KAESER KOMPRESSOREN MOBILAIR M58utility User manual

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

Original instructions
/KKW/M58U 2.08 en Z1 SBA-MOBILAIR
20220512 154416

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 alerts and their symbols ............................................................................ 2
2 Technical Data
2.1 Nameplate ........................................................................................................................ 4
2.2 Vehicle identification number ........................................................................................... 4
2.3 Options ............................................................................................................................. 4
2.3.1 Air Treatment ...................................................................................................... 5
2.3.2 Tool lubricator ..................................................................................................... 5
2.3.3 Air distributor ....................................................................................................... 5
2.3.4 Low temperature equipment ............................................................................... 5
2.3.5 Equipment for fire hazard areas ......................................................................... 6
2.3.6 Automatic engine start/stop ................................................................................ 6
2.3.7 GSM/GPS unit .................................................................................................... 6
2.4 Machine (without options) ................................................................................................ 6
2.4.1 Sound pressure level .......................................................................................... 6
2.4.2 Tightening torque ................................................................................................ 7
2.4.3 Ambient conditions ............................................................................................. 7
2.4.4 Additional information according to the machine's operating licence ................. 8
2.5 Compressor ...................................................................................................................... 8
2.5.1 Working gauge pressure and volumetric flow rate .............................................. 8
2.5.2 Compressed air outlet ......................................................................................... 8
2.5.3 Safety valves ...................................................................................................... 8
2.5.4 Temperature ....................................................................................................... 9
2.5.5 Cooling oil recommendation ............................................................................... 9
2.5.6 Cooling oil charge quantity ................................................................................. 10
2.6 Engine .............................................................................................................................. 11
2.6.1 Engine specification ............................................................................................ 11
2.6.2 Oil recommendation ............................................................................................ 12
2.6.3 Fuel recommendation ......................................................................................... 12
2.6.4 Engine coolant recommendation ........................................................................ 13
2.6.5 Fluid volumes ...................................................................................................... 14
2.6.6 Battery ................................................................................................................ 15
2.7 Options ............................................................................................................................. 15
2.7.1 Air treatment options ........................................................................................... 15
2.7.2 Low temperature equipment ............................................................................... 15
2.7.3 Auxiliary electrical systems ................................................................................. 16
2.7.4 GSM/GPS unit .................................................................................................... 16
3 Safety and Responsibility
3.1 Basic instructions ............................................................................................................. 18
3.2 Specified use .................................................................................................................... 18
3.3 Incorrect Use .................................................................................................................... 18
3.4 User's Responsibilities ..................................................................................................... 18
3.4.1 Observe statutory and universally accepted regulations .................................... 18
3.4.2 Determining personnel ........................................................................................ 19
3.4.3 Complying with inspection schedules and accident prevention regulations ....... 19
3.5 Dangers ............................................................................................................................ 20
3.5.1 Safely dealing with sources of danger ................................................................ 20
Contents
No.: 901779 08 USE
Operator Manual Portable Rotary Screw Compressor
MOBILAIR M58utility SIGMA CONTROL SMART i

3.5.2 Safe machine operation ...................................................................................... 23
3.5.3 Organizational Measures .................................................................................... 26
3.5.4 Danger areas ...................................................................................................... 26
3.6 Safety devices .................................................................................................................. 26
3.7 Safety signs ...................................................................................................................... 27
3.8 Noise control requirements .............................................................................................. 30
3.9 Emergencies .................................................................................................................... 30
3.9.1 Correct actions in the event of a fire ................................................................... 30
3.9.2 Treating injuries from handling operating fluids/materials .................................. 31
3.10 Warranty ........................................................................................................................... 31
3.10.1 Noise emissions warranty ................................................................................... 32
3.11 Identifying the effects of improper modifications .............................................................. 32
3.12 Environmental protection ................................................................................................. 33
4 Design and Function
4.1 Bodywork ......................................................................................................................... 34
4.2 Machine structure ............................................................................................................. 35
4.3 Machine function .............................................................................................................. 38
4.4 Operating modes and control mode ................................................................................. 39
4.4.1 Machine operating modes .................................................................................. 39
4.4.2 MODULATING control ........................................................................................ 39
4.5 Safety devices .................................................................................................................. 40
4.5.1 Monitoring functions with shut-down ................................................................... 40
4.5.2 Further safety devices ........................................................................................ 41
4.5.3 Battery isolating switch ....................................................................................... 41
4.6 SIGMA CONTROL SMART operator panel ..................................................................... 42
4.7 Exhaust gas after-treatment ............................................................................................. 43
4.7.1 Engine optimisation ............................................................................................ 43
4.7.2 Exhaust gas treatment system ........................................................................... 44
4.7.3 Regeneration of the diesel particulate filter ........................................................ 45
4.8 Sealed floor pan ............................................................................................................... 46
4.9 Options ............................................................................................................................. 46
4.9.1 Air treatment options ........................................................................................... 47
4.9.2 Auxiliary electrical systems ................................................................................. 49
4.9.3 Low temperature equipment options .................................................................. 50
4.9.4 Options for operating in fire hazard areas .......................................................... 50
4.9.5 Start/stop/automatic options ............................................................................... 51
4.9.6 GSM/GPS unit .................................................................................................... 51
5 Installation and Operating Conditions
5.1 Ensuring safety ................................................................................................................ 52
5.2 Installation conditions ....................................................................................................... 52
5.2.1 Complying with installation conditions when installing on a truck load platform . 53
5.2.2 Observing the conditions of stationary installation ............................................. 53
6 Installation
6.1 Ensuring safety ................................................................................................................ 55
6.2 Reporting Transport Damage ........................................................................................... 55
6.3 Mounting the machine on the truck platform .................................................................... 55
6.3.1 Mounting the machine mounts/rubber pads on the machine .............................. 55
6.3.2 Mounting the machine on the truck platform ....................................................... 56
6.4 Have the «Remote ON Contact» of the automatic start/stop system connected ............. 56
6.5 Electrical connection of the battery charger ..................................................................... 57
7 Initial Start-up
7.1 Ensuring safety ................................................................................................................ 58
Contents
ii
Operator Manual Portable Rotary Screw Compressor
MOBILAIR M58utility SIGMA CONTROL SMART No.: 901779 08 USE

7.2 Before initial start-up (or recommissioning) ...................................................................... 58
7.2.1 Instructions to be observed before commissioning or recommissioning ............ 58
7.2.2 Special measures for re-commissioning after storage or de-commissioning ..... 59
7.3 Checking installation and operating conditions ................................................................ 59
7.4 Low-temperature operation (winter) ................................................................................. 60
7.4.1 Starting assistance ............................................................................................. 60
7.4.2 Starting up low-temperature equipment .............................................................. 62
7.5 Commissioning electrical equipment ................................................................................ 63
8 Operation
8.1 Ensuring safety ................................................................................................................ 64
8.2 Starting and stopping ....................................................................................................... 65
8.2.1 Follow the brief operating instructions ................................................................ 66
8.2.2 Commissioning the machine ............................................................................... 67
8.2.3 Starting the machine ........................................................................................... 68
8.2.4 Regulating the shut-off valve .............................................................................. 69
8.2.5 Setting the compressed air discharge pressure ................................................. 70
8.2.6 Shutting down the machine ................................................................................ 72
8.2.7 Shutting down in an emergency ......................................................................... 73
8.3 Refueling the machine ..................................................................................................... 74
8.3.1 Use the specified fuel type .................................................................................. 74
8.3.2 Filling the fuel tank at a pump by means of a refueling nozzle ........................... 76
8.3.3 Filling the fuel tank on a construction site by means of a canister ..................... 77
8.4 Confirming alarm and warning messages ........................................................................ 77
8.4.1 Confirming alarm messages ............................................................................... 77
8.4.2 Confirming warning messages ........................................................................... 78
8.5 Cleaning the machine after operation .............................................................................. 78
8.5.1 Cleaning the exterior of the machine .................................................................. 79
8.5.2 Cleaning the interior of the machine ................................................................... 80
8.6 Operating the options ....................................................................................................... 82
8.6.1 Operating the machine with the "Start-stop automatic" option ........................... 82
8.6.2 Operating the tool lubricator ............................................................................... 84
8.6.3 Using the low-temperature equipment ................................................................ 85
9 Fault Recognition and Rectification
9.1 Basic instructions ............................................................................................................. 86
9.2 Analysing SIGMA CONTROL SMART messages ........................................................... 86
9.2.1 Alarm messages on the controller (machine off) ................................................ 86
9.2.2 Warning messages on the controller .................................................................. 89
9.3 Evaluating engine faults and alarms ................................................................................ 91
9.3.1 Engine stops or fails to start ............................................................................... 91
9.3.2 Drive engine does not reach full speed .............................................................. 92
9.3.3 Drive engine knocking or fails to start ................................................................. 92
9.4 Analysing compressor faults and alarms ......................................................................... 93
9.4.1 Working pressure too high .................................................................................. 93
9.4.2 Working pressure too low. .................................................................................. 93
9.4.3 Pressure relief valve blowing off ......................................................................... 94
9.4.4 Machine overheating .......................................................................................... 94
9.4.5 Too much oil residue in the compressed air ....................................................... 95
9.4.6 Oil flows from the compressor air filter after shutdown ....................................... 95
9.4.7 High moisture content in the compressed air ..................................................... 95
10 Maintenance
10.1 Ensuring safety ................................................................................................................ 96
10.2 Note the maintenance messages on the controller .......................................................... 97
10.2.1 Evaluating the maintenance message ................................................................ 97
Contents
No.: 901779 08 USE
Operator Manual Portable Rotary Screw Compressor
MOBILAIR M58utility SIGMA CONTROL SMART iii

10.2.2 Concluding the maintenance .............................................................................. 98
10.3 Maintenance schedules ................................................................................................... 98
10.3.1 Logging maintenance work ................................................................................. 98
10.3.2 Preventive maintenance ..................................................................................... 98
10.3.3 Maintenance tasks after commissioning ............................................................. 99
10.3.4 Regular maintenance tasks ................................................................................ 99
10.4 Drive engine maintenance ............................................................................................... 104
10.4.1 Coolant cooler maintenance ............................................................................... 104
10.4.2 Engine air filter maintenance .............................................................................. 109
10.4.3 Fuel system maintenance ................................................................................... 112
10.4.4 Checking the engine oil level .............................................................................. 117
10.4.5 Engine oil filling and topping up .......................................................................... 118
10.4.6 Changing the engine oil ...................................................................................... 119
10.4.7 Replace the engine oil filter ................................................................................ 121
10.4.8 Drive belt maintenance ....................................................................................... 122
10.4.9 Battery maintenance ........................................................................................... 126
10.4.10 Change the oil separator element ....................................................................... 129
10.4.11 Checking the fastening of the fuel tank .............................................................. 130
10.5 Servicing the components of the emission after-treatment system .................................. 131
10.6 Compressor Maintenance ................................................................................................ 131
10.6.1 Check the cooling oil level .................................................................................. 131
10.6.2 Cooling oil filling and topping up ......................................................................... 132
10.6.3 Changing the cooling oil ..................................................................................... 133
10.6.4 Replacing the compressor oil filter ...................................................................... 135
10.6.5 Oil separator tank dirt trap maintenance ............................................................. 137
10.6.6 Changing the oil separator cartridge ................................................................... 138
10.6.7 Compressor air filter maintenance ...................................................................... 140
10.6.8 Fit the flexible pipe connection ........................................................................... 143
10.7 Cleaning the cooler .......................................................................................................... 144
10.7.1 Cleaning the compressor cooler and engine radiator ......................................... 144
10.7.2 Cleaning the compressed air after-cooler ........................................................... 145
10.8 Checking screw connections ............................................................................................ 146
10.9 Maintenance of rubber sealing strips ............................................................................... 147
10.10 Check/replace hose lines ................................................................................................. 148
10.10.1 Replace the fuel lines of the drive engine ........................................................... 148
10.10.2 Replace the pressure hoses of the engine ......................................................... 148
10.10.3 Replace the pressure hoses of the compressor ................................................. 148
10.11 Draining liquid accumulation within the machine ............................................................. 149
10.12 Check safety functions ..................................................................................................... 149
10.12.1 Check the EMERGENCY STOP push button ..................................................... 149
10.12.2 Have the activating pressure of the safety relief valve checked ......................... 150
10.12.3 Having excessive temperature shut-down function checked .............................. 151
10.13 Maintenance for Optional Items ....................................................................................... 151
10.13.1 Tool lubricator maintenance ............................................................................... 151
10.13.2 Centrifugal separator maintenance ..................................................................... 153
10.13.3 Spark arrestor cleaning ....................................................................................... 154
10.14 Documenting maintenance and service work .................................................................. 156
11 Spares, Operating Materials, Service
11.1 Note the nameplate .......................................................................................................... 157
11.2 Ordering consumable parts and operating fluids/materials .............................................. 157
11.3 KAESER AIR SERVICE ................................................................................................... 158
11.4 Service Addresses ........................................................................................................... 158
11.5 Replacement parts for service and repair ........................................................................ 158
Contents
iv
Operator Manual Portable Rotary Screw Compressor
MOBILAIR M58utility SIGMA CONTROL SMART No.: 901779 08 USE

12 Decommissioning, Storage and Transport
12.1 Decommissioning ............................................................................................................. 193
12.1.1 Temporary decommissioning .............................................................................. 193
12.1.2 Long-term de-commissioning and storage ......................................................... 194
12.2 Transport .......................................................................................................................... 195
12.2.1 Safety .................................................................................................................. 195
12.2.2 Transport with a crane ........................................................................................ 195
12.2.3 Transport with a forklift truck ............................................................................... 196
12.2.4 Transporting the machine as load ...................................................................... 197
12.3 Storage ............................................................................................................................. 198
12.4 Disposal ........................................................................................................................... 199
12.4.1 Removing the batteries ....................................................................................... 199
12.4.2 Draining operating fluids ..................................................................................... 200
12.4.3 Draining condensate ........................................................................................... 200
12.4.4 Removing filters/filter elements ........................................................................... 201
12.4.5 Disposing of the machine ................................................................................... 201
13 Annex
13.1 Identification ..................................................................................................................... 202
13.1.1 Identification of the machine ............................................................................... 202
13.1.2 Identification of the drive engine ......................................................................... 202
13.1.3 Identification of the exhaust gas after-treatment system .................................... 203
13.2 Pipeline and instrument flow diagram (P+I diagram) ....................................................... 203
13.3 Dimensional Drawing ....................................................................................................... 207
13.4 Electrical Diagram ............................................................................................................ 209
13.5 Battery charger electrical diagram ................................................................................... 236
13.6 Fuel circulation diagram ................................................................................................... 240
Contents
No.: 901779 08 USE
Operator Manual Portable Rotary Screw Compressor
MOBILAIR M58utility SIGMA CONTROL SMART v

Contents
vi
Operator Manual Portable Rotary Screw Compressor
MOBILAIR M58utility SIGMA CONTROL SMART No.: 901779 08 USE

Fig. 1 Location of safety signs (outside) ............................................................................................... 27
Fig. 2 Location of safety signs (inside) ................................................................................................. 29
Fig. 3 Overview of bodywork ................................................................................................................ 34
Fig. 4 Left side (access side), panel removed ...................................................................................... 35
Fig. 5 Right side, panels removed ........................................................................................................ 35
Fig. 6 Access door (operating side), open ............................................................................................ 36
Fig. 7 View from above, machine roof removed ................................................................................... 37
Fig. 8 Underside of the machine .......................................................................................................... 37
Fig. 9 Machine overview ....................................................................................................................... 38
Fig. 10 Stepless regulation of volumetric flow (standstill) ....................................................................... 40
Fig. 11 Battery isolating switch ............................................................................................................... 41
Fig. 12 SIGMA CONTROL SMART operator panel – overview ............................................................. 42
Fig. 13 Principle of treatment devices .................................................................................................... 44
Fig. 14 Position of service openings in the closed floor pan .................................................................. 46
Fig. 15 Compressed air options ............................................................................................................. 47
Fig. 16 Tool lubricator ............................................................................................................................. 48
Fig. 17 Principle tool lubricator ............................................................................................................... 49
Fig. 18 Service work on the machine roof: ............................................................................................. 50
Fig. 19 Installation on a truck load platform ............................................................................................ 53
Fig. 20 Minimum distance from excavations/slopes and walls ............................................................... 54
Fig. 21 Mounting the machine mount/rubber pad ................................................................................... 56
Fig. 22 Jumper cable connection diagram ............................................................................................. 61
Fig. 23 Connect auxiliary electrical systems .......................................................................................... 63
Fig. 24 Starting instruments ................................................................................................................... 65
Fig. 25 Instrument panel keys and indicators ......................................................................................... 66
Fig. 26 Brief instructions on starting procedure ...................................................................................... 66
Fig. 27 Brief instructions on stopping procedure .................................................................................... 67
Fig. 28 «Battery isolating switch» ........................................................................................................... 68
Fig. 29 Control line shut-off valve ........................................................................................................... 70
Fig. 30 Quick access adjustment compressed air output pressure ........................................................ 71
Fig. 31 Setting the compressed air discharge pressure ......................................................................... 71
Fig. 32 Filling the tank with the correct fuel type .................................................................................... 75
Fig. 33 Make the "Start-stop automatic" ready to start. .......................................................................... 83
Fig. 34 Setting the tool lubricator ............................................................................................................ 84
Fig. 35 Checking the coolant level ......................................................................................................... 105
Fig. 36 Recommended mixture ratio for coolant .................................................................................... 107
Fig. 37 Draining the coolant from the engine coolant cooler .................................................................. 108
Fig. 38 Cleaning the dust evacuator valve ............................................................................................. 110
Fig. 39 Engine air filter maintenance ...................................................................................................... 110
Fig. 40 Service cover engine air filter ..................................................................................................... 111
Fig. 41 Cleaning the filter element .......................................................................................................... 111
Fig. 42 Fuel system maintenance .......................................................................................................... 113
Fig. 43 Bleeding the fuel system ............................................................................................................ 113
Fig. 44 Warning messages: Fuel filter water level .................................................................................. 114
Fig. 45 Emptying the fuel pre-filter and water trap ................................................................................. 115
Fig. 46 Changing the fuel pre-filter cartridge .......................................................................................... 116
Fig. 47 Fuel fine filter maintenance ........................................................................................................ 117
Fig. 48 Checking the engine oil level ...................................................................................................... 118
Fig. 49 Draining the engine oil ................................................................................................................ 120
Fig. 50 Change the oil filter .................................................................................................................... 121
Fig. 51 Belt guard attachment ................................................................................................................ 122
Fig. 52 Checking the drive belt seating .................................................................................................. 123
Fig. 53 Manually checking the belt tension ............................................................................................ 123
Fig. 54 Tension the belt .......................................................................................................................... 124
List of Illustrations
No.: 901779 08 USE
Operator Manual Portable Rotary Screw Compressor
MOBILAIR M58utility SIGMA CONTROL SMART vii

Fig. 55 Replace the drive belt. ................................................................................................................ 125
Fig. 56 Safety signs - warning stickers on the battery ............................................................................ 126
Fig. 57 Change the oil separator element .............................................................................................. 130
Fig. 58 Check the cooling oil level .......................................................................................................... 132
Fig. 59 Draining the compressor cooling oil ........................................................................................... 134
Fig. 60 Change the oil filter .................................................................................................................... 136
Fig. 61 Oil separator tank dirt trap maintenance .................................................................................... 137
Fig. 62 Changing the oil separator cartridge .......................................................................................... 139
Fig. 63 Compressor air filter maintenance ............................................................................................. 141
Fig. 64 Cleaning the filter element .......................................................................................................... 142
Fig. 65 Fit the flexible pipe connection ................................................................................................... 143
Fig. 66 Cleaning the compressor cooler and engine radiator ................................................................. 145
Fig. 67 Cleaning the compressed air after-cooler .................................................................................. 146
Fig. 68 Tool lubricator maintenance ....................................................................................................... 152
Fig. 69 Cleaning the condensate drain ................................................................................................... 153
Fig. 70 Spark arrestor cleaning .............................................................................................................. 155
Fig. 71 Transporting using a forklift truck ............................................................................................... 197
Fig. 72 Guys to secure the freight .......................................................................................................... 198
Fig. 73 Battery labelling .......................................................................................................................... 200
Fig. 74 Identification of the machine ....................................................................................................... 202
Fig. 75 Identification of the drive engine ................................................................................................. 202
Fig. 76 Identification of the exhaust gas after-treatment system ............................................................ 203
List of Illustrations
viii
Operator Manual Portable Rotary Screw Compressor
MOBILAIR M58utility SIGMA CONTROL SMART No.: 901779 08 USE

Tab. 1 Danger levels and their definitions (personal injury) .................................................................. 1
Tab. 2 Danger levels and their definition (damage to property) ............................................................ 2
Tab. 3 Nameplate .................................................................................................................................. 4
Tab. 4 Extract from the options label ..................................................................................................... 5
Tab. 5 Optional air treatment equipment ............................................................................................... 5
Tab. 6 Tool lubricator option .................................................................................................................. 5
Tab. 7 Compressed air distributor option .............................................................................................. 5
Tab. 8 Low temperature equipment options .......................................................................................... 5
Tab. 9 Optional equipment for fire hazard areas ................................................................................... 6
Tab. 10 Automatic engine start/stop ........................................................................................................ 6
Tab. 11 GSM/GPS unit ............................................................................................................................ 6
Tab. 12 Sound pressure level ................................................................................................................. 6
Tab. 13 Torques for M4–M8 screws ........................................................................................................ 7
Tab. 14 Torques for M10–M24 screws .................................................................................................... 7
Tab. 15 Torque cover fixing screws oil separator tank ............................................................................ 7
Tab. 16 Ambient conditions ..................................................................................................................... 7
Tab. 17 Working pressure an volumetric flow (installation of the machine within the EU) ...................... 8
Tab. 18 Working pressure an volumetric flow (installation of the machine outside of the EU) ................ 8
Tab. 19 Compressed air distributor ......................................................................................................... 8
Tab. 20 Safety valve opening pressure ................................................................................................... 9
Tab. 21 Required temperatures readiness to switch to LOAD mode ...................................................... 9
Tab. 22 Airend discharge temperature .................................................................................................... 9
Tab. 23 Cooling oil recommendations ..................................................................................................... 9
Tab. 24 Cooling oil recommendation (food processing) .......................................................................... 10
Tab. 25 Cooling oil charge quantity ......................................................................................................... 10
Tab. 26 Kubota V 2403–CR Engine specifications .................................................................................. 11
Tab. 27 Engine specifications .................................................................................................................. 11
Tab. 28 Engine oil recommendation ........................................................................................................ 12
Tab. 29 Initial engine oil quantity ............................................................................................................. 12
Tab. 30 Water quality parameters for cooling water ................................................................................ 13
Tab. 31 Initial filling of engine water cooler ............................................................................................. 14
Tab. 32 Fluid volumes ............................................................................................................................. 14
Tab. 33 Battery ........................................................................................................................................ 15
Tab. 34 Road breaker lubricant recommendation ................................................................................... 15
Tab. 35 Interrelation between compressed air treatment and compressed air quality ............................ 15
Tab. 36 Environmental conditions, low temperature equipment .............................................................. 15
Tab. 37 Power supply details .................................................................................................................. 16
Tab. 38 Technical data – Cooling water pre-heating device .................................................................... 16
Tab. 39 Battery charger specification ...................................................................................................... 16
Tab. 40 GSM/GPS unit ............................................................................................................................ 16
Tab. 41 Inspection intervals according to Ordinance on Industrial Health and Safety ............................ 20
Tab. 42 Danger areas .............................................................................................................................. 26
Tab. 43 Safety signs ................................................................................................................................ 27
Tab. 44 Safety signs ................................................................................................................................ 29
Tab. 45 Instrument panel keys and displays ........................................................................................... 42
Tab. 46 Measures for re-commissioning the compressor after a long period of storage or de-
commissioning ............................................................................................................................
59
Tab. 47 Installation conditions checklist .................................................................................................. 59
Tab. 48 Measures required should the fuel tank be filled with the incorrect fuel type ............................. 74
Tab. 49 Fuel / fuel specification ............................................................................................................... 76
Tab. 50 Plug sockets on the exterior of the machine .............................................................................. 80
Tab. 51 High-pressure washer setting ..................................................................................................... 81
Tab. 52 Alarm messages and actions concerning the engine. ................................................................ 86
Tab. 53 Alarm messages and actions concerning the compressor unit .................................................. 88
List of Tables
No.: 901779 08 USE
Operator Manual Portable Rotary Screw Compressor
MOBILAIR M58utility SIGMA CONTROL SMART ix

Tab. 54 Alarm messages and actions concerning the controller. ............................................................ 88
Tab. 55 Alarm messages and troubleshooting in "General faults" .......................................................... 89
Tab. 56 Warning messages and measures relating to the engine. ......................................................... 89
Tab. 57 Warning messages and measures relating to the compressor .................................................. 90
Tab. 58 General warning messages and measures ................................................................................ 91
Tab. 59 Fault: “Engine does not start or stops” ....................................................................................... 91
Tab. 60 Fault: “Engine not reaching full speed” ....................................................................................... 92
Tab. 61 Fault: “Drive engine knocking or fails to start” ............................................................................ 92
Tab. 62 Fault: working pressure too high ................................................................................................ 93
Tab. 63 Fault: working pressure too low .................................................................................................. 93
Tab. 64 Fault: pressure relief valve blowing off ....................................................................................... 94
Tab. 65 Fault: machine overheating ........................................................................................................ 94
Tab. 66 Alarm: "Too much oil residue in the compressed air" ................................................................. 95
Tab. 67 Alarm: "Oil flows from the compressor air filter after shutdown" ................................................ 95
Tab. 68 Fault: high moisture content in the compressed air .................................................................... 95
Tab. 69 Advise others that the machine is being serviced. ..................................................................... 96
Tab. 70 Maintenance messages and required actions ............................................................................ 97
Tab. 71 Maintenace tasks on the machine after commissioning ............................................................. 99
Tab. 72 Maintenance intervals and regular maintenance tasks .............................................................. 99
Tab. 73 Regular machine maintenance tasks ......................................................................................... 100
Tab. 74 Regular maintenance task options ............................................................................................. 103
Tab. 75 Coolant mixture table ................................................................................................................. 107
Tab. 76 Starter battery charge level ........................................................................................................ 127
Tab. 77 Dimensions of the flexible pipe connection ................................................................................ 143
Tab. 78 Relief valve activating pressure .................................................................................................. 150
Tab. 79 Safety shut-down at excessive airend discharge temperature ................................................... 151
Tab. 80 Maintenance log ......................................................................................................................... 156
Tab. 81 Compressor consumables .......................................................................................................... 157
Tab. 82 Consumable engine parts .......................................................................................................... 157
Tab. 83 "Temporarily decommissioned" information notice .................................................................... 193
Tab. 84 "Long-term decommissioning and storage" checklist ................................................................. 194
Tab. 85 Notice text: "Long-term decommissioned and storage" ............................................................. 195
Tab. 86 Machine fluids ............................................................................................................................ 200
Tab. 87 Machine filters/filter elements ..................................................................................................... 201
List of Tables
x
Operator Manual Portable Rotary Screw Compressor
MOBILAIR M58utility SIGMA CONTROL SMART No.: 901779 08 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 dangers that may result in injury when disregarded.
Warning notices indicate three levels of danger identified by the corresponding signal word:
Signal term Meaning Consequences of ignoring the warning
DANGER Warns of an imminent danger Will result in death or severe injury
WARNING Warns of a potentially imminent danger May result in death or severe injury
CAUTION Warns of a potentially dangerous situation May result in a moderate physical injury
Tab. 1 Danger levels and their definitions (personal injury)
Warning notices preceding a chapter apply to the entire chapter, including all sub-sections.
1 Regarding this Document
1.1 Using this document
No.: 901779 08 USE
Operator Manual Portable Rotary Screw Compressor
MOBILAIR M58utility SIGMA CONTROL SMART 1

For example,
These show the kind of danger and its source.
The possible consequences of ignoring a warning are shown here.
If you ignore the warning notice, the "DANGER" signal word indicates a lethal or severe in‐
jury will occur.
➤ The measures required to protect yourself from danger are shown here.
Warning notes referring to a sub-section or the subsequent action are integrated into the procedure
and numbered as an action.
For example,
1.
These show the kind of danger and its source.
The possible consequences of ignoring a warning are shown here.
If you ignore the warning notice, the "WARNING" signal word indicates that death or severe
injury may occur.
➤ 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
Unlike the warnings shown above, damage warnings do not indicate a potential personal injury.
Warning notices for damages are identified by their signal term.
Signal term Meaning Consequences of ignoring the warning
NOTE Warns of a potentially dangerous situation Damage to property is possible
Tab. 2 Danger levels and their definition (damage to property)
For example,
These show the kind of danger and its source.
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.
1.4.3 Other alerts 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 stage of a task.
1 Regarding this Document
1.4 Symbols and labels
2
Operator Manual Portable Rotary Screw Compressor
MOBILAIR M58utility SIGMA CONTROL SMART No.: 901779 08 USE

1. For instructions with several steps ...
2. ... the sequence of actions 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
cyclone moisture separator"). Option codes used in this service manual are explained in chap‐
ter 2.3.
Information referring to potential problems are 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.: 901779 08 USE
Operator Manual Portable Rotary Screw Compressor
MOBILAIR M58utility SIGMA CONTROL SMART 3
Option da

2 Technical Data
2.1 Nameplate
The model designation and important technical information are given on the machine's nameplate.
The nameplate is located on the outside of the machine (see illustration in chapter 13.1).
➤ Enter here the nameplate data as a reference:
Feature Value
Vehicle identity no.
Options
Model
Material number
Serial number
Year of manufacture
Total weight
Engine speed
Maximum working pressure
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
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 (centre of the label, option: code letters).
This label can be found:
■ on the outside of the machine,
■ front right, beneath the access door (see chapter 13.1)
The following tables list all possible options.
Only codes for options available in the machine appear on the label!
2 Technical Data
2.1 Nameplate
4
Operator Manual Portable Rotary Screw Compressor
MOBILAIR M58utility SIGMA CONTROL SMART No.: 901779 08 USE

Tab. 4 Extract from the options label
➤ 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
Air Treatment
Option Option code Available?
Aftercooler and cyclone separator da
Tab. 5 Optional air treatment equipment
2.3.2 Option ec
Tool lubricator
Option Option code Available?
Tool lubricator ec
Tab. 6 Tool lubricator option
2.3.3 Option fc
Air distributor
Option Option code Available?
Separated compressed air lines downstream of the
option
fc
Tab. 7 Compressed air distributor option
2.3.4 Option ba
Low temperature equipment
Option Option code Available?
Low temperature equipment ba
2 Technical Data
2.3 Options
No.: 901779 08 USE
Operator Manual Portable Rotary Screw Compressor
MOBILAIR M58utility SIGMA CONTROL SMART 5

Option Option code Available?
Engine coolant pre-heating bb
Tab. 8 Low temperature equipment options
2.3.5 Option la
Equipment for fire hazard areas
Option Option code Available?
Spark arrestor la
Tab. 9 Optional equipment for fire hazard areas
2.3.6 Option ob, od
Automatic engine start/stop
Option Option code Available?
Automatic engine start/stop ob
Trickle charging for starter batteries od
Tab. 10 Automatic engine start/stop
2.3.7 Option oc
GSM/GPS unit
Option Option code Available?
GSM/GPS unit oc
Tab. 11 GSM/GPS unit
2.4 Machine (without options)
2.4.1 Sound pressure level
Sound pressure levels comply with the American EPA Standard.
Measurement distance: 23 ft
M58utility
Guaranteed sound pressure level(1) [dB(A)] 76
(1) Applies exclusively to machines lined with sound proofing material.
Tab. 12 Sound pressure level
2 Technical Data
2.4 Machine (without options)
6
Operator Manual Portable Rotary Screw Compressor
MOBILAIR M58utility SIGMA CONTROL SMART No.: 901779 08 USE

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. 13 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. 14 Torques for M10–M24 screws
2.4.2.2 Torque cover fixing screws oil separator tank
Recommended values for screws corresponding to the strength category:
Screws Strength category Thread Torque [lbf in]
Hex-head screw 8.8 M16 1770
Tab. 15 Torque cover fixing screws oil separator tank
2.4.3 Ambient conditions
Positioning Limit value
Maximum altitude amsl* [ft] 3000
Minimum ambient temperature [°F] 14
Maximum ambient temperature [°F] 122
* Higher altitudes are permissible only after consultation with the manufacturer.
Tab. 16 Ambient conditions
2 Technical Data
2.4 Machine (without options)
No.: 901779 08 USE
Operator Manual Portable Rotary Screw Compressor
MOBILAIR M58utility SIGMA CONTROL SMART 7

2.4.4 Additional information according to the machine's operating licence
For specifications according to the machine's operating licence, such as:
■ Dimensions,
■ Footprint
are to be found in the dimensioned drawing in chapter 13.3.
The dimensional drawing also shows the position of the following inlets and outlets:
■ Cooling air inlet
■ Cooling air outlet
■ Compressed air outlet
■ Exhaust
2.5 Compressor
2.5.1 Working gauge pressure and volumetric flow rate
Definition of volumetric flow: Constant delivery volume relative to intake conditions.
Volumetric flow in accordance with ISO 1217:2009. Annex D
Installation of the machine within the EU
Maximum working pressure [psi] 100 145
SIGMA airend 265 260
Volumetric flow [cfm] 180 154
Tab. 17 Working pressure an volumetric flow (installation of the machine within the EU)
Installation of the machine outside of the EU:
Maximum working pressure [psi] 100 145
SIGMA airend 265 260
Flow rate [cfm] 210 175
Tab. 18 Working pressure an volumetric flow (installation of the machine outside of the EU)
2.5.2 Compressed air outlet
Outlet valve ["] Number
G 3/4 2
G 1 1
Tab. 19 Compressed air distributor
2.5.3 Safety valves
Maximum working pressure: see machine nameplate
2 Technical Data
2.5 Compressor
8
Operator Manual Portable Rotary Screw Compressor
MOBILAIR M58utility SIGMA CONTROL SMART No.: 901779 08 USE