KAESER M135 SIGMA CONTROL MOBIL User manual

Service Manual
Screw Compressor
M135 SIGMA CONTROL MOBIL
No.: 9_6975 00 E
Manufacturer:
KAESER KOMPRESSOREN GmbH
96410 Coburg • PO Box 2143 • GERMANY • Tel. [phone] • Fax [phone]
http://www.kaeser.com

Original instructions
/KKW/M135 1.00 en SBA-MOBILAIR

1 Regarding this document
1.1 Using the Document ......................................................................................................... 1
1.2 Further documents ........................................................................................................... 1
1.3 Copyright .......................................................................................................................... 1
1.4 Symbols and markings ..................................................................................................... 1
1.4.1 Warning notices .................................................................................................. 1
1.4.2 Other notices and symbols ................................................................................. 2
2Technical Specification
2.1 Nameplate ........................................................................................................................ 3
2.2 List of Options .................................................................................................................. 3
2.2.1 Compressed air treatment plant ......................................................................... 4
2.2.2 Compressed air distributor .................................................................................. 4
2.2.3 Check valve function ........................................................................................... 5
2.2.4 Low temperature equipment ............................................................................... 5
2.2.5 Chassis ............................................................................................................... 5
2.2.6 Lighting ............................................................................................................... 5
2.2.7 Pedestrian protection .......................................................................................... 6
2.3 Machine (without options) ................................................................................................ 6
2.3.1 Sound emission ................................................................................................. 6
2.3.2 Torques ............................................................................................................... 7
2.3.3 Ambient conditions ............................................................................................. 7
2.3.4 Additional specifications ..................................................................................... 7
2.4 Chassis ........................................................................................................................... 7
2.4.1 Weights ............................................................................................................... 7
2.4.2 Tyres ................................................................................................................... 8
2.4.3 Wheel nut/bolt tightening torque ......................................................................... 8
2.4.4 Towbar tightening torque .................................................................................... 8
2.5 Compressor ..................................................................................................................... 8
2.5.1 Working pressure and FAD ................................................................................ 8
2.5.2 Compressed air outlet ......................................................................................... 9
2.5.3 Pressure relief valve ........................................................................................... 9
2.5.4 Temperature ....................................................................................................... 9
2.5.5 Cooling oil recommendation ............................................................................... 9
2.5.6 Cooling oil charge ............................................................................................... 10
2.6 Engine ............................................................................................................................. 10
2.6.1 Engine specification ............................................................................................ 10
2.6.2 Oil recommendation ............................................................................................ 11
2.6.3 Engine coolant recommendation ........................................................................ 11
2.6.4 Fluid volumes ...................................................................................................... 11
2.6.5 Batteries .............................................................................................................. 11
2.7 Options ............................................................................................................................ 12
2.7.1 Low temperature equipment ............................................................................... 12
2.7.2 Generator ............................................................................................................ 13
3 Safety and Responsibility
3.1 Basic Information ............................................................................................................. 16
3.2 Specified use .................................................................................................................... 16
3.3 Improper Use ................................................................................................................... 16
3.4 User's Responsibilities ..................................................................................................... 16
3.4.1 Observe statutory and universally accepted regulations. ................................... 16
3.4.2 Defining personnel .............................................................................................. 17
3.4.3 Adherence to inspection schedules and accident prevention regulations .......... 17
3.5 Dangers ............................................................................................................................ 18
3.5.1 Safely dealing with sources of danger ................................................................ 18
Contents
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3.5.2 Safe machine operation ...................................................................................... 20
3.5.3 Organisational Measures .................................................................................... 22
3.5.4 Danger areas ...................................................................................................... 23
3.6 Safety Devices ................................................................................................................. 23
3.7 Safety signs ...................................................................................................................... 23
3.8 Generator operation ......................................................................................................... 25
3.8.1 Protection against dangerous electric current .................................................... 25
3.8.2 Instructions for safe generator operation ............................................................ 25
3.8.3 Connection of extension cables .......................................................................... 25
3.8.4 Maximum power supply loading ......................................................................... 25
3.8.5 Regular generator inspections ............................................................................ 26
3.9 Emergencies .................................................................................................................... 26
3.9.1 Correct fire fighting ............................................................................................. 26
3.9.2 Contact with operating fluids/materials ............................................................... 26
3.10 Warranty ........................................................................................................................... 27
3.11 Environmental Protection ................................................................................................. 27
4 Design and Function
4.1 Bodywork ......................................................................................................................... 28
4.2 Component identification .................................................................................................. 29
4.3 Machine function .............................................................................................................. 29
4.4 Operating modes and control modes ............................................................................... 31
4.4.1 Operating modes ................................................................................................ 31
4.4.2 MODULATING control mode .............................................................................. 31
4.5 Safety devices .................................................................................................................. 32
4.5.1 Monitoring functions with shutdown .................................................................... 32
4.5.2 Further safety devices ........................................................................................ 32
4.6 SIGMA CONTROL MOBIL keys and displays ................................................................. 33
4.7 SIGMA CONTROL MOBIL function ................................................................................. 34
4.7.1 Display ................................................................................................................ 34
4.7.2 SIGMA CONTROL MOBIL operating sequence ................................................. 37
4.7.3 Menu structure of the SIGMA CONTROL MOBIL ............................................. 38
4.8 List of menus .................................................................................................................... 39
4.8.1 SIGMA CONTROL MOBIL main menu ............................................................... 41
4.8.2 SIGMA CONTROL MOBIL settings menu .......................................................... 42
4.8.3 SIGMA CONTROL MOBIL event memory .......................................................... 45
4.9 Air treatment options ........................................................................................................ 48
4.9.1 Air cooler ............................................................................................................. 49
4.9.2 Cyclone separator ............................................................................................... 49
4.9.3 Heat exchanger .................................................................................................. 49
4.9.4 Filter combination ............................................................................................... 49
4.9.5 Breathing air filter ................................................................................................ 50
4.10 Low temperature equipment option .................................................................................. 50
4.11 Generator option .............................................................................................................. 51
4.11.1 Operating modes ................................................................................................ 51
4.11.2 Operating controls .............................................................................................. 51
4.11.3 Note when operating the generator .................................................................... 52
4.12 Transport options ............................................................................................................. 53
4.12.1 Chassis ............................................................................................................... 53
4.12.2 Chassis ............................................................................................................... 53
4.12.3 Chassis ............................................................................................................... 53
4.12.4 Stationary frame ................................................................................................. 54
4.12.5 Stationary frame ................................................................................................. 54
4.13 Pedestrian protection option ............................................................................................ 54
Contents
ii
Service Manual Screw Compressor
M135 SIGMA CONTROL MOBIL No.: 9_6975 00 E

5 Installation and Operating Conditions
5.1 Safety ............................................................................................................................... 55
5.2 Positioning conditions ...................................................................................................... 55
6 Installation
6.1 Safety ............................................................................................................................... 57
6.2 Reporting Transport Damage ........................................................................................... 57
6.3 Fitting the towbar .............................................................................................................. 57
6.4 Adjusting the chassis ....................................................................................................... 58
6.4.1 Adjusting the towbar height ................................................................................ 59
6.4.2 Changing the towing eye .................................................................................... 59
7 Initial Start-up
7.1 Safety ............................................................................................................................... 63
7.2 Instructions to be observed before commissioning or recommissioning .......................... 63
7.3 Checking installation and operating conditions ................................................................ 63
7.4 Setting the displayed units ............................................................................................... 64
7.5 Entering a password ........................................................................................................ 65
7.6 Engine settings ................................................................................................................. 66
7.7 Changing the parameters of the start/stop/automatic option ........................................... 68
7.8 After storing the machine for a long period ...................................................................... 70
7.9 Low-temperature operation (winter) ................................................................................. 70
7.9.1 Starting assistance ............................................................................................. 70
7.9.2 Starting up low-temperature equipment .............................................................. 72
7.10 Putting the generator into operation ................................................................................. 73
8 Operation
8.1 Safety ............................................................................................................................... 75
8.2 Starting and stopping ....................................................................................................... 75
8.2.1 Follow the brief instructions ................................................................................ 75
8.2.2 Commissioning the machine ............................................................................... 76
8.2.3 Starting the engine .............................................................................................. 77
8.2.4 Setting the output pressure ................................................................................. 77
8.2.5 Shutting down the machine ................................................................................ 79
8.2.6 Shutting down in an emergency ......................................................................... 80
8.3 Setting parameters ........................................................................................................... 80
8.4 Acknowledging alarm, warning and maintenance messages .......................................... 80
8.5 Displaying machine operating data .................................................................................. 81
8.6 Using the external fuel pump option ................................................................................. 82
8.7 Using the low-temperature equipment ............................................................................. 83
8.8 Generator operation ......................................................................................................... 83
8.8.1 Switching in the generator .................................................................................. 84
8.8.2 Switching off the generator ................................................................................. 84
9 Fault Recognition and Rectification
9.1 Basic instructions ............................................................................................................. 85
9.2 SIGMA CONTROL MOBIL messages ............................................................................. 85
9.2.1 Alarm messages on the controller (machine off) ................................................ 85
9.2.2 Warning message on the controller .................................................................... 88
9.3 Engine faults and alarms .................................................................................................. 90
9.3.1 Engine refuses to start or does not turn over ...................................................... 90
9.3.2 Engine does not reach full speed ....................................................................... 91
9.4 Compressor faults and alarms ......................................................................................... 91
9.4.1 Working pressure too high .................................................................................. 91
9.4.2 Working pressure too low ................................................................................... 92
9.4.3 Pressure relief valve blowing off ......................................................................... 92
Contents
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9.4.4 Machine overheating .......................................................................................... 93
9.4.5 Too much oil residue in the compressed air ....................................................... 93
9.4.6 Oil flows from the compressor air filter after shutdown ....................................... 94
9.4.7 High moisture content in the compressed air ..................................................... 94
9.5 Generator faults and alarms ............................................................................................. 94
9.5.1 There is no voltage or too low a voltage from the generator .............................. 94
9.5.2 Generator voltage too high ................................................................................. 95
10 Maintenance
10.1 Safety ............................................................................................................................... 96
10.2 Maintenance message on the controller .......................................................................... 96
10.3 Maintenance schedules ................................................................................................... 97
10.3.1 Logging maintenance work ................................................................................. 97
10.3.2 Maintenance tasks after commissioning ............................................................. 97
10.3.3 Regular maintenance tasks ................................................................................ 98
10.4 Engine .............................................................................................................................. 102
10.4.1 Radiator maintenance ......................................................................................... 103
10.4.2 Air filter maintenance .......................................................................................... 108
10.4.3 Fuel system maintenance ................................................................................... 110
10.4.4 Checking the engine oil level .............................................................................. 114
10.4.5 Engine oil filling and topping up .......................................................................... 114
10.4.6 Changing the engine oil ...................................................................................... 115
10.4.7 Changing the oil filter .......................................................................................... 117
10.4.8 Checking the drive belts ..................................................................................... 118
10.4.9 Battery maintenance ........................................................................................... 120
10.5 Compressor ...................................................................................................................... 123
10.5.1 Checking cooling oil level ................................................................................... 123
10.5.2 Cooling oil filling and topping up ......................................................................... 124
10.5.3 Changing the cooling oil ..................................................................................... 124
10.5.4 Changing the oil filter .......................................................................................... 127
10.5.5 Oil separator tank dirt trap maintenance ............................................................. 129
10.5.6 Changing the oil separator cartridge ................................................................... 130
10.5.7 Air filter maintenance .......................................................................................... 131
10.5.8 Checking pressure relief valves ......................................................................... 133
10.6 Cleaning the coolers and radiator .................................................................................... 133
10.6.1 Cleaning the compressed air aftercooler ............................................................ 135
10.7 Rubber sealing strip maintenance .................................................................................... 136
10.8 Chassis ............................................................................................................................ 136
10.8.1 Wheel checks ..................................................................................................... 136
10.8.2 Towbar maintenance .......................................................................................... 136
10.8.3 Brake maintenance ............................................................................................. 138
10.9 Options ............................................................................................................................. 141
10.9.1 Cyclone separator maintenance ......................................................................... 141
10.9.2 Combination filter maintenance .......................................................................... 142
10.9.3 Breathing air filter maintenance .......................................................................... 145
10.9.4 Generator drive belt maintenance ...................................................................... 147
10.10 Document maintenance and service work. ...................................................................... 150
11 Spares, Operating Materials, Service
11.1 Note the Nameplate ......................................................................................................... 151
11.2 Ordering consumable parts and operating materials ....................................................... 151
11.3 KAESER AIR SERVICE .................................................................................................. 152
11.4 Service Addresses ........................................................................................................... 152
12 Decommissioning, Storage and Transport
12.1 De-commissioning ............................................................................................................ 153
Contents
iv
Service Manual Screw Compressor
M135 SIGMA CONTROL MOBIL No.: 9_6975 00 E

12.1.1 Temporary decommissioning .............................................................................. 153
12.1.2 Long-term decommissioning ............................................................................... 154
12.2 Transporting ..................................................................................................................... 155
12.2.1 Towing the compressor on the road ................................................................... 155
12.2.2 Parking the compressor ...................................................................................... 160
12.2.3 Transporting with a crane ................................................................................... 162
12.2.4 Transporting with a forklift truck .......................................................................... 162
12.2.5 Transporting as a load ........................................................................................ 163
12.3 Storage ............................................................................................................................. 164
12.4 Disposal ........................................................................................................................... 165
13 Annex
13.1 Marking ............................................................................................................................ 166
13.2 Pipeline and instrument flow diagram (P+I diagram) ....................................................... 166
13.3 Dimensional drawing, chassis with height-adjustable tow bar ......................................... 171
13.4 Dimensional drawing, chassis with fixed height tow bar .................................................. 173
13.5 Dimensional drawing, chassis without parking brake ...................................................... 175
13.6 Dimensional drawings of stationary machine (skids) ....................................................... 177
13.7 Dimensional drawings of stationary machine (base frame) ............................................. 179
13.8 Electrical Diagram ............................................................................................................ 181
13.9 Lighting and signalling system connection ....................................................................... 205
13.10 Lighting and signalling system connection ....................................................................... 210
13.11 Generator electrical diagram, 400 V, 3-ph ....................................................................... 213
13.12 Generator electrical diagram, 230 V, 3-ph ....................................................................... 225
13.13 Fuel circulation diagram ................................................................................................... 235
13.14 SIGMA CONTROL MOBIL message codes ..................................................................... 238
13.15 Operating instructions for compressed air filter (combination filter) ................................. 241
13.16 Operating instructions for compressed air filter (breathing air filter) ................................ 262
Contents
No.: 9_6975 00 E
Service Manual Screw Compressor
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Contents
vi
Service Manual Screw Compressor
M135 SIGMA CONTROL MOBIL No.: 9_6975 00 E

Fig. 1 Location of safety signs .............................................................................................................. 23
Fig. 2 Bodywork .................................................................................................................................... 28
Fig. 3 Right-hand door opened ............................................................................................................. 29
Fig. 4 Left-hand door opened ............................................................................................................... 29
Fig. 5 General design ........................................................................................................................... 30
Fig. 6 Stepless regulation of FAD (standstill) ....................................................................................... 32
Fig. 7 Instrument panel keys and displays ........................................................................................... 33
Fig. 8 Opening page ............................................................................................................................. 34
Fig. 9 Engine preheating ...................................................................................................................... 35
Fig. 10 Display of operating mode (example) ......................................................................................... 35
Fig. 11 Menu structure of the SIGMA CONTROL MOBIL ..................................................................... 39
Fig. 12 Machine data symbol ................................................................................................................. 41
Fig. 13 Symbolic settings menu ............................................................................................................. 44
Fig. 14 Event memory ............................................................................................................................ 45
Fig. 15 Event memory example: Alarm message ................................................................................... 47
Fig. 16 Event memory example: Warning message ............................................................................... 47
Fig. 17 Event memory example: Maintenance message ....................................................................... 47
Fig. 18 Message code structure ............................................................................................................. 48
Fig. 19 Air treatment options .................................................................................................................. 49
Fig. 20 Coolant pre-heating .................................................................................................................... 50
Fig. 21 Generator instrument panel - control box, 400 V, 3-phase ........................................................ 52
Fig. 22 Generator instrument panel - control box, 230 V, 3-phase ........................................................ 52
Fig. 23 Minimum distance from excavations/slopes and walls ............................................................... 55
Fig. 24 Fitting the towbar ........................................................................................................................ 58
Fig. 25 Fitting the towbar ........................................................................................................................ 58
Fig. 26 Towbar height adjustment .......................................................................................................... 59
Fig. 27 Changing the towing eye (height-adjustable towbar) ................................................................. 60
Fig. 28 Changing the towing eye (fixed height towbar, GB chassis version) ......................................... 61
Fig. 29 Changing the towing eye (fixed height towbar, USA chassis version) ....................................... 61
Fig. 30 Temperature display setting ....................................................................................................... 64
Fig. 31 Unit of pressure setting .............................................................................................................. 65
Fig. 32 Waiting for password entry ......................................................................................................... 65
Fig. 33 Password level 1 activated. ........................................................................................................ 66
Fig. 34 Engine settings menu ................................................................................................................. 67
Fig. 35 Settings in start/stop/automatic .................................................................................................. 69
Fig. 36 Jumper cable connection diagram ............................................................................................. 71
Fig. 37 Coolant pre-heating .................................................................................................................... 73
Fig. 38 Insulation monitoring - 400 V, 3-phase generator ...................................................................... 73
Fig. 39 Insulation monitoring - 230 V, 3-phase generator ...................................................................... 74
Fig. 40 Starting instruments ................................................................................................................... 75
Fig. 41 Brief instructions on starting and stopping ................................................................................. 76
Fig. 42 «Battery isolating switch» .......................................................................................................... 76
Fig. 43 Select menu option "set pressure in the oil separator tank" ....................................................... 78
Fig. 44 Setting the output pressure ........................................................................................................ 78
Fig. 45 Operating data menu .................................................................................................................. 82
Fig. 46 External fuel pump switch-on symbol ......................................................................................... 83
Fig. 47 Checking coolant level ............................................................................................................... 104
Fig. 48 Draining the coolant from the radiator ........................................................................................ 106
Fig. 49 Radiator with centralised drainage ............................................................................................. 107
Fig. 50 Engine air filter maintenance ...................................................................................................... 108
Fig. 51 Cleaning the filter element .......................................................................................................... 109
Fig. 52 Fuel system maintenance .......................................................................................................... 110
Fig. 53 Warning indication: Fuel filter water level ................................................................................... 111
Fig. 54 Emptying the fuel prefilter water trap .......................................................................................... 112
List of Illustrations
No.: 9_6975 00 E
Service Manual Screw Compressor
M135 SIGMA CONTROL MOBIL vii

Fig. 55 Changing the fuel prefilter cartridge ........................................................................................... 112
Fig. 56 Fuel filter maintenance ............................................................................................................... 113
Fig. 57 Checking the engine oil level ...................................................................................................... 114
Fig. 58 Draining the engine oil ................................................................................................................ 116
Fig. 59 Draining the engine oil, central drain point ................................................................................. 117
Fig. 60 Changing the oil filter .................................................................................................................. 118
Fig. 61 Belt tension checking by hand .................................................................................................... 119
Fig. 62 Safety signs - warning stickers on the battery. ........................................................................... 120
Fig. 63 Checking cooling oil level ........................................................................................................... 123
Fig. 64 Changing the cooling oil ............................................................................................................. 125
Fig. 65 Central compressor oil drainage ................................................................................................ 126
Fig. 66 Changing the oil filter .................................................................................................................. 128
Fig. 67 Cleaning the dirt trap .................................................................................................................. 129
Fig. 68 Changing the oil separator cartridge .......................................................................................... 130
Fig. 69 Compressor air filter maintenance ............................................................................................. 132
Fig. 70 Cleaning the filter element .......................................................................................................... 132
Fig. 71 Cooler/radiator cleaning ............................................................................................................. 134
Fig. 72 Cleaning the compressed air aftercooler .................................................................................... 135
Fig. 73 Overrun braking mechanism maintenance ................................................................................. 137
Fig. 74 Ball coupling maintenance ......................................................................................................... 138
Fig. 75 Ball coupling maintenance (USA version) .................................................................................. 138
Fig. 76 Checking the brake lining thickness ........................................................................................... 139
Fig. 77 Brake adjustment ....................................................................................................................... 140
Fig. 78 Cleaning the dirt trap .................................................................................................................. 141
Fig. 79 Combination filter maintenance .................................................................................................. 143
Fig. 80 Breathing air filter maintenance .................................................................................................. 145
Fig. 81 Generator belt tensioning ........................................................................................................... 147
Fig. 82 Towing alignment ....................................................................................................................... 156
Fig. 83 Ball coupling (ALKO-EU) ............................................................................................................ 157
Fig. 84 Ball coupling (ALKO-USA) ......................................................................................................... 158
Fig. 85 Safety sign - secure the chocks ................................................................................................. 159
Fig. 86 Breakaway cable attachment ..................................................................................................... 160
Fig. 87 Injury can occur if the towbar is unsupported and allowed to fall. .............................................. 160
Fig. 88 Safety sign - secure the chocks ................................................................................................. 161
Fig. 89 Transporting using a forklift truck ............................................................................................... 163
Fig. 90 Load secured by strapping ......................................................................................................... 164
Fig. 91 Marking ....................................................................................................................................... 166
List of Illustrations
viii
Service Manual Screw Compressor
M135 SIGMA CONTROL MOBIL No.: 9_6975 00 E

Tab. 1 The levels of danger and their meaning ..................................................................................... 2
Tab. 2 Nameplate .................................................................................................................................. 3
Tab. 3 Combined label for coupling load and options fitted ................................................................... 4
Tab. 4 Compressed air treatment plant ................................................................................................. 4
Tab. 5 Compressed air distributor ......................................................................................................... 4
Tab. 6 Check valve function .................................................................................................................. 5
Tab. 7 Low temperature equipment ....................................................................................................... 5
Tab. 8 Chassis ....................................................................................................................................... 5
Tab. 9 Lighting ....................................................................................................................................... 5
Tab. 10 Pedestrian protection ................................................................................................................. 6
Tab. 11 Guaranteed sound power level .................................................................................................. 6
Tab. 12 Emission sound pressure level ................................................................................................... 6
Tab. 13 Guaranteed sound pressure level .............................................................................................. 6
Tab. 14 Torques for hex-head screws ..................................................................................................... 7
Tab. 15 Ambient conditions ..................................................................................................................... 7
Tab. 16 Machine weights ......................................................................................................................... 7
Tab. 17 Tyres .......................................................................................................................................... 8
Tab. 18 Wheel nut/bolt tightening torque ................................................................................................. 8
Tab. 19 Towbar tightening torque ............................................................................................................ 8
Tab. 20 Working pressure and FAD ........................................................................................................ 8
Tab. 21 Compressed air distributor ......................................................................................................... 9
Tab. 22 Relief valve activating pressure .................................................................................................. 9
Tab. 23 Machine temperatures ................................................................................................................ 9
Tab. 24 Cooling oil recommendation ....................................................................................................... 9
Tab. 25 Cooling oil charge ....................................................................................................................... 10
Tab. 26 Engine specification ................................................................................................................... 10
Tab. 27 Engine oil recommendation ........................................................................................................ 11
Tab. 28 Engine fluid volumes .................................................................................................................. 11
Tab. 29 Batteries ..................................................................................................................................... 11
Tab. 30 Ambient conditions ..................................................................................................................... 12
Tab. 31 Batteries ..................................................................................................................................... 12
Tab. 32 Coolant pre-heater ..................................................................................................................... 12
Tab. 33 Generator data ........................................................................................................................... 13
Tab. 34 Delivery in generator mode ........................................................................................................ 13
Tab. 35 Connection sockets .................................................................................................................... 13
Tab. 36 Overload protection switch ......................................................................................................... 14
Tab. 37 Generator operating limits .......................................................................................................... 14
Tab. 38 Maximum three-phase mains loading ........................................................................................ 15
Tab. 39 Maximum single-phase mains loading ....................................................................................... 15
Tab. 40 Inspection intervals according to regulations ............................................................................. 18
Tab. 41 Danger areas .............................................................................................................................. 23
Tab. 42 Safety signs ................................................................................................................................ 24
Tab. 43 Instrument panel keys and displays ........................................................................................... 33
Tab. 44 Display of messages prior to starting ......................................................................................... 35
Tab. 45 Operating mode display ............................................................................................................. 35
Tab. 46 Display of operational state ........................................................................................................ 36
Tab. 47 SIGMA CONTROL MOBIL operating sequence ........................................................................ 37
Tab. 48 Menu structure of the SIGMA CONTROL MOBIL ..................................................................... 38
Tab. 49 Settings menu ............................................................................................................................ 39
Tab. 50 Menu selection ........................................................................................................................... 39
Tab. 51 Menu option list .......................................................................................................................... 40
Tab. 52 Navigation (menu) ...................................................................................................................... 40
Tab. 53 Symbolic display of engine oil pressure ..................................................................................... 41
Tab. 54 Engine data display .................................................................................................................... 41
List of Tables
No.: 9_6975 00 E
Service Manual Screw Compressor
M135 SIGMA CONTROL MOBIL ix

Tab. 55 Display of compressor operating data ........................................................................................ 42
Tab. 56 Password level ........................................................................................................................... 42
Tab. 57 Menu guidance ........................................................................................................................... 43
Tab. 58 Event memory outline ................................................................................................................. 46
Tab. 59 Message code structure ............................................................................................................. 48
Tab. 60 Generator/compressor operation ............................................................................................... 51
Tab. 61 Generator operating modes ....................................................................................................... 51
Tab. 62 Installation and operating conditions checklist ........................................................................... 63
Tab. 63 Measures for re-commissioning the compressor after a long period of storage ........................ 70
Tab. 64 Test instructions for a generator with an insulation monitoring .................................................. 74
Tab. 65 Fault messages and actions concerning the engine. ................................................................. 85
Tab. 66 Fault messages and actions concerning the compressor unit ................................................... 87
Tab. 67 Fault messages and actions concerning the controller. ............................................................. 87
Tab. 68 General fault messages and measures ...................................................................................... 87
Tab. 69 Warning messages and measures relating to the engine. ......................................................... 89
Tab. 70 Warning messages and measures relating to the compressor .................................................. 89
Tab. 71 General warning messages and measures ................................................................................ 90
Tab. 72 Fault: engine refuses to start or comes to a stop. ...................................................................... 90
Tab. 73 Fault: engine does not reach full speed. .................................................................................... 91
Tab. 74 Fault: working pressure too high ................................................................................................ 91
Tab. 75 Fault: working pressure too low .................................................................................................. 92
Tab. 76 Fault: pressure relief valve blowing off ....................................................................................... 92
Tab. 77 Fault: machine overheating ........................................................................................................ 93
Tab. 78 Fault: too much oil residue in the compressed air ...................................................................... 93
Tab. 79 Fault: oil flows from the compressor air filter after shutdown ..................................................... 94
Tab. 80 Fault: high moisture content in the compressed air .................................................................... 94
Tab. 81 There is no voltage or too low a voltage from the generator ...................................................... 94
Tab. 82 Generator voltage too high ......................................................................................................... 95
Tab. 83 Maintenance messages and measures connected with engine maintenance. .......................... 97
Tab. 84 Maintenance messages and measures connected with compressor maintenance. .................. 97
Tab. 85 Maintenance tasks after commissioning .................................................................................... 98
Tab. 86 Maintenance intervals and regular maintenance tasks .............................................................. 98
Tab. 87 Regular maintenance tasks ........................................................................................................ 99
Tab. 88 Regular maintenance tasks for options ...................................................................................... 102
Tab. 89 KAESER coolant mixture table ................................................................................................... 105
Tab. 90 Logged maintenance tasks ........................................................................................................ 150
Tab. 91 Compressor consumables .......................................................................................................... 151
Tab. 92 Consumable engine parts .......................................................................................................... 151
Tab. 93 "Temporarily decommissioned" information notice .................................................................... 153
Tab. 94 Long-term decommissioning checklist ....................................................................................... 154
Tab. 95 Text for the long-term decommissioned information notice ........................................................ 155
Tab. 96 Message code range 1100 – 1199: engine faults ....................................................................... 238
Tab. 97 Message code range 1200 – 1299: compressor unit faults ........................................................ 239
Tab. 98 Message code range 1300 – 1399: controller faults ................................................................... 239
Tab. 99 Message code range 1400 – 1499: general faults ..................................................................... 239
Tab. 100 Message code range 2100 – 2199: engine maintenance ........................................................... 240
Tab. 101 Message code range 2200 – 2299: compressor unit maintenance ............................................ 240
Tab. 102 Message code range 3100 – 3199: engine warnings ................................................................. 240
Tab. 103 Message code range 3200 – 3299: compressor unit warnings .................................................. 240
Tab. 104 Message code range 3400 – 3499: general warnings ................................................................ 240
List of Tables
x
Service Manual Screw Compressor
M135 SIGMA CONTROL MOBIL No.: 9_6975 00 E

1 Regarding this document
1.1 Using the Document
The service manual is part of the machine. It describes the machine as it was at the time of first
delivery after manufacture.
➤ Keep the service manual in a safe place throughout the life of the machine.
➤ Pass the manual on to the next owner/user of the machine.
➤ Ensure that all amendments received are entered in the manual.
➤ Enter details from the machine nameplate and individual items of equipment in the table in chap‐
ter 2.
1.2 Further documents
Included with this service manual are additional documents intended to assist in the safe operation
of the machine:
■ Certificate of acceptance / operating instructions for the pressure vessel
■ Manufacturer's declaration / declaration of conformity in accordance with applicable directives
■ Engine documentation (compressors driven by internal combustion engine)
Missing documents can be requested from KAESER.
➤ Make sure all documents are complete and observe the instructions contained in them.
➤ Make sure you give the data from the nameplate when ordering documents.
1.3 Copyright
This service manual is copyright protected. Queries regarding use or duplication of the documentation
should be referred to KAESER. Correct use of information will be fully supported.
1.4 Symbols and markings
1.4.1 Warning notices
Warning notices indicate three levels of danger signified by the signal word.
■ DANGER
■ WARNING
■ CAUTION
DANGER
These show the kind of danger and its source.
The possible consequences of ignoring a warning are shown here.
The signal word "DANGER" indicates that death or severe injury can result from ignoring the warn‐
ing.
➤ The measures required to protect yourself from danger are shown here.
1 Regarding this document
1.1 Using the Document
No.: 9_6975 00 E
Service Manual Screw Compressor
M135 SIGMA CONTROL MOBIL 1

➤ Always read and comply with warning instructions.
Signal word Meaning Consequences of non-observance
DANGER Warns of an imminent threat of danger Death or serious injury may result
WARNING Warns of possible danger Death or serious injury are possible
CAUTION Warns of a possibly dangerous situa‐
tion
Light injuries or material damage are possible
Tab. 1 The levels of danger and their meaning
1.4.2 Other notices and symbols
This symbol refers to particularly 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.
Here conditions relevant to safety are named that will help you to avoid dangerous situations.
➤ This symbol is is placed by lists of actions comprising one stage of a task.
In lists of actions with several stages the sequence of actions is numbered.
Information that refers to only one option is marked with a code (e.g.: "option da" means that this
section is only valid for machines with the air treatment components "aftercooler and cyclone
separator"). Option codes used in this service manual are explained in chapter 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 protection.
Further information Here, your attention is drawn to further topics.
1 Regarding this document
1.4 Symbols and markings
2
Service Manual Screw Compressor
M135 SIGMA CONTROL MOBIL No.: 9_6975 00 E
Option da

2 Technical Specification
2.1 Nameplate
The model designation and important technical information are given on the machine's nameplate.
The nameplate is located on the outside of the machine (see illustration in chapter 13.1)
➤ Enter the data from the nameplate here as a reference.
Characteristic Value
Vehicle identity no.
Permissible total weight
Permissible axle load
Permissible coupling load
Compressor model
Material number
serial number
Year of manufacture
Total weight
Lifting point load capacity
Rated engine power
Engine speed
Maximum working pressure
Tab. 2 Nameplate
2.2 List of Options
A list of the options fitted to your machine helps to relate the information in this service manual.
A list of options fitted is given as code letters on the right side of the coupling load / options label.
The label 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 label.
2 Technical Specification
2.1 Nameplate
No.: 9_6975 00 E
Service Manual Screw Compressor
M135 SIGMA CONTROL MOBIL 3

➤ Take a list of fitted options from the combined coupling load / options label.
M121 MATNR SERNR
Options fitted
Here is given the specified coupling load.
02-M0277
sg
tc
tb
ta
sc sdsa
shsi
ba bb
ga
fa
te
dd
dc
db
da
hd
hc
va
Tab. 3 Combined label for coupling load and options fitted
2.2.1 Option da, db, dc, dd
Compressed air treatment plant
➤ Enter the fitted options as reference.
Option Option code Exists?
Aftercooler and cyclone separator da
Heat exchanger db
Breathing air filter dc
Filter combination dd
Tab. 4 Compressed air treatment plant
2.2.2 Option fa
Compressed air distributor
➤ Enter the fitted option as reference.
Option Option code Exists?
Non-separated compressed air distribution line fa
Tab. 5 Compressed air distributor
2 Technical Specification
2.2 List of Options
4
Service Manual Screw Compressor
M135 SIGMA CONTROL MOBIL No.: 9_6975 00 E

2.2.3 Option hc, hd
Check valve function
➤ Enter the fitted option as reference.
Option Option code Exists?
Check valve hc, hd
Tab. 6 Check valve function
2.2.4 Option ba, bb
Low temperature equipment
➤ Enter the fitted option as reference.
Option Option code Exists?
Low temperature equipment ba
Low temperature equipment + engine coolant pre-
heating
bb
Tab. 7 Low temperature equipment
2.2.5 Option sa, sc, sd, sh, si
Chassis
➤ Enter the fitted option as reference.
Option Permissible
axle load [kg]
(remarks)
Option code Exists?
Height adjustable towbar 2700 sa
Fixed height towbar 2700 sd
Fixed height towbar
without parking brake
2700 sh
Stationary, on skids – sc
Stationary, on a base frame – si
Tab. 8 Chassis
2.2.6 Option ta, tb, tc, te
Lighting
➤ Enter the fitted option as reference.
Option Option code Exists?
None (stationary) ta
Reflective warning triangle tb
EG - 12 V tc
2 Technical Specification
2.2 List of Options
No.: 9_6975 00 E
Service Manual Screw Compressor
M135 SIGMA CONTROL MOBIL 5

Option Option code Exists?
USA 12 V (DOT conformity) te
Tab. 9 Lighting
2.2.7 Option sg
Pedestrian protection
➤ Enter the fitted option as reference.
Option Option code Exists?
Pedestrian protection sg
Tab. 10 Pedestrian protection
2.3 Machine (without options)
2.3.1 Sound emission
2.3.1.1 Sound emission
Model M135
Guaranteed sound power level* [dB(A)] 99
* To Directive 2000/14/EC
Tab. 11 Guaranteed sound power level
Model M135
Emission sound pressure level* [dB(A)]
According to EN ISO 11203: 1995 number 6.2.3.d.
80.5
Measurement distance: d = 1 m
Logarithmic surface ratio: Q2 = 18dB(A)
* Calculated from the guaranteed sound power level (2000/14/EC Directive, Sound Emission Stand‐
ard ISO 3744)
Tab. 12 Emission sound pressure level
2.3.1.2 Sound pressure level
Model M135
Sound pressure level* [dB(A)] 76
Measurement distance: 7 m
* Sound pressure levels comply with the American EPA Standard.
Tab. 13 Guaranteed sound pressure level
2 Technical Specification
2.3 Machine (without options)
6
Service Manual Screw Compressor
M135 SIGMA CONTROL MOBIL No.: 9_6975 00 E

2.3.2 Torques
Recommended values for hexagonal bolts of strength category 8.8
Hex-head screws
Thread M6 M8 M10 M12 M14 M16 M18
Torque [Nm] 9,5 23 46 80 127 195 280
Tab. 14 Torques for hex-head screws
2.3.3 Ambient conditions
Installation Limit value
Maximum altitude AMSL* [m] 1000
Minimum ambient temperature [°C] −10
Maximum ambient temperature [°C] +50
* Higher altitudes are permissible only after consultation with the manufacturer.
Tab. 15 Ambient conditions
2.3.4 Additional specifications
For specifications according to the machine's operating licence, such as:
■ dimensions,
■ track width,
■ footprint,
see the dimensional drawing in chapters 13.3, 13.4, 13.5, 13.6 and 13.7.
The dimensional drawing also shows the position of the following inlets and outlets:
■ Cooling air inlet
■ Cooling air outlet
■ Compressed air outlet
■ Exhaust
2.4 Chassis
2.4.1 Weights
Maximum weights are shown. Actual weights of individual machines are dependent on equip‐
ment fitted (see machine nameplate).
Characteristic Chassis Stationary
Height adjustment with without –
Actual total weight [kg]*
* Enter here for reference, the actual total weight taken from the nameplate.
2 Technical Specification
2.4 Chassis
No.: 9_6975 00 E
Service Manual Screw Compressor
M135 SIGMA CONTROL MOBIL 7

Characteristic Chassis Stationary
Permissible axle load [kg] 2700 2700 –
* Enter here for reference, the actual total weight taken from the nameplate.
Tab. 16 Machine weights
2.4.2 Tyres
Characteristic/marking Axle load up to
2700
Tyre size 215/75R 17.5
Maximum and recommen‐
ded tyre pressure [bar]
5.75
Wheel bolts M 18 x 1.5
Tab. 17 Tyres
Further information See tyre side wall for maximum pressure.
2.4.3 Wheel nut/bolt tightening torque
Fixing medium Thread Wrench size Torque [Nm]
Wheel bolt M 18 x 1.5 34 325
Tab. 18 Wheel nut/bolt tightening torque
2.4.4 Towbar tightening torque
Component Thread Strength category Torque [Nm]
Ball coupling M16 8.8 210
Towing eye M16 8.8 210
Towbar M20 10.9 540–560
M24 8.8 670–690
Tab. 19 Towbar tightening torque
2.5 Compressor
2.5.1 Working pressure and FAD
Maximum working pressure [bar] 10 12 14
SIGMA airend 29 G
Free air delivery [m3/min] 13.0 12.0 10.5
Tab. 20 Working pressure and FAD
2 Technical Specification
2.5 Compressor
8
Service Manual Screw Compressor
M135 SIGMA CONTROL MOBIL No.: 9_6975 00 E