Name: KAESER KOMPRESSOREN SIGMA CONTROL SMART MOBILAIR M82
Brand: KAESER KOMPRESSOREN
Rating: 4 (1 reviews)

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Operator Manual

Portable Rotary Screw Compressor

MOBILAIR M82 SIGMA CONTROL SMART

No.: 901783 08 USE

Manufacturer:

KAESER KOMPRESSOREN SE

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

www.kaeser.com

Table of Contents3
Regarding this Document Using this Document15
Further Documents15
Copyright15
Symbols and Labels15
Warnings15
Potential Damage Warnings16
Tab. 1 Danger Levels and Their Definition (Personal Injury)16
Tab. 2 Danger Levels and Their Definition (Damage to Property)16
Other Alert Notes and Their Symbols17
Technical Data Nameplate18
Vehicle Identification Number18
Options - Options Label18
Tab. 3 Nameplate18
Compressed Air Treatment Devices19
Tool Lubricator19
Compressed Air Distributor19
Tab. 4 Extract from the Options Label19
Tab. 5 Air Treatment Options19
Tab. 6 Tool Lubricator Option19
Tab. 7 Compressed Air Distributor Option19
Low Temperature Equipment20
Equipment for Fire Hazard Areas20
Automatic Engine Start/Stop20
GSM/GPS Unit20
Lighting20
Tab. 8 Low Temperature Equipment Options20
Tab. 9 Optional Equipment for Fire Hazard Areas20
Tab. 10 Automatic Engine Start/Stop20
Tab. 11 GSM/GPS Unit20
Tab. 12 Lighting Options20
Generator21
Closed Floor Pan21
Anti-Theft Device21
Pedestrian Protection21
Machine (Without Options)21
Sound Pressure Level21
Tab. 13 Generator Option21
Tab. 14 Closed Floor Pan Option21
Tab. 15 Anti-Theft Device Option21
Tab. 16 Pedestrian Protection Option21
Tightening Torque22
Tab. 18 Torques for M4-M8 Screws22
Tab. 19 Torques for M10-M24 Screws22
Tab. 20 Torques for Lifting Eye Screws22
Tab. 21 Torque Cover Fixing Screws Oil Separator Tank22
Ambient Conditions23
Additional Specifications23
Chassis23
Chassis Options23
Machines with Stationary Frame Design23
Weight of Machines with Stationary Frame Design23
Tab. 22 Ambient Conditions23
Tab. 23 Weight of the Machine23
Compressor24
Working Gauge Pressure and Volumetric Flow Rate24
Compressed Air Outlet24
Safety Valves24
Temperature24
Tab. 24 Working Gauge Pressure and Volumetric Flow Rate24
Tab. 25 Compressed Air Distributor24
Tab. 26 Safety Valve Opening Pressure24
Tab. 27 Required Temperatures Readiness to Switch to LOAD Mode24
Tab. 28 Airend Discharge Temperature24
Cooling Oil Recommendation25
Tab. 29 Cooling Oil Recommendation25
Tab. 30 Cooling Oil Recommendation (Food Processing)25
Cooling Oil Charge26
Engine26
Engine Specification26
Tab. 31 Cooling Oil Charge26
Tab. 32 Kubota / V 3307-CRT Engine Specifications26
Oil Recommendation27
Tab. 33 Engine Specifications27
Fuel Recommendation28
Tab. 34 Engine Oil Recommendation28
Tab. 35 Initial Engine Oil Quantity28
Engine Coolant Recommendation29
Tab. 36 Water Quality Parameters for Cooling Water29
Fluid Volumes30
Batteries30
Tab. 37 Initial Filling of Engine Water Cooler30
Tab. 38 Fluid Volumes30
Tab. 39 Batteries30
Options31
Air Treatment Options31
Tab. 40 Road Breaker Lubricant Recommendation31
Tab. 41 Fresh Air Filter Conditions31
Tab. 42 Interrelation between Compressed Air Treatment and Compressed Air Quality31
Low Temperature Equipment32
Auxiliary Electrical Systems32
Tab. 43 Ambient Conditions, Low Temperature Equipment32
Tab. 44 Power Supply Connection Details32
Tab. 45 Technical Data - Coolant Pre-Heating Device32
Generator33
Tab. 46 Battery Charger Specification33
Tab. 47 Generator Specification33
Tab. 48 Flow Rate in Generator Mode33
Tab. 49 Connection Sockets34
Tab. 50 Circuit Breaker34
Tab. 51 Generator Operating Limits34
GSM/GPS Unit35
Tab. 52 Maximum Three-Phase Mains Loading35
Tab. 53 Maximum Single-Phase Mains Loading35
Tab. 54 Power Reduction at Elevated Ambient Temperatures35
Tab. 55 GSM/GPS Unit35
Safety and Responsibility Basic Instructions36
Specified Use36
Incorrect Use36
User's Responsibilities36
Observe Statutory and Universally Accepted Regulations36
Determining Personnel37
Complying with Inspection Schedules and Accident Prevention Regulations37
Taking the Machine for General Inspection38
Tab. 56 Inspection Intervals According to Ordinance on Industrial Health and Safety38
Tab. 57 General Inspection Intervals38
Documenting the Mileage of the Machine as Trailer39
Dangers39
Safely Dealing with Sources of Danger39
Safe Machine Operation42
Organizational Measures45
Danger Areas46
Safety Devices46
Safety Signs46
Tab. 58 Danger Areas46
Fig. 1 Location of Safety Signs (Outside)47
Fig. 2 Location of Safety Signs (Inside)50
Tab. 59 Safety Signs50
Tab. 60 Safety Signs50
Noise Control Requirements51
Generator Operation52
Comply with the Protective Measures against Dangerous Electric Current52
Safe Generator Operation52
Connecting Extension Cables52
Do Not Exceed the Maximum Supply System Load53
Perform Regular Generator Inspections53
Emergencies53
Correct Actions in the Event of a Fire53
Treating Injuries from Handling Operating Fluids/Materials54
Warranty54
Noise Emissions Warranty55
Identifying the Effects of Improper Modifications55
Environmental Protection56
Design and Function Bodywork57
Fig. 3 Overview of Bodywork57
Machine Layout58
Fig. 4 Right-Hand Door Opened58
Fig. 5 Left-Hand Door Opened58
Machine Function59
Fig. 6 View from Above, Machine Roof Removed59
Fig. 7 Machine Overview60
Operating Modes and Control Mode61
Machine Operating Modes61
MODULATING Control61
Safety Devices62
Monitoring Functions with Shut-Down62
Further Safety Devices62
Fig. 8 Continuous Regulation of Volumetric Flow (Standstill)62
Battery Isolating Switch63
SIGMA CONTROL SMART Control Panel63
Fig. 9 Battery Isolating Switch63
Fig. 10 SIGMA CONTROL SMART Operator Panel - Overview63
Exhaust Gas After-Treatment64
Tab. 61 Instrument Panel Keys and Displays64
Engine Optimisation65
Exhaust Gas Treatment System65
Options66
Fig. 11 Principle of Treatment Devices66
Air Treatment Options67
Fig. 12 Compressed Air Options67
Tab. 62 Compressed Air Quality With/Without Heat Exchanger68
Fig. 13 Tool Lubricator70
Fig. 14 Principle Tool Lubricator70
Auxiliary Electrical Systems71
Low Temperature Equipment Options71
Options for Operating in Fire Hazard Areas72
Generator Option72
Tab. 63 Generator / Compressor Operation72
Fig. 15 Instrument Panel - Generator Control Box, 400 V Three Phase73
Tab. 64 Generator Operating Modes73
Fig. 16 Instrument Panel - Generator Control Box, 230 V Three Phase74
Fig. 17 Control Panel, Generator Control Box, 115 V AC74
Start/Stop/Automatic Options75
GSM/GPS Unit75
Transport Options76
Frame Design Options for Stationary Machines76
Closed Floor Pan Option76
Tab. 65 Stationary Machines76
Pedestrian Protection Option77
Fig. 18 Position of Service Openings in the Closed Floor Pan77
Fig. 19 Drain Points for Oil and Coolant from Engine and Compressor77
Installation and Operating Conditions78
Ensuring Safety78
Installation Conditions78
Fig. 20 Minimum Distance from Excavations/Slopes and Walls78
Machine with Stationary Frame Structure79
Installation80
Ensuring Safety80
Reporting Transport Damage80
Perform Regular Maintenance on the Chassis80
Installing a Machine with Stationary Frame Superstructure on a Truck Platform80
Have the "Remote on Contact" of the Automatic Start/Stop System Connected81
Electrical Connection of the Battery Charger81
Initial Start-Up Ensuring Safety82
Before Initial Start-Up (or Recommissioning)82
Instructions to be Observed before Commissioning or Recommissioning82
Special Measures for Recommissioning after Storage83
Checking Installation and Operating Conditions83
Tab. 66 Measures for Recommissioning the Compressor after a Long Period of Storage83
Tab. 67 Positioning and Operating Conditions Checklist83
Low-Temperature Operation (Winter)84
Jump Starting the Machine84
Fig. 21 Jumper Cable Connection Diagram85
Starting up Low-Temperature Equipment86
Commissioning Electrical Equipment87
Activating the Generator87
Checking the Generator87
Fig. 22 Connect Auxiliary Electrical Systems87
Fig. 23 Insulation Monitoring - 400 V Three-Phase Generator88
Fig. 24 Insulation Monitoring - 230 V Three-Phase Generator88
Fig. 25 Insulation Monitoring - 115 V Single Phase Generator89
Tab. 68 Test Instructions for a Generator with an Earth Leak Detection Device89
Operation90
Ensuring Safety90
Starting and Stopping91
Fig. 26 Starting Instruments91
Follow the Brief Operating Instructions92
Fig. 27 Instrument Panel Keys and Indicators92
Fig. 28 Brief Instructions on Starting Procedure92
Commissioning the Machine93
Fig. 29 Brief Instructions on Stopping Procedure93
Starting the Machine94
Fig. 30 "Battery Isolating Switch94
Setting the Compressed Air Discharge Pressure95
Fig. 31 Quick Access Adjustment Compressed Air Output Pressure96
Shutting down the Machine97
Fig. 32 Setting the Compressed Air Discharge Pressure97
Shutting down in an Emergency99
Confirming Alarm and Warning Messages99
Confirming Alarm Messages99
Confirming Warning Messages100
Operating the Options100
Operating the Machine with the "Automatic Start/Stop" Option100
Fig. 33 Preparing Start of the "Automatic Start/Stop101
Operating the Tool Lubricator102
Fig. 34 Setting the Tool Lubricator103
Using the Low-Temperature Equipment104
Bypassing and Activating the Heat Exchanger104
Tab. 69 Shut-Off Valve Position and Selected Compressed Air Quality104
Fig. 35 Heat Exchanger Without Bypass Operation (with Compressed Air Heating)105
Fig. 36 Heat Exchanger with Bypass Operation (no Compressed Air Heating)106
Generator Operation107
Tab. 70 Shut-Off Valve Position and Selected Compressed Air Quality107
Cleaning the Machine after Operation108
Refuelling the Machine109
Use the Correct Type of Fuel109
Fig. 37 Filling the Tank with the Correct Fuel Type110
Tab. 71 Measures Required Should the Fuel Tanks be Filled with the Incorrect Fuel Type110
Filling the Fuel Tank at a Pump by Means of a Refuelling Nozzle111
Tab. 72 Fuel Type/Fuel Specification111
Filling the Fuel Tank on a Construction Site by Means of a Canister112
Fault Recognition and Rectification113
Basic Instructions113
Analysing SIGMA CONTROL SMART Messages113
Alarm Messages on the Controller (Machine Off)113
Tab. 73 Alarm Messages and Actions Concerning the Motor/Engine114
Tab. 74 Alarm Messages and Actions Concerning the Compressor Unit115
Tab. 75 Alarm Messages and Actions Concerning the Controller115
Warning Messages on the Controller116
Tab. 76 Alarm Messages and Troubleshooting in "General Faults116
Tab. 77 Warning Messages and Measures Relating to the Engine117
Tab. 78 Warning Messages and Measures Relating to the Compressor117
Evaluating Engine Faults and Alarms118
Engine Refuses to Start or Does Not Turn over118
Tab. 79 General Warning Messages and Measures118
Engine Does Not Reach Full Speed119
Analysing Compressor Faults and Alarms119
Working Pressure too High119
Tab. 80 Fault: Engine Refuses to Start or Comes to a Stop119
Tab. 81 Alarm: "Engine Does Not Reach Full Speed119
Tab. 82 Fault: Working Pressure too High119
Working Pressure too Low120
Safety Valve Blows off120
Machine Overheating120
Tab. 83 Fault: Working Pressure too Low120
Tab. 84 Fault: Safety Valve Blowing off120
Too Much Oil Residue in the Compressed Air121
Tab. 85 Fault: Machine Overheating121
Tab. 86 Alarm: "Too Much Oil Residue in the Compressed Air121
Oil Flows from the Compressor Air Filter after Shutdown122
High Moisture Content in the Compressed Air122
Generator Faults and Alarms122
No Voltage or too Low a Voltage from the Generator122
Tab. 87 Alarm: "Oil Flows from the Compressor Air Filter after Shutdown122
Tab. 88 Fault: High Moisture Content in the Compressed Air122
Generator Voltage too High123
Tab. 89 Fault: no Voltage or too Low a Voltage from the Generator123
Tab. 90 Fault: Generator Voltage too High123
10 Maintenance124
Ensuring Safety124
Tab. 91 Advise Others that the Machine Is Being Serviced124
Note the Maintenance Messages on the Controller125
Evaluating the Maintenance Message125
Concluding the Maintenance126
Maintenance Schedules126
Logging Maintenance Work126
Preventive Maintenance126
Tab. 92 Maintenance Messages and Required Actions126
Maintenance Tasks after Commissioning127
Regular Maintenance Tasks127
Tab. 93 Maintenance Tasks on the Machine after Commissioning127
Tab. 94 Maintenance Intervals and Regular Maintenance Tasks128
Tab. 95 Regular Machine Maintenance Tasks131
Drive Engine Maintenance132
Tab. 96 Regular Maintenance Task Options132
Coolant Cooler Maintenance133
Fig. 38 Checking the Coolant Level134
Fig. 39 Recommended Mixture Ratio for Coolant135
Tab. 97 Coolant Mixture Table136
Fig. 40 Draining the Coolant from the Engine Coolant Cooler137
Fig. 41 Draining the Coolant from the Engine Coolant Cooler (Closed Floor Pan/Stationary Machine)138
Engine Air Filter Maintenance139
Fig. 42 Cleaning the Dust Evacuator Valve140
Fig. 43 Engine Air Filter Maintenance140
Fig. 44 Cleaning the Filter Element141
Fuel System Maintenance142
Fig. 45 Service Fuel System142
Fig. 46 Bleeding the Fuel System143
Fig. 47 Warning Message: Fuel Filter Water Level144
Fig. 48 Empty the Fuel Prefilter and Water Separator144
Fig. 49 Change the Fuel Prefilter Cartridge145
Fig. 50 Fuel Filter Maintenance146
Checking the Engine Oil Level147
Fig. 51 Checking the Engine Oil Level147
Engine Oil Filling and Topping up148
Changing the Engine Oil148
Fig. 52 Draining the Engine Oil149
Fig. 53 Draining the Engine Oil (Stationary Machine)150
Replace the Engine Oil Filter151
Fig. 54 Change the Oil Filter151
Drive Belt Maintenance152
Fig. 55 Belt Guard Attachment153
Fig. 56 Checking the Drive Belt Seating153
Fig. 57 Manually Checking the Belt Tension154
Fig. 58 Tension the Belt155
Fig. 59 Replace the Drive Belt156
Battery Maintenance157
Fig. 60 Safety Signs - Warning Labels on the Battery157
Tab. 98 Starter Battery Charge Level158
Change the Oil Separator Cartridge159
Fig. 61 Change the Oil Separator Cartridge159
Servicing the Components of the Emission After-Treatment System160
Compressor Maintenance160
Check the Cooling Oil Level160
Cooling Oil Filling and Topping up161
Fig. 62 Check the Cooling Oil Level161
Changing the Cooling Oil162
Fig. 63 Draining the Compressor Cooling Oil163
Fig. 64 Draining the Cooling Oil (Closed Floor Pan - Stationary Machine)164
Replacing the Compressor Oil Filter165
Fig. 65 Change the Oil Filter166
Oil Separator Tank Dirt Trap Maintenance167
Fig. 66 Oil Separator Tank Dirt Trap Maintenance167
Changing the Oil Separator Cartridge168
Fig. 67 Changing the Oil Separator Cartridge169
Compressor Air Filter Maintenance171
Fig. 68 Compressor Air Filter Maintenance171
Fig. 69 Cleaning the Filter Element172
Cleaning the Cooler173
Cleaning the Compressor Cooler and Engine Radiator173
Cleaning the Compressed Air After-Cooler174
Fig. 70 Cleaning the Compressor Cooler and Engine Radiator174
Checking Screw Connections175
Fig. 71 Cleaning the Compressed Air After-Cooler175
Check Wing Doors176
Check Sound Proofing Material177
Maintenance of Rubber Sealing Strips177
Performing Maintenance Tasks on the Chassis178
Check/Replace Hose Lines178
Replace the Fuel Lines of the Drive Engine178
Replace the Pressure Hoses of the Engine179
Replace the Pressure Hoses of the Compressor179
Check Safety Functions179
Check the EMERGENCY STOP Push Button179
Have the Actuating Pressure of the Safety Relief Valve Checked180
Having Excessive Temperature Shut-Down Function Checked180
Tab. 99 Safety Valve Actuating Pressure180
Maintenance for Optional Items181
Tool Lubricator Maintenance181
Tab. 100 Safety Shut-Down at Excessive Airend Discharge Temperature181
Fig. 72 Tool Lubricator Maintenance182
Centrifugal Separator Maintenance183
Fig. 73 Cleaning the Condensate Drain183
Combination Filter Maintenance184
Fig. 74 Filter Combination185
Fig. 75 Combination Filter Maintenance185
Fresh Air Filter Maintenance188
Fig. 76 Fresh Air Filter Maintenance188
Spark Arrestor Maintenance191
Fig. 77 Cleaning the Spark Arrestor (Floor Pan with Service Openings)191
Fig. 78 Cleaning the Spark Arrestor (Sealed Floor Pan)192
Maintaining the Generator Drive Belt193
Fig. 79 Securing the Belt Guard at the Generator194
Fig. 80 Tighten the Generator Drive Belt195
Draining Liquid Accumulation Within the Machine196
Documenting Maintenance and Service Work198
Tab. 101 Maintenance Log198
11 Spares, Operating Materials, Service199
Note the Nameplate199
Ordering Consumable Parts and Operating Fluids/Materials199
Tab. 102 Compressor Consumables199
Kaeser Air Service200
Replacement Parts for Service and Repair200
Tab. 103 Consumable Engine Parts200
Tab. 104 Replacement Parts, Combination Filter200
Tab. 105 Replacement Parts, Fresh Air Filter200
12 Decommissioning, Storage and Transport265
Decommissioning265
Temporary Decommissioning265
Tab. 106 "Temporarily Decommissioned" Information Notice265
Long-Term Decommissioning and Storage266
Tab. 107 Long-Term Decommissioning and Storage Checklist266
Transport267
Safety267
Transporting the Machine as Trailer267
Transporting the Machine by Crane267
Tab. 108 Text for the Long-Term Decommissioned and Storage Information Notice267
Transporting the Machine by Forklift269
Transporting the Machine as Load269
Fig. 81 Transporting Using a Forklift Truck269
Fig. 82 Bracing to Secure the Load270
Storage271
Disposal272
Removing the Batteries272
Draining Operating Fluids273
Draining Condensate273
Fig. 83 Battery Labelling273
Tab. 109 Machine Fluids273
Tab. 110 Machine Option Fluids273
Removing Filters/Filter Elements274
Disposing of the Machine274
Tab. 111 Machine Filters/Filter Elements274
Tab. 112 Machine Option Filters/Filter Elements274
13 Annex275
Identification275
Pipeline and Instrument Flow Diagram (P+I Diagram)275
Fig. 84 Identification275
Dimensional Drawings280
Dimensional Drawing - Chassis280
Dimensional Drawing, Chassis Options282
Dimensional Drawing, Chassis Options284
Dimensional Drawing, Chassis Options286
Dimensional Drawing, Stationary Version288
Dimensional Drawing, Stationary Version290
Wiring Diagrams292
Electrical Diagram292
Lighting and Signaling System Connection320
Lighting and Signaling System Connection328
Generator Electrical Diagram, 400V, 3-Ph333
Generator Electrical Diagram, 230V, 3-Ph342
Generator Electrical Diagram, 115 V, 2-Ph351
Battery Charger Electrical Diagram360
Fuel Circulation Diagram364
Compressed Air Flow Rate in Generator Mode367
Operating Instructions for Compressed Air Filter (Combination Filter)369
Operating Instructions for Compressed Air Filter (Fresh Air Filter)397
Maintenance Tasks for the Generator411
Oil-Injected MOBILAIR Service Intervals411
Tab. 113 Service Maintenance Package - (1X Service Per Year)411
Tab. 114 Service Intervals for MOBILAIR Parts, Filter SET Group (Compressor and Engine)412
Tab. 115 Service Intervals for MOBILAIR Parts, Compressor Group414
Tab. 116 Service Intervals for MOBILAIR Parts, Filter SET Group Engine415
Tab. 117 Service Intervals for MOBILAIR Parts, Engine Group417

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KAESER KOMPRESSOREN SIGMA CONTROL SMART MOBILAIR M82 Specifications

General

Brand	KAESER KOMPRESSOREN
Model	SIGMA CONTROL SMART MOBILAIR M82
Category	Air Compressor
Language	English

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KAESER KOMPRESSOREN SIGMA CONTROL SMART MOBILAIR M82 User Manual

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KAESER KOMPRESSOREN SIGMA CONTROL SMART MOBILAIR M82 Specifications

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