KAESER KOMPRESSOREN SIGMA CONTROL SMART M114

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Operator Manual

Screw Compressor

M114 SIGMA CONTROL SMART

No.: 901765 05 USE

Manufacturer:

KAESER KOMPRESSOREN SE

96410 Coburg • PO Box 2143 • GERMANY • Tel. +49-(0)9561-6400 • Fax +49-(0)9561-640130

http://www.kaeser.com

Main Page

Table of Contents3
Regarding this Document Using this Document13
Further Documents13
Copyright13
Symbols and Labels13
Warnings13
Tab. 1 Danger Levels and Their Definitions (Personal Injury)13
Potential Damage Warnings14
Other Alerts and Their Symbols14
Tab. 2 Danger Levels and Their Definition (Damage to Property)14
Technical Data Nameplate16
Options - Options Label16
Tab. 3 Nameplate16
Compressed Air Treatment Devices17
Tool Lubricator17
Compressed Air Distributor17
Tab. 4 Extract from the Options Label17
Tab. 5 Compressed Air Treatment Options17
Tab. 6 Tool Lubricator Option17
Tab. 7 Compressed Air Distributor Option17
Low Temperature Equipment18
Equipment for Fire Hazard Areas18
Automatic Engine Start/Stop18
GSM/GPS Modem18
Chassis18
Tab. 8 Low Temperature Equipment Options18
Tab. 9 Optional Equipment for Fire Hazard Areas18
Tab. 10 Automatic Engine Start/Stop18
Tab. 11 GSM/GPS Modem18
Lighting19
Sealed Floor Pan19
Anti-Theft Device19
Tab. 12 Chassis Options19
Tab. 13 Options, Stationary Frame19
Tab. 14 Lighting Options19
Tab. 15 Sealed Floor Pan Option19
Tab. 16 Anti-Theft Device Option19
Pedestrian Protection20
Machine (Without Options)20
Sound Pressure Level20
Tightening Torques for Screws20
Ambient Conditions20
Additional Specifications20
Tab. 17 Pedestrian Protection Option20
Tab. 18 Sound Pressure Level20
Tab. 19 Tightening Torques for Screws (Property Class 8.8, Coefficient of Friction Μ = 0.12)20
Tab. 20 Ambient Conditions20
Chassis21
Mass21
Tires21
Fig. 1 Example for Tire Information on the Side Wall21
Tab. 21 Mass of the Machine21
Wheel Nut/Bolt Tightening Torque22
Towbar Tightening Torque22
Compressor22
Working Pressure and FAD22
Compressed Air Outlet22
Safety Valves22
Tab. 22 Tires22
Tab. 23 Wheel Nut/Bolt Tightening Torque22
Tab. 24 Towbar Tightening Torque22
Tab. 25 Working Gauge Pressure and FAD22
Temperature23
Cooling Oil Recommendation23
Tab. 27 Safety Relief Valve Opening Pressure23
Tab. 28 Required Temperatures Readiness to Switch to LOAD Mode23
Tab. 29 Airend Discharge Temperature23
Tab. 30 Cooling Oil Recommendations23
Cooling Oil Charge24
Tab. 31 Cooling Oil Recommendation (Food Processing)24
Engine25
Engine Specification25
Oil Recommendation25
Tab. 32 Cooling Oil Charge25
Tab. 33 Engine Specification25
Fuel Recommendation26
Tab. 34 Engine Oil Recommendation26
Tab. 35 Initial Engine Oil Quantity26
Engine Coolant Recommendation27
Fluid Volumes27
Batteries27
Tab. 36 Water Quality Parameters for Cooling Water27
Tab. 37 Fluid Volumes27
Tab. 38 Batteries27
Options28
Air Treatment Options28
Tab. 39 Road Breaker Lubricant Recommendation28
Tab. 40 Fresh Air Filter Conditions28
Low Temperature Equipment29
Trickle Charging for Starter Batteries29
Tab. 41 Interrelation between Compressed Air Treatment and Compressed Air Quality29
Tab. 42 Environmental Conditions, Low Temperature Equipment29
Tab. 43 Coolant Pre-Heater29
Tab. 44 Batteries, Low-Temperature Equipment29
Tab. 45 Battery Charger Specification30
Tab. 46 Power Supply Details30
Safety and Responsibility Basic Instructions31
Specified Use31
Incorrect Use31
User's Responsibilities31
Observe Statutory and Universally Accepted Regulations31
Determining Personnel32
Adherence to Inspection Schedules and Accident Prevention Regulations32
Taking the Machine for General Inspection32
Documenting the Mileage of the Machine as Trailer33
Dangers33
Safely Dealing with Sources of Danger33
Tab. 47 General Inspection Intervals33
Safe Machine Operation36
Organizational Measures40
Danger Areas40
Safety Devices40
Safety Signs40
Tab. 48 Danger Areas40
Fig. 2 Location of Safety Signs41
Noise Control Requirements44
Emergencies44
Correct Fire Fighting44
Tab. 49 Safety Signs44
Contact with Operating Fluids/Materials45
Warranty45
Noise Emissions Warranty46
Identifying the Effects of Improper Modifications46
Environmental Protection47
Design and Function Bodywork48
Fig. 3 Overview of Bodywork48
Machine Structure49
Machine Function49
Fig. 4 Right-Hand Door Opened49
Fig. 5 Left-Hand Door Opened49
Fig. 35 "Battery Isolating Switch49
Fig. 6 Machine Overview50
Operating Modes and Control Mode51
Machine Operating Modes51
MODULATING Control51
Safety Devices52
Monitoring Functions with Shut-Down52
Further Safety Devices52
Fig. 7 Stepless Regulation of FAD(Standstill)52
Battery Isolating Switch53
SIGMA CONTROL SMART Control Panel53
Fig. 8 Battery Isolating Switch53
Fig. 9 SIGMA CONTROL SMART Operator Panel - Overview53
Emission After-Treatment54
Tab. 50 Instrument Panel Keys and Displays54
Options55
Fig. 10 Principle of Treatment Devices55
Air Treatment Options56
Fig. 11 Compressed Air Options56
Fig. 12 Tool Lubricator58
Fig. 13 Principle Tool Lubricator58
Low Temperature Equipment Options59
Options for Operating in Fire Hazard Areas59
Fig. 14 Coolant Pre-Heating59
Fig. 15 Engine Air Shut-Off Valve60
Start/Stop/Automatic Options61
GSM/GPS Modem" Option61
Transport Options61
Fig. 16 Access Engine Air Shut-Off Valve61
Sealed Floor Pan Option63
Fig. 17 Position of Service Openings in the Sealed Floor Pan63
Optional Anti-Theft Device64
Pedestrian Protection Option64
Fig. 18 Drain Points for Oil and Coolant from Engine and Compressor64
Installation and Operating Conditions65
Ensuring Safety65
Installation Conditions65
Fig. 19 Minimum Distance from Excavations/Slopes and Walls65
Machine with Stationary Frame Structure66
Installation67
Ensuring Safety67
Reporting Transport Damage67
Fitting the Tow Bar67
Fitting the Height Adjustable Tow Bar68
Fig. 20 Height Adjustable Tow Bar, Fitted68
Fig. 21 Fitting the Height Adjustable Tow Bar68
Fitting a Non-Adjustable Tow Bar69
Fig. 22 Non-Adjustable Tow Bar Fitted69
Fig. 23 Fitting the Overrun Braking Mechanism of the Non-Adjustable Tow Bar70
Adjusting the Chassis71
Fig. 24 Fitting the Jockey Wheel of the Non-Adjustable Tow Bar71
Adjusting the Tow Bar Height72
Changing the Towing Eye/Ball Hitch72
Fig. 25 Tow Bar Height Adjustment72
Fig. 26 Changing the Towing Eye (Height-Adjustable Tow-Bar)73
Fig. 27 Changing the Towing Eye/Ball Hitch (Fixed Height Tow Bar)74
Fig. 28 Changing the Towing Eye (Fixed Height Tow Bar, USA Chassis Version)75
Connecting the Battery Trickle Charger76
Installing a Machine with Stationary Frame Superstructure on a Truck Platform76
Initial Start-Up Ensuring Safety78
Before Initial Start-Up (or Recommissioning)78
Instructions to be Observed before Commissioning or Recommissioning78
Special Measures for Recommissioning after Storage79
Checking Installation and Operating Conditions79
Tab. 51 Measures for Recommissioning the Compressor after a Long Period of Storage79
Tab. 52 Positioning and Operating Conditions Checklist79
Low-Temperature Operation (Winter)80
Starting Assistance80
Fig. 29 Jumper Cable Connection Diagram81
Starting up Low-Temperature Equipment82
Trickle-Charging the Battery83
Fig. 30 Coolant Pre-Heating83
Fig. 31 Battery Charger84
Tab. 53 Standard Battery Charger Readings84
Operation85
Ensuring Safety85
Starting and Stopping86
Fig. 32 Starting Instruments86
Follow the Brief Instructions87
Fig. 33 Instrument Panel Keys and Indicators87
Fig. 34 Brief Instructions on Starting and Stopping87
Starting the Machine88
Setting the Compressed Air Discharge Pressure89
Fig. 36 Setting the Quick Access for the Compressed Air Discharge Pressure90
Shutting down the Machine91
Fig. 37 Setting the Compressed Air Discharge Pressure91
Shutting down in an Emergency93
Confirming Alarm and Warning Messages93
Acknowledging Alarm Messages93
Acknowledging Warning Messages94
Operating the Tool Lubricator94
Fig. 38 Setting the Tool Lubricator95
Using the Low-Temperature Equipment96
Shut down the Machine if any Dangerous Situation Arises96
Fig. 39 Handle for Manually Closing the Engine Air Intake Valve96
Cleaning the Machine after Operation97
Fault Recognition and Rectification98
Basic Instructions98
Analysing SIGMA CONTROL SMART Messages98
Alarm Messages on the Controller (Machine Off)98
Tab. 54 Alarm Messages and Actions Concerning the Engine99
Tab. 55 Alarm Messages and Actions Concerning the Compressor Unit100
Tab. 56 Alarm Messages and Actions Concerning the Controller100
Warning Message on the Controller101
Tab. 57 General Alarm Messages and Measures101
Tab. 58 Warning Messages and Measures Relating to the Engine102
Evaluating Engine Faults and Alarms103
Tab. 59 Warning Messages and Measures Relating to the Compressor103
Tab. 60 General Warning Messages and Measures103
Engine Does Not Reach Full Speed104
Tab. 61 Fault: Engine Refuses to Start or Comes to a Stop104
Tab. 62 Alarm: "Engine Does Not Reach Full Speed104
Analysing Compressor Faults and Alarms105
Working Pressure too High105
Working Pressure too Low105
Tab. 63 Fault: Working Pressure too High105
Tab. 64 Fault: Working Pressure too Low105
Pressure Relief Valve Blowing off106
Machine Overheating106
Tab. 65 Fault: Pressure Relief Valve Blowing off106
Tab. 66 Fault: Machine Overheating106
Too Much Oil Residue in the Compressed Air107
Oil Flows from the Compressor Air Filter after Shutdown107
High Moisture Content in the Compressed Air107
Tab. 67 Alarm: "Too Much Oil Residue in the Compressed Air107
Tab. 68 Alarm: "Oil Flows from the Compressor Air Filter after Shutdown107
Tab. 69 Fault: High Moisture Content in the Compressed Air107
10 Maintenance108
Ensuring Safety108
Tab. 70 Advise Others that the Machine Is Being Serviced108
Noting the Maintenance Messages on the Controller109
Evaluating the Maintenance Message109
Tab. 71 Maintenance Messages and Required Actions109
Maintenance Messages110
Maintenance Schedules110
Logging Maintenance Work110
Maintenance Tasks after Commissioning110
Regular Maintenance Tasks111
Tab. 72 Maintenace Tasks on the Machine after Commissioning111
Tab. 73 Maintenance Tasks on the Chassis after Commissioning111
Tab. 74 Maintenance Intervals and Regular Maintenance Tasks112
Tab. 75 Regular Machine Maintenance Tasks114
Tab. 76 Regular Maintenance Task Options115
Tab. 77 Chassis Maintenance Intervals and Regular Maintenance Tasks115
Tab. 78 Regular Chassis Maintenance Tasks116
Engine Maintenance117
Water Cooler Maintenance117
Fig. 40 Checking Coolant Level118
Tab. 79 KAESER Coolant Mixture Table119
Fig. 41 Draining the Coolant from the Radiator120
Engine Air Filter Maintenance121
Fig. 42 Engine Air Filter Maintenance122
Fig. 43 Cleaning the Filter Element122
Fuel System Maintenance123
Fig. 44 Fuel System Maintenance124
Fig. 45 Bleeding the Fuel System124
Fig. 46 Warning Messages: Fuel Filter Water Level125
Fig. 47 Emptying the Fuel Pre-Filter and Water Trap126
Fig. 48 Changing the Fuel Pre-Filter Cartridge127
Fig. 49 Fuel Fine Filter Maintenance128
Checking the Engine Oil Level129
Fig. 50 Checking the Engine Oil Level129
Engine Oil Filling and Topping off130
Changing the Engine Oil130
Fig. 51 Draining the Engine Oil131
Replace the Engine Oil Filter132
Fig. 52 Change the Oil Filter132
Engine Belt Maintenance133
Fig. 53 Belt Guard Attachment134
Fig. 54 Checking the Drive Belt Seating134
Fig. 55 Manually Checking the Belt Tension135
Fig. 56 Changing/Tensioning the Drive Belt136
Battery Maintenance138
Fig. 57 Safety Signs - Warning Stickers on the Battery138
Checking the Fastening of the Fuel Tank140
Compressor Maintenance141
Checking the Cooling Oil Level141
Cooling Oil Filling and Topping off142
Fig. 58 Check the Cooling Oil Level142
Changing the Cooling Oil143
Fig. 59 Draining the Compressor Cooling Oil144
Replacing the Compressor Oil Filter145
Fig. 60 Change the Oil Filter146
Oil Separator Tank Dirt Trap Maintenance147
Fig. 61 Oil Separator Tank Dirt Trap Maintenance147
Changing the Oil Separator Cartridge148
Fig. 62 Changing the Oil Separator Cartridge149
Compressor Air Filter Maintenance150
Fig. 63 Compressor Air Filter Maintenance151
Fig. 64 Cleaning the Filter Element152
Checking Safety Relief Valves153
Fit the Flexible Pipe Connection153
Fig. 65 Fit the Flexible Pipe Connection153
Tab. 80 Dimensions of the Flexible Pipe Connection153
Cleaning the Cooler154
Cleaning the Compressor Cooler and Engine Radiator154
Cleaning the Compressed Air Aftercooler155
Fig. 66 Cleaning the Compressor Cooler and Engine Radiator155
Maintenance of Rubber Sealing Strips156
Fig. 67 Cleaning the Compressed Air Aftercooler156
Chassis Maintenance157
Wheel Checks157
Towbar Maintenance157
Fig. 68 Tow Bar Maintenance158
Fig. 69 Maintaining the Fixed Height Towbar158
Fig. 70 Ball Coupling ( EC Version)159
Brake Maintenance160
Fig. 71 Ball Coupling (USA Version)160
Fig. 72 Checking the Brake Lining Thickness161
Fig. 73 Brake System Adjustment161
Fig. 74 Brake Rod Adjustment162
Maintenance for Optional Items163
Tool Lubricator Maintenance163
Fig. 75 Tool Lubricator Maintenance164
Cyclone Separator Maintenance165
Fig. 76 Cleaning the Dirt Trap165
Combination Filter Maintenance166
Fig. 77 Filter Combination167
Fig. 78 Combination Filter Maintenance167
Fresh Air Filter Maintenance170
Fig. 79 Fresh Air Filter Maintenance170
Engine Air Intake Shut-Off Valve Maintenance173
Fig. 80 Maintain the Engine Air Shut-Off Valve173
Fig. 81 Checking Manual Operation of the Engine Air Intake Valve174
Spark Arrestor Maintenance175
Fig. 82 Cleaning the Spark Arrestor (Floor Pan with Service Openings)176
Fig. 83 Cleaning the Spark Arrestor (Sealed Floor Pan)176
Draining Liquid Accumulation Within the Machine177
Documenting Maintenance and Service Work179
Tab. 81 Maintenance Log179
11 Spares, Operating Materials, Service180
Note the Nameplate180
Ordering Consumable Parts and Operating Fluids/Materials180
Tab. 82 Compressor Spare Parts180
Kaeser Air Service181
Service Addresses181
Replacement Parts for Service and Repair181
Tab. 83 Consumable Engine Parts181
Tab. 84 Replacement Parts, Combination Filter181
Tab. 85 Replacement Parts, Fresh-Air Filter181
12 Decommissioning, Storage and Transport236
Commissioning236
Temporary De-Commissioning236
Tab. 86 "Temporarily Decommissioned" Information Notice236
Long-Term Decommissioning and Storage237
Tab. 87 Long-Term Decommissioning and Storage Checklist237
Transport238
Safety238
Towing the Compressor on the Road238
Tab. 88 Text for the Long-Term Decommissioned and Storage Information Notice238
Fig. 84 Transport Position240
Fig. 85 Ball Coupling (ALKO-EU)241
Fig. 86 Wear Alert, Ball Coupling (ALKO-EU)242
Tab. 89 Ball Coupling Wear Indicator242
Fig. 87 Ball Coupling (ALKO-USA)243
Fig. 88 Release the Parking Brake243
Fig. 89 Automatic Jockey Wheel in Transport Position244
Fig. 90 Safety Signs: Secure the Chocks245
Fig. 91 Breakaway Cable Attachment246
Fig. 92 Attach Safety Chains246
Parking the Machine247
Fig. 93 Warning "Injury Can Occur if the Tow Bar Is Allowed to Fall247
Fig. 94 Tow Bar with Automatic Jockey Wheel248
Fig. 95 Actuating the Parking Brake248
Fig. 96 Safety Signs: Secure with Chocks249
Transport with a Crane250
Transport with a Forklift Truck251
Transporting the Machine as Load251
Fig. 97 Transporting Using a Forklift Truck251
Fig. 98 Guys to Secure the Freight252
Storage253
Disposal253
13 Annex254
Marking254
Pipeline and Instrument Flow Diagram (P+I Diagram)254
Fig. 99 Marking254
Dimensional Drawings259
Dimensional Drawing - Chassis259
Dimensional Drawing, Chassis Options261
Dimensional Drawing, Chassis Options263
Dimensional Drawing, Chassis Options265
Dimensional Drawing, Stationary Version267
Dimensional Drawing, Stationary Version269
Wiring Diagrams271
Electrical Diagram271
Lighting and Signaling System Connection289
Lighting and Signaling System Connection297
Battery Charger Electrical Diagram302
Fuel Circulation Diagram312
Assembly Diagrams - Chassis315
Assembly Diagrams - Chassis EU Version315
Assembly Diagrams - Chassis GB/US Version317
Assembly Diagram Brake Rod320
Operating Instructions for Compressed Air Filter (Combination Filter)322
Operating Instructions for Compressed Air Filter (Fresh Air Filter)350

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KAESER KOMPRESSOREN SIGMA CONTROL SMART M114 Specifications

General

Brand	KAESER KOMPRESSOREN
Model	SIGMA CONTROL SMART M114
Category	Air Compressor
Language	English

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KAESER KOMPRESSOREN SIGMA CONTROL SMART M114 - User Manual

Table of Contents

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