KAESER KOMPRESSOREN SIGMA CONTROL SMART M114 Operator's Manual
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KAESER KOMPRESSOREN SIGMA CONTROL SMART M114 Operator's Manual

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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

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Summary of Contents for KAESER KOMPRESSOREN SIGMA CONTROL SMART M114

  • Page 1 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...
  • Page 2 Original instructions /KKW/M114 2.05 en Z1 SBA-MOBILAIR 20160726 075645...

  • Page 3: Table Of Contents

    Contents Regarding this Document Using this document ......................Further documents ......................Copyright .......................... Symbols and labels ......................1.4.1 Warnings ......................1.4.2 Potential damage warnings ................1.4.3 Other alerts and their symbols ................Technical Data Nameplate ........................Options – options label ..................... 2.2.1 Compressed air treatment devices ..............
  • Page 4 Contents Specified use ........................Incorrect Use ........................User's Responsibilities ..................... 3.4.1 Observe statutory and universally accepted regulations ........3.4.2 Determining personnel ..................3.4.3 Adherence to inspection schedules and accident prevention regulations ..3.4.4 Taking the machine for general inspection ............3.4.5 Documenting the mileage of the machine as trailer ...........
  • Page 5 Contents Fitting the tow bar ......................6.3.1 Fitting the height adjustable tow bar ..............6.3.2 Fitting a non-adjustable tow bar ................Adjusting the chassis ....................... 6.4.1 Adjusting the tow bar height ................6.4.2 Changing the towing eye/ball hitch ..............Connecting the battery trickle charger ................Installing a machine with stationary frame superstructure on a truck platform ....
  • Page 6 Contents 10.2.1 Evaluating the maintenance message ..............10.2.2 Maintenance messages ..................10.3 Maintenance schedules ....................10.3.1 Logging maintenance work ................. 10.3.2 Maintenance tasks after commissioning ............. 10.3.3 Regular maintenance tasks ................10.4 Engine maintenance ......................10.4.1 Water cooler maintenance .................. 105 10.4.2 Engine air filter maintenance ................
  • Page 7 Contents 12.1.2 Long-term decommissioning and storage ............225 12.2 Transport .......................... 226 12.2.1 Safety ........................226 12.2.2 Towing the compressor on the road ..............226 12.2.3 Parking the machine ................... 235 12.2.4 Transport with a crane ..................238 12.2.5 Transport with a forklift truck ................239 12.2.6 Transporting the machine as load ..............
  • Page 8 Contents Operator Manual Screw Compressor M114 SIGMA CONTROL SMART No.: 901765 05 USE...
  • Page 9 List of Illustrations Fig. 1 Example for Tire information on the side wall ................Fig. 2 Location of safety signs ......................Fig. 3 Overview of bodywork ........................ Fig. 4 Right-hand door opened ......................Fig. 5 Left-hand door opened ....................... Fig. 6 Machine overview ........................
  • Page 10 List of Illustrations Fig. 55 Manually checking the belt tension .................... Fig. 56 Changing/tensioning the drive belt ..................... 124 Fig. 57 Safety signs - warning stickers on the battery................126 Fig. 58 Check the cooling oil level ......................130 Fig.
  • Page 11 List of Tables Tab. 1 Danger levels and their definitions (personal injury) ..............Tab. 2 Danger levels and their definition (damage to property) ............Tab. 3 Nameplate ..........................Tab. 4 Extract from the options label ..................... Tab. 5 Compressed air treatment options ..................... Tab.
  • Page 12 List of Tables Tab. 55 Alarm messages and actions concerning the compressor unit ..........Tab. 56 Alarm messages and actions concerning the controller............. Tab. 57 General alarm messages and measures ................... Tab. 58 Warning messages and measures relating to the engine............Tab.

  • Page 13: Regarding This Document Using This Document

    Regarding this Document Using this document 1 Regarding this Document Using this document The operating manual is a component of the product. It describes the machine as it was at the time of first delivery after manufacture. ➤ Keep the operating manual in a safe place throughout the life of the machine. ➤...

  • Page 14: Potential Damage Warnings

    Regarding this Document Symbols and labels For example, These show the kind of danger and its source. The possible consequences of ignoring a warning are shown here. If you ignore the warning notice, the "DANGER" signal word indicates a lethal or severe in‐ jury will occur.
  • Page 15 Regarding this Document Symbols and labels 1. For instructions with several steps ... 2..the sequence of actions is numbered. Result Shows the expected conclusion of the previous action. Option da ➤ Information relating to one option only is marked with an option code (e.g., "option da" means that this section is only valid for machines with the air treatment components "aftercooler and cyclone moisture separator").

  • Page 16: Technical Data Nameplate

    Technical Data Nameplate 2 Technical Data Nameplate The machine's nameplate provides the model designation and important technical information. The nameplate is located on the outside of the machine (see illustration in chapter 13.1). ➤ Enter the nameplate data here as a reference: Feature Value Vehicle Identification No.

  • Page 17: Compressed Air Treatment Devices

    Technical Data Options – options label * r1 - r5 = place holders for chassis options: ■ r1 = rb; rc; rd ■ r3 = rm; ro ■ r4 = rr; rs; rt ■ r5 = rw; rx Tab. 4 Extract from the options label ➤...

  • Page 18: Low Temperature Equipment

    Technical Data Options – options label 2.2.4 Option ba Low temperature equipment Option Option code Available? Low temperature equipment Engine coolant pre-heating Stronger batteries Tab. 8 Low temperature equipment options 2.2.5 Option la, lb Equipment for fire hazard areas Option Option code Available? Spark arrestor...

  • Page 19: Lighting

    Technical Data Options – options label Chassis Option code Available? EU chassis GB chassis US chassis Height adjustment (rm, ro): With height adjustment Without height adjustment Service brake (rs): With overrun brake Tab. 12 Chassis options Stationary frame Chassis Option code Available? Stationary (rw, rx): on skids...

  • Page 20: Pedestrian Protection

    Technical Data Machine (without options) 2.2.12 Option sg Pedestrian protection Option Option code Available? Pedestrian protection Tab. 17 Pedestrian protection option Machine (without options) 2.3.1 Sound pressure level Sound pressure levels comply with the American EPA Standard. Measurement distance: 23 ft M114 Guaranteed sound pressure level [dB(A)] Tab.

  • Page 21: Chassis

    Technical Data Chassis The dimensional drawings also show the position of the following inlets and outlets: ■ Cooling air inlet ■ Cooling air outlet ■ Compressed air outlet ■ Exhaust Chassis 2.4.1 Mass The values shown are maximum values. Actual mass of individual machines are dependent on equipment fitted (see machine nameplate).

  • Page 22: Wheel Nut/Bolt Tightening Torque

    Technical Data Compressor Characteristic/marking Value Wheel nuts/bolts M 12 x 1.5 Tab. 22 Tires Further information See tire side wall for maximum pressure. 2.4.3 Wheel nut/bolt tightening torque Fixing medium Thread Wrench size Torque [lbf in] Wheel nuts/bolts M 12 x 1.5 Tab.

  • Page 23: Temperature

    Technical Data Compressor Maximum working gauge Activating pressure [psi] pressure [psi] 15.9 Tab. 27 Safety relief valve opening pressure 2.5.4 Temperature Required temperatures readiness to switch to LOAD Values mode Airend discharge temperature (ADT) [°F] The engine coolant temperature (ECT) [°F] Tab.

  • Page 24: Cooling Oil Charge

    Technical Data Compressor SIGMA FLUID S-460 S-570 Viscosity at 6.8 mm 7.2 mm 8.0 mm 212°F (DIN 51562-1) (D 445; ASTM test) (D 445; ASTM test) Flash point 428°F 460°F 496°F (ISO 2592) (D 92; ASTM test) (D 92; ASTM test) Density at —...

  • Page 25: Engine

    Technical Data Engine Cooling oil Fluid volume [gal] Compressor unit + heat exchanger 25.0 (Option db) Tab. 32 Cooling oil charge Engine 2.6.1 Engine specification Feature Specification Make/Model Deutz / TCD 3.6 L4 Engine control Electronic Fuel injection Common rail system Rated engine power [hp] Speed at LOAD mode [rpm] 2200...

  • Page 26: Fuel Recommendation

    Technical Data Engine Ambient temperatures [°F] Viscosity class −35 ..40 SAE 0 W / 40 SAE 5 W / 40 −20 ..30 SAE 10 W / 30 −20 ..40 SAE 10 W / 40 −15 ..40 SAE 15 W / 40 −5 ..

  • Page 27: Engine Coolant Recommendation

    Technical Data Engine 2.6.4 Engine coolant recommendation In fluid-cooled engines, the cooling fluid must be treated and monitored to prevent engine damage. Water quality: An important factor for treating the cooling fluid is the correct water quality. As a rule, clear and clean fresh water complying with the following analysis values must be used: Feature Value pH value...

  • Page 28: Options

    Technical Data Options Feature Value PTC testing current [A] (according to EN 50342) Tab. 38 Batteries Options 2.7.1 Air treatment options 2.7.1.1 Option ea, ec Tool lubricator Name Temperature range [°F] Fluid volume [gal] Special road breaker lubricant −25 ..50 Tab.

  • Page 29: Low Temperature Equipment

    Technical Data Options Air Treatment Compressed air quality Option designation Components Characteristics Abbreviation ea / ec Tool lubricator Lubricated Tab. 41 Interrelation between compressed air treatment and compressed air quality The compressed air outlets at the air distributor are labelled with the identifiers of com‐ pressed air quality.

  • Page 30: Tab. 45 Battery Charger Specification

    Technical Data Options Battery charger Value Charging voltage [V] 26.6 Charging current [A] >0.5 Maximum charging current [A] Enclosure protection IP 54 Tab. 45 Battery charger specification Power supply details Mains supply Value Mains voltage [V/1~/N/PE] Frequency [Hz] Supply cable cross-section [AWG] 5 x 1.5 (Cu multi-core) User's fusing +-[A]...

  • Page 31: Safety And Responsibility Basic Instructions

    Safety and Responsibility Basic instructions 3 Safety and Responsibility Basic instructions The machine is manufactured to the latest engineering standards and acknowledged safety regula‐ tions. Nevertheless, dangers can arise through its operation: ■ danger to life and limb of the operator or third parties, ■...

  • Page 32: Determining Personnel

    Safety and Responsibility User's Responsibilities 3.4.2 Determining personnel Suitable personnel are experts who, by virtue of their training, knowledge, and experience as well as their knowledge of relevant regulations can assess the work to be done and recognize the pos‐ sible dangers involved.

  • Page 33: Documenting The Mileage Of The Machine As Trailer

    Safety and Responsibility Dangers These intervals are determined by: ■ Date of initial registration of the machine as trailer on public roads ■ Permissible overall weight of the trailer 1. Take the machine for general inspection at due date. General inspection intervals: Machine weight [lb] ≤...
  • Page 34 Safety and Responsibility Dangers Fire and explosion Spontaneous ignition and combustion of fuel can result in serious injury or death. ➤ Do not allow open flames or sparks at the place of use. ➤ Do not smoke while refueling. ➤ Never refuel the machine when it is running. ➤...
  • Page 35 Safety and Responsibility Dangers Spring forces Springs under tension or compression store energy. Uncontrolled release of this energy can cause serious injury or death. Minimum pressure / check valves, safety relief valves, and inlet valves are powerfully spring-loa‐ ded. ➤ Do not open or dismantle any valves. Rotating components Touching the fan wheel, the coupling, or the belt drive while the machine is switched on can result in serious injury.

  • Page 36: Safe Machine Operation

    Safety and Responsibility Dangers ➤ Do not eat or drink while handling fuel, cooling and lubricating fluids, or antifreeze. ➤ Keep suitable fire extinguishing agents ready for use. ➤ Use only KAESER approved operating materials. Unsuitable spare parts Unsuitable spare parts compromise the safety of the machine. ➤...
  • Page 37 Safety and Responsibility Dangers ➤ The maximum permissible load for the towing vehicle coupling and the maximum coupling load given for the machine must not be exceeded. ➤ Avoid causing a shift in the centre of gravity by an excessive or incorrectly distributed load. ➤...
  • Page 38 Safety and Responsibility Dangers General instructions A suitable installation location for the machine prevents accidents and faults. ➤ Do not position the machine under roofs or coverings. A build up of heat from the exhaust can damage the machine. ➤ Ensure accessibility so that all work on the machine can be carried out without danger or hin‐ drance.
  • Page 39 Safety and Responsibility Dangers ➤ Wear close-fitting, flame-resistant clothing. Wear protective clothing as necessary. ➤ Switch off the machine and lock out the supply disconnecting device. ➤ De-pressurise all pressurised components and enclosures. ■ Wait until the machine has automatically vented. ■...

  • Page 40: Organizational Measures

    Safety and Responsibility Safety devices 3.5.2.4 De-commissioning, storage and disposal Improper handling of old operating fluids and components represent a danger for the environment. ➤ Drain off fluids and dispose of them according to environmental regulations. These include, for example, fuel, engine oil and compressor cooling oil and engine coolant. ➤...

  • Page 41: Fig. 2 Location Of Safety Signs

    Safety and Responsibility Safety signs During cleaning or maintenance work, a check should be made that safety signs have not been removed or obliterated . Have missing or illegible signs replaced! Fig. 2 Location of safety signs Item Sign Meaning 190* Wrong cooling oil level.
  • Page 42 Safety and Responsibility Safety signs Item Sign Meaning Injury or damage from open machine. ➤ Operate the machine only when closed. ➤ Transport the machine only when closed. 320* Loud noise and oil mist when the safety relief valve opens. Ear damage and burns can result.
  • Page 43 Safety and Responsibility Safety signs Item Sign Meaning Loud noise and compressed air blast! Damage to hearing and injury if ball valve is opened without a compressed air hose being connected. ➤ Connect a compressed air hose. ➤ Open the ball valve. 500** Drawbar load and ground clearance.

  • Page 44: Noise Control Requirements

    Safety and Responsibility Noise control requirements Item Sign Meaning 1650** Machine damage if switched while the engine is running! ➤ Use the «battery isolating switch» only with the engine stopped. ➤ Do not use the «battery isolating switch» as a main or emergency switch.

  • Page 45: Contact With Operating Fluids/Materials

    Safety and Responsibility 3.10 Warranty Extinguishing substances ➤ Suitable extinguishing agents: Foam Carbon dioxide Sand or soil ➤ Unsuitable extinguishing agents: Strong jet of water 3.9.2 Contact with operating fluids/materials The following operating fluids/materials are in the machine: ■ Fuel ■...

  • Page 46: Noise Emissions Warranty

    Safety and Responsibility 3.11 Identifying the effects of improper modifications A condition of our warranty is that the machine is used for the purpose for which it is intended un‐ der the conditions specified. Due to the multitude applications for which the machine is suitable the obligation lies with the user to determine its suitability for his specific application.

  • Page 47: Environmental Protection

    Safety and Responsibility 3.12 Environmental protection In machines requiring a national road traffic permit, remodeling or modifications may adversely af‐ fect their approval for road traffic. ■ Exhaust emission limits may not be met. ■ The prerequisites for approval are no longer given. Remodeling or modifications restrict the service work that can be performed for you (examples): ■...

  • Page 48: Design And Function Bodywork

    Design and Function Bodywork 4 Design and Function Bodywork Bodywork is understood to be the exterior of the machine mounted on the chassis. Fig. 3 Overview of bodywork Right-hand wing door Lower body Sound damping louvre Left-hand wing door Handle Cover for lifting eye Snap fastener The bodywork has several functions when it is closed:...

  • Page 49: Machine Structure

    Design and Function Machine structure Machine structure Fig. 4 Right-hand door opened Instrument panel (cover closed) Fuel filter «QUICK STOP» button Cooling water expansion tank Oil separator tank Fuel filter with water trap Fuel tank Fuel pump Drive motor Control valve with proportional controller Minimum pressure check valve Fig.

  • Page 50: Fig. 6 Machine Overview

    Design and Function Machine function Item numbers correspond to the pipe and instrument flow diagram (P&ID) in chapter 13.2. Fig. 6 Machine overview Compressor air filter Thermostatic valve (oil temperature con‐ Inlet valve trol) Airend Oil cooler Oil separator tank Oil filter Oil separator cartridge Proportional controller...

  • Page 51: Operating Modes And Control Mode

    Design and Function Operating modes and control mode Operating modes and control mode 4.4.1 Machine operating modes The machine operates in the following modes: ■ WARM-UP ─ The inlet valve is nearly fully closed. ─ The minimum intake air volume escapes via the venting valve. ─...

  • Page 52: Safety Devices

    Design and Function Safety devices Fig. 7 Stepless regulation of FAD(standstill) Inlet valve Venting valve Airend Nozzle Oil separator tank Control valve Proportional controller (electric) Control valve (proportional valve) Safety devices 4.5.1 Monitoring functions with shut-down The SIGMA CONTROL SMART monitors important machine parameters. The machine is automat‐ ically shut down if an alarm occurs.

  • Page 53: Battery Isolating Switch

    Design and Function SIGMA CONTROL SMART control panel ■ Pressure relief valves Pressure relief valves protect the system against unacceptable pressure rise. They are factory set. ■ Housing and covers for moving parts and electrical connections: Protect against accidental contact. 4.5.3 Battery isolating switch The «battery isolating switch»...

  • Page 54: Emission After-Treatment

    Design and Function Emission after-treatment Item Sign Name Function Background LED – Indicator field or Graphic display – display «Up» and ■ Scrolls upwards or downwards – «Down» keys through the menu options. ■ Enter settings. ■ Change values. ■ Switch between menu pages.

  • Page 55: Options

    Design and Function Options Fig. 10 Principle of treatment devices Engine control unit (ECU) Cooler exhaust gas return (EGR) Common rail system Air flow meter Engine block Turbocharger Exhaust gas return valve (EGR) System exhaust gas treatment Inlet throttle Diesel oxidation catalytic converter (DOC) Intercooler Sensors Exhaust gas recirculation (EGR)

  • Page 56: Air Treatment Options

    Design and Function Options 4.8.1 Option da, db, dc, dd, ea, ec Air treatment options For some applications, the compressed air generated by this machine must be treated before use. The following describes the possible air treatment options that may be fitted to the machine. Fig.
  • Page 57 Design and Function Options 4.8.1.4 Option dd Filter combination The dried compressed air passes through a pre-filter and micro-filter combination and emerges oil- free. 4.8.1.5 Option dc Fresh air filter Compressed air from oil-injected compressors may not be used directly as breathing air. The concentration of contaminants will increase during the compression of the intake ambient air and cooling oil and abraded particles can enter the compressed air.

  • Page 58: Fig. 12 Tool Lubricator

    Design and Function Options Fig. 12 Tool lubricator Tool lubricator Oil tank Air line Metering knob Shut-off ball valve Fig. 13 Principle tool lubricator Compressed air inlet Tool lubricator upper part with oil filling port Oil tank Filler plug with dipstick and integrated riser Tool oil outlet tube Metering knob...

  • Page 59: Low Temperature Equipment Options

    Design and Function Options Option fc Points to be observed with separate compressed air lines Lubrication with tool oil. Air tools that must not be lubricated can be damaged. ➤ Blow any residual oil out of the line before connecting such an air tool. 4.8.2 Option ba Low temperature equipment options...

  • Page 60: Fig. 15 Engine Air Shut-Off Valve

    Design and Function Options For the operation in fire hazard areas, the machine is equipped with the following accessories: ■ Engine air shut-off valve ■ Spark arrestor 4.8.3.1 Option lb Engine air shut-off valve If flammable gases and vapors are drawn by the Diesel engine from the environment into the air intake, they will act like catalytic converters.

  • Page 61: Start/Stop/Automatic Options

    Design and Function Options Fig. 16 Access engine air shut-off valve Handle 4.8.3.2 Option la Spark arrestor Sparks in exhaust fumes represent a considerable risk in environments with flammable materials. Flying sparks combined with flammable materials may cause fires and explosions. A spark arrestor on the exhaust silencer is required when operating a diesel engine in a fire hazard area and in forestry and agricultural applications.
  • Page 62 Design and Function Options Option rs - Chassis with overrun brake The chassis has the following features: ■ Permissible axle load: 4189 lb ■ Single-axle ■ Height adjustable tow bar ■ Rubber-spring axle ■ With service brake ■ May be operated on public roads. 4.8.6.2 Option rc/ro/rs Chassis...

  • Page 63: Sealed Floor Pan Option

    Design and Function Options ■ Use as stationary machine ■ Mounted on truck/trailer platform 4.8.6.5 Option rx Stationary frame Option rx - Frame The frame has the following features: ■ Frame ■ Use as stationary machine ■ Mounted on truck/trailer platform 4.8.7 Option oe Sealed floor pan option...

  • Page 64: Optional Anti-Theft Device

    Design and Function Options Drain points for oil and coolant from engine and compressor Fig. 18 Drain points for oil and coolant from engine and compressor Engine oil drain Coolant drain - water cooler engine Coolant drain - oil cooler - compressor Coolant oil drain - oil separator tank - com‐...

  • Page 65: Installation And Operating Conditions

    Installation and Operating Conditions Ensuring safety 5 Installation and Operating Conditions Ensuring safety The conditions in which the machine is installed and operated effect the safety of personnel and surroundings. Warning instructions are located before a potentially dangerous task. Disregard of warning instructions can cause serious injuries! Complying with safety warnings Disregard of safety warnings can cause unforeseeable dangers! ➤...

  • Page 66: Machine With Stationary Frame Structure

    Installation and Operating Conditions Machine with stationary frame structure 2. Ensure that the machine is as level as possible. The machine can be temporarily operated on a slope of not more than 15°. Option oe: Except for machines with closed floor pans - these should always be installed on as horizon‐ tal a surface as possible! 3.

  • Page 67: Installation

    Installation Ensuring safety 6 Installation Ensuring safety Follow the instructions below for safe installation. Warning instructions are located before a potentially dangerous task. Disregard of warning instructions can cause serious injuries! Complying with safety warnings Disregard of safety warnings can cause unforeseeable dangers! ➤...

  • Page 68: Fitting The Height Adjustable Tow Bar

    Installation Fitting the tow bar 6.3.1 Option rb/rm/rs Fitting the height adjustable tow bar Option rb/rm/rs Fig. 20 Height adjustable tow bar, fitted Overrun braking mechanism Locking lever with split pin Handle Hand brake lever, parking brake Tie bar Fixing with bolt and nut Option rb/rm/rs Fig.

  • Page 69: Fitting A Non-Adjustable Tow Bar

    Installation Fitting the tow bar 11. Insert the splint pin. 12. Pull up the parking brake (pull the hand brake lever up). 6.3.2 Option rc/ro/rs, rd/ro/rs Fitting a non-adjustable tow bar Option rc/ro/rs, rd/ro/rs Fig. 22 Non-adjustable tow bar fitted Overrun braking mechanism Jockey wheel Brake transfer cable...

  • Page 70: Fig. 23 Fitting The Overrun Braking Mechanism Of The Non-Adjustable Tow Bar

    Installation Fitting the tow bar Fitting the overrun braking mechanism of the non-adjustable tow bar: Option rc/ro/rs, rd/ro/rs Fig. 23 Fitting the overrun braking mechanism of the non-adjustable tow bar Overrun braking mechanism Pivot mount Tow bar Hexagonal locking nut Fixing bolt Hexagon nut (locknut) Washer...

  • Page 71: Adjusting The Chassis

    Installation Adjusting the chassis Fitting the jockey wheel of the non-adjustable tow bar: Option rc/ro/rs, rd/ro/rs Fig. 24 Fitting the jockey wheel of the non-adjustable tow bar Overrun braking mechanism Washer Jockey wheel Hexagon nut (self locking) Fastening screw 1. Place a U-washer on each securing screw and insert each of these into the top four securing holes on the jockey wheel mounting plate.

  • Page 72: Adjusting The Tow Bar Height

    Installation Adjusting the chassis 6.4.1 Option rb/rm/rs Adjusting the tow bar height Option rb/rm/rs Fig. 25 Tow bar height adjustment Locking lever Split pin properly inserted Split pin Handle 1. Pull out the split pin and unscrew the locking lever to the stop. 2.

  • Page 73: Fig. 26 Changing The Towing Eye (Height-Adjustable Tow-Bar)

    Installation Adjusting the chassis Material Protective gloves Wrench Hammer Self-locking hexagon nuts Precondition The machine is switched off. The machine is disconnected from the towing vehicle and safely parked. ➤ Ascertain which towing device is fitted to the machine. 6.4.2.1 Option rb/rm/rs Changing the towing eye/ball hitch on a height-adjustable tow bar The following alternative tasks must be carried out to change the towing eye or coupling.

  • Page 74: Fig. 27 Changing The Towing Eye/Ball Hitch (Fixed Height Tow Bar)

    Installation Adjusting the chassis Fitting the ball coupling Fitting the towing eye 1. Fit the new ball coupling to the tow bar. 1. Slide the towing eye into or onto the tow 2. Position the various parts so that the bolts can be freely inserted.

  • Page 75: Fig. 28 Changing The Towing Eye (Fixed Height Tow Bar, Usa Chassis Version)

    Installation Adjusting the chassis Option rd/ro/rs Fig. 28 Changing the towing eye (fixed height tow bar, USA chassis version) Self-locking hexagon nut Draw bar Hexagon bolt Shock absorber Shock absorber fixing eye Mounting pin Hexagon bolt Ball coupling Bellows Towing eye 1.

  • Page 76: Connecting The Battery Trickle Charger

    Installation Connecting the battery trickle charger Option od Connecting the battery trickle charger The battery charger is wired ready for operation and only needs to be connected to the user's pow‐ er supply. The charger is factory set for use on a 400 V, 3-phase supply. For use with a 230 V, 1-phase supply, the charger connections must be changed as shown in the electrical diagram in chap‐...
  • Page 77 Installation Installing a machine with stationary frame superstructure on a truck platform 1. Position the machine on the loading platform according to chapter 5.3, Installation conditions. 2. Use suitable screws to fasten the machine with the bolt-down machine feet to the loading plat‐ form.

  • Page 78: Initial Start-Up Ensuring Safety

    Initial Start-up Ensuring safety 7 Initial Start-up Ensuring safety Follow the instructions below for safe commissioning of the machine. Warning instructions are located before a potentially dangerous task. Disregard of warning instructions can cause serious injuries! Complying with safety warnings Disregard of safety warnings can cause unforeseeable dangers! ➤...

  • Page 79: Special Measures For Recommissioning After Storage

    Initial Start-up Checking installation and operating conditions 7.2.2 Special measures for recommissioning after storage ➤ Carry out the following before every start-up after long period of storage: Storage Remedy period longer than: 5 months ➤ Remove the desiccant from the openings in the air intake filters of the engine and compressor.

  • Page 80: Low-Temperature Operation (Winter)

    Initial Start-up Low-temperature operation (winter) Low-temperature operation (winter) The machine's electrical equipment is designed for starting at ambient temperatures as low as 14 °F. ➤ In temperatures below 32°F, use the following operating materials/components: ■ Winter-grade engine oil, ■ Low viscosity cooling oil for the compressor ■...

  • Page 81: Fig. 29 Jumper Cable Connection Diagram

    Initial Start-up Low-temperature operation (winter) Fig. 29 Jumper cable connection diagram Engine battery (receiving battery) Positive pole clamp (red) on engine battery Assisting vehicle battery (external donor Negative pole clamp (black/blue) on engine battery) battery Negative pole clamp (black/blue) on bat‐ Bare metal point on the engine block tery of assisting vehicle (ground)

  • Page 82: Starting Up Low-Temperature Equipment

    Initial Start-up Low-temperature operation (winter) Connecting the battery jumper cables 1. Clamp the first terminal clamp of the red jumper cable to the positive pole of the engine's battery. 2. Clamp the second terminal clamp of the red jumper cable to the positive pole of the assist‐ ing vehicle's battery.

  • Page 83: Trickle-Charging The Battery

    Initial Start-up Trickle-charging the battery Option bb Fig. 30 Coolant pre-heating Operating panel Coolant pre-heating Connection for the coolant pre-heater Engine block Power cable Danger of fatal injury from electric shock! Serious injury or death can result from a short-circuit in the electric coolant pre-heater. ➤...

  • Page 84: Fig. 31 Battery Charger

    Initial Start-up Trickle-charging the battery Fig. 31 Battery charger Voltmeter Overload protection switch (main switch) Ammeter Safety cut-out 1. Switch on the «overload protection switch». 2. Switch on the «safety cut-out». Result The meters indicate the charging voltage and current. Checking battery charger function The charger function should be checked weekly.

  • Page 85: Operation

    Operation Ensuring safety 8 Operation Ensuring safety Follow the instructions below for safe operation. Warning instructions are located before a potentially dangerous task. Disregard of warning instructions can cause serious injuries! Complying with safety warnings Disregard of safety warnings can cause unforeseeable dangers! ➤...

  • Page 86: Starting And Stopping

    Operation Starting and stopping Condensate formation in compressed air receivers Compressed air stored in a containers will cool down. The compressed air precipitates moisture that collects at the container's bottom. Corrosion may damage the container. ➤ Regularly drain the condensate. Further information Details of authorized personnel are found in chapter 3.4.2.

  • Page 87: Follow The Brief Instructions

    Operation Starting and stopping Fig. 33 Instrument panel keys and indicators Controller voltage ON «Up» and «Down» keys READY (flashes) «Enter» key «LOAD/IDLE» toggle key Menu bar Settings menu «STOP» key «START» key Navigation menu Status bar 8.2.1 Follow the brief instructions Brief instructions containing symbolic information on starting and stopping are attached at the in‐...

  • Page 88: Starting The Machine

    Operation Starting and stopping 8.2.2 Starting the machine Notes concerning snow and ice Considerable snow or ice may build up on the machine under low temperature conditions. ➤ Remove any snow and ice from the machine before operating. As a safety measure, check the function of the «QUICK STOP» push button. «QUICK STOP»...

  • Page 89: Setting The Compressed Air Discharge Pressure

    Operation Starting and stopping 2. Switch on the «Controller ON» key. ■ The controller boots up and the operating indicators appear on the display. Ready indicator flashes if the controller has no fault. ■ Starting the engine ➤ Press the «START» key. ■...

  • Page 90: Fig. 36 Setting The Quick Access For The Compressed Air Discharge Pressure

    Operation Starting and stopping ■ You can adjust the settings in increments of 0,1 psi or 1 bar. ■ The adjustment is displayed. Danger from incorrectly set pressure! Danger from malfunctioning or not functioning compressed air tools when the machine's dis‐ charge pressure is set incorrectly.

  • Page 91: Shutting Down The Machine

    Operation Starting and stopping Fig. 37 Setting the compressed air discharge pressure Settings for compressed air discharge pressure Setting 1. Press «Down» for a short time. The "Setting compressed air discharge pressure" line is framed. 2. Press «Enter». The frame flashes and thus signals that input is possible. You can set the required compressed air discharge pressure.
  • Page 92 Operation Starting and stopping Switching the machine to the run-on phase ➤ Switch the machine to the run-on phase. ■ ➤ Press «LOAD/IDLE» key. unloaded run-on . ■ The machine switches to ─ The engine runs at IDLE speed. ─ Oil separator tank (OST) is vented.

  • Page 93: Shutting Down In An Emergency

    Operation Confirming alarm and warning messages 3. Close all «compressed air outlet valves» on the air distributor. 4. Close the operating panel cover and all doors. Lock if necessary. 8.2.6 Shutting down in an emergency Stop the machine in case of danger by pressing the «QUICK STOP» button. Use the «QUICK STOP»...

  • Page 94: Acknowledging Warning Messages

    Operation Operating the tool lubricator 8.3.2 Acknowledging warning messages Before an alarm, the system displays a warning and the following happens at the same time: ■ The assigned signal indicator illuminates orange. Precondition The cause of the warning is rectified. ➤...

  • Page 95: Fig. 38 Setting The Tool Lubricator

    Operation Operating the tool lubricator Fig. 38 Setting the tool lubricator Shut-off valve I – open 0 – closed Metering knob ➤ Open the right-hand access door. Adding lubricating oil 1. Open the shut-off valve. 2. Close the access door. Setting the oil flow The amount of oil the compressed air should contain depends on the application and must be de‐...

  • Page 96: Using The Low-Temperature Equipment

    Operation Using the low-temperature equipment Option ba Using the low-temperature equipment Option bb Pre-heating the engine cooling water ➤ Start the engine coolant pre-heating as described in chapter 7.4.2. Option lb Shut down the machine if any dangerous situation arises If there is a danger of the engine drawing in flammable gas the air intake shut-off valve can be manually closed to bring it to an immediate stop.

  • Page 97: Cleaning The Machine After Operation

    Operation Cleaning the machine after operation 1. Check the position of the air intake valve handle. The pull wire is not yet completely drawn in: wait until the handle has automatically returned to its original position. The pull wire is completely drawn in. The machine can now be started. 2.

  • Page 98: Fault Recognition And Rectification

    Fault Recognition and Rectification Basic instructions 9 Fault Recognition and Rectification Basic instructions The following tables are intended to assist in fault finding and rectification. 1. Do not attempt fault rectification measures other than those given in this manual! 2. In all other cases: Have the fault rectified by an authorized KAESER service representative.

  • Page 99: Tab. 54 Alarm Messages And Actions Concerning The Engine

    Fault Recognition and Rectification Analysing SIGMA CONTROL SMART messages Code Meaning Remedy Where can I get help? chapter 1110 Fault – coolant tempera‐ Check the coolant level. 10.4.1 – – ture high Clean the cooler. 10.6 – – Check the water cooling –...

  • Page 100: Tab. 55 Alarm Messages And Actions Concerning The Compressor Unit

    Fault Recognition and Rectification Analysing SIGMA CONTROL SMART messages Alarm codes, range 1200 – 1299 “compressor faults”: Code Meaning Remedy Where can I get help? chapter 1200 Fault - ADT high Check operating condi‐ – – tions. Allow the machine to cool down.

  • Page 101: Warning Message On The Controller

    Fault Recognition and Rectification Analysing SIGMA CONTROL SMART messages Alarm codes, range 1400 – 1499 “general faults”: Code Meaning Remedy Where can I get help? chapter 1400 Fault message EMER‐ Unlatch the 8.2.6 – – GENCY STOP «QUICK STOP» button («QUICK STOP»).

  • Page 102: Tab. 58 Warning Messages And Measures Relating To The Engine

    Fault Recognition and Rectification Analysing SIGMA CONTROL SMART messages Code Meaning Remedy Where can I get help? chapter Specialized Kaeser workshop Service 3124 Warning - air flow meter Have checked. – faulty. 3130 Warning – engine fuel Refuel. – – –...

  • Page 103: Evaluating Engine Faults And Alarms

    Fault Recognition and Rectification Evaluating engine faults and alarms Code Meaning Remedy Where can I get help? chapter Specialized Kaeser workshop service 3201 Warning - OST pressure Have checked. – – high. SW = specialized workshop; KS = KAESER SERVICE ADT = Airend discharge temperature;...

  • Page 104: Engine Does Not Reach Full Speed

    Fault Recognition and Rectification Evaluating engine faults and alarms Possible cause Remedy Where can I get help? Defective control fuse or relay. Have repaired or replaced if necessary. Airend discharge temperature Have checked. – too high. SIGMA CONTROL SMART de‐ Have repaired/changed.

  • Page 105: Analysing Compressor Faults And Alarms

    Fault Recognition and Rectification Analysing compressor faults and alarms Analysing compressor faults and alarms 9.4.1 Working pressure too high Possible cause Remedy Where can I get help? Proportional controller defective. Have repaired or replaced if – necessary. Inlet valve does not close. Check the controller, the control –...

  • Page 106: Pressure Relief Valve Blowing Off

    Fault Recognition and Rectification Analysing compressor faults and alarms 9.4.3 Pressure relief valve blowing off Possible cause Remedy Where can I get help? Oil separator cartridge heavily Change, see chapter 10.5.6. – – clogged. Inlet valve does not close. Check the controller, the control –...

  • Page 107: Too Much Oil Residue In The Compressed Air

    Fault Recognition and Rectification Analysing compressor faults and alarms 9.4.5 Too much oil residue in the compressed air Possible cause Remedy Where can I get help? Oil separator cartridge scavenge Clean the oil separator cartridge – line clogged. dirt trap or replace the strainer and nozzle if necessary.

  • Page 108: 10 Maintenance

    Maintenance 10.1 Ensuring safety 10 Maintenance 10.1 Ensuring safety Follow the instructions below to ensure safe machine maintenance. Warning instructions are located before a potentially dangerous task. Disregard of warning instructions can cause serious injuries! Complying with safety notes Disregard of safety notes can cause unforeseeable dangers! ➤...

  • Page 109: Noting The Maintenance Messages On The Controller

    Maintenance 10.2 Noting the maintenance messages on the controller ■ Carefully open the compressed air outlet valve. ■ Check: The pressure gauge must read 0 psig! ➤ Do not open or dismantle any valves. When working on the drive system Touching rotating, very hot or current-carrying components can cause severe injuries.

  • Page 110: Maintenance Messages

    Maintenance 10.3 Maintenance schedules 10.2.2 Maintenance messages Acknowledge the maintenance message Precondition Maintenance has been carried out. ➤ Acknowledge the maintenance message as described in chapter 8.3. Resetting the maintenance interval counter Precondition Maintenance is carried out and the maintenance message is acknowledged. ➤...

  • Page 111: Regular Maintenance Tasks

    Maintenance 10.3 Maintenance schedules 10.3.2.1 Maintenace tasks on the machine after commissioning ➤ Carry out maintenance tasks according to the following schedule. Component: Task Engine: Check the fuel lines and clamps. KS; SW If necessary, tighten the hose clamps. E50 = after the first 50 operating hours KS = contact KAESER SERVICE;...

  • Page 112: Tab. 74 Maintenance Intervals And Regular Maintenance Tasks

    Maintenance 10.3 Maintenance schedules Maintenance interval Short description Every 3,000 operating hours A4500 Every 36,000 h, at least every six years A36000 Tab. 74 Maintenance intervals and regular maintenance tasks The table below lists regular maintenance tasks. ➤ Carry out maintenance tasks punctually taking ambient and operating conditions into consider‐ ation.
  • Page 113 Maintenance 10.3 Maintenance schedules Component: Task Emptying the fuel pre-filter (wa‐ 10.4.3 ter trap) Clean the fuel filter. 10.4.3 KS; SW Have the fuel pump cleaned. KS; SW Clean the tank fuel strainer. Cleaning the fuel tank. Check fuel lines and hose KS;...

  • Page 114: Tab. 75 Regular Machine Maintenance Tasks

    Maintenance 10.3 Maintenance schedules Component: Task Chassis/bodywork Check all screw connections, hinges, locks, handles and snap fasteners of the doors for wear and secure fixing. Grease the door hinges. Carry out rubber sealing strip 10.7 maintenance. Have lifting eye and fixings KS;...

  • Page 115: Tab. 76 Regular Maintenance Task Options

    Maintenance 10.3 Maintenance schedules Option: Task Drain condensate. 10.9.3 Change the filter elements. 10.9.3 Option dc – fresh air filter:setting dimension: Drain condensate. 10.9.4 Check the oil indicator. 10.9.4 Change the filter elements. 10.9.4 Option bb/od – Auxiliary electric devices: Have the coolant pre-heating and associated wiring checked.

  • Page 116: Tab. 78 Regular Chassis Maintenance Tasks

    Maintenance 10.3 Maintenance schedules ➤ Carry out maintenance tasks according to the following schedule. Component: Task Wheels: Check the tire pressures. 10.8.1 Check wheel bolts and nut for 10.8.1 tightness. after wheel change: Check wheel bolts and nut for tightness. Check the tires and rims.

  • Page 117: Engine Maintenance

    Maintenance 10.4 Engine maintenance 10.4 Engine maintenance ➤ Perform maintenance tasks according to the schedule in chapter 10.3.3.1. 10.4.1 Water cooler maintenance Material Coolant Coolant tester Receptacle Funnel Cleaning cloths Precondition The machine is switched off. The machine is standing level. The machine is fully vented, the pressure gauge reads 0 psig.

  • Page 118: Fig. 40 Checking Coolant Level

    Maintenance 10.4 Engine maintenance Fig. 40 Checking coolant level Coolant level Water cooler Maximum check mark (FULL) Overflow Minimum check mark (LOW) Filler neck with cap Coolant equalising tank 1. Check the level of coolant in the expansion tank. Top up when the coolant level falls below the minimum check mark : Replenish the coolant.

  • Page 119: Tab. 79 Kaeser Coolant Mixture Table

    Maintenance 10.4 Engine maintenance The engine can be damaged if the antifreeze concentration is insufficient. Corrosion Damage to the cooling system. Engine casing fracture ➤ Check coolant. ➤ Protect the coolant against frost. ➤ Top up as necessary. 2. Use the coolant tester as instructed by the manufacturer to test the coolant. Concentration of antifreeze is too low: Change the coolant.

  • Page 120: Fig. 41 Draining The Coolant From The Radiator

    Maintenance 10.4 Engine maintenance Precondition The «battery isolating switch» is turned off. 1. Twist and remove the expansion tank filler cap. 2. Mix a quantity of coolant according to the table and replenish to the mark. maximum mark Replenish the coolant just below the 3.

  • Page 121: Engine Air Filter Maintenance

    Maintenance 10.4 Engine maintenance 1. Unscrew and remove the expansion tank filler cap. 2. Position a receptacle beneath the drainage location of the water cooler. 3. Open the shut-off valve on the radiator base. 4. Unscrew the drain plug and allow the coolant to drain into the receptacle. 5.

  • Page 122: Fig. 42 Engine Air Filter Maintenance

    Maintenance 10.4 Engine maintenance Fig. 42 Engine air filter maintenance Maintenance indicator Filter element Red zone indicator scale Retaining clip Indicating piston of the maintenance indi‐ Filter cap cator Reset knob maintenance indicator Fig. 43 Cleaning the filter element Compressed air gun with blast pipe bent to 90° at the end Filter element ➤...

  • Page 123: Fuel System Maintenance

    Maintenance 10.4 Engine maintenance 3. Cleaning the filter element: ■ Use dry compressed air (≤ 72.5 psi!) at an angle to blow dust from the element from inside to outside until no further dust develops. ■ The blast pipe must be long enough to reach the bottom of the element. ■...

  • Page 124: Fig. 44 Fuel System Maintenance

    Maintenance 10.4 Engine maintenance Fig. 44 Fuel system maintenance Fuel tank Fuel pre-filter with integrated water trap Fuel strainer Fuel pump Fuel micro-filter ➤ Open the right-hand access door. 10.4.3.1 Bleeding the fuel system Air can enter the fuel system if the fuel tank is empty after a fuel filter change or when carrying out work on the fuel lines.

  • Page 125: Fig. 46 Warning Messages: Fuel Filter Water Level

    Maintenance 10.4 Engine maintenance 6. Switch on the «Controller ON/OFF» key. The fuel pump runs and air is bled out of the fuel system. 7. After approx. 20 seconds switch off the «Controller ON/OFF» switch. 8. Open the right-hand access door. 9.

  • Page 126: Fig. 47 Emptying The Fuel Pre-Filter And Water Trap

    Maintenance 10.4 Engine maintenance Fig. 47 Emptying the fuel pre-filter and water trap Fuel prefilter Water draining stopper with integrated lev‐ Filter cartridge with integrated water re‐ el sensor ceptacle. I - open 0 - close Electrical outlet for water level sensor 1.

  • Page 127: Fig. 48 Changing The Fuel Pre-Filter Cartridge

    Maintenance 10.4 Engine maintenance Changing the filter cartridge: Fig. 48 Changing the fuel pre-filter cartridge Filter head Electrical outlet for water level sensor Filter cartridge with integrated water re‐ Direction of rotation to unscrew the filter ceptacle. cartridge and the water trap Draining stopper with integrated level sen‐...

  • Page 128: Fig. 49 Fuel Fine Filter Maintenance

    Maintenance 10.4 Engine maintenance Dispose of fuel and any materials and components contaminated with it in accordance with environmental protection regulations. 10.4.3.3 Fuel fine filter maintenance Fig. 49 Fuel fine filter maintenance Filter holder Fine filter cartridge Turn in this direction to unscrew the filter cartridge. 1.

  • Page 129: Checking The Engine Oil Level

    Maintenance 10.4 Engine maintenance 5. Tighten all fittings. 6. Close the door. 10.4.4 Checking the engine oil level The engine oil is indicated by a dipstick in the oil sump. The oil level should ideally be between the minimum level . two marks on the dipstick.

  • Page 130: Engine Oil Filling And Topping Off

    Maintenance 10.4 Engine maintenance 10.4.5 Engine oil filling and topping off Material Engine oil Cleaning cloths Funnel Precondition The machine is switched off. The machine is standing level. The machine is fully vented, the pressure gauge reads 0 psig. All compressed air consumers are disconnected and the air outlet valves are open. The negative cable to the battery is disconnected.

  • Page 131: Fig. 51 Draining The Engine Oil

    Maintenance 10.4 Engine maintenance Material Engine oil Oil receptacle Wrench Cleaning cloths Precondition The machine is switched off. The machine is standing level. The machine is fully vented, the pressure gauge reads 0 psig. Engine at operating temperature. All compressed air consumers are disconnected and the air outlet valves are open. The «battery isolating switch»...

  • Page 132: Replace The Engine Oil Filter

    Maintenance 10.4 Engine maintenance 4. Unscrew the filler plug at the oil drain. 5. Open the shut-off valve at the engine's oil pan and catch the engine oil. 6. Close the shut-off valve and replace the screwed sealing cap. 7. Replace the plug in the filler port. 8.

  • Page 133: Engine Belt Maintenance

    Maintenance 10.4 Engine maintenance 5. Lightly oil the new filter's gasket. 6. Turn the oil filter clockwise by hand to tighten. 7. Check the engine oil level. Low oil level: Replenish engine oil. 8. Open the left-hand door. 9. Turn on the «battery isolating switch». 10.

  • Page 134: Fig. 53 Belt Guard Attachment

    Maintenance 10.4 Engine maintenance Removing the belt guard: Fig. 53 Belt guard attachment Belt guard Screw connection ➤ Unscrew the securing screws of the belt guard and remove the belt guard. 10.4.8.1 Carry out visual check Visual inspection for damages: ➤...

  • Page 135: Fig. 55 Manually Checking The Belt Tension

    Maintenance 10.4 Engine maintenance 10.4.8.2 Checking belt tension Check belt tension when they are warm, not hot, to avoid length variations through temperature. The belt tension can be checked by hand: To check the tension, press the belt inwards with the thumb at the mid-point between pulleys.

  • Page 136: Fig. 56 Changing/Tensioning The Drive Belt

    Maintenance 10.4 Engine maintenance 10.4.8.3 Changing/tensioning the drive belt Fig. 56 Changing/tensioning the drive belt Alternator drive belt Fan drive belt Alternator Tension disk Tensioning device Tensioning frame Hexagon screw (securing screw) Tensioning frame eye Hexagon screw (securing screw) Hexagon screw (tensioning screw) Hexagon screw (securing screw) Hexagon screw (securing screw) Hexagon screw (setting screw)
  • Page 137 Maintenance 10.4 Engine maintenance 4. Check the belt tension (see Fig. 55, II). Belt tension too low: Pull the alternator further outward (⃕+). Belt tension too high: Slightly move the alternator inward (−⃔). Replacing the fan drive belt: 1. Loosen the tensioning frame securing screw and clamping nut until the drive belt can be taken off the pulleys.

  • Page 138: Battery Maintenance

    Maintenance 10.4 Engine maintenance Old belts must be disposed of in accordance with the applicable environmental regulations. 10.4.9 Battery maintenance ➤ Check the charging system if the batteries discharge without reason. 10.4.9.1 Safety Danger of acid burns from escaping electrolyte! ➤...
  • Page 139 Maintenance 10.4 Engine maintenance 10.4.9.2 Battery checking and care Even so-called 'maintenance-free' batteries need a degree of care to obtain their maximum opera‐ tional life. The outside of the battery and the terminals should be cleaned regularly with a soft cloth. This avoids current leaks and minimizes the discharge rate.

  • Page 140: Checking The Fastening Of The Fuel Tank

    Maintenance 10.4 Engine maintenance 2. Check the battery charge weekly. Recharge as necessary. 3. If the machine is to be unused for a number of weeks, remove the battery and store in a frost‐ proof room. In extreme cases, the use of a heavy-duty cold-start battery and/or an additional booster bat‐ tery is recommended.

  • Page 141: Compressor Maintenance

    Maintenance 10.5 Compressor Maintenance Precondition The machine is shut down. The machine is standing level. The machine is fully vented, the pressure gauge reads 0 psig. The machine is cooled down. All compressed air consumers are disconnected and the air outlet valves are open. The lashing strip of the fuel tank is overly tightened.

  • Page 142: Cooling Oil Filling And Topping Off

    Maintenance 10.5 Compressor Maintenance Fig. 58 Check the cooling oil level Oil separator tank Minimum level Oil filler port Maximum level Screw plug 1. Open the right-hand access door. 2. Slowly unscrew and withdraw the plug from the oil filler port. 3.

  • Page 143: Changing The Cooling Oil

    Maintenance 10.5 Compressor Maintenance 4. Top off the cooling oil to the maximum level with the help of a funnel. 5. Check the oil level. 6. Check the filler plug gasket for damage. Damaged gasket: replace gasket. 7. Replace the plug in the filler port. 8.

  • Page 144: Fig. 59 Draining The Compressor Cooling Oil

    Maintenance 10.5 Compressor Maintenance There is risk of burns from hot components and escaping oil. ➤ Wear long-sleeved clothing and gloves. ➤ Open both doors. 10.5.3.1 Draining the cooling oil The drain points for compressor cooling oil and engine coolant are led to a central point outside. The cooling oil is drained via pipes which are screwed into the drain openings of the oil separator tank and the airend and are closed with a shut-off valve.

  • Page 145: Replacing The Compressor Oil Filter

    Maintenance 10.5 Compressor Maintenance Draining the oil from the oil cooler 1. Place the oil receptacle below the oil separator tank drain point 2. Unscrew the corresponding screwed sealing cap at the cooling oil drain. 3. Open the shut-off valve at the drain connection of the oil cooler and catch the draining cool‐...

  • Page 146: Fig. 60 Change The Oil Filter

    Maintenance 10.5 Compressor Maintenance Fig. 60 Change the oil filter Oil filter Thermostatic valve Direction of rotation to unscrew the oil filter. Changing the oil filter: 1. Open the left-hand door. 2. Prepare a receptacle. 3. Loosen the filter by turning counter-clockwise and catch any escaping oil. 4.

  • Page 147: Oil Separator Tank Dirt Trap Maintenance

    Maintenance 10.5 Compressor Maintenance 10.5.5 Oil separator tank dirt trap maintenance The control valve is mounted on the oil separator tank cover. The control valve has two different dirt traps that must be cleaned at least once a year. Material Cleaning cloths Wrench Small screwdriver...

  • Page 148: Changing The Oil Separator Cartridge

    Maintenance 10.5 Compressor Maintenance 6. Check the nozzle, strainer and sealing ring for wear. Replace components if they are heavily worn. 7. Fit the nozzle and strainer to the screw-in connector. 8. Screw in the connector making sure the sealing ring seats properly. 9.

  • Page 149: Fig. 62 Changing The Oil Separator Cartridge

    Maintenance 10.5 Compressor Maintenance Material Spare parts Cleaning cloths Wrench Precondition The machine is switched off. The machine is fully vented, the pressure gauge reads 0 psig. The machine has cooled down. All compressed air consumers are disconnected and the air outlet valves are open. The negative cable to the battery is disconnected.

  • Page 150: Compressor Air Filter Maintenance

    Maintenance 10.5 Compressor Maintenance 6. Carefully lift the cover and put to one side. Take care that the oil scavenge pipe screwed to the underside of the cover is not bent in the process. 7. Remove the old oil separator cartridge and the gaskets 8.

  • Page 151: Fig. 63 Compressor Air Filter Maintenance

    Maintenance 10.5 Compressor Maintenance Renew the air filter element after 2 years or after it has been cleaned 5 times. ■ Using the machine without an air filter element is not permitted! ■ Do not use a filter element with damaged folds or gasket. ■...

  • Page 152: Fig. 64 Cleaning The Filter Element

    Maintenance 10.5 Compressor Maintenance Fig. 64 Cleaning the filter element Compressed air gun with blast pipe bent to 90° at the end Filter element ➤ Open both doors. Checking the contamination level of the air filter Air filter maintenance is necessary when the yellow piston inside the maintenance indicator rea‐ ches the red zone.

  • Page 153: Checking Safety Relief Valves

    Maintenance 10.5 Compressor Maintenance 10.5.8 Checking safety relief valves ➤ Have safety relief valves checked by an authorized KAESER service representative in accord‐ ance with the maintenance schedule. 10.5.9 Fit the flexible pipe connection With the machine stopped, the clamping bolts must be freely movable by hand and parallel with the pipe.

  • Page 154: Cleaning The Cooler

    Maintenance 10.6 Cleaning the cooler 5. Tighten up the clamping bolts with the self-locking nuts It must be just possible to manually move the screw connections. 10.6 Cleaning the cooler The frequency of cleaning is mainly dependent on local operating conditions. Severe clogging of the coolers causes overheating and machine damage.

  • Page 155: Cleaning The Compressed Air Aftercooler

    Maintenance 10.6 Cleaning the cooler Fig. 66 Cleaning the compressor cooler and engine radiator Front end of machine, sound insulation Turbo air cooler (engine) (radiator grill) removed Radiator (engine) Direction of impacting water or steam jet Sound damping louvres (from outside to inside). Compressor oil cooler Cleaning the cooler 1.

  • Page 156: Maintenance Of Rubber Sealing Strips

    Maintenance 10.7 Maintenance of rubber sealing strips Option da, db, dc, dd Fig. 67 Cleaning the compressed air aftercooler Compressed air after-cooler Direction of impacting water or steam jet (from inside to outside). 1. Seal off the air intakes of the engine and compressor air filters before starting cleaning. 2.

  • Page 157: Chassis Maintenance

    Maintenance 10.8 Chassis maintenance 10.8 Chassis maintenance ➤ Perform maintenance tasks according to the schedule in chapter 10.3.3.1. 10.8.1 Wheel checks Check the wheels for tightness, visible damage and tire pressures: ■ after the first 30 miles ■ after every wheel change ■...

  • Page 158: Fig. 68 Tow Bar Maintenance

    Maintenance 10.8 Chassis maintenance Option rb/rm/rs Fig. 68 Tow bar maintenance Handle Lubricating points Transfer cable Greasing points Option rc/ro/rs, rd/ro/rs Fig. 69 Maintaining the fixed height towbar Greasing points 10.8.2.1 Checking the tow bar 1. Check the tow bar for correct function and movement. 2.

  • Page 159: Fig. 70 Ball Coupling ( Ec Version)

    Maintenance 10.8 Chassis maintenance Option rb/rm/rs, rc/ro/rs Maintaining the parking brake 1. Lightly lubricate the pins and adjustment joints. 2. Check free rotation of the parking brake lever. Option rb/rm/rs, rc/ro/rs, Maintaining the jockey wheel: rd/ro/rs 1. Check the jockey wheel for condition, correct function, and movement. Are individual parts twisted or damaged? Have the jockey wheel replaced.

  • Page 160: Brake Maintenance

    Maintenance 10.8 Chassis maintenance Option rd/ro/rs Fig. 71 Ball coupling (USA version) Lubricating points Greasing points 1. Check the ball coupling for correct function and movement. 2. Clean the ball coupling. Grease or oil the ball cup, joints and bearings. 10.8.3 Brake maintenance The brake adjusting procedure ensures even wear on the brake linings by adjusting the brake...

  • Page 161: Fig. 72 Checking The Brake Lining Thickness

    Maintenance 10.8 Chassis maintenance 10.8.3.2 Checking wheel brake lining wear Fig. 72 Checking the brake lining thickness Inspection hole Brake linings 1. Remove the plug from the inspection hole. 2. With the aid of a torch, check the brake lining thickness. Brake linings less than 0.1 inch thick should be replaced by a specialized workshop.

  • Page 162: Fig. 74 Brake Rod Adjustment

    Maintenance 10.8 Chassis maintenance 6. Check the position of the equaliser on the brake rod If the equaliser is perpendicular to the brake rod, the brake clearance is the same on each wheel. If the equaliser is oblique to the brake rod, adjust the brake rod. 7.

  • Page 163: Maintenance For Optional Items

    Maintenance 10.9 Maintenance for Optional Items 10.8.3.4 Greasing the brake rods Grease the brake rods when necessary (stiff movement) but at least annually. Material Lithium-enriched multi-purpose grease Cleaning cloths Precondition The machine is shut down. The machine is disconnected from the towing vehicle and safely parked. ➤...

  • Page 164: Fig. 75 Tool Lubricator Maintenance

    Maintenance 10.9 Maintenance for Optional Items Fig. 75 Tool lubricator maintenance Filler plug with dipstick and integrated riser Oil tank tube O-ring Minimum and recommended oil level Tool oil Tool lubricator upper part with oil filling port ➤ Open the right-hand access door. Checking the tool lubricator oil level Check the oil level daily.

  • Page 165: Cyclone Separator Maintenance

    Maintenance 10.9 Maintenance for Optional Items 5. Insert the plug in the filler port. 6. Close the door. Further information See chapter 2.7.1.1 for suitable oil grade and volume. 10.9.2 Option da, db, dc, dd Cyclone separator maintenance Clean the cyclone separator dirt trap if the moisture content in the compressed air is too high. Material Cleaning cloths Wrench...

  • Page 166: Combination Filter Maintenance

    Maintenance 10.9 Maintenance for Optional Items 3. Use the small screwdriver to unscrew the nozzle from the dirt trap housing. 4. Clean the nozzle, strainer, screw plug, O-ring and dirt trap housing with cleaning solvent or spirit. 5. Check the nozzle, strainer and O-ring for wear. Replace components if they are heavily worn.

  • Page 167: Fig. 77 Filter Combination

    Maintenance 10.9 Maintenance for Optional Items Option dd Fig. 77 Filter combination Filter combination Shut-off valve condensate drain Option dd Fig. 78 Combination filter maintenance Filter combination Filter head Pre-filter Filter element Microfilter Casing gasket Condensate drain hose fitting Filter housing Shut-off valves (ball valve) for condensate drain 0 –...
  • Page 168 Maintenance 10.9 Maintenance for Optional Items 10.9.3.1 Drain condensate Material Oil receptacle Cleaning cloths 1. Place the receptacle under the combination filter hose lines. 2. Open the pre-filter and micro-filter condensate drain shut off valves. 3. Close the door. 4. Start up the machine and run in IDLE. The condensate collecting in the filter housings is blown out.
  • Page 169 Maintenance 10.9 Maintenance for Optional Items 4. Check the housing gasket. Housing gasket is damaged: replace gasket. 5. Insert a new filter element. Wear gloves! 6. Screw on the filter housing clockwise. Changing the pre-filter element 1. Unscrew the filter housing counter-clockwise. 2.

  • Page 170: Fresh Air Filter Maintenance

    Maintenance 10.9 Maintenance for Optional Items 10.9.4 Option dc Fresh air filter maintenance Before commencing work on the fresh air filter, read and understand the operating instructions giv‐ en in chapter 13.8. Precondition The machine is switched off. The machine is standing level. The machine is fully vented, the pressure gauge reads 0 psig.
  • Page 171 Maintenance 10.9 Maintenance for Optional Items 4. Switch the machine on and run it in IDLE mode for approx. 2 minutes. The condensate collecting in the filter housings is blown out. 5. Shut down the machine. 6. Open both doors. 7.
  • Page 172 Maintenance 10.9 Maintenance for Optional Items 5. Insert a new lower filter element. Wear protective gloves! 6. Screw on the lower housing clockwise. Changing the upper filter element (adsorption insert) 1. Unscrew the upper housing counter-clockwise. 2. Draw the filter element up and out. 3.

  • Page 173: Engine Air Intake Shut-Off Valve Maintenance

    Maintenance 10.9 Maintenance for Optional Items 10.9.5 Option lb Engine air intake shut-off valve maintenance Material Compressed air for blowing out Petroleum ether or spirit Cleaning cloths Precondition The machine is switched off. The machine is fully vented, the pressure gauge reads 0 psig. The machine has cooled down.

  • Page 174: Fig. 81 Checking Manual Operation Of The Engine Air Intake Valve

    Maintenance 10.9 Maintenance for Optional Items Cleaning the engine air shut-off valve The engine air intake shut-off valve does not close fully. The machine does not shut down? Destruction of the engine and explosion and/or fire are pos‐ sible. ➤ Do not grease the valve, as this may cause a build up of dust and valve sticking. Opened engine air inlet manifold Dirt can enter the engine and cause damage (turbocharger).

  • Page 175: Spark Arrestor Maintenance

    Maintenance 10.9 Maintenance for Optional Items 1. Start the machine and switch to LOAD operation. 2. Pull the handle to the stop and hold. The engine should stop in a few seconds. Engine does not stop: ➤ Have the engine air intake valve checked by a specialist workshop or an authorized KAESER SERVICE representative.

  • Page 176: Fig. 82 Cleaning The Spark Arrestor (Floor Pan With Service Openings)

    Maintenance 10.9 Maintenance for Optional Items Cleaning the spark arrestor (floor pan with service openings) Fig. 82 Cleaning the spark arrestor (floor pan with service openings) Exhaust silencer end pipe Soot drain port with plug Opening in floor panel to access drain port Exhaust silencer with integrated spark ar‐...

  • Page 177: Draining Liquid Accumulation Within The Machine

    Maintenance 10.9 Maintenance for Optional Items 1. Unscrew the service opening plug. 2. Unscrew the soot drain plug. 3. Push one end of the hose over the drain port and place the other end in the receptacle. 4. Start the compressor engine. 5.
  • Page 178 Maintenance 10.9 Maintenance for Optional Items 2. Unscrew and remove the bung(s) from the service openings. The liquid will drain. 3. Clean the bungs and service openings. 4. Close all service openings with bungs. The machine body is sealed. 5. Using the cleaning cloth, remove any dirt within the machine. 6.

  • Page 179: Documenting Maintenance And Service Work

    Maintenance 10.10 Documenting maintenance and service work 10.10 Documenting maintenance and service work Machine model/part number: ➤ Enter maintenance and service work carried out in this list. Date Maintenance task carried out Operating hours Signature Tab. 81 Maintenance log Operator Manual Screw Compressor No.: 901765 05 USE M114 SIGMA CONTROL SMART...

  • Page 180: 11 Spares, Operating Materials, Service

    Spares, Operating Materials, Service 11.1 Note the nameplate 11 Spares, Operating Materials, Service 11.1 Note the nameplate The nameplate contains all information to identify your machine. This information is essential to us in order to provide you with optimal service. ➤...

  • Page 181: Kaeser Air Service

    Spares, Operating Materials, Service 11.3 KAESER AIR SERVICE Name Quantity Number Engine oil 1925 Tab. 83 Consumable engine parts Option dd Filter combination Name Quantity Number Filter element for pre-filter 1550 Filter element for micro-filter 1551 Casing gasket 1548 Tab. 84 Replacement parts, combination filter Option dc Fresh air filter...
  • Page 182 Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Personal injury or machine damage due to incorrect working on the machine! Incorrect inspection, service or repair can damage the machine or severely impair its func‐ tion. Personal injury may result from damage. ➤...
  • Page 183 Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor No.: 901765 05 USE M114 SIGMA CONTROL SMART...
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  • Page 236: 12 Decommissioning, Storage And Transport

    Decommissioning, Storage and Transport 12.1 De-commissioning 12 Decommissioning, Storage and Transport 12.1 De-commissioning De-commissioning is necessary, for example, under the following circumstances: ■ The machine is temporarily not needed ■ The machine will not be needed for a considerable time. ■...

  • Page 237: Long-Term Decommissioning And Storage

    Decommissioning, Storage and Transport 12.1 De-commissioning 2. Remove the battery (batteries) and store in a frost-free room. 3. Make sure batteries are fully charged. 12.1.2 Long-term decommissioning and storage Decommissioning the machine for 5 months or longer. Material Receptacle Preserving oil Preservative Desiccant Plastic sheeting...

  • Page 238: Transport

    Decommissioning, Storage and Transport 12.2 Transport ➤ Attach the following notice on the instrument panel to inform of the decommissioning measures taken. Attention! 1. The machine is decommissioned. 2. It is filled with preserving oil. 3. For recommissioning: ■ Take measures for recommissioning the compressor after a long period of storage. ■...
  • Page 239 Decommissioning, Storage and Transport 12.2 Transport Risk of accident when towing non-roadworthy machines on public roads. Death or severe injury possible due to accidents with unbraked and/or unilluminated trailer. ➤ Do not tow machines without service brake and/or illumination equipment on public roads. ➤...

  • Page 240: Fig. 84 Transport Position

    Decommissioning, Storage and Transport 12.2 Transport Fig. 84 Transport position Danger from problematic driving dynamics! The permissible loading range may be exceeded or undercut. Personal injury may result from towing. Damage to the machine and/or towing vehicle is possible. ➤ Do not couple up the machine at an angle to the towing vehicle. ➤...

  • Page 241: Fig. 85 Ball Coupling (Alko-Eu)

    Decommissioning, Storage and Transport 12.2 Transport Fig. 85 Ball coupling (ALKO-EU) Coupling handle Towing vehicle ball hitch Ball coupling Locking indicator (protruding) There is considerable danger of injury caused by trapped fingers. They can be trapped in the spring-loaded closing mechanism. ➤...

  • Page 242: Fig. 86 Wear Alert, Ball Coupling (Alko-Eu)

    Decommissioning, Storage and Transport 12.2 Transport Fig. 86 Wear alert, ball coupling (ALKO-EU) Ball coupling Green zone (OK) Wear indicator Red zone (wear tolerance exceeded) – Danger of accident from worn coupling! The machine may detach from the towing vehicle. ➤...

  • Page 243: Fig. 87 Ball Coupling (Alko-Usa)

    Decommissioning, Storage and Transport 12.2 Transport Fig. 87 Ball coupling (ALKO-USA) Coupling handle Safety pin Ball coupling Fixing hole for the security pin Towing vehicle ball hitch Ball coupling properly secured There is considerable danger of injury caused by trapped fingers. They can be trapped in the spring-loaded closing mechanism.

  • Page 244: Fig. 89 Automatic Jockey Wheel In Transport Position

    Decommissioning, Storage and Transport 12.2 Transport Fig. 89 Automatic jockey wheel in transport position Option rb/rm/rs Preparing the machine for transport (height-adjustable chassis): 1. Check that the tow bar is adjusted to the correct height. (see also chapter 6.4.1) Check if: ■...

  • Page 245: Fig. 90 Safety Signs: Secure The Chocks

    Decommissioning, Storage and Transport 12.2 Transport Option rd/ro/rs Preparing the machine for transport (fixed-height chassis, without parking brake): Option rd/ro/rs Fig. 90 Safety signs: Secure the chocks Missing chocks Serious injury or death can result from an unsecured machine rolling away. ➤...

  • Page 246: Fig. 91 Breakaway Cable Attachment

    Decommissioning, Storage and Transport 12.2 Transport Fig. 91 Breakaway cable attachment Breakaway cable Breakaway cable guide (eye) Connection (spring clip) Unintentional brake application. If the breakaway cable is too short it can apply the brakes when rounding a curve. This impo‐ ses high wear on the braking system.

  • Page 247: Parking The Machine

    Decommissioning, Storage and Transport 12.2 Transport 12.2.3 Parking the machine The machine is generally only moved by being coupled to a towing vehicle. The parking brake is not a running brake and is used only to lock the wheels when the machine is positioned.

  • Page 248: Fig. 94 Tow Bar With Automatic Jockey Wheel

    Decommissioning, Storage and Transport 12.2 Transport Fig. 94 Tow bar with automatic jockey wheel Bead Retaining pin Wheel suspension Fig. 95 Actuating the parking brake Parking brake with gas spring assistance Parking brake with ratchet and spring load‐ Parking brake lever Gas spring Ratchet Marking: “Dead point zone”...

  • Page 249: Fig. 96 Safety Signs: Secure With Chocks

    Decommissioning, Storage and Transport 12.2 Transport 3. Strongly pull the parking brake upward past the dead point zone (see Ill.95, figure a). The gas spring holds the brake under tension. 4. Detach the breakaway cable. 5. Lower the jockey wheel until the towing mechanism is stress-free. 6.

  • Page 250: Transport With A Crane

    Decommissioning, Storage and Transport 12.2 Transport 3. Lower the jockey wheel until the towing mechanism is stress-free. 4. Place chocks under the wheels. 5. Remove the lighting and signalling system. 6. Uncouple the compressor from the towing vehicle: ■ Withdraw the security pin from the ball coupling. ■...

  • Page 251: Transport With A Forklift Truck

    Decommissioning, Storage and Transport 12.2 Transport 12.2.5 Option rw Transport with a forklift truck Precondition The machine is switched off. All connecting lines and hoses disconnected and removed. Damage to the machine by incorrect lifting with a fork truck. The machine may fall or be damaged by the forks. ➤...

  • Page 252: Fig. 98 Guys To Secure The Freight

    Decommissioning, Storage and Transport 12.2 Transport Carry out a freight securing: ■ National directives and regulations for securing loads should be followed. ■ Load securing is taken to mean that by full braking or sudden turning the load will not slide, fall, roll or cause unnecessary noise.

  • Page 253: Storage

    Decommissioning, Storage and Transport 12.3 Storage 2. Remove all dangerous fluids/materials. These include: ■ Residues of fuel or fuel vapours ■ Lubricants in engine and compressor ■ Battery electrolyte ■ Residual quantities of tool lubricating oil in the tool lubricator (option ea, ec) 12.3 Storage Moisture can lead to corrosion, particularly in the engine, airend and oil separator tank.

  • Page 254: 13 Annex

    Annex 13.1 Marking 13 Annex 13.1 Marking Fig. 99 Marking Machine nameplate with system serial Options label number Engine nameplate with engine serial num‐ VIN *) (stamped in the bodywork) * Vehicle identity number 13.2 Pipeline and instrument flow diagram (P+I diagram) Operator Manual Screw Compressor M114 SIGMA CONTROL SMART...
  • Page 255 Annex 13.2 Pipeline and instrument flow diagram (P+I diagram) Operator Manual Screw Compressor No.: 901765 05 USE M114 SIGMA CONTROL SMART...
  • Page 256 Annex 13.2 Pipeline and instrument flow diagram (P+I diagram) Operator Manual Screw Compressor M114 SIGMA CONTROL SMART No.: 901765 05 USE...
  • Page 257 Annex 13.2 Pipeline and instrument flow diagram (P+I diagram) Operator Manual Screw Compressor No.: 901765 05 USE M114 SIGMA CONTROL SMART...
  • Page 258 Annex 13.2 Pipeline and instrument flow diagram (P+I diagram) Operator Manual Screw Compressor M114 SIGMA CONTROL SMART No.: 901765 05 USE...

  • Page 259: Dimensional Drawings

    Annex 13.3 Dimensional drawings 13.3 Dimensional drawings 13.3.1 Option rb/rk/rm/rs Dimensional drawing – chassis ■ Option rb - Chassis, EU type ■ Option rk - Chassis with low axle load ■ Option rm - Chassis with height adjustment ■ Option rs - Chassis with overrun brake Operator Manual Screw Compressor No.: 901765 05 USE...
  • Page 260 Annex 13.3 Dimensional drawings Operator Manual Screw Compressor M114 SIGMA CONTROL SMART No.: 901765 05 USE...

  • Page 261: Dimensional Drawing, Chassis Options

    Annex 13.3 Dimensional drawings 13.3.2 Option rc/ro/rs Dimensional drawing, chassis options ■ Option rc - Chassis GB version ■ Option ro - Chassis with fixed height towbar ■ Option rs - Chassis with overrun brake Operator Manual Screw Compressor No.: 901765 05 USE M114 SIGMA CONTROL SMART...
  • Page 262 Annex 13.3 Dimensional drawings Operator Manual Screw Compressor M114 SIGMA CONTROL SMART No.: 901765 05 USE...

  • Page 263: Dimensional Drawing, Chassis Options

    Annex 13.3 Dimensional drawings 13.3.3 Option rd/ro/rs Dimensional drawing, chassis options ■ Option rd - Chassis USA version ■ Option ro - Chassis with fixed height towbar ■ Option rs - Chassis with overrun brake Operator Manual Screw Compressor No.: 901765 05 USE M114 SIGMA CONTROL SMART...
  • Page 264 Annex 13.3 Dimensional drawings Operator Manual Screw Compressor M114 SIGMA CONTROL SMART No.: 901765 05 USE...

  • Page 265: Dimensional Drawing, Chassis Options

    Annex 13.3 Dimensional drawings 13.3.4 Option rb/rl/rm/rs Dimensional drawing, chassis options ■ Option rb - Chassis EU version ■ Option rl - Chassis with higher axle load ■ Option rm - Chassis with height-adjustable towbar ■ Option rs - Chassis with overrun brake Operator Manual Screw Compressor No.: 901765 05 USE...
  • Page 266 Annex 13.3 Dimensional drawings Operator Manual Screw Compressor M114 SIGMA CONTROL SMART No.: 901765 05 USE...

  • Page 267: Dimensional Drawing, Stationary Version

    Annex 13.3 Dimensional drawings 13.3.5 Option rw Dimensional drawing, stationary version ■ Option rw - Skid frame on runners Operator Manual Screw Compressor No.: 901765 05 USE M114 SIGMA CONTROL SMART...
  • Page 268 Annex 13.3 Dimensional drawings Operator Manual Screw Compressor M114 SIGMA CONTROL SMART No.: 901765 05 USE...

  • Page 269: Dimensional Drawing, Stationary Version

    Annex 13.3 Dimensional drawings 13.3.6 Option rx Dimensional drawing, stationary version ■ Option rx - On frame Operator Manual Screw Compressor No.: 901765 05 USE M114 SIGMA CONTROL SMART...
  • Page 270 Annex 13.3 Dimensional drawings Operator Manual Screw Compressor M114 SIGMA CONTROL SMART No.: 901765 05 USE...

  • Page 271: Wiring Diagrams

    Annex 13.4 Wiring diagrams 13.4 Wiring diagrams 13.4.1 Electrical Diagram Operator Manual Screw Compressor No.: 901765 05 USE M114 SIGMA CONTROL SMART...
  • Page 272 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor M114 SIGMA CONTROL SMART No.: 901765 05 USE...
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  • Page 288 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor M114 SIGMA CONTROL SMART No.: 901765 05 USE...

  • Page 289: Lighting And Signaling System Connection

    Annex 13.4 Wiring diagrams 13.4.2 Option tc Lighting and signaling system connection Operator Manual Screw Compressor No.: 901765 05 USE M114 SIGMA CONTROL SMART...
  • Page 290 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor M114 SIGMA CONTROL SMART No.: 901765 05 USE...
  • Page 291 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor No.: 901765 05 USE M114 SIGMA CONTROL SMART...
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  • Page 296 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor M114 SIGMA CONTROL SMART No.: 901765 05 USE...

  • Page 297: Lighting And Signaling System Connection

    Annex 13.4 Wiring diagrams 13.4.3 Option te Lighting and signaling system connection Operator Manual Screw Compressor No.: 901765 05 USE M114 SIGMA CONTROL SMART...
  • Page 298 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor M114 SIGMA CONTROL SMART No.: 901765 05 USE...
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  • Page 302: Battery Charger Electrical Diagram

    Annex 13.4 Wiring diagrams 13.4.4 Option od Battery charger electrical diagram Operator Manual Screw Compressor M114 SIGMA CONTROL SMART No.: 901765 05 USE...
  • Page 303 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor No.: 901765 05 USE M114 SIGMA CONTROL SMART...
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  • Page 310 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor M114 SIGMA CONTROL SMART No.: 901765 05 USE...
  • Page 311 Annex 13.4 Wiring diagrams Operator Manual Screw Compressor No.: 901765 05 USE M114 SIGMA CONTROL SMART...

  • Page 312: Fuel Circulation Diagram

    Annex 13.5 Fuel circulation diagram 13.5 Fuel circulation diagram Operator Manual Screw Compressor M114 SIGMA CONTROL SMART No.: 901765 05 USE...
  • Page 313 Annex 13.5 Fuel circulation diagram Operator Manual Screw Compressor No.: 901765 05 USE M114 SIGMA CONTROL SMART...
  • Page 314 Annex 13.5 Fuel circulation diagram Operator Manual Screw Compressor M114 SIGMA CONTROL SMART No.: 901765 05 USE...

  • Page 315: Assembly Diagrams - Chassis

    Annex 13.6 Assembly diagrams - chassis 13.6 Assembly diagrams - chassis 13.6.1 Assembly diagrams - chassis EU version Operator Manual Screw Compressor No.: 901765 05 USE M114 SIGMA CONTROL SMART...
  • Page 316 Annex 13.6 Assembly diagrams - chassis Operator Manual Screw Compressor M114 SIGMA CONTROL SMART No.: 901765 05 USE...

  • Page 317: Assembly Diagrams - Chassis Gb/Us Version

    Annex 13.6 Assembly diagrams - chassis 13.6.2 Assembly diagrams - chassis GB/US version Operator Manual Screw Compressor No.: 901765 05 USE M114 SIGMA CONTROL SMART...
  • Page 318 Annex 13.6 Assembly diagrams - chassis Operator Manual Screw Compressor M114 SIGMA CONTROL SMART No.: 901765 05 USE...
  • Page 319 Annex 13.6 Assembly diagrams - chassis Operator Manual Screw Compressor No.: 901765 05 USE M114 SIGMA CONTROL SMART...

  • Page 320: Assembly Diagram Brake Rod

    Annex 13.6 Assembly diagrams - chassis 13.6.3 Assembly diagram brake rod Operator Manual Screw Compressor M114 SIGMA CONTROL SMART No.: 901765 05 USE...
  • Page 321 Annex 13.6 Assembly diagrams - chassis Operator Manual Screw Compressor No.: 901765 05 USE M114 SIGMA CONTROL SMART...

  • Page 322: Operating Instructions For Compressed Air Filter (Combination Filter)

    Annex 13.7 Operating instructions for compressed air filter (combination filter) 13.7 Option dd Operating instructions for compressed air filter (combination filter) Operator Manual Screw Compressor M114 SIGMA CONTROL SMART No.: 901765 05 USE...
  • Page 323 Annex 13.7 Operating instructions for compressed air filter (combination filter) Filters for Compressed Air 005-055 (AO, AA, ACS, AR, AAR) EN Original Language FILTER DH-OIL-X EVO AO AA_01- Operator Manual Screw Compressor No.: 901765 05 USE M114 SIGMA CONTROL SMART...
  • Page 324 Annex 13.7 Operating instructions for compressed air filter (combination filter) FILTER DH-OIL-X EVO AO AA_01- Operator Manual Screw Compressor M114 SIGMA CONTROL SMART No.: 901765 05 USE...
  • Page 325 Annex 13.7 Operating instructions for compressed air filter (combination filter) AO, AA, ACS, AR, AAR 005 - 055 • Highlights actions or procedures, which if not performed correctly, may lead to personal injury or death. • Benadrukt de acties of procedures die, indien niet juist uitgevoerd, lichamelijk letsel of de dood kunnen veroorzaken. •...
  • Page 326 Annex 13.7 Operating instructions for compressed air filter (combination filter) AO, AA, ACS, AR, AAR 005 - 055 • Pressure. • Druk • Druck. • Pression. • Paine. • Tryck • Trykk • Tryk • Πίεση • Presión. • Pressão. •...
  • Page 327 Annex 13.7 Operating instructions for compressed air filter (combination filter) AO, AA, ACS, AR, AAR 005 - 055 Warning! This product must be installed and maintained by competent and authorised personnel only, under strict observance of these operating instructions, any relevant standards and legal requirements where appropriate. Retain this user guide for future reference Waarschuwing! Dit product mag alleen geïnstalleerd en onderhouden worden door deskundig en bevoegd personeel met strikte inachtneming van deze...
  • Page 328 Annex 13.7 Operating instructions for compressed air filter (combination filter) AO, AA, ACS, AR, AAR 005 - 055 Attenzione L’installazione e la manutenzione del prodotto devono essere affidate a personale competente e autorizzato, nel rigoroso rispetto delle presenti istruzioni di funzionamento, degli standard applicabili e delle normative in vigore, qualora appropriato. Conservare questa guida utente per consultarla in seguito Ostrzeżenie! Instalacja i konserwacja urządzenia muszą...
  • Page 329 Annex 13.7 Operating instructions for compressed air filter (combination filter) AO, AA, ACS, AR, AAR 005 - 055 Index • Index • Stichwortverzeichnis • Index • Sisältö • Index • Innholdsfortegnelse • Indeks • Eυρετήριο • Índice • Índice • Indice • Skorowidz •...
  • Page 330 Annex 13.7 Operating instructions for compressed air filter (combination filter) AO, AA, ACS, AR, AAR 005 - 055 FILTER DH-OIL-X EVO AO AA_01- Operator Manual Screw Compressor M114 SIGMA CONTROL SMART No.: 901765 05 USE...
  • Page 331 Annex 13.7 Operating instructions for compressed air filter (combination filter) AO, AA, ACS, AR, AAR 005 - 055 Technical Specification • Technische specificaties • Technische Angaben • Caractéristiques techniques • Tekniset tiedot • Tekniska specifikationer • Tekniske spesifikasjoner • Tekniske specifikationer • Τεχνικές προδιαγραφές • Especificaciones técnicas • Especificações Técnicas •...
  • Page 332 Annex 13.7 Operating instructions for compressed air filter (combination filter) AO, AA, ACS, AR, AAR 005 - 055 Weights and Dimensions • Gewichten en afmetingen • Gewicht und Abmessungen • Poids et dimensions • Painot ja mitat • Vikter och mått • Vekt og dimensjone •...
  • Page 333 Annex 13.7 Operating instructions for compressed air filter (combination filter) AO, AA, ACS, AR, AAR 005 - 055 1/4” F 1/2” M FILTER DH-OIL-X EVO AO AA_01- Operator Manual Screw Compressor No.: 901765 05 USE M114 SIGMA CONTROL SMART...
  • Page 334 Annex 13.7 Operating instructions for compressed air filter (combination filter) AO, AA, ACS, AR, AAR 005 - 055 050 & 055 The lower closure plate may move when the filter is not pressurised. Het onderste sluitplaatje zou kunnen bewegen wanneer het filter niet onder druk staat. Die untere Verschlussplatte kann sich bewegen, wenn der Filter nicht mit Druck beaufschlagt ist.
  • Page 335 Annex 13.7 Operating instructions for compressed air filter (combination filter) AO, AA, ACS, AR, AAR 005 - 055 Pokrywa dolna może się przesuwać, gdy filtr nie będzie pod ciśnieniem. Ak filter nie je natlakovaný, spodná uzatváracia platňa sa môže posunúť. Spodní...
  • Page 336 Annex 13.7 Operating instructions for compressed air filter (combination filter) AO, AA, ACS, AR, AAR 005 - 055 Startup and Operation • Starten en bediening • Start und Betrieb • Démarrage et exploitation • Käynnistys ja toiminta • Start och drift • Oppstart og betjening •...
  • Page 337 Annex 13.7 Operating instructions for compressed air filter (combination filter) AO, AA, ACS, AR, AAR 005 - 055 Ανοίξτε αργά τη βαλβίδα εισαγωγής για να ανέβει σταδιακά η πίεση της µονάδας. Ανοίξτε αργά τη βαλβίδα εξαγωγής για να ανέβει η πίεση της σωλήνωσης κατάντι Μην...
  • Page 338 Annex 13.7 Operating instructions for compressed air filter (combination filter) AO, AA, ACS, AR, AAR 005 - 055 Lēnām atveriet ieplūdes vārstu, lai iekārtā pamazām paaugstinātu spiedienu. Lēnām atveriet izplūdes vārstu, lai caurulēs plūsmas virzienā samazinātu spiedienu Neatveriet ieplūdes un izplūdes vārstus strauji, pretējā gadījumā attiecīgajā iekārtā var rasties pārmērīgi liels spiediens vai tā var sabojāties. Lėtai atidarydami įleidimo vožtuvą, palaipsniui sudarykite slėgį...
  • Page 339 Annex 13.7 Operating instructions for compressed air filter (combination filter) AO, AA, ACS, AR, AAR 005 - 055 Accessories • Toebehoren • Zubehör • Accessoires • Lisävarusteet • Tillbehör • Tilbehør • Tilbehør • Eξαρτήµατα • Accesorios • Acessórios • Accessori •...
  • Page 340 Annex 13.7 Operating instructions for compressed air filter (combination filter) AO, AA, ACS, AR, AAR 005 - 055 Spare Parts (Service Kits) • Reserve-onderdelen (servicekits) • Ersatzteile (Service-Kits) • Pièces de rechange (nécessaires d’entretien) • Varaosat (Huoltopakkaukset) • Reservdelar (servicesatser) • Reservedeler (service-sett) • Reservedele (Servicekit) • Ανταλλακτικά (Πακέτα τεχνικής υποστήριξης) •...
  • Page 341 Annex 13.7 Operating instructions for compressed air filter (combination filter) AO, AA, ACS, AR, AAR 005 - 055 EMAK EMAK1 005 - 010 EMAK2 015 - 020 EMAK3 025 - 030 EMAK4 035 - 045 EMAK5 050 - 055 Maintenance •...
  • Page 342 Annex 13.7 Operating instructions for compressed air filter (combination filter) AO, AA, ACS, AR, AAR 005 - 055 0 bar 0 bar 0 psi 0 psi 0 bar 0 psi FILTER DH-OIL-X EVO AO AA_01- Operator Manual Screw Compressor M114 SIGMA CONTROL SMART No.: 901765 05 USE...
  • Page 343 Annex 13.7 Operating instructions for compressed air filter (combination filter) AO, AA, ACS, AR, AAR 005 - 055 0 bar 0 bar 0 psi 0 psi 2009 Align the arrow to the month and year of the next ervice Breng de pijl op een lijn met de maand en het jaar van de volgende onderhoud beurt Stellen Sie den Pfeil auf Monat und Jahr de näch ten Wartung termin Alignez la flèche ur le moi et l'année de la prochaine révi ion Kohdi ta nuoli euraavan huollon kuukauteen ja vuoteen...
  • Page 344 Annex 13.7 Operating instructions for compressed air filter (combination filter) AO, AA, ACS, AR, AAR 005 - 055 FILTER DH-OIL-X EVO AO AA_01- Operator Manual Screw Compressor M114 SIGMA CONTROL SMART No.: 901765 05 USE...
  • Page 345 Annex 13.7 Operating instructions for compressed air filter (combination filter) AO, AA, ACS, AR, AAR 005 - 055 FILTER DH-OIL-X EVO AO AA_01- Operator Manual Screw Compressor No.: 901765 05 USE M114 SIGMA CONTROL SMART...
  • Page 346 Annex 13.7 Operating instructions for compressed air filter (combination filter) AO, AA, ACS, AR, AAR 005 - 055 Declaration of Conformity Déclaration de conformité Parker Hannifin ltd domn ck hunter divis on Parker Hannifin ltd domn ck hunter division Dukesway TVTE Gateshead Tyne & Wear NE11 0PZ UK Dukesway TVTE Gateshead Tyne &...
  • Page 347 Annex 13.7 Operating instructions for compressed air filter (combination filter) AO, AA, ACS, AR, AAR 005 - 055 Konformitetserk ær ng Declaración de conformidad Parker Hannifin ltd domn ck hunter divis on Parker Hannifin ltd domn ck hunter division Dukesway TVTE Gateshead Tyne & Wear NE11 0PZ UK Dukesway TVTE Gateshead Tyne &...
  • Page 348 Annex 13.7 Operating instructions for compressed air filter (combination filter) AO, AA, ACS, AR, AAR 005 - 055 Deklaracja zgodno ci Vastavusdeklaratsioon Parker Hannifin ltd domn ck hunter divis on Parker Hannifin ltd domn ck hunter division Dukesway TVTE Gateshead Tyne & Wear NE11 0PZ UK Dukesway TVTE Gateshead Tyne &...
  • Page 349 Annex 13.7 Operating instructions for compressed air filter (combination filter) AO, AA, ACS, AR, AAR 005 - 055 FILTER DH-OIL-X EVO AO AA_01- Operator Manual Screw Compressor No.: 901765 05 USE M114 SIGMA CONTROL SMART...

  • Page 350: Operating Instructions For Compressed Air Filter (Fresh Air Filter)

    Annex 13.8 Operating instructions for compressed air filter (fresh air filter) 13.8 Option dc Operating instructions for compressed air filter (fresh air filter) Operator Manual Screw Compressor M114 SIGMA CONTROL SMART No.: 901765 05 USE...
  • Page 351 Annex 13.8 Operating instructions for compressed air filter (fresh air filter) domnick hunter AC010 - AC030 OIL VAPOUR & ODOUR REMOVAL FILTERS Original Language OLIEDAMP & GEUR VERWIJDERINGSFILTERS FILTER ZUM ENTFERNEN VON ÖLNEBEL UND GERÜCHEN FILTRES D'ÉLIMINATION DES ODEURS ET DES VAPEURS D'HUILE ÖLJYHÖYRYN JA HAJUN POISTOSUODATTIMET FILTER FÖR AVLÄGSNING AV OLJEÅNGOR OCH LUKT OLJEDAMP- OG OLJELUKTFJERNINGSFILTRE...
  • Page 352 Annex 13.8 Operating instructions for compressed air filter (fresh air filter) Operator Manual Screw Compressor M114 SIGMA CONTROL SMART No.: 901765 05 USE...
  • Page 353 Annex 13.8 Operating instructions for compressed air filter (fresh air filter) AC010 - AC030 • Highlights actions or procedures, which if not performed correctly, may lead to personal injury or death. • Benadrukt de acties of procedures die, indien niet juist uitgevoerd, lichamelijk letsel of de dood kunnen veroorzaken. •...
  • Page 354 Annex 13.8 Operating instructions for compressed air filter (fresh air filter) AC010 - AC030 • Pressure. • Druk • Druck. • Pression. • Paine. • Tryck • Trykk • Tryk • Πίεση • Presión. • Pressão. • Pressione. • Ciśnienie •...
  • Page 355 Annex 13.8 Operating instructions for compressed air filter (fresh air filter) AC010 - AC030 Warning! This product must be installed and maintained by competent and authorised personnel only, under strict observance of these operating instructions, any relevant standards and legal requirements where appropriate. Retain this user guide for future reference Waarschuwing! Dit product mag alleen geïnstalleerd en onderhouden worden door deskundig en bevoegd personeel met strikte inachtneming van deze...
  • Page 356 Annex 13.8 Operating instructions for compressed air filter (fresh air filter) AC010 - AC030 Rakkomandazzjonijiet g[all-Installazzjoni Nirrakkomandaw li l-arja kompressata ti;i trattata qabel ma tid[ol fis-sistema ta’ distribuzzjoni kif ukoll fil-punti / l-applikazzjonijiet kriti/i ta’ l-u]u. L-installazzjoni ta’ tag[mir li jnixxef l-arja kumpressata fuq sistema li kienet imxarrba jista’ jirri]ulta f’aktar tag[bija ta’ [mie; g[all-filtri li jintu]aw f’punt wie[ed, g[all-perjodu sakemm is-sistema ta’...
  • Page 357 Annex 13.8 Operating instructions for compressed air filter (fresh air filter) AC010 - AC030 1/4” 1/2” FILTER-DH-OIL-XEVOLUTION 01 Operator Manual Screw Compressor No.: 901765 05 USE M114 SIGMA CONTROL SMART...
  • Page 358 Annex 13.8 Operating instructions for compressed air filter (fresh air filter) AC010 - AC030 Spare Parts (Service Kits) Reserve-onderdelen (servicekits) • Ersatzteile (Service-Kits) • Pièces de rechange (nécessaires d’entretien) • Varaosat (Huoltopakkaukset) • Reservdelar (servicesatser) • Reservedeler (service-sett) • Reservedele (Servicekit) • Ανταλλακτικά (Πακέτα τεχνικής υποστήριξης) •...
  • Page 359 Annex 13.8 Operating instructions for compressed air filter (fresh air filter) AC010 - AC030 Maintenance Onderhoud • Wartung • Entretien • Kunnossapito • Underhåll • Vedlikehold • Vedligeholdelse • Συντήρηση • Mantenimiento • Manutenção • Manutenzione • Konserwacja • Údržba • Údržba • Hooldus • Karbantartás • Tehniskā apkope • Techninė priežiūra • Обслуживание •...
  • Page 360 Annex 13.8 Operating instructions for compressed air filter (fresh air filter) AC010 - AC030 0 bar 0 bar 0 psi 0 psi FILTER-DH-OIL-XEVOLUTION 01 Operator Manual Screw Compressor M114 SIGMA CONTROL SMART No.: 901765 05 USE...
  • Page 361 Annex 13.8 Operating instructions for compressed air filter (fresh air filter) AC010 - AC030 0 bar 0 psi 0 bar 0 bar 0 psi 0 psi 0 bar 0 psi FILTER-DH-OIL-XEVOLUTION 01 Operator Manual Screw Compressor No.: 901765 05 USE M114 SIGMA CONTROL SMART...
  • Page 362 Annex 13.8 Operating instructions for compressed air filter (fresh air filter) AC010 - AC030 FILTER-DH-OIL-XEVOLUTION 01 Operator Manual Screw Compressor M114 SIGMA CONTROL SMART No.: 901765 05 USE...
  • Page 363 Annex 13.8 Operating instructions for compressed air filter (fresh air filter) AC010 - AC030 Operator Manual Screw Compressor No.: 901765 05 USE M114 SIGMA CONTROL SMART...
  • Page 364 Annex 13.8 Operating instructions for compressed air filter (fresh air filter) Operator Manual Screw Compressor M114 SIGMA CONTROL SMART No.: 901765 05 USE...

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