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
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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
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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