KAESER KOMPRESSOREN SIGMA CONTROL SMART M114 User manual

Operator Manual
Screw Compressor
M114 SIGMA CONTROL SMART
No.: 901765 05 USE
Manufacturer:
KAESER KOMPRESSOREN SE
96410 Coburg • PO Box 2143 • GERMANY • Tel. [phone] • Fax [phone]
http://www.kaeser.com

Original instructions
/KKW/M114 2.05 en Z1 SBA-MOBILAIR
20160726 075645

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 Options – options label ..................................................................................................... 4
2.2.1 Compressed air treatment devices ..................................................................... 5
2.2.2 Tool lubricator ..................................................................................................... 5
2.2.3 Compressed air distributor .................................................................................. 5
2.2.4 Low temperature equipment ............................................................................... 6
2.2.5 Equipment for fire hazard areas ......................................................................... 6
2.2.6 Automatic engine start/stop ................................................................................ 6
2.2.7 GSM/GPS Modem .............................................................................................. 6
2.2.8 Chassis ............................................................................................................... 6
2.2.9 Lighting ............................................................................................................... 7
2.2.10 Sealed floor pan .................................................................................................. 7
2.2.11 Anti-theft device .................................................................................................. 7
2.2.12 Pedestrian protection .......................................................................................... 8
2.3 Machine (without options) ................................................................................................ 8
2.3.1 Sound pressure level .......................................................................................... 8
2.3.2 Tightening torques for screws ............................................................................. 8
2.3.3 Ambient conditions ............................................................................................. 8
2.3.4 Additional specifications ..................................................................................... 8
2.4 Chassis ............................................................................................................................ 9
2.4.1 Mass ................................................................................................................... 9
2.4.2 Tires .................................................................................................................... 9
2.4.3 Wheel nut/bolt tightening torque ......................................................................... 10
2.4.4 Towbar tightening torque .................................................................................... 10
2.5 Compressor ...................................................................................................................... 10
2.5.1 Working pressure and FAD ................................................................................ 10
2.5.2 Compressed air outlet ......................................................................................... 10
2.5.3 Safety valves ...................................................................................................... 10
2.5.4 Temperature ....................................................................................................... 11
2.5.5 Cooling oil recommendation ............................................................................... 11
2.5.6 Cooling oil charge ............................................................................................... 12
2.6 Engine .............................................................................................................................. 13
2.6.1 Engine specification ............................................................................................ 13
2.6.2 Oil recommendation ............................................................................................ 13
2.6.3 Fuel recommendation ......................................................................................... 14
2.6.4 Engine coolant recommendation ........................................................................ 15
2.6.5 Fluid volumes ...................................................................................................... 15
2.6.6 Batteries .............................................................................................................. 15
2.7 Options ............................................................................................................................. 16
2.7.1 Air treatment options ........................................................................................... 16
2.7.2 Low temperature equipment ............................................................................... 17
2.7.3 Trickle charging for starter batteries ................................................................... 17
3 Safety and Responsibility
3.1 Basic instructions ............................................................................................................. 19
Contents
No.: 901765 05 USE
Operator Manual Screw Compressor
M114 SIGMA CONTROL SMART i

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 Adherence to inspection schedules and accident prevention regulations .......... 20
3.4.4 Taking the machine for general inspection ......................................................... 20
3.4.5 Documenting the mileage of the machine as trailer ........................................... 21
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 .................................................................................................................... 32
3.9.1 Correct fire fighting ............................................................................................. 32
3.9.2 Contact with operating fluids/materials ............................................................... 33
3.10 Warranty ........................................................................................................................... 33
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 ............................................................................................................. 37
4.3 Machine function .............................................................................................................. 37
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 ........................................................................................ 40
4.5.3 Battery isolating switch ....................................................................................... 41
4.6 SIGMA CONTROL SMART control panel ........................................................................ 41
4.7 Emission after-treatment .................................................................................................. 42
4.8 Options ............................................................................................................................. 43
4.8.1 Air treatment options ........................................................................................... 44
4.8.2 Low temperature equipment options .................................................................. 47
4.8.3 Options for operating in fire hazard areas .......................................................... 47
4.8.4 Start/stop/automatic options ............................................................................... 49
4.8.5 "GSM/GPS modem" option ................................................................................. 49
4.8.6 Transport options ................................................................................................ 49
4.8.7 Sealed floor pan option ....................................................................................... 51
4.8.8 Optional anti-theft device .................................................................................... 52
4.8.9 Pedestrian protection option ............................................................................... 52
5 Installation and Operating Conditions
5.1 Ensuring safety ................................................................................................................ 53
5.2 Installation conditions ....................................................................................................... 53
5.3 Machine with stationary frame structure .......................................................................... 54
6 Installation
6.1 Ensuring safety ................................................................................................................ 55
6.2 Reporting Transport Damage ........................................................................................... 55
Contents
ii
Operator Manual Screw Compressor
M114 SIGMA CONTROL SMART No.: 901765 05 USE

6.3 Fitting the tow bar ............................................................................................................. 55
6.3.1 Fitting the height adjustable tow bar ................................................................... 56
6.3.2 Fitting a non-adjustable tow bar .......................................................................... 57
6.4 Adjusting the chassis ....................................................................................................... 59
6.4.1 Adjusting the tow bar height ............................................................................... 60
6.4.2 Changing the towing eye/ball hitch ..................................................................... 60
6.5 Connecting the battery trickle charger ............................................................................. 64
6.6 Installing a machine with stationary frame superstructure on a truck platform ................ 64
7 Initial Start-up
7.1 Ensuring safety ................................................................................................................ 66
7.2 Before initial start-up (or recommissioning) ...................................................................... 66
7.2.1 Instructions to be observed before commissioning or recommissioning ............ 66
7.2.2 Special measures for recommissioning after storage ......................................... 67
7.3 Checking installation and operating conditions ................................................................ 67
7.4 Low-temperature operation (winter) ................................................................................. 68
7.4.1 Starting assistance ............................................................................................. 68
7.4.2 Starting up low-temperature equipment .............................................................. 70
7.5 Trickle-charging the battery .............................................................................................. 71
8 Operation
8.1 Ensuring safety ................................................................................................................ 73
8.2 Starting and stopping ....................................................................................................... 74
8.2.1 Follow the brief instructions ................................................................................ 75
8.2.2 Starting the machine ........................................................................................... 76
8.2.3 Starting the machine ........................................................................................... 76
8.2.4 Setting the compressed air discharge pressure ................................................. 77
8.2.5 Shutting down the machine ................................................................................ 79
8.2.6 Shutting down in an emergency ......................................................................... 81
8.3 Confirming alarm and warning messages ........................................................................ 81
8.3.1 Acknowledging alarm messages ........................................................................ 81
8.3.2 Acknowledging warning messages ..................................................................... 82
8.4 Operating the tool lubricator ............................................................................................. 82
8.5 Using the low-temperature equipment ............................................................................. 84
8.6 Shut down the machine if any dangerous situation arises ............................................... 84
8.7 Cleaning the machine after operation .............................................................................. 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 message on the controller .................................................................... 89
9.3 Evaluating engine faults and alarms ................................................................................ 91
9.3.1 Engine does not reach full speed ....................................................................... 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 Noting the maintenance messages on the controller ....................................................... 97
Contents
No.: 901765 05 USE
Operator Manual Screw Compressor
M114 SIGMA CONTROL SMART iii

10.2.1 Evaluating the maintenance message ................................................................ 97
10.2.2 Maintenance messages ...................................................................................... 98
10.3 Maintenance schedules ................................................................................................... 98
10.3.1 Logging maintenance work ................................................................................. 98
10.3.2 Maintenance tasks after commissioning ............................................................. 98
10.3.3 Regular maintenance tasks ................................................................................ 99
10.4 Engine maintenance ........................................................................................................ 105
10.4.1 Water cooler maintenance .................................................................................. 105
10.4.2 Engine air filter maintenance .............................................................................. 109
10.4.3 Fuel system maintenance ................................................................................... 111
10.4.4 Checking the engine oil level .............................................................................. 117
10.4.5 Engine oil filling and topping off .......................................................................... 118
10.4.6 Changing the engine oil ...................................................................................... 118
10.4.7 Replace the engine oil filter ................................................................................ 120
10.4.8 Engine belt maintenance .................................................................................... 121
10.4.9 Battery maintenance ........................................................................................... 126
10.4.10 Checking the fastening of the fuel tank .............................................................. 128
10.5 Compressor Maintenance ................................................................................................ 129
10.5.1 Checking the cooling oil level ............................................................................. 129
10.5.2 Cooling oil filling and topping off ......................................................................... 130
10.5.3 Changing the cooling oil ..................................................................................... 131
10.5.4 Replacing the compressor oil filter ...................................................................... 133
10.5.5 Oil separator tank dirt trap maintenance ............................................................. 135
10.5.6 Changing the oil separator cartridge ................................................................... 136
10.5.7 Compressor air filter maintenance ...................................................................... 138
10.5.8 Checking safety relief valves .............................................................................. 141
10.5.9 Fit the flexible pipe connection ........................................................................... 141
10.6 Cleaning the cooler .......................................................................................................... 142
10.6.1 Cleaning the compressor cooler and engine radiator ......................................... 142
10.6.2 Cleaning the compressed air aftercooler ............................................................ 143
10.7 Maintenance of rubber sealing strips ............................................................................... 144
10.8 Chassis maintenance ....................................................................................................... 145
10.8.1 Wheel checks ..................................................................................................... 145
10.8.2 Towbar maintenance .......................................................................................... 145
10.8.3 Brake maintenance ............................................................................................. 148
10.9 Maintenance for Optional Items ....................................................................................... 151
10.9.1 Tool lubricator maintenance ............................................................................... 151
10.9.2 Cyclone separator maintenance ......................................................................... 153
10.9.3 Combination filter maintenance .......................................................................... 154
10.9.4 Fresh air filter maintenance ................................................................................ 158
10.9.5 Engine air intake shut-off valve maintenance ..................................................... 161
10.9.6 Spark arrestor maintenance ............................................................................... 163
10.9.7 Draining liquid accumulation within the machine ................................................ 165
10.10 Documenting maintenance and service work .................................................................. 167
11 Spares, Operating Materials, Service
11.1 Note the nameplate .......................................................................................................... 168
11.2 Ordering consumable parts and operating fluids/materials .............................................. 168
11.3 KAESER AIR SERVICE ................................................................................................... 169
11.4 Service Addresses ........................................................................................................... 169
11.5 Replacement parts for service and repair ........................................................................ 169
12 Decommissioning, Storage and Transport
12.1 De-commissioning ............................................................................................................ 224
12.1.1 Temporary de-commissioning ............................................................................ 224
Contents
iv
Operator Manual Screw Compressor
M114 SIGMA CONTROL SMART No.: 901765 05 USE

12.1.2 Long-term decommissioning and storage ........................................................... 225
12.2 Transport .......................................................................................................................... 226
12.2.1 Safety .................................................................................................................. 226
12.2.2 Towing the compressor on the road ................................................................... 226
12.2.3 Parking the machine ........................................................................................... 235
12.2.4 Transport with a crane ........................................................................................ 238
12.2.5 Transport with a forklift truck ............................................................................... 239
12.2.6 Transporting the machine as load ...................................................................... 239
12.3 Storage ............................................................................................................................. 241
12.4 Disposal ........................................................................................................................... 241
13 Annex
13.1 Marking ............................................................................................................................ 242
13.2 Pipeline and instrument flow diagram (P+I diagram) ....................................................... 242
13.3 Dimensional drawings ...................................................................................................... 247
13.3.1 Dimensional drawing – chassis ........................................................................... 247
13.3.2 Dimensional drawing, chassis options ............................................................... 249
13.3.3 Dimensional drawing, chassis options ............................................................... 251
13.3.4 Dimensional drawing, chassis options ................................................................ 253
13.3.5 Dimensional drawing, stationary version ............................................................ 255
13.3.6 Dimensional drawing, stationary version ............................................................ 257
13.4 Wiring diagrams ............................................................................................................... 259
13.4.1 Electrical Diagram ............................................................................................... 259
13.4.2 Lighting and signaling system connection .......................................................... 277
13.4.3 Lighting and signaling system connection .......................................................... 285
13.4.4 Battery charger electrical diagram ...................................................................... 290
13.5 Fuel circulation diagram ................................................................................................... 300
13.6 Assembly diagrams - chassis ........................................................................................... 303
13.6.1 Assembly diagrams - chassis EU version ........................................................... 303
13.6.2 Assembly diagrams - chassis GB/US version .................................................... 305
13.6.3 Assembly diagram brake rod .............................................................................. 308
13.7 Operating instructions for compressed air filter (combination filter) ................................. 310
13.8 Operating instructions for compressed air filter (fresh air filter) ....................................... 338
Contents
No.: 901765 05 USE
Operator Manual Screw Compressor
M114 SIGMA CONTROL SMART v

Contents
vi
Operator Manual Screw Compressor
M114 SIGMA CONTROL SMART No.: 901765 05 USE

Fig. 1 Example for Tire information on the side wall ............................................................................ 9
Fig. 2 Location of safety signs .............................................................................................................. 29
Fig. 3 Overview of bodywork ................................................................................................................ 36
Fig. 4 Right-hand door opened ............................................................................................................. 37
Fig. 5 Left-hand door opened ............................................................................................................... 37
Fig. 6 Machine overview ....................................................................................................................... 38
Fig. 7 Stepless regulation of FAD(standstill) ........................................................................................ 40
Fig. 8 Battery isolating switch ............................................................................................................... 41
Fig. 9 SIGMA CONTROL SMART operator panel – overview ............................................................. 41
Fig. 10 Principle of treatment devices .................................................................................................... 43
Fig. 11 Compressed air options ............................................................................................................. 44
Fig. 12 Tool lubricator ............................................................................................................................. 46
Fig. 13 Principle tool lubricator ............................................................................................................... 46
Fig. 14 Coolant pre-heating .................................................................................................................... 47
Fig. 15 Engine air shut-off valve ............................................................................................................. 48
Fig. 16 Access engine air shut-off valve ................................................................................................. 49
Fig. 17 Position of service openings in the sealed floor pan .................................................................. 51
Fig. 18 Drain points for oil and coolant from engine and compressor .................................................... 52
Fig. 19 Minimum distance from excavations/slopes and walls ............................................................... 53
Fig. 20 Height adjustable tow bar, fitted ................................................................................................. 56
Fig. 21 Fitting the height adjustable tow bar ........................................................................................... 56
Fig. 22 Non-adjustable tow bar fitted ...................................................................................................... 57
Fig. 23 Fitting the overrun braking mechanism of the non-adjustable tow bar ....................................... 58
Fig. 24 Fitting the jockey wheel of the non-adjustable tow bar ............................................................... 59
Fig. 25 Tow bar height adjustment ......................................................................................................... 60
Fig. 26 Changing the towing eye (height-adjustable tow-bar) ................................................................ 61
Fig. 27 Changing the towing eye/ball hitch (fixed height tow bar) .......................................................... 62
Fig. 28 Changing the towing eye (fixed height tow bar, USA chassis version) ...................................... 63
Fig. 29 Jumper cable connection diagram ............................................................................................. 69
Fig. 30 Coolant pre-heating .................................................................................................................... 71
Fig. 31 Battery charger ........................................................................................................................... 72
Fig. 32 Starting instruments ................................................................................................................... 74
Fig. 33 Instrument panel keys and indicators ......................................................................................... 75
Fig. 34 Brief instructions on starting and stopping ................................................................................. 75
Fig. 35 «Battery isolating switch» ........................................................................................................... 76
Fig. 36 Setting the quick access for the compressed air discharge pressure ........................................ 78
Fig. 37 Setting the compressed air discharge pressure ......................................................................... 79
Fig. 38 Setting the tool lubricator ............................................................................................................ 83
Fig. 39 Handle for manually closing the engine air intake valve ............................................................ 84
Fig. 40 Checking coolant level ............................................................................................................... 106
Fig. 41 Draining the coolant from the radiator ........................................................................................ 108
Fig. 42 Engine air filter maintenance ...................................................................................................... 110
Fig. 43 Cleaning the filter element .......................................................................................................... 110
Fig. 44 Fuel system maintenance .......................................................................................................... 112
Fig. 45 Bleeding the fuel system ............................................................................................................ 112
Fig. 46 Warning messages: Fuel filter water level .................................................................................. 113
Fig. 47 Emptying the fuel pre-filter and water trap ................................................................................. 114
Fig. 48 Changing the fuel pre-filter cartridge .......................................................................................... 115
Fig. 49 Fuel fine filter maintenance ........................................................................................................ 116
Fig. 50 Checking the engine oil level ...................................................................................................... 117
Fig. 51 Draining the engine oil ................................................................................................................ 119
Fig. 52 Change the oil filter .................................................................................................................... 120
Fig. 53 Belt guard attachment ................................................................................................................ 122
Fig. 54 Checking the drive belt seating .................................................................................................. 122
List of Illustrations
No.: 901765 05 USE
Operator Manual Screw Compressor
M114 SIGMA CONTROL SMART vii

Fig. 55 Manually checking the belt tension ............................................................................................ 123
Fig. 56 Changing/tensioning the drive belt ............................................................................................. 124
Fig. 57 Safety signs - warning stickers on the battery. ........................................................................... 126
Fig. 58 Check the cooling oil level .......................................................................................................... 130
Fig. 59 Draining the compressor cooling oil ........................................................................................... 132
Fig. 60 Change the oil filter .................................................................................................................... 134
Fig. 61 Oil separator tank dirt trap maintenance .................................................................................... 135
Fig. 62 Changing the oil separator cartridge .......................................................................................... 137
Fig. 63 Compressor air filter maintenance ............................................................................................. 139
Fig. 64 Cleaning the filter element .......................................................................................................... 140
Fig. 65 Fit the flexible pipe connection ................................................................................................... 141
Fig. 66 Cleaning the compressor cooler and engine radiator ................................................................. 143
Fig. 67 Cleaning the compressed air aftercooler .................................................................................... 144
Fig. 68 Tow bar maintenance ................................................................................................................. 146
Fig. 69 Maintaining the fixed height towbar ............................................................................................ 146
Fig. 70 Ball coupling ( EC version) ......................................................................................................... 147
Fig. 71 Ball coupling (USA version) ........................................................................................................ 148
Fig. 72 Checking the brake lining thickness ........................................................................................... 149
Fig. 73 Brake system adjustment ........................................................................................................... 149
Fig. 74 Brake rod adjustment ................................................................................................................. 150
Fig. 75 Tool lubricator maintenance ....................................................................................................... 152
Fig. 76 Cleaning the dirt trap .................................................................................................................. 153
Fig. 77 Filter combination ....................................................................................................................... 155
Fig. 78 Combination filter maintenance .................................................................................................. 155
Fig. 79 Fresh air filter maintenance ........................................................................................................ 158
Fig. 80 Maintain the engine air shut-off valve ......................................................................................... 161
Fig. 81 Checking manual operation of the engine air intake valve ......................................................... 162
Fig. 82 Cleaning the spark arrestor (floor pan with service openings) ................................................... 164
Fig. 83 Cleaning the spark arrestor (sealed floor pan) ........................................................................... 164
Fig. 84 Transport position ....................................................................................................................... 228
Fig. 85 Ball coupling (ALKO-EU) ............................................................................................................ 229
Fig. 86 Wear alert, ball coupling (ALKO-EU) .......................................................................................... 230
Fig. 87 Ball coupling (ALKO-USA) ......................................................................................................... 231
Fig. 88 Release the parking brake. ........................................................................................................ 231
Fig. 89 Automatic jockey wheel in transport position ............................................................................. 232
Fig. 90 Safety signs: Secure the chocks ................................................................................................ 233
Fig. 91 Breakaway cable attachment ..................................................................................................... 234
Fig. 92 Attach safety chains ................................................................................................................... 234
Fig. 93 Warning "Injury can occur if the tow bar is allowed to fall." ........................................................ 235
Fig. 94 Tow bar with automatic jockey wheel ......................................................................................... 236
Fig. 95 Actuating the parking brake ........................................................................................................ 236
Fig. 96 Safety signs: Secure with chocks ............................................................................................... 237
Fig. 97 Transporting using a forklift truck ............................................................................................... 239
Fig. 98 Guys to secure the freight .......................................................................................................... 240
Fig. 99 Marking ....................................................................................................................................... 242
List of Illustrations
viii
Operator Manual Screw Compressor
M114 SIGMA CONTROL SMART No.: 901765 05 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 Compressed air treatment options ............................................................................................. 5
Tab. 6 Tool lubricator option .................................................................................................................. 5
Tab. 7 Compressed air distributor option .............................................................................................. 5
Tab. 8 Low temperature equipment options .......................................................................................... 6
Tab. 9 Optional equipment for fire hazard areas ................................................................................... 6
Tab. 10 Automatic engine start/stop ........................................................................................................ 6
Tab. 11 GSM/GPS Modem ...................................................................................................................... 6
Tab. 12 Chassis options .......................................................................................................................... 6
Tab. 13 Options, stationary frame ........................................................................................................... 7
Tab. 14 Lighting options .......................................................................................................................... 7
Tab. 15 Sealed floor pan option .............................................................................................................. 7
Tab. 16 Anti-theft device option ............................................................................................................... 7
Tab. 17 Pedestrian protection option ....................................................................................................... 8
Tab. 18 Sound pressure level ................................................................................................................. 8
Tab. 19 Tightening torques for screws (property class 8.8, coefficient of friction µ = 0.12) .................... 8
Tab. 20 Ambient conditions ..................................................................................................................... 8
Tab. 21 Mass of the machine .................................................................................................................. 9
Tab. 22 Tires ........................................................................................................................................... 9
Tab. 23 Wheel nut/bolt tightening torque ................................................................................................. 10
Tab. 24 Towbar tightening torque ............................................................................................................ 10
Tab. 25 Working gauge pressure and FAD ............................................................................................. 10
Tab. 26 Compressed air distributor ......................................................................................................... 10
Tab. 27 Safety relief valve opening pressure .......................................................................................... 11
Tab. 28 Required temperatures readiness to switch to LOAD mode ...................................................... 11
Tab. 29 Airend discharge temperature .................................................................................................... 11
Tab. 30 Cooling oil recommendations ..................................................................................................... 11
Tab. 31 Cooling oil recommendation (food processing) .......................................................................... 12
Tab. 32 Cooling oil charge ....................................................................................................................... 12
Tab. 33 Engine specification ................................................................................................................... 13
Tab. 34 Engine oil recommendation ........................................................................................................ 13
Tab. 35 Initial engine oil quantity ............................................................................................................. 14
Tab. 36 Water quality parameters for cooling water ................................................................................ 15
Tab. 37 Fluid volumes ............................................................................................................................. 15
Tab. 38 Batteries ..................................................................................................................................... 15
Tab. 39 Road breaker lubricant recommendation ................................................................................... 16
Tab. 40 Fresh air filter conditions ............................................................................................................ 16
Tab. 41 Interrelation between compressed air treatment and compressed air quality ............................ 16
Tab. 42 Environmental conditions, low temperature equipment .............................................................. 17
Tab. 43 Coolant pre-heater ..................................................................................................................... 17
Tab. 44 Batteries, low-temperature equipment ....................................................................................... 17
Tab. 45 Battery charger specification ...................................................................................................... 17
Tab. 46 Power supply details .................................................................................................................. 18
Tab. 47 General inspection intervals ....................................................................................................... 21
Tab. 48 Danger areas .............................................................................................................................. 28
Tab. 49 Safety signs ................................................................................................................................ 29
Tab. 50 Instrument panel keys and displays ........................................................................................... 42
Tab. 51 Measures for recommissioning the compressor after a long period of storage .......................... 67
Tab. 52 Positioning and operating conditions checklist ........................................................................... 67
Tab. 53 Standard battery charger readings ............................................................................................. 72
Tab. 54 Alarm messages and actions concerning the engine. ................................................................ 86
List of Tables
No.: 901765 05 USE
Operator Manual Screw Compressor
M114 SIGMA CONTROL SMART ix

Tab. 55 Alarm messages and actions concerning the compressor unit .................................................. 88
Tab. 56 Alarm messages and actions concerning the controller. ............................................................ 88
Tab. 57 General alarm messages and measures ................................................................................... 89
Tab. 58 Warning messages and measures relating to the engine. ......................................................... 89
Tab. 59 Warning messages and measures relating to the compressor .................................................. 90
Tab. 60 General warning messages and measures ................................................................................ 91
Tab. 61 Fault: engine refuses to start or comes to a stop. ...................................................................... 91
Tab. 62 Alarm: "engine does not reach full speed". ................................................................................ 92
Tab. 63 Fault: working pressure too high ................................................................................................ 93
Tab. 64 Fault: working pressure too low .................................................................................................. 93
Tab. 65 Fault: pressure relief valve blowing off ....................................................................................... 94
Tab. 66 Fault: machine overheating ........................................................................................................ 94
Tab. 67 Alarm: "Too much oil residue in the compressed air" ................................................................. 95
Tab. 68 Alarm: "Oil flows from the compressor air filter after shutdown" ................................................ 95
Tab. 69 Fault: high moisture content in the compressed air .................................................................... 95
Tab. 70 Advise others that the machine is being serviced. ..................................................................... 96
Tab. 71 Maintenance messages and required actions ............................................................................ 97
Tab. 72 Maintenace tasks on the machine after commissioning ............................................................. 99
Tab. 73 Maintenance tasks on the chassis after commissioning ............................................................ 99
Tab. 74 Maintenance intervals and regular maintenance tasks .............................................................. 99
Tab. 75 Regular machine maintenance tasks ......................................................................................... 100
Tab. 76 Regular maintenance task options ............................................................................................. 102
Tab. 77 Chassis maintenance intervals and regular maintenance tasks ................................................ 103
Tab. 78 Regular chassis maintenance tasks ........................................................................................... 104
Tab. 79 KAESER coolant mixture table ................................................................................................... 107
Tab. 80 Dimensions of the flexible pipe connection ................................................................................ 141
Tab. 81 Maintenance log ......................................................................................................................... 167
Tab. 82 Compressor spare parts ............................................................................................................. 168
Tab. 83 Consumable engine parts .......................................................................................................... 168
Tab. 84 Replacement parts, combination filter ........................................................................................ 169
Tab. 85 Replacement parts, fresh-air filter .............................................................................................. 169
Tab. 86 "Temporarily decommissioned" information notice .................................................................... 224
Tab. 87 Long-term decommissioning and storage checklist ................................................................... 225
Tab. 88 Text for the long-term decommissioned and storage information notice .................................... 226
Tab. 89 Ball coupling wear indicator ........................................................................................................ 230
List of Tables
x
Operator Manual Screw Compressor
M114 SIGMA CONTROL SMART No.: 901765 05 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.: 901765 05 USE
Operator Manual Screw Compressor
M114 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 Screw Compressor
M114 SIGMA CONTROL SMART No.: 901765 05 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 2.2.
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.: 901765 05 USE
Operator Manual Screw Compressor
M114 SIGMA CONTROL SMART 3
Option da

2 Technical Data
2.1 Nameplate
The machine's nameplate provides the model designation and important technical information.
The nameplate is located on the outside of the machine (see illustration in chapter 13.1).
➤ Enter the nameplate data here as a reference:
Feature Value
Vehicle Identification No.
Permissible total weight
Permissible coupling load
Permissible axle load
Portable compressor
Part no.
Serial no.
Year of manufacture
Total weight
Lifting point load capacity
Rated engine power
Engine speed
Maximum working pressure
Tab. 3 Nameplate
2.2 Options – options label
A list of the options fitted to your machine helps to relate the information in this service manual.
Options fitted to the machine are listed on the options label (code letters).
The nameplate is to be found:
■on the outside of the machine,
■ on the front (see chapter 13.1)
The following table lists all possible options.
Only the codes for those options fitted appear on the nameplate.
2 Technical Data
2.1 Nameplate
4
Operator Manual Screw Compressor
M114 SIGMA CONTROL SMART No.: 901765 05 USE

* r1 - r5 = place holders for chassis options:
■r1 = rb; rc; rd
■ r3 = rm; ro
■ r4 = rr; rs; rt
■ r5 = rw; rx
Tab. 4 Extract from the options label
➤ Take a list of fitted options from the options label and enter the fitted options as reference.
2.2.1 Option da, db, dc, dd
Compressed air treatment devices
Option Option code Available?
Aftercooler and cyclone separator da
Heat exchanger db
Fresh air filter dc
Filter combination dd
Tab. 5 Compressed air treatment options
2.2.2 Option ea, ec
Tool lubricator
Option Option code Available?
Tool lubricator (with option fa) ea
Tool lubricator (with option fc) ec
Tab. 6 Tool lubricator option
2.2.3 Option fa, fc
Compressed air distributor
Option Option code Available?
Non-separated compressed air distribution line fa
Separated compressed air distribution lines, down‐
stream of the option
fc
Tab. 7 Compressed air distributor option
2 Technical Data
2.2 Options – options label
No.: 901765 05 USE
Operator Manual Screw Compressor
M114 SIGMA CONTROL SMART 5

2.2.4 Option ba
Low temperature equipment
Option Option code Available?
Low temperature equipment ba
Engine coolant pre-heating bb
Stronger batteries bd
Tab. 8 Low temperature equipment options
2.2.5 Option la, lb
Equipment for fire hazard areas
Option Option code Available?
Spark arrestor la
Spark arrestor and engine air intake shut-off valve
(automatic)
lb
Tab. 9 Optional equipment for fire hazard areas
2.2.6 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
2.2.7 Option oc
GSM/GPS Modem
Option Option code Available?
GSM/GPS Modem oc
Tab. 11 GSM/GPS Modem
2.2.8 Option rb/rm/rs, rc/ro/rs, rd/ro/rs, rw, rx
Chassis
Chassis are defined by the combination of several option designations as follows:
Version/axle load/height adjustment/service brake
Example: rb/rm/rs means
EU chassis with height-adjustable tow bar and overrun brake
Chassis:
Chassis Option code Available?
Model (rb, rc, rd):
2 Technical Data
2.2 Options – options label
6
Operator Manual Screw Compressor
M114 SIGMA CONTROL SMART No.: 901765 05 USE

Chassis Option code Available?
EU chassis rb
GB chassis rc
US chassis rd
Height adjustment (rm, ro):
With height adjustment rm
Without height adjustment ro
Service brake (rs):
With overrun brake rs
Tab. 12 Chassis options
Stationary frame
Chassis Option code Available?
Stationary (rw, rx):
on skids rw
on frame rx
Tab. 13 Options, stationary frame
2.2.9 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. 14 Lighting options
2.2.10 Option oe
Sealed floor pan
Option Option code Available?
Sealed floor pan oe
Tab. 15 Sealed floor pan option
2.2.11 Option sf
Anti-theft device
Option Option code Available?
Anti-theft device sf
Tab. 16 Anti-theft device option
2 Technical Data
2.2 Options – options label
No.: 901765 05 USE
Operator Manual Screw Compressor
M114 SIGMA CONTROL SMART 7

2.2.12 Option sg
Pedestrian protection
Option Option code Available?
Pedestrian protection sg
Tab. 17 Pedestrian protection option
2.3 Machine (without options)
2.3.1 Sound pressure level
Sound pressure levels comply with the American EPA Standard.
Measurement distance: 23 ft
M114
Guaranteed sound pressure level [dB(A)] 76
Tab. 18 Sound pressure level
2.3.2 Tightening torques for screws
Recommended values for screws of property class 8.8
Thread M4 M5 M6 M8 M10 M12 M14 M16 M18 M20
Torque [lbf-in] 3.0 5.9 10.0 24.5 48.0 84.0 133.0 206.0 295.0 415.0
Tab. 19 Tightening torques for screws (property class 8.8, coefficient of friction µ = 0.12)
2.3.3 Ambient conditions
Positioning Limit value
Maximum altitude amsl* [ft] 1000
Minimum ambient temperature [°F] −10
Maximum ambient temperature [°F] +45
* Higher altitudes are permissible only after consultation with the manufacturer.
Tab. 20 Ambient conditions
2.3.4 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.
2 Technical Data
2.3 Machine (without options)
8
Operator Manual Screw Compressor
M114 SIGMA CONTROL SMART No.: 901765 05 USE