SERVICE MANUAL E

Base Mounted Reciprocating Compressor

Model: K 1000 --- 2 --- G / H 35
GL---Nr.: 1_2617_10130---02 01

Part No.: 1.2617.10130

Serial No.: ...............................................

Manufacturer:

KAESER KOMPRESSOREN GmbH

96410 Coburg S PO Box 2143 S GERMANY S Tel. +49---(0)9561---6400 S Fax +49---(0)9561---640130
http://www.kaeser.com
K 1000 - 2 - G / H 35
1.2617.10130
 Table of Contents
Chapter --- Page

1 Technical Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1

1.1 Base Mounted Compressor Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1
1.2 Sound Pressure Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1
1.3 Compressor Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1
1.4 Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1
1.5 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 2
1.6 Safety Valve Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 2
1.7 Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 2
1.8 Recommended Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 3
1.9 Dimensional Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 3

2 Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 5

2.1 Explanation of Symbols and References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 5
2.2 Safety Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 6
2.3 Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 7
2.4 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 7
2.5 Environmental Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 7

3 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 9
3.1 Correct Use of the Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 9
3.2 Incorrect Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 9
3.3 Compressed Air Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 9
3.4 Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 9
3.5 Accompanying Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 10
3.6 Handling the Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 10
3.7 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 10

4 Transport and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 11

4.1 Take the machine out of service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 11
4.2 Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 11
4.3 Transport Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 12
4.4 Transporting with a fork lift truck or pallet truck . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 12
4.5 Transport Using a Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 12
4.6 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 13

5 Construction and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 14

5.1 Principle of Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 14
5.2 Short Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 14
5.3 Components of the Base---Mounted Reciprocating Compressor . . . . . . . . . . . . 5 --- 15

i
 Table of Contents
Chapter --- Page

6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 16
6.1 Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 16
6.2 Fitting the Antivibration Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 16
6.3 Assembling the sound enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 17
6.4 Connection of the Compressed Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 17
6.5 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 18
6.6 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 18
6.7 Pipe and Instrument Flow Diagram (P & I Diagram) . . . . . . . . . . . . . . . . . . . . . . . 6 --- 18
6.8 Compulsory Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 21
6.8.1 Motor overload protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 21
6.8.2 Pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 21
6.8.3 Unloaded starting valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 21
6.8.4 Nonreturn valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 21
6.8.5 Working pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 21

7 Putting into Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 22

7.1 Points to be Observed before Putting into Operation . . . . . . . . . . . . . . . . . . . . . . 7 --- 22
7.2 Direction of Rotation Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 22
7.3 Adjusting the Motor Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 23
7.3.1 Compressor motor: star---delta start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 23
7.3.2 Compressor motor: direct on---line start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 23

8 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 24
8.1 Switching the machine on and off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 24
8.2 Faults and their Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 24
8.2.1 Compressor does not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 24
8.2.2 Compressor starts with difficulty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 25
8.2.3 Compressor overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 25
8.2.4 Compressor runs continuously, discharge pressure not reached . . . . . . . . . . . 8 --- 25
8.2.5 Whistling noises at the cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 26
8.2.6 Safety valve blowing off prematurely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 26
8.2.7 Oil consumption of compressor too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 26
8.2.8 Compressor unit squealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 26
8.2.9 Filter in the venting line clogged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 26

9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 27
9.1 Observe the following during all maintenance and servicing. . . . . . . . . . . . . . . . 9 --- 27
9.2 Regular Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 28
9.3 Checking the Oil Level and Topping Up (Compressor Block) . . . . . . . . . . . . . . . 9 --- 29
9.4 Oil Change (Compressor Block) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 30
9.5 Checking the V ---Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 31
9.6 Tensioning the V ---belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 31
9.7 V ---Belt Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 32
9.8 Clean or Renew the Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 33
9.9 Checking the Safety Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 34
9.10 Clean or Replace the Dirt Trap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 35

ii
 Table of Contents
Chapter --- Page

9.11 Cleaning or Changing the Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 36

9.11.1 Cleaning the solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 36
9.11.2 Changing the solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 37
9.12 Check and empty the filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 38
9.13 Maintenance of the Motor Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 39
9.14 Inspect the cylinder head and valves and renew if required . . . . . . . . . . . . . . . . 9 --- 39
9.15 Maintenance Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 40

10 Spare Parts and After Sales Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 41

10.1 Service Parts and Expendable Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 41
10.2 Ordering Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 42
10.3 Technical Information, Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 42

iii
 Technical Specification

1 Technical Specification

1.1 Base Mounted Compressor Unit

Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K 1000 --- 2 --- G / H 35
Maximum gauge working pressure . . . . . . . . . . . . . . . . . . . . . 35 bar
Weight, overall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 610 kg
Drawings:
Dimensional drawing . . . . . . . . . . . . . . . . . . . K1_2617_10130.00
Electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ---
P & I flow diagram . . . . . . . . . . . . . . . FKKK1000---2G---00044.01
(Pipework and Instrument flow diagram)

1.2 Sound Pressure Level

Operational state of the compressor unit:
Full load, the compressor unit runs at: rated speed, rated pressure, rated capacity.
Setting up conditions:
Free field measurement
Measurement to CAGI/PNEUROP PN8 NTC 2.3:
Sound Pressure Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 dB (A)

1.3 Compressor Block

Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K 1050 --- 2
Theoretical inlet capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1050 l/min
Free air delivered at 12 bar gauge working pressure$#liefml/min
Maximum gauge working pressure . . . . . . . . . . . . . . . . . . . . . 35 bar
Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1130 min --- 1
Oil capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 l
Oil top---up quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,65 l

1.4 Drive Motor

Three---phase motor 400 ± 10% / 690 ± 10% V
Rated power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 kW
Rated speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3000 min --- 1
Enclosure protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IP 55
Max. switching frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 per hour

1 --- 1
 Technical Specification

1.5 Power Supply

Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 / N / PE
Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Hz
Possible starting systems
Star--Delta Υ∆ at 400 ± 10% V power supply
Maximum rated current IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19,4 A
Maximum mains fusing (slow or gl) . . . . . . . . . . . . . . . . . . . . . 25 A
Supply cable core cross---section (multicore) . . . . . . . . . . . 4 x 4 mm2
Direct-- online ∆ at 400 ± 10% V power supply
Maximum rated current IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19,4 A
Maximum mains fusing (slow or gl) . . . . . . . . . . . . . . . . . . . . . 50 A
Supply cable core cross---section (multicore) . . . . . . . . . . 4 x 10 mm2

Direct-- online Υ at 690 ± 10% V power supply

Maximum rated current IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11,2 A
Maximum mains fusing (slow or gl) . . . . . . . . . . . . . . . . . . . . . 25 A
Supply cable core cross---section (multicore) . . . . . . . . . . . 4 x 4 mm2
This machine is designed to operate from a power supply with a system impedance Zmax
and maximum 0,022 Ω (direct---online---starting)and/or 0,080 Ω (star/delta starting) at the
main distribution board . The user must ensure that the equipment is only operated on a
power supply that meets these requirements. If necessary, the local power utility company
will provide information on system impedance.

1.6 Safety Valve Settings

Opening pressures
Interstage safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 bar
Safety valve on the aftercooler . . . . . . . . . . . . . . . . . . . . . . . . . . 38 bar

1.7 Installation Requirements

Max. height above sea level at place of installation . . . . . . 1000 m
Min. ambient temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 ˚C
Max. ambient temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 ˚C
Recommended minimum compressor space size
(floor area x room height) . . . . . . . . . . . . . . . . . . . . . . . 35 m2 x 3 m
Ventilation of installation space
Inlet air opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,75 m2
Exhaust air opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,75 m2

1 --- 2
 Technical Specification

1.8 Recommended Oil

As standard,the machine is filled with VDL 150 at the factory.
D For special applications FGP oil is used and the machine carries a sticker indicating
this.

Oil type VDL 150 FGP

Description Mineral oil Synthetic oil
Application: Suitable for all applica- Specially for use in compressors
tions except in con- where the air comes in direct
nection with foodstuff contact with foodstuff.
processing.
Maximal permissible fluid 500/1* 1000/2*
change interval in operating
hours/years
Material (part) number / 9.0894.0/ 9.0874.0/
quantity [l] 1,0 1,0
Type of oil filled**
* Cool to moderate ambient temperatures, low humidity, high duty cycle
** Mark the type of oil in your machine in the table

1.9 Dimensional Drawing

(see following page)

1 --- 3
 Safety

2 Safety Regulations

Disregarding this notice can result in serious injury!

This manual should be read and the instructions it contains followed before initial start---up
and before carrying out maintenance work.
The machine is constructed to the latest technological standards and to accepted safety
regulations.
Despite this fact, physical danger to the user or third parties or damage to the machine
and other property exists.
Use the machine as specified according to the service manual and only if it is in perfect
technical order!
Repair defects that could degrade safety (or have them repaired) immediately!

2.1 Explanation of Symbols and References

This symbol is placed before all regulations concerning safety where
danger to life and limb can occur during work. It is especially import-
ant that these regulations are observed and that extreme care is taken.
For their own protection, inform all other users of these safety regula-
tions. Observe all general safety and accident prevention regulations
as well as the those laid down in this service manual.

Attention! This symbol is placed by text where considerable attention must be

paid to recommendations, regulations, references and the correct se-
quence of work so that damage and/or destruction of the compressor
unit and/or other equipment is prevented.

This symbol identifies environmental care measures.

. This symbol indicates operations and actions to be carried out by the

operator or service technician.

D This bullet identifies listings.

Explanation of the warning label on the compressor unit:

Warning:
Do not touch hot surfaces.

2 --- 5
 Safety

2.2 Safety Notes

Work on power-- driven equipment may only be carried out or super-

vised by persons trained in that particular equipment or by a special-
ist.

Work on electrical equipment in the compressor may only be carried

out according to electrical engineering regulations by a qualified elec-
trician, or trained personnel under the supervision of a qualified elec-
trician.

Before work is carried out on electrical systems, carry out the follow-
ing measures in the sequence shown:

Switch off all phases.

Ensure the unit cannot be switched on again.

Check that no voltage is present.

The following actions must be carried out in the order given before
working on any pressurised parts or enclosures (e.g. pipes, vessels,
valves).

1. Shut off and depressurize all pressurized components and enclos-

ures

2. Secure them in the depressurized state

3. Check that they are indeed de-- pressurized

Attention! Any alterations or reconstruction carried out without consultation with

and the previous consent of KAESER COMPRESSORS will invalidate
the warranty.

Attention! No welding, heat-- treatment or mechanical work may be carried out on

pressure retaining conponents, e.g. pipes, air mains, receivers, etc.

Safety devices may not be modified or deactivated.

Signs and marks of reference may not be removed or rendered un-

readable.

We also recommend observation of the following:

D Allow no open flame and flying sparks in the place of installation.
D During any necessary welding on the compressor unit or nearby ensure that sparks or
high temperatures cannot cause fire or explosion.
D Ensure that the compressor unit is supplied with clean air free of damaging compo-
nents.
D The ambient temperature should not rise above or fall below the limits defined in
chapter 1.7. If this is the case, special measures must be agreed between the manu-
facturer and the user.

2 --- 6
 Safety

D This machine is not explosion---proof.

It may not be operated in areas in which specific requirements with regard to ex-
plosion protection are applied.
These are, for example, the requirements for “specified use in hazardous explosive
environments” according to the 94/9/EU ATEX Directive.

2.3 Electrical Safety

Attention! The electrical system of a compressor unit must comply with the provi-
sions of the European Standards EN 1012 -- 1 and EN 60204 -- 1) and,
if necessary, with the local electricity supply authority regulations.

Compressor units must be fitted with a main isolating device, the oper-
ation of which determines the start and end of the energy supply.

Main isolating devices can be main switches or plug and socket con-
nections.

For this reason the following measures must be taken at the place of
installation:

Compressor units fitted with a drive motor of drive power 3 kW or

more and a current rating of 16 amperes or more must be fitted with a
lockable main switch (see EN 60204 -- 1, para. 5.3) and mains fuses.

The main switch must be designed according to the maximum rated

current IN (see chapter 1.5).

See chapter 1.5 for details of the cable cross-- sections and mains
fuses.

Compressor units fitted with a drive motor of drive power less than
3 kW and a current rating of less than 16 amperes may be fitted with a
mains plug connection.

2.4 Spare Parts

Safe and reliable operation of the compressor unit is guaranteed only with KAESER original
spare parts.

2.5 Environmental Protection

Condensate drainage

Condensate accumulating during compression must be drained via a

suitable draining system and collected in disposal canisters. The con-
densate must be disposed of according to environmental regulations.

Operational and repair materials, used parts

Dispose of all used materials and parts accumulating during oper-

ation, maintenance and repair of the compressor unit according to
environmental care regulations!

2 --- 7
 Safety

Disposing of the Machine

When disposing of a machine, drain out all liquids and remove dirty filters.

Any parts contaminated with oil must be disposed of in accordance

with local environment regulations.

. Take the machine out of service (see chapter 8.1).

. Drain all oil completely from the machine.
. Remove dirty filters.
Use the services of an approved local disposal specialist to ensure environmentally correct
disposal of the empty machine.

2 --- 8
 General

3 General

Attention! The service manual must always be available at the compressor unit’s
place of use

3.1 Correct Use of the Compressor

The compressor unit is intended solely for the purpose of generating compressed air. Any
other use is considered incorrect. The manufacturer cannot accept liability for any damage
caused by such incorrect use; the user alone is liable for any risks incurred.
Correct use of the compressor also encompasses compliance with the installation, re-
moval, commissioning, operational and maintenance conditions laid down by the manufac-
turer.

Attention! The equipment may only be used or serviced by persons who are au-
thorised and trained.

The machine is intended solely for industrial use and application in industrial facilities. Any
other use or application is forbidden. The manufacturer is not liable for any damages resul-
ting from such unspecified use or application. The user or operator alone bears the risk for
such damages.
This applies especially to the obligation
D to become acquainted with the fundamental safety regulations that apply
to compressed air engineering
D to refuse access to the machine by persons under the age of fourteen, and
D to have the technical condition of the machine inspected within the intervals
prescribed for industrial use.

3.2 Incorrect Use

Never direct compressed air toward persons. Compressed air is a con-

centrated form of energy and as such is dangerous to life.

Attention! Inlet air may not contain any explosive or chemically unstable gas or
vapour.

3.3 Compressed Air Treatment

Never use compressed air for breathing purposes and production

methods where the air has direct contact with food without subjecting
the compressed air to additional treatment.

3.4 Copyright
The copyright of this service manual is the property of the KAESER Company. This service
manual is intended for operating personnel, maintenance personnel and supervisory per-
sonnel use only. It contains instructions and technical diagrams that may not be copied,
either completely or partly, distributed or evaluated by unauthorised persons for the pur-
pose of competition, or divulged to any other third party.

3 --- 9
 General

3.5 Accompanying Documents

With this Service Manual are documents intended to assist in safe and sure operation of
the compressor:
D Conformity or Manufacturer’s Declaration in accordance with applicable directives
. Make sure all documents are to hand and their contents understood.
Request the supply of any missing documents from KAESER.
Make sure you give the data from the nameplate.

3.6 Handling the Document

The service manual is part of the machine.
. Keep the service manual safe throughout the life of the machine.
. Pass the manual on the the next owner/user of the machine.
. Ensure that all amendments are entered in the manual.

3.7 Warranty
This service manual contains no independent warranty committment.
Our general terms and conditions of business apply with regard to warranty.
A condition of our warranty is that the machine is used for the purpose for which it is in-
tended under 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.
. Obtain confirmation from the manufacturer that the machine is suitable for your spe-
cific application.
Furthermore, we accept no warranty obligation for:
D the use of unsuitable parts or operating materials,
D unauthorised modifications,
D incorrect maintenance,
D incorrect repair.
Correct maintenance and repair includes the use of genuine Kaeser spare parts and oper-
ating materials.

3 --- 10
 Transport

4 Transport and Storage

4.1 Take the machine out of service

The machine must be correctly taken out of service in preparation for transport for trans-
port.
. Switch the machine off (see chapter 8.1).

Electric shock can kill!

DANGER Touching electrically live components can cause serious injury or death.
Power and control terminals may still be live when the motor is stopped.
. Switch off and lock out the main switch.
. Wait at least five minutes before checking for electrical voltage.
. Work carefully.

. Isolate the machine from the air main by closing the user’s compressed air inlet and
outlet shut---off valves. Initial and final pressure gauges must read zero.
Allow the machine to cool down completely.
. If the machine is water---cooled, shut off the water supply, drain the water completely
from the heat exchanger and dispose of it according to environmental regulations.
. Disconnect all supply lines.

4.2 Packaging
Always observe the instructions in chapter 4.6 when packaging the machine for storage.
Use packaging suitable for the intended route if the machine is to be transported further by
the customer.
Overland
The machine should be protected from mechanical damage by a sturdy crate and from
moisture by plastic sheeting.
By sea or air
Special packaging instructions can be obtained from KAESER.

Dispose of the packaging according to environmental regulations and

recycle where possible.

4 --- 11
 Transport

4.3 Transport Instructions

A fork lift truck or lifting cradle should be used to avoid damaging to the machine.

4.4 Transporting with a fork lift truck or pallet truck

In order to move the machine by means of a fork or pallet truck it must be on a suitable
pallet or transport frame.

4.5 Transport Using a Crane

Attention! If the compressor unit is transported by a crane the safety regulations

concerning lifting appliances must be observed.

Do not stand underneath hanging loads.

Do not exceed the max. permitted lifting weight of the lifting appliance.

Always use a sling when transporting the compressor unit with a crane.

Attention! Take care not to damage parts of the compressor when lifting with the
sling.

4 --- 12
 Transport

4.6 Storage
The machine must be adequately packed.
. Store the machine in a dry, frost---free room.
. Prevent entry of moisture and condensation.
If the equipment is to stand idle for a long period the prescribed measures must be taken
to avoid damage.
If any measures can not be taken, advice should be sought from the authorised KAESER
Service depot.
As an alternative to storage, the equipment can be run once a week for 30 minutes at op-
erating temperature to ensure adequate corrosion protection.
Otherwise, the measures described under ’Storage for longer than 6 months’ are to be
taken.
Storage for longer than 6 months
Ensure the machine is dry and cover in plastic sheeting. Protect the interior with sufficient
quantities of desiccant (silica gel or similar).

Storage for longer than 12 months

Carry out the following additional maintenance tasks before putting into operation:
. In oil---lubricated machines the oil and, where present, the oil filter must be changed.
. have the motor bearings checked by an authorised KAESER service technician.

Storage for longer than 3 years:

after 3 years at the latest the complete technical condition of the machine must be
checked before start---up.

Damage to the machine can occur if the condition is not checked.

CAUTION . start---up
Have the the start ---up carried out by an authorised KAESER service
technician.

4 --- 13
 Construction and Operation

5 Construction and Operation

Items in ( ) refer to components with item number in the schematic diagram of the com-
pressor unit (see chapter 5.3).

5.1 Principle of Compression

This reciprocating compressor is an air cooled, oil lubricated compressor using the prin-
ciple of two stage compression
Atmospheric air is drawn into the compression chamber of the compressor block (2)
through the air filter (1). Air is drawn in via the valve plate in the cylinder head during the
downward motion of the piston from the top to the bottom dead centres. After the piston
has reached the bottom dead centre position the air is compressed within the cylinder by
the upwards motion of the piston. Simultaneously the inlet valves in the valve plate close
and the discharge valves open.
The compressed air leaving the cylinder head enters the second cylinder head for boosting
via the interstage cooling pipe.
Protection of the high pressure stage is ensured by a safety valve (9) placed between the
first and second stage.
The compressed air now enters the aftercooler (11).

5.2 Short Description

The compressor block is driven by an electric motor (3) via V ---belts. The compressor is a
V ---type with two single cylinders. Cooling fins on the cylinders and heads dissipate the
heat generated by compression.
The compressorblock (2) crankshaft is supported by ball and roller bearings; the connect-
ing rods are supported by plain bearings. The cylinder liners, pistons, crankshaft and con-
necting rods are automatically splash lubricated.
A filter is installed in the venting line. Filtered condensate and dirt is trapped in the filter
bowl. The bowl must be emptied regularly. A pressure relief valve is installed to protect the
filter.

5 --- 14
 Construction and Operation

5.3 Components of the Base ---Mounted Reciprocating Compressor

7 10 3 8 11 9 5 6 2 1 4 12 14 13 12 15

KMZ089211

1 Air filter
cleans the inlet air

2 Compressor block
draws in the air and compresses it to the discharge pressure

3 Electric motor
drives the compressor block via the belt drive
4 Oil level sight glass
5 Oil filler

6 Oil drain plug

7 Compressed air discharge

8 Arrow on the drive belt guard showing direction of rotation

9 Safety valve;
protects the high pressure stage against excessive input pressure
10 Safety valve on the aftercooler
11 Aftercooler
cools the compressed air
12 Solenoid valve
13 Pressure relief valve
protects the filter

14 Filter
traps condensate and dirt

15 Dirt trap
in the venting line to protect the solenoid valve

5 --- 15
 Installation

6 Installation

6.1 Installation Instructions

To ensure sufficient cooling of the base mounted compressor unit the specified minimum
compressor space size, minimum distance to the walls and minimum size of the ventilation
inlet and exhaust openings must be complied with (see chapter 1.7).
The cooling air flow of the compressor unit is not greatly influenced in smaller spaces even
when the door is opened if the air flowing in through the door takes the shortest route to
the exhaust opening without flowing around the compressor.
Safe operation of the base mounted compressor unit is only guaranteed if the ambient
temperature remains within the limits set in chapter 1.7).

Exhaust 800
opening

500
Inlet opening

Dimensions in mm

6.2 Fitting the Antivibration Mounts

The antivibration mounts supplied (as a separate pack fixed to the compressor block) must
be fitted before the compressor package is first put into operation.
Attention! Always use lifting belts to lift the compressor package. Follow the in-
structions in chapter 4.5.

The compressor package can tip because of its high point of gravity
and its own weight.

KFB002221

2
1

1 Antivibration mount 3 Spring washer

2 Washer 4 Hexagonal nut
. Lift up the compressor package with a lifting belt. Observe the instructions in
chapter 4.5.
. Fit the antivibration mounts with washer, spring washer and hexagonal bolt to the feet
of the compressor package.

6 --- 16
 Installation

6.3 Assembling the sound enclosure

. Lift the compressor slightly at the fan end. Align the rear panel with the welded or
screwed brackets such that the compressor’s antivibration mounts fit in the guide
rings.
. Clamp the left side panel to the rear panel of the sound enclosure.
. Connect the gas line (see chapter 6.4) and mains power (see chapter 6.5) to the com-
pressor.
. Clamp the right side panel to the rear panel of the sound enclosure.
. Fit the cover panel to the sound enclosure.
. Fit the front panel (or access door if selected) to the enclosure.

Attention! The machine must be shut down and secured from re-- starting before
opening an access door to carry out a maintenance task.

6.4 Connection of the Compressed Air Supply

The connection from the compressor to the air main or to consumers must be made via a
flexible hose or pipe connection.
KFB001921

1 Compressed air discharge connection

6 --- 17
 Installation

6.5 Power Supply

The connection to the power supply and the protective measures
necessary are to be carried out to the provisions of the European Stan-
dards EN 1012 -- 1 and EN 60204 -- 1 and to the regulations of the
local Electricity Supply Authority by an authorized electrician.

Attention! For this reason, the following measures must be carried out at the
place of installation:

Compressor units fitted with a drive motor of drive power 3 kW or

more and a current rating of 16 amperes or more must be fitted with a
lockable main switch (see EN 60204 -- 1, para. 5.3) and mains fuses.

Compressor units must be fitted with a main isolating device, the oper-
ation of which determines the start and end of the energy supply.

Main isolating devices can be main switches or plug and socket con-
nections.

The main switch must be designed according to the maximum rated

current IN (see chapter 1.5).

Compressor units fitted with a drive motor of drive power less than
3 kW and a current rating of less than 16 amperes may be fitted with a
mains plug connection.

Attention! The supply cable and fuses are selected to DIN VDE 0100 Part 430
and 513 for an ambient temperature of 30 ˚C. Under other operating
conditions such as a higher ambient temperature or longer supply
cables (longer than 50 metres) the cross-- section of the supply cables
and the fuses must be checked and selected according to
DIN VDE 0100 and to the regulations of the local Electricity Supply
Authority.

See chapter 1.5 for details of the cable cross-- sections and mains
fuses.

6.6 Control
An electrical starter control conforming to EN 60 204 must be provided for the connection
to the power supply.
The compressor package is fitted with two solenoid valves (230 V) that are open when
de---energised. Both solenoid valves must be wired in parallel and are used to ensure an
unloaded start.
The electrical components required must be designed for the corresponding motor power
(see chapter 1.4) and the selected starting mode (see chapter 1.5).
The motor, pressure switch and the solenoid valves must be activated by the controller.
The unloaded start solenoid valve must be activated such that the solenoid valve first
closes when the motor has run up to normal operating speed.
The components are fitted to the compressor as shown in the accompanying P & I flow diagram.

6.7 Pipe and Instrument Flow Diagram (P & I Diagram)

(see following pages)

6 --- 18
 Installation

6.8 Compulsory Safety Equipment

Attention! Safety and regulating equipment must be installed by the user to en-
sure safe operation of the compressor.

6.8.1 Motor overload protection

To ensure that three---phases motors are cut---out under conditions of fluctuating voltage,
they may only be driven with a correctly adjusted motor overload protection.

Attention! The warranty is invalidated if the compressor is operated without

motor overload protection.

6.8.2 Pressure switch

A pressure switch must be provided for the regulation of the compressed air demand. This
pressure switch regulates the compressor between the cut---out and cut---on pressures.

6.8.3 Unloaded starting valve

An unloading valve must be provided to ensure an unloaded start of the compressor when
switching on or after a power supply failure.

Unloaded starting using an unloading valve mounted on the pressure switch

D The unloaded start is regulated mechanically via a pressure switch with an unloading
valve. This type of unloading is preferred for three---phase motors in direct online start
configuration or for single---phase motors.

Unloaded starting using a solenoid valve

Attention! Take care that an open when de-- energised solenoid is chosen when
selecting the solenoid valve.

D Unloaded starting using a solenoid valve is preferred for three---phase motors in star/
delta start configuration but can also be used for three---phase motors in direct online
start configuration or with single phase motors.

Attention! A dirt trap must be fitted upstream of the solenoid valve to warrant its
functional reliability.

6.8.4 Nonreturn valve

To prevent the compressed air from flowing back into the compressor block, a nonreturn
valve must be fitted between the compressor block and the compressed air discharge.

Attention! The sizing of the nonreturn valve depends upon the maximum working
pressure (see chapter 1.3) and the cross-- section of the connection to
the air main (see dimensional diagram) from the compressor.

6.8.5 Working pressure gauge

A pressure gauge must be provided to monitor the gauge working pressure. The selection
of this pressure gauge depends upon the maximum gauge working pressure (see chapter
1.3) of the compressor.

6 --- 21
 Initial Start-up

7 Putting into Operation

7.1 Points to be Observed before Putting into Operation

Every compressor package is given a test run in the factory and carefully checked before
shipment. The test run confirms that the compressor package conforms to the specifica-
tion data and runs perfectly. However, independent of the checks made at the factory, the
compressor package could be damaged during transport. For this reason, we recommend
that it is examined for such possible damage. Observe the compressor package carefully
during the first hours of operation for any possible malfunction.

Attention! Work on power driven systems may only be carried out by trained or
specialised personnel.

Work on the electrical system and equipment of the compressor pack-

age may only be carried out by a skilled electrician or by instructed
personnel under the supervision and guidance of a skilled electrician
and in accordance with electrical engineering rules and regulations.

Attention! Important functional components in the compressor package such as

solenoid valves and safety valves are set up and fitted at the factory to
precise setting up regulations. Changes are not permitted without
previous consultation with KAESER.

The solenoid valves and the safety valves are spring loaded.

Points to be observed before starting the compressor unit:

ANY NON-- OBSERVANCE OF THESE OR OTHER REFERENCES

(WARNING; ATTENTION) CAN LEAD TO ACCIDENTS CAUSING IN-
JURY TO PERSONNEL OR DAMAGE TO EQUIPMENT.

The machine restarts automatically after a power failure provided the

air main pressure is lower than the cut-- out pressure level set on the
air main pressure switch.

D It is expected that the operator employs safe working methods and that all valid and, if
applicabel, all local operating and safety regulations are complied with when operating
the machine.
D The user of this machine is responsible for its safe operating condition.
D Do not operate this machine in spaces where high dust pollution, poisonous or inflam-
mable vapours or gases could exist.
D Do not connect the machine to a supply voltage other than that stated on the name-
plate.
D Do not install the machine in a space subject to freezing temperatures, whereby the air
temperature conditions at the compressor’s air inlet must be complied with (see
chapter 1.7).
D Check the level of the oil in the compressor block. If necessary, top up according to
the oil recommendations (see chapter 1.8).

7.2 Direction of Rotation Check

D Check the direction of rotation of the compressor block by switching it on for a short
period. If the direction of rotation does not coincide with the arrow located on the fan
guard, change over terminals L1 and L2.

7 --- 22
 Initial Start-up

7.3 Adjusting the Motor Overload Protection

Attention! It is not permitted to operate the compressor without a correctly set
motor overload trip or overload protection switch.
The warranty is invalidated if this requirement is not observed.

The setting of the overload protection trip is dependent on the type of compressor start.

7.3.1 Compressor motor: star-- delta start

If star---delta starting is used the motor phase windings are fed via the motor overload
protection trip. The motor phase current is 0.58 times the rated motor power IN.
See the nameplate on the motor for the rated motor power.
Setting: The value to be set is IN x 0.58.
The set value can be 10 % higher than the calculated phase current to prevent the motor
overload protection tripping under conditions of fluctuating power supply voltage.
If the motor is overloaded the overload protection trips and shuts down the compressor
package.
If the overload protection trip has shut down the compressor package, it can be restarted
by pressing the reset pushbutton.

7.3.2 Compressor motor: direct on-- line start

In direct on---line start the rated current of the motor flows through the overload protection
trip.
Set value: see nameplate on the motor for the rated motor current.
The set value can be 10 % higher than the phase current to prevent the motor overload
protection tripping under conditions of fluctuating power supply voltage.
If the motor is overloaded the overload protection trips and shuts down the compressor
package.
If the overload protection has shut down the compressor package, it can be restarted
again by pressing the reset pushbutton.

7 --- 23
 Operation

8 Operation

8.1 Switching the machine on and off

Compressed air can cause serious injury!

WARNING Serious skin injury possible.

. Never direct compressed air at a person!

. Ensure that:
--- no one is working on the machine,
--- all panels are in place.
The machine should be switched on and off via the main switch.
Switching the machine on
. Switch on the main switch (see chapter 2.3).

Make sure the direction of rotation is correct when starting the

machine.
CAUTION see chapter 7.2

Switching the machine off

. Switch the main switch off.

8.2 Faults and their Removal

Always comply with all general and local safety regulations when
carrying out faultfinding and repair.

Restarting after a fault:

see chapter 7.”Initial Start---up”
Explanation of symbols in the following faultfinding help:
: 1 --- have checked by a specialist.
: 2 --- contact KAESER service support.

8.2.1 Compressor does not start

Possible cause: Remedy:

No motor power supply, fuses blown. Replace the fuses; : 1.

8 --- 24
 Operation

8.2.2 Compressor starts with difficulty

Possible cause: Remedy:

Solenoid valve not opening Check the electrical connection, clean or

change the valve (see chapters
9.11.1/9.11.2)

Damaged bearings Renew the bearings or fit an exchange

compressor

Piston seized Change the piston and cylinder

(no oil or wrong oil) (see chapter 9.14)

Power supply fault (2---phase running) Check the power supply (fuses); : 1

Oil level too high Reduce the oil level to the maximum mark
on the oil level sight glass (see chapter 9.3

8.2.3 Compressor overheating

Possible cause: Remedy:

Ambient temperature too high Lower the ambient temperature (see chap-
(over 40 ˚C). ter 1.7).

Wrong direction of rotation Change over L1 and L2 terminals (see

(observe the direction arrow). chapter 7.2); : 1.

The fan cannot draw in air freely. Ensure that inlet air is available for the fan.

Valve plate leaking, coked or the valve Check, decoke or renew valve plate; : 1
reeds are broken. and : 2.

8.2.4 Compressor runs continuously, discharge pressure not reached

Possible cause: Remedy:

Air filter clogged. Clean or renew the air filter

(see chapter 9.8); : 1.

Valve plate gasket defective or wrongly Fit new gaskets.

fitted.

Valve plate valves coked up or defective. Clean or change the valves

(see chapter 9.14).

Pressure losses within the compressor Brush soapy water on piping and fittings,
package. seal leaks, renew leaking parts; : 1.

Air demand higher than the capacity of the Extend the compressed air supply.
compressor.

Solenoid valve blowing off constantly, coil Check the solenoid valve, clean the valve or
burnt out or defective actuation. change the coil.

8 --- 25
 Operation

8.2.5 Whistling noises at the cylinder head

Possible cause: Remedy:

Loose cylinder head bolts or defective gas- Tighten the bolts or renew the gaskets; : 1
kets. and : 2.

8.2.6 Safety valve blowing off prematurely

Possible cause: Remedy:

Safety valve blows, even though the cut--- Check that the pressure gauge functions
out pressure is not yet reached. correctly, replace if necessary.
Check the pressure setting.

Defective valve spring. Renew the safety valve; : 1.

Safety valve was opened, dirt particles Open the safety valve completely for a short
stuck in valve seat. period to allow it to blow itself clean.

8.2.7 Oil consumption of compressor too high

Possible cause: Remedy:

Viscosity of oil too low. Fill with correct oil

(see chapter 1.8); : 1.

Defective crankcase venting plug. Clean or renew the crankcase venting plug;
: 1.

Piston rings worn or damaged. Renew piston and cylinder; : 2.

Piston rings worn or damaged after only a Renew piston and cylinder; : 2.
short period. (ensure that the inlet air is clean, e.g. by
using an air filter with a higher grade of fil-
tration).

8.2.8 Compressor unit squealing

Possible cause Remedy

V ---belt(s) slipping Tension the V ---belt(s)

(see chapter 9.5)

Sealing ring on the shaft of the fan pulley Oil the sealing ring
running dry

8.2.9 Filter in the venting line clogged

Possible cause Remedy

Liquid flows out of the damper. Check and empty the filter
(see chapter 9.12)

8 --- 26
 Maintenance

9 Maintenance

9.1 Observe the following during all maintenance and servicing.

Disregarding these notes and/or improper handling may result in seri-
ous injury.

Work on power-- driven equipment may only be carried out or super-

vised by persons trained in that particular equipment or by a special-
ist.

Work on electrical equipment in the machine may only be carried out

according to electrical engineering regulations by a qualified electri-
cian, or trained personnel under the supervision of a qualified electri-
cian.

Before starting any maintenance work switch off at the main switch
and lock off to secure against unwanted or accidental switching on.

Make sure the machine is shut-- off or isolated from the air main during
maintenance work to ensure that no compressed air flows back from
the main.

Before switching on again ensure that all maintenance personnel are

clear of the machine, that all panels are replaced and all access doors
closed.

The following points must be observed when handling lubricating and

cooling materials:

Avoid contact with skin and eyes.

Do not inhale vapours and oil mist.
Do not eat or drink when handling such materials.
Fire, open flame and smoking are strictly forbidden.

Ensure that all lubricants, consumable materials and replacement

parts accumulating during operation and servicing of the compressor
package are disposed of according to environmental regulations.

9 --- 27
 Maintenance

9.2 Regular Maintenance

Period Work to be done See chapter

Daily check the oil level in the crankcase 9.3

24 hours after first put- check the V ---belt tension 9.5

ting into operation and
after changing the V ---
belt

50 hours after first put- check all electrical screw connections for tight- 7.1
ting into operation ness and tighten if necessary

carry out a compressor oil change 9.4

Weekly * check and empty the filter 9.12
500 hours or at least check and clean the air filter * 9.8
anually
check and clean the dirt trap 9.10

check the V ---belt tension 9.5

check the safety valve 9.9

clean the solenoid valve 9.11.1

Variable Change the compressor oil * 9.4

2000 hours renew the solenoid valve 9.11.2

3000 hours check the cylinder head and valves for correct 9.14
function

10000 hours renew the motor bearings 9.13

carry out a general overhaul of the compressor 9.14

* The maintenance interval can vary according to model, installation, starting frequency
and the ambient conditions.
We recommend that a record is kept of all maintenance work.
A sample maintenance record is provided in chapter 9.15.

Attention! If daily maintenance is impractical because the machine is used so

little, it should be carried out every 24 operating hours.

9 --- 28
 Maintenance

9.3 Checking the Oil Level and Topping Up (Compressor Block)

Check the oil level at the oil level sight glass daily and before each start.

Attention! If the oil level has sunk to the lower mark, top up the oil immediately
according to the oil recommendations (see chapter 1.8).

Never top up to a level exceeding the maximum oil mark on the oil
level sight glass.

Attention! When topping up the oil always use a strainer or pour the oil directly
from the new oil can.

KFB007521

max.
1 min.

1 Oil filler with crankcase venting plug

2 Oil level sight glass

. Shut down the compressor (see chapter 8.1).

Break the power supply by operating and locking out the main isolat-
ing device (main switch or mains plug) to prevent an accidental com-
pressor start.

. Remove the crankcase venting plug (1) from the oil filler.

Attention! As the oil must flow through the crankcase first, the maximum oil level
is reached after a few minutes have elapsed.

. Fill with oil until the maximum oil level mark is reached. See chapter 1.3 for the quan-
tity of oil required for topping up from the minimum mark to the maximum mark.
. Replace the crankcase venting plug in the oil filler.

9 --- 29
 Maintenance

9.4 Oil Change (Compressor Block)

Change the oil with the compressor unit at normal operating temperature.

Danger of scalding by hot oil

Danger of burns from hot components

Change the oil after approximately the first 50 service hours.

Change the oil futher: see chapter 1.8.
If, under unsuitable operational conditions condensed water is observed in the oil, recog-
nisable by the milky colour in the oil level sight gauge (2), carry out an oil change immedi-
ately.

KFB007621

1
max.
2 min.

1 Oil filler
2 Oil level sight glass
3 Oil drain plug

. Shut down the compressor (see chapter 8.1).

Break the power supply by operating and locking out the main isolat-
ing device (main switch or mains plug) to prevent an accidental com-
pressor start.

. Remove the crankcase venting plug (1) from the oil filler.
. Prepare a container to catch the oil.

Collect the used oil and dispose of according to environmental care

regulations!

. Unscrew the oil drain plug (3) and drain the oil into the container.
. Flush out the crankcase with a small quantity of new oil.
. Screw the oil drain plug back into the crankcase.

Attention! When topping up the oil always use a strainer or pour the oil directly
from the new oil can.

. Fill up with new oil (see chapter 9.3).

9 --- 30
 Maintenance

9.5 Checking the V---Belt Tension

Check the tension of the V ---belt after the first 24 service hours and then again after 500
service hours.
. Shut down the compressor (see chapter 8.1).

Break the power supply by operating and locking out the main isolat-
ing device (main switch or mains plug) to prevent an accidental com-
pressor start.

. Remove the belt guard.

. Press down the V ---belt with the thumb.
If the V ---belt can be depressed more than 1 to 2 cm it must be tightened.

9.6 Tensioning the V---belt

. Shut down the compressor unit (see chapter 8.1).

Break the power supply by operating and locking out the main isolat-
ing device (main switch or mains plug) to prevent an accidental com-
pressor start.

. Remove the belt guard

. Loosen the hexagonal nuts on the motor mounts.
. Slide the motor until the V ---belt is tight again, i.e. it cannot be depressed more than 1
to 2 cm.
. Tighten the hexagonal bolts.
. Fit the belt guard again.

KFB008121

2 1
2

1 Hexagonal nut
2 Square ---headed bolts

9 --- 31
 Maintenance

9.7 V---Belt Change

. Shut down the compressor unit (see chapter 8.1).

Break the power supply by operating and locking out the main isolat-
ing device (main switch or mains plug) to prevent an accidental com-
pressor start.

. Remove the belt guard.

. Loosen the hexagonal bolts on the motor mounts.
. Slide the motor in the direction of the compressor block until the V ---belt can be re-
moved over the motor and compressor pulley.
. Place the new V ---belt over the motor and compressor pulley without straining it.
. Slide the motor in the opposite direction until the V ---belt is correctly tensioned.
. Tighten up the hexagonal bolts.
. Check the tension after the first four service hours and then again after a further 24
service hours. Tighten, if necessary (see chapter 9.5).

Attention! Spare V-- belts must be of the same length in each set and absolutely
impervious to oil. For this reason we recommend that only original
KAESER V-- belts are used.

Attention! V-- belts may only be replaced as a set.

. Fit the belt guard again.

9 --- 32
 Maintenance

9.8 Clean or Renew the Air Filter

The filter cartridge (3) of the air filter (1) consists of oil wetted knitted coconut fibre.
Clean the filter cartridge (3) at the latest after 500 service hours. If the cartridge is heavily
contaminated or has been cleaned often, renew the air filter complete.

1 4 3 2

KFB007721

1 Air filter
2 Air inlet
3 Filter cartridge
4 Spring clips

. Shut down the compressor (see chapter 8.1).

Break the power supply by operating and locking out the main isolat-
ing device (main switch or mains plug) to prevent an accidental com-
pressor start.

. Unscrew the air filter (1) from the cylinder head.

. Unhook the spring clips (4) and open the filter cap.

Attention! Clean the filter with diesel fuel in the open air. Observe the regulations
concerning the handling of combustible fluids.

. Clean the filter cap, especially the sealing surfaces.

. Wash out the filter cartridge (3) with diesel fuel or clean with a steam jet.
. When the filter cartridge (3) is dry wet lightly with oil.

Attention! When screwing on the air filter take care that the air inlet in the filter
cap (2) is facing downwards.

. Screw on the air filter (1), fit the cap.

Attention! If the cartridge is heavily contaminated or has been cleaned often,

renew the air filter complete.

9 --- 33
 Maintenance

9.9 Checking the Safety Valve

If the maximum permissible gauge working pressure is exceeded at the discharge end and
between stages, the safety valves open and blow off the excess air to protect the com-
pressor unit and the consumers connected to the air main.
To prevent the valve seat from sticking, open the safety valve every 500 service hours or at
least annually.

KGB006111
2

1 Knurled ring
2 Safety valve

Attention! It is essential to wear ear protection when testing the pressure relief
valve because of the loud noise produced by escaping air.

. Switch the compressor off (see chapter 8.1).

Isolate from the power supply by means of the main switch or by with-
drawing the mains plug and lock out the switch to prevent an inadver-
tent start.

. Turn the knurled screw on the pressure relief valve anticlockwise until air escapes and
then turn back again.

Attention! A defective pressure relief valve must be renewed completely.

Attention! Tampering with the pressure relief valve and damaging the lead seal is
forbidden and will invalidate all liability.

9 --- 34
 Maintenance

9.10 Clean or Replace the Dirt Trap

The trap prevents contamination of the solenoid valve.
The dirt trap must be cleaned if the compressor registers a fault during idling or unloaded
starting and after 500 operating hours at the latest.

1
2

5 4 3

GB09013711

1 Plug
2 Strainer
3 Dirt trap strainer venting line
4 Dirt trap strainer venting line cooler
5 Dirt trap strainer compressed air aftercooler

. Shut down the compressor (see chapter 8.1).

Break the power supply by operating and locking out the main isolat-
ing device (main switch or mains plug) to prevent an accidental com-
pressor start.

. Unscrew the plug (1).

Do not direct compressed air at the skin or other parts of the body.
There is danger of injury. Always wear working gloves or protective
goggles.

. Remove the strainer (2) and clean by blowing out.

Attention! If the strainer is very dirty or has been cleaned often it should be
renewed.

. Screw the strainer (2) and plug (1) back in again.

9 --- 35
 Maintenance

9.11 Cleaning or Changing the Solenoid Valve

If the solenoid valve leaks during operation the cause is often dirt settling on the plunger or
the solenoid core. Clean the solenoid valve every 500 service hours and change after 2000
service hours.

9.11.1 Cleaning the solenoid valve

. Shut down the compressor (see chapter 8.1)

Break the power supply by operating and locking out the main isolat-
ing device (main switch or mains plug) to prevent an accidental com-
pressor unit start.

Attention! Take care not to lose individual parts when taking out the coil.

KFB009421

5
4
1
6
7
8
9

1 Solenoid valve 6 Spring

2 Cylinder head screw 7 Plunger
3 Coil 8 Lip seal
4 Solenoid core 9 Direction of flow
5 Spring

. Unscrew the cylinder head screws (2). The electrical cable must not be removed from
the coil when taking off the solenoid valve.
. Disassemble the solenoid valve (1) into its individual parts.
. Clean the plunger (7) and the solenoid core (4).
. Grease the lip seal (8) with Vaseline.
. If the springs and seals are badly worn or damaged they must be changed.

Attention! Take care that the individual parts are assembled in the correct order
(see illustration) when reassembling the solenoid valve.

. Reassemble in the reverse order.

9 --- 36
 Maintenance

9.11.2 Changing the solenoid valve

. Shut down the compressor (see chapter 8.1).

Break the power supply by operating and locking out the main isolat-
ing device (main switch or mains plug) to prevent an accidental com-
pressor unit start.

Attention! Isolate the booster package from the air main by interrupting the
supply of compressed air (by closing the ball valve) when changing
the solenoid valve on the inlet side.

KFB009521

1
2

1 Solenoid valve
2 Pipe fitting

. Open the pipe fitting.

. Remove the electrical cable from the solenoid valve by removing the valve plug.
. Electrically connect the new solenoid valve.

Attention! Take care that the valve is installed with the correct direction of flow
(see chapter 9.11.1).

. Fit the solenoid valve and gasket into the piping.

9 --- 37
 Maintenance

9.12 Check and empty the filter

The filter (1) separates condensate and contaminants (oil vapours, scale, rust, etc.) from
the air and these collect in the filter bowl (4).
The bowl must be checked weekly and emptied regularly.
Clean the sintered filter insert when necessary.
The bowl must be emptied immediately if fluid is seen to drip from the damper (2).
GB011211

2
6
1
5

3
4

1 Filter
2 Damper
3 Bowl securing ring
4 Bowl
5 Nut
6 Sintered filter insert

Attention! The damper (2) must be able to blow off freely to ensure proper oper-
ation of the machine.
Connection of a pipe downstream of the filter is not allowed.

Checking and emptying

. Switch the machine off (see chapter 8.1).

Isolate from the power supply by means of the main switch (or by with-
drawing the mains plug) and lock out the switch to prevent an inadver-
tent start.

. Prepare a receptacle.

Catch the fluid and dispose in accordance with environmental regula-

tions.

Hot fluid; beware of scalding.

Danger of burning from hot components.

. Unscrew the securing ring (3) and remove the bowl (4).
. Empty the bowl contents into the prepared receptacle.
. Clean the bowl (4) with an aqueous cleaning agent.
Rinse finally with warm water.

9 --- 38
 Maintenance

Clean the damper and sintered filter insert

. Use an air blast (< 5 bar) to clean out the damper (2).
. Remove the retaining nut (5) and the sintered filter insert (6).
. Clean the sintered filter insert (6) with an aqueous cleaning agent.
Use an air blast to blow through the insert from the inside to the outside.
. Assemble the filter in the reverse order as described above.
. Switch the compressor on again.

9.13 Maintenance of the Motor Bearings

D The motor bearings are permanently greased.
D Under normal operating conditions, with ambient temperatures around 25 ˚C, the
motor bearings should be renewed approximately every 10 000 service hours.
D The wear on the bearings increases with higher ambient temperatures. With very high
ambient temperatures of around 35 ˚C renew the bearings approximately every 6000
hours.
D Change the motor bearings every 3 years independent of service hours.

Attention! The bearings must be changed by KAESER-- Service when the above
maintenance is due.

9.14 Inspect the cylinder head and valves and renew if required
Check the function of the cylinder head and valves after 3 000 operating hours.
In addition, inspect the valve plates for coking and clean if necessary.
If the cylinder head or valves show sign of malfunction they should be repaired or
renewed by an authorised KAESER technician.
A general overhaul of the machine should be carried out by a KAESER technician after
10 000 operating hours.

9 --- 39
 Maintenance

9.15 Maintenance Record

Model: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Serial number: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Date Description of work Operating hours Signature

9 --- 40
 Spare Parts and After Sales Service

10 Spare Parts and After Sales Service

10.1 Service Parts and Expendable Parts

Name No. off Part number

Air filter 1 off 6.0187.0

Set of V ---belts 2 x SPA x 2832 6.2586.0

Solenoid valve 1 off 7.0318.0

Solenoid valve 1 off 7.1360.0

Dirt trap strainer 1 off 8.0414.00020

in the venting line

Gasket 1 off 6.1524.0

Dirt trap strainer 1 off 8.0504.0

in the venting line cooler

Gasket 1 off 6.3492.0

Dirt trap strainer 1 off 8.0502.0

compressed air aftercooler

Gasket 1 off 6.3494.0

Sintered filter insert 1 off 9.0505.00100

KAESER KOMPRESSOREN GmbH

Carl--- Kaeser--- Str. 26, 96450 Coburg
GERMANY Telefon +49 95 61 64 00
Fax +49 95 61 640--- 130

Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Part No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Serial No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Year of production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Max. working press. (g) . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar
Free air delivered . . . . . . . . . . . . . . . . . . . . . l/min . . ( . . . bar)
Rated voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rated motor speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rpm
Rated power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . kW
Ambient temperature . . . . . . . . . . . . . . . . . . ˚C / . . . . . . . . ˚C

10 --- 41
 Spare Parts and After Sales Service

10.2 Ordering Spare Parts

When ordering spare parts always state (see nameplate):
--- Compressor model
--- Year of manufacture
--- Part number
--- Serial number
Important for all queries:
. Enter the data from the nameplate of the compressor unit in the nameplate illustrated
above.
Always quote the data on the nameplate when ordering spare parts or making enquiries.

Attention! Do not fit inferior consumable or spare parts. Use only original parts
supplied by the compressor manufacturer.

We must point out that maintenance parts, spare parts and accessories not delivered by
KAESER are also not tested and cleared by us. The fitting and/or use of such products
can, under certain circumstances, change the design characteristics of the compressor
unit negatively and therefore affect the active and/or passive safety of the unit.
The use of such parts or accessories exempts KAESER from all liabilities and warranties for
consequential damage caused by such parts or accessories.

10.3 Technical Information, Pressure Relief Valve

10 --- 42
Sicherheitsventil / safety valve Typ L08

Zulassung / homologation : CE 97/23/EG

Druckbereich / pressure range: 0,3-47,0 bar
Anschlussgewinde / inlet connection : G ¼“, G 3/8 oder / or G 1/2“
Ausgangsgewinde / outlet connection: frei abblasend / free outlet
Nennweite / nominal size: 8 mm
Temperaturbereich / temperature range: -10°C bis + 180°C

AnschlußGewinde Druckbereich H (mm) l (mm) Drehmoment Schlüsselweite d1 (mm)

Threaded connection Pressure range (bar) Torque (Nm) Width across (mm)
G¼ 0,3-0,9 72 10 14 22 21,8
9,4-21,0 81 10 14 22 21,8
21,1-47,0 88 10 14 24 23,8
G 3/8 0,3-0,9 72 10 40 22 21,8
9,4-21,0 81 10 40 22 21,8
21,1-47,0 88 10 40 24 23,8
G ½ 0,3-0,9 73 12 65 27 26,8
9,4-21,0 82 12 65 27 26,8
21,1-47,0 90 12 65 27 26,8
M 18 x 1,5 0,3-0,9 72 10 40 22 21,8
9,4-21,0 81 10 40 22 21,8
21,1-47,0 88 10 40 24 23,8

Bezeichnung / Werkstoff / material

Gehäuse / body Messing / brass
Dichtung / seal Elastomere (Silikon (0,3-2,3 bar, VITON 2,4-47 bar)
Kegel / cone Messing / brass
Zugstange / spindle Messing / brass
Einstellschraube / adjusting screw Messing / brass
Druckfeder / spring Stahl/steel EN 10270-1 DH

Technische Änderungen, Druckfehler oder Irrtümer vorbehalten, die Abbildungen sind nicht verbindlich.
We reserve the right to make technikal modifikations. Errors or printing errors excepted. Illustrations are not binding TDB-8.2092.0_00D
Sicherheitsventil / safety valve Typ L08

Leistungsdaten / flow rate**

Druck / m3/h l/min

Set pressure (bar)
1 46 758
2 69 1157
3 67 1116
4 85 1410
5 102 1697
6 132 2208
7 151 2516
8 171 2848
9 190 3166
10 209 3483
12 248 4133
14 286 4767
16 325 5405
18 364 6067
20 402 6701
22 445 7450
24 479 7983
26 517 8625
28 555 9266
30 599 9983
32 632 10548
34 671 11189
36 709 11830
38 748 12471
40 796 13267
42 825 13753
44 863 14394
46 902 15035
47 921 15356

**Die angegebenen Leistungen werden bei 10% (PE <1 bar, + 0,1bar) Druckanstieg erreicht, gemessen mit Druckluft bei 20°C. Für andere
Gase und Temperaturen ändern sich die Abblaseleistungen.
**The specified rates are measured at 10% (PE <1 bar, + 0,1 bar) pressure rise over the set pressure with compressed air at 20°C. The blow-
off rates are different for other gases and temperatures

Technische Änderungen, Druckfehler oder Irrtümer vorbehalten, die Abbildungen sind nicht verbindlich.
We reserve the right to make technikal modifikations. Errors or printing errors excepted. Illustrations are not binding
 SAFETY VALVES

Design DN 8 PN 50 -25 bis 180 °C Type tested

SVW/SVWN/SVWC

Applications:
ð Suitable for compressed, similar non-inflammable and non-toxic gases; free discharge, not suitable
for fluids and vapours.

Types:
SVW ð 2.0401 (brass)
SVWC ð 1.4104 (stainless steel)
SVWN ð 1.4571 (stainless steel)

Characteristics:
Opening design +++ elastic seal (Viton) +++ spring of stainless steel
+++ lifting device +++ connection thread according to DIN 3852 +++
mark of typetest TÜV +++ TÜV similar test and certificate (DIN EN
10204 / Germanischer Lloyd).

connection SW
(d1) set pressure d2 l1 l2 SVW SVWN
[bar] [mm] [mm] [mm] SVWC
00,30 – 14,20 63
M 16x1,5 20 12
14,21 – 40,00 75
40,01 – 50,00 82
00,30 – 14,20 63
G 1/4 A 18 10 20 22
14,21 – 40,00 75
40,01 – 50,00 82
00,30 – 14,20 63
G 3/8 A 20 12
14,21 – 40,00 75
40,01 – 50,00 82
00,30 – 14,20 63
G 1/2 A
14,21 – 40,00 75
24 14 24 24
40,01 – 50,00 82

Order term: (Please pay attention to advices at the reverse)

z.B. SVW 8 – 11 bar – G ¼ A – ...

special design
connection thread
set pressure
nominal diameter
design

Armaturen- und Metallwerke Zöblitz GmbH

Bahnhofstraße 16, 09517 Zöblitz Tel. 037363 480-0 / Fax 037363 480-90 Seite
Internet: www.armaturen-zoeblitz.de e-mail: [email protected] 1/2
 SAFETY VALVES

Design DN 8 PN 50 -25 bis 180 °C Type tested

SVW/SVWN/SVWC

Discharge capacity

pe qm [m³/h] pe qm [m³/h]
[bar] bei 0°C/760 Torr [bar] bei 0°C/760 Torr
0,3 13,6 23 571,8
0,8 19,3 24 595,8
0,9 37,6 25 619,7
1,4 48,1 26 643,6
1,9 58,6 27 667,6
2 69,2 28 691,5
2,5 81,2 29 715,4
3 93,2 30 739,4
3,5 105,1 31 763,3
4 117,1 32 787,2
5 141,0 33 811,2
6 165,0 34 835,1
7 188,9 35 859,0
8 212,8 36 883,0
9 236,4 37 906,9
10 260,7 38 930,8
11 284,6 39 954,8
12 308,6 40 978,7
13 332,5 41 1.002,6
14 356,4 42 1.026,6
15 380,4 43 1.050,5
16 404,3 44 1.074,4
17 428,2 45 1.098,4
18 452,2 46 1.122,3
19 476,1 47 1.146,3
20 500,0 48 1.170,2
21 524,0 49 1.194,1
22 547,9 50 1.218,1

Discharge capacities by 10% accumulation over the set pressure.

General notes:

Working temperautre for safety valves type SVWC –10 to 180°C.

Valves are delivered tested and sealed. Special designs (other connection thread, e. g. nickel-plated) on inquery.
Ordering safety valves please declare medium, temperature and other relevant details (if possible).
All rights are reserved for design changes. Safety notes and direction of maintenance you will find at backsite of our test
certification or an inqury.

Armaturen- und Metallwerke Zöblitz GmbH

Bahnhofstraße 16, 09517 Zöblitz Tel. 037363 480-0 / Fax 037363 480-90 Seite
Internet: www.armaturen-zoeblitz.de e-mail: [email protected] 2/2