you provide the data from the nameplate when ordering documents.
1.3 Copyright
This operator manual is copyright protected. Queries regarding use or duplication of the documen‐
tation should be referred to KAESER. Correct use of information will be fully supported.
1.4 Symbols and labels
➤ Please note the symbols and labels used in this document.
1.4.1 Warnings
Warning notices indicate risks potentially resulting in personal injury, if the measures specified are
not taken.
Warning notices indicate three levels of danger identified by the corresponding signal word:
Signal word Meaning Consequences of ignoring the warning
DANGER Warns of an imminent danger Will very likely result in death or severe injury
WARNING Warns of a potentially imminent dan‐
ger
May result in death or severe injury
1 Regarding this Document
1.1 Using this document
No.: 902366 10 USE
Operator Manual Portable Rotary Screw Compressor
MOBILAIR M55 PE SIGMA CONTROL SMART pV 1

Signal word Meaning Consequences of ignoring the warning
CAUTION Warns of a potentially dangerous sit‐
uation
May result in a moderate physical injury
Tab. 1 Danger levels and their definition (personal injury)
Some warning notes may precede a chapter. They apply to the entire chapter including all subsec‐
tions.
Example:
The type and source of the imminent danger is shown here!
The possible consequences of ignoring a warning are shown here.
The word "DANGER" indicates that death or severe injury can very likely result from ignoring
the warning.
➤ The measures required to protect yourself from danger are shown here.
Warning notes referring to a subsection or the subsequent action are integrated into the procedure
and numbered as an action.
Example:
1.
The type and source of the imminent danger is shown here!
The possible consequences of ignoring a warning are shown here.
The word "WARNING" indicates that death or severe injury may result from ignoring the warn‐
ing.
➤ The measures required to protect yourself from danger are shown here.
2. Always read and comply with warning instructions.
1.4.2 Potential damage warnings
Contrary to the warnings shown above, damage warnings do not indicate a potential personal in‐
jury.
Damage warnings have only one danger level, identified with this signal word:
Signal word Meaning Consequences of non-compliance
NOTE Warns of a potentially dangerous situation Damage to property is possible
Tab. 2 Danger levels and their definition (damage to property)
Example:
The type and source of the imminent danger is shown here!
Potential effects when ignoring the warning are indicated here.
➤ The protective measures against the damages are shown here.
➤ Carefully read and fully comply with warnings against damages.
1 Regarding this Document
1.4 Symbols and labels
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Operator Manual Portable Rotary Screw Compressor
MOBILAIR M55 PE SIGMA CONTROL SMART pV No.: 902366 10 USE

1.4.3 Other alert notes and their symbols
This symbol indicates particular important information.
Material Here you will find details on special tools, operating materials or spare parts.
Precondition Here you will find conditional requirements necessary to carry out the task.
The conditions relevant to safety shown here will help you to avoid dangerous situations.
➤ This symbol is placed by lists of actions comprising one step of a task.
1. In process instructions with several steps ...
2. ... the sequence of steps is numbered.
Result Shows the expected conclusion of the previous action.
➤ Information relating to one option only is marked with an option code (e.g., "option da" means
that this section is only valid for machines with the air treatment components "aftercooler and
centrifugal separator"). Option codes used in this operating manual are explained in chap‐
ter 2.3.
Information referring to potential problems is identified by a question mark.
The cause is named in the help text ...
➤ ... and a remedy given.
This symbol refers to important information or measures concerning environmental protec‐
tion.
Further information Further topics are introduced here.
1 Regarding this Document
1.4 Symbols and labels
No.: 902366 10 USE
Operator Manual Portable Rotary Screw Compressor
MOBILAIR M55 PE SIGMA CONTROL SMART pV 3
Option da

2 Technical Data
2.1 Nameplate
The machine's nameplate contains the model type and important technical information.
The nameplate is located on the outside of the machine (see illustration in chapter 13.1).
➤ Enter the data from the nameplate here as a reference:
Feature Value
Portable rotary screw compressor
Material no. / Serial no.
Actual total weight
Lifting point load capacity
Rated power
Rated engine speed
Maximum gauge working pressure PS
Tab. 3 Nameplate
2.2 Vehicle identification number
The vehicle identification number (VIN) is the only unmodifiable and therefore the most important
identification feature on the machine.
The vehicle identification number remains associated with the machine throughout the entire dura‐
tion of its service life. The vehicle identification number is stamped into the bodywork of the ma‐
chine.
Further information For the location of the VIN stamp, see chapter 13.1.
2.3 Options overview
A list of the options built into your machine helps to correlate the information in this Operating Man‐
ual.
Available options are listed on the options label (option: code letters).
This label can be found:
■ on the outside of the machine.
■ see chapter 13.1.
Only the codes for those options fitted appear on the options label!
Options fitted:
2 Technical Data
2.1 Nameplate
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Operator Manual Portable Rotary Screw Compressor
MOBILAIR M55 PE SIGMA CONTROL SMART pV No.: 902366 10 USE

Fig. 1 Option label MOBILAIR M55PE with options
r1 Place holders for chassis options
r3 Place holders for chassis options
r4 Place holders for chassis options
r5 Place holder for frame design options for
stationary machines
➤ See the separate document "Chassis Operating Manual" for information about the option co‐
des.
➤ Take a list of available options from the options label and enter these options as reference in
the below overviews.
2.3.1 Option da, df, dd
Air treatment
Option Option code Equipped?
Compressed air aftercooler and water separator da
Heat exchanger (with bypass) df
Filter combination dd
Tab. 4 Air treatment options
2.3.2 Option fa
Air distributor
Option Option code Available?
Direct air flow fa
— —
Tab. 5 Air distributor option
2.3.3 Option ba, bb
Low temperature equipment
Option Option code Equipped?
Low temperature equipment ba
2 Technical Data
2.3 Options overview
No.: 902366 10 USE
Operator Manual Portable Rotary Screw Compressor
MOBILAIR M55 PE SIGMA CONTROL SMART pV 5

Option Option code Equipped?
Coolant preheating —
Tab. 6 Low temperature equipment options
2.3.4 Option lc, lf
Exhaust gas after-treatment
Option Option code Available?
Exhaust gas after-treatment with diesel particulate
filter
lc + lf
Exhaust gas after-treatment with diesel oxidation
catalytic converter
lf
Tab. 7 Exhaust gas after-treatment options
2.3.5 Option oc
GSM/GPS modem
Option Option code Available?
GSM/GPS modem oc
Tab. 8 GSM/GPS modem
2.3.6 Option ta, tb, tc, te
Lighting
Option Option code Available?
None (stationary) ta
Reflective warning triangle tb
EG - 12 V tc
USA - 12 V (DOT conformity) te
Tab. 9 Lighting options
2.3.7 Option rw,rx
Frame design for stationary machines
The frame design for stationary machines is defined by the option designations as follows:
Frame designs
Frame Option code Equipped?
Stationary (rw, rx):
On skids rw
2 Technical Data
2.3 Options overview
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Operator Manual Portable Rotary Screw Compressor
MOBILAIR M55 PE SIGMA CONTROL SMART pV No.: 902366 10 USE

Frame Option code Equipped?
On frame rx
Tab. 10 Options for stationary frame design
2.4 Machine (without options)
2.4.1 Sound pressure level [dB(A)]
The sound pressure level conforms to the US EPA Standard.
Measuring distance: 23 ft
Sound Pressure Level M55PE
Sound pressure level [dB(A)] 76
Tab. 11 Guaranteed sound pressure level [dB(A)]
2.4.2 Tightening torque
2.4.2.1 Tightening torques for screws
Overview:
■ Standard values for M4–M8 screws
─ Surface finish: zinc plated (bright)
■ Standard values for M10–M24 screws
─ Surface finish: zinc flake coating (matte).
➤ Set the torque as appropriate for the surface finish and friction coefficient.
Standard values for M4–M8 screws with steel grade 8.8:
Thread M4 M5 M6 M8
Torque [lbf-in] 26.6 52.2 88.5 216.8
Surface finish: zinc plated (bright)
Standards based on VDI 2230.
Tab. 12 Torques for M4–M8 screws
Standard values for M10–M24 screws with steel grade 8.8:
Thread M10 M12 M14 M16 M20 M24
Torque [lbf-in] 354 620 929 1416 2832 4868
Surface finish: zinc flake coating (matte).
Standards based on VDI 2230.
Tab. 13 Torques for M10–M24 screws
2.4.2.2 Torques for lifting eye
Recommended values for screws corresponding to the strength category:
2 Technical Data
2.4 Machine (without options)
No.: 902366 10 USE
Operator Manual Portable Rotary Screw Compressor
MOBILAIR M55 PE SIGMA CONTROL SMART pV 7

Screws Strength category Thread Torque [lbf-in]
Mushroom head screw 8.8 M12 620
Mushroom head screw 8.8 M12 620
Tab. 14 Torques for lifting eye screws
2.4.3 Ambient conditions
Positioning Limit value
Maximum altitude amsl* [ft] 3000
Minimum ambient temperature [°F] 14
Maximum ambient temperature [°F] 113
* Higher altitudes are permissible only after consultation with the manufacturer.
Tab. 15 Ambient conditions
2.4.4 Additional specifications
For specifications, according to the machine's operating license, such as:
■ dimensions,
■ track width,
■ footprint,
can be found in the dimensioned drawings in Chapter 13.3.
The dimensional drawings also show the position of the following inlets and outlets:
■ Cooling air inlet
■ Cooling air outlet
■ Compressed air outlet
■ Exhaust
2.5 Chassis
2.5.1 Chassis options
➤ See the technical data relating to the chassis in the separate document "Chassis Operating
Manual".
2.6 Machines with stationary frame design
2.6.1 Option rw, rx
Weight of machines with stationary frame design
Actual weight of individual machines is dependent on equipment fitted (see machine nameplate).
2 Technical Data
2.5 Chassis
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Operator Manual Portable Rotary Screw Compressor
MOBILAIR M55 PE SIGMA CONTROL SMART pV No.: 902366 10 USE