Catalogo Booster n753

SERVICE MANUAL USE
Reciprocating Compressor
Model: N 753 --- G 145 psi / 580 psi
Serial No.: ...............................................
Index: 060901
GL---Nr.: N753---G---1.2301.20190---YD---02
Table of Contents
Chapter --- Page
1 Technical Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1

1.1 Booster Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1
1.2 Noise Level Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1
1.3 Compressor Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1
1.4 Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1
1.5 Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 2
1.6 Air Pressure Switch Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 2
1.7 Inlet Pressure Switch Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 2
1.8 Safety Relief Valve Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 3
1.9 Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 3
1.10 Oil Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 3
1.11 Cooling Water Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 5
1.12 Cooling Water Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 5
1.13 Dimensional Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 5
2 Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 8

2.1 Explanation of Symbols and References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 8
2.2 General References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 8
2.3 Additional Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 9
2.4 Electrical Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 9
2.5 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 9
2.6 Compressed Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 9
2.7 Environmental Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 9
3 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 10
3.1 Proper Use of the Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 10
3.2 Improper Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 10
3.3 Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 10
4 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 11
4.1 Transport Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 11
4.2 Transport with a Lift Truck or Fork ---lift Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 11
4.3 Transport Using a Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 11
4.4 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 12
5 Construction and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 13

5.1 Principle of Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 13
5.2 Brief Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 13
5.3 DUAL Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 14
5.4 Components of the Base---Mounted Booster Package . . . . . . . . . . . . . . . . . . . . 5 --- 15
i
Table of Contents
Chapter --- Page
6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 18
6.1 Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 18
6.2 Fitting the Antivibration Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 18
6.3 Compulsory Safety and Regulating Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 19
6.3.1 Starter control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 19
6.3.2 Pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 19
6.3.3 Flexible hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 19
6.3.4 Check valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 19
6.3.5 Air inlet filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 19
6.4 Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 20
6.5 Connection of the Compressed Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 20
6.5.1 Air connection to low pressure air main 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 20
6.5.2 Connection to high pressure network 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 21
6.6 Cooling Water Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 22
6.7 Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 22
6.7.1 Motor connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 22
6.7.2 Solenoid valve connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 23
6.8 The Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 24
6.9 Pipe and Instrument Flow Diagram (P & I Diagram) . . . . . . . . . . . . . . . . . . . . . . . 6 --- 25
7 Putting into Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 28

7.1 Points to be Observed before Putting into Operation . . . . . . . . . . . . . . . . . . . . . . 7 --- 28
7.2 Points to be Observed before Starting the Compressor Unit . . . . . . . . . . . . . . . 7 --- 28
7.3 Direction of Rotation Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 29
7.4 Motor Overload Relay Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 29
7.5 Setting the Idle Timer Relay for Dual Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 29
7.6 Setting the Air Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 30
7.7 Setting the Inlet Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 31
7.7.1 Cut ---in frequency of the compressor unit from ‘‘standstill” to ‘‘load” . . . . . . . . 7 --- 32
8 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 33
8.1 Starting and Stopping the Compressor Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 33
8.2 KAESER CONTROL Safety System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 33
8.3 Shutdown of the Compressor Package by Safety Devices . . . . . . . . . . . . . . . . . 8 --- 34
8.4 Temperature gauge with switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 34
8.5 Trouble Shooting: Possible cause --- Remedy . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 34
8.5.1 Compressor does not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 35
8.5.2 Compressor starts with difficulty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 35
8.5.3 Compressor overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 35
8.5.4 Compressor runs continuously, discharge pressure not reached . . . . . . . . . . . 8 --- 35
8.5.5 Whistling noises at the cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 36
8.5.6 Safety valve blowing off prematurely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 36
8.5.7 Oil consumption of compressor too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 36
8.5.8 Compressor unit squealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 36
ii
Table of Contents
Chapter --- Page
9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 37
9.1 Observe the following rules during all maintenance and servicing work: . . . . . 9 --- 37
9.2 Regular Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 38
9.3 Regular Maintenance of the Automatic Condensate Separator . . . . . . . . . . . . . 9 --- 39
9.4 Oil Level Check and Top Off (Compressor Block) . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 39
9.5 Oil Change (Compressor Block) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 40
9.6 Changing the oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 41
9.7 Cleaning or Replacing the Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 42
9.8 Cleaning or Replacing the Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 43
9.9 Clean or Renew the Dirt Trap in the Air After Cooler . . . . . . . . . . . . . . . . . . . . . . . 9 --- 43
9.10 Cleaning or Replacing the Dirt Trap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 44
9.10.1 Check and clean the dirt trap on the crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 45
9.11 Changing the Oil Filter on the Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 46
9.12 Checking V---belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 47
9.13 Adjusting the V---belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 47
9.14 V---belt change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 48
9.15 Testing the Safety Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 48
9.16 Maintenance of the Motor Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 49
9.17 Renewing the Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 49
9.18 Check or Replace the Cylinder Heads and Valves (Compressor Block) . . . . . . 9 --- 50
9.19 Cleaning the AfterCooler --- Leakage check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 50
10 Spare Parts and After Sales Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 51

10.1 Service Parts and Maintenance Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 51
10.2 Ordering Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 51
11 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 52
11.1 Electrical Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 52
11.2 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 73
iii
Technical Specification
1 Technical Specification
1.1 Booster Unit

Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N 753 --- G
Overall weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,918 lbs
Diagrams:
Dimensional diagram . . . . . . . . . . . . . . . . . . . . . . . . 1.2301.20140
Electrical diagram . . . . . . . . . . . . . SKK---U0928.00/SKK---U0927
P & I flow diagram . . . . . . . . . . . . . . . FKKN753---GW---00075.02
(Pipework and Instrument flow diagram)
1.2 Noise Level Data

Noise level value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 dB (A)
1.3 Compressor Block

Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N 753
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.1 cfm
Capacity CFM (FAD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299 cfm
at 580 psig working pressure
Inlet pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 psig
Maximum working pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . 580 psig
Maximum duty cycle:
Pressure ratio $ 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 %
Pressure ratio 3 (load 60 min., idle 15 min.) . . . . . . . . . . . . 80 %
Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1170 rpm
Oil capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 qts.
Oil top ---off quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2 qts.
1.4 Electrical Connection

Main voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 V 3---phase
Full load current FLA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 A
Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Hz
Recommended main disconnect fuses
(Dual element or time---delay) . . . . . . . . . . . . . . . . . . . . . . . . . 150 A
Recommended power supply cable (Cu multi---stranded )
cross---section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/0 AWG
Attention! Maximum dual element time -- delay fuses are selected according to
1996 N.E.C. Article 240 -- 6, 430 -- 52 and Tables 430 -- 148 & 150.
Select multi-- strand copper core wire at 40C ambient temperature

according to 1996 N.E.C. 110 -- 14(c), 220 -- 3, 310 -- 15, Table 310 -- 16,
430 -- 6, 430 -- 22 and Tables 430 -- 148 & 150.
1 --- 1
1.5 Drive Motor

Rated power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 hp
Rated speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3600 rpm
Enclosure rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TEFC
Max. starts per hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 times
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wye---Delta
1.6 Air Pressure Switch Setting
650
MDR 53/45 Possible setting
600
range of the air
550 pressure switch
psig
500
450
Cut ---in pressure
400
350
300
250
200
150
150 200 250 300 350 400 450 500 550 600 650
Cut ---out pressure psig
1.7 Inlet Pressure Switch Setting
220
psig
MDR 43/16 Possible setting range

200
of the air pressure switch
180
160
cut ---in pressure
140
120
100
80
60
80 100 120 140 160 180 200 220 240
cut ---out pressure psig
Factory settings:
Cut ---in pressure p min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 psig
Cut ---out pressure p max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 psig
1 --- 2
1.8 Safety Relief Valve Setting

Set point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 638 psig
1.9 Installation Requirements

Max. height above sea level at place of installation . . . . . . 3000 ft.
Min. ambient temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 F
Max. ambient temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 F
Recommended minimum compressor space size
(floor area x room height) . . . . . . . . . . . . . . . . . . . . 110 sq.ft. x 8 ft.
Ventilation of installation space
Inlet air opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 sq.ft.
Exhaust air opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 sq.ft.
1.10 Oil Recommendations

Lubrication of an air compressor is essential to reliable operation. Carbon and varnish can
form in compressor oils. These deposits block the flow of lubricant and cause excessive
wear and failure of moving parts. Contamination of the oil can allow the formation of acids,
causing extensive internal corrosion. Water may be condensed decreasing the oil’s lubric-
ity.
KAESER COMPRESSORS has several lubricants available that are specially formulated to
match these demands. They feature excellent lubricity, outstanding demulsibility (ability to
separate from water), and long life.
RECOMMENDED KAESER LUBRICANTS
SIGMA DESCRIPTION MAXIMUM RECOMMENDED

LUBRICANT CHANGE INTERVAL*
First Oil Change Subsequent Oil

Change
M---150 ISO 100 Semi---Synthetic 50 Hours 1,000 Hours

Lubricant
S---150 ISO 100 Synthetic Lubricant 100 Hours 2,000 Hours
* Oil changes may need to be more frequent depending on ambient conditions.

When high ambient temperatures or dirty conditions are present, oil changes may be
necessary every 500 hours (1,000 hours for synthetic) or even shorter intervals. Oil
change intervals required should be determined through periodic oil analysis.
M -- SERIES SEMI -- SYNTHETIC LUBRICANTS
- M---Series SIGMA compressor fluids are the highest quality petroleum lubricants.
M---150 is specially blended to provide reliable performance in KAESER reciprocating
compressors.
S-- SERIES SYNTHETIC LUBRICANTS
- S---Series SIGMA compressor oils are formulated from the most advanced synthetic
lubricants. These ”synthetic” lubricants begin as high quality petroleum feed stock.
They are then refined, processed and purified into fluids with very consistent molecular
structure. These oils are carefully blended to produce extremely lubricants with su-
perior properties. SIGMA synthetic lubricants feature all the advantages of both PAO
and diester fluids.
1 --- 3
- S---150 lubricant is recommended for compressors operating in ambient temperatures

between 40F and 105F.
Specialty KAESER LUBRICANTS
- FG---150 synthetic hydrocarbon based food grade lubricant is designed for use in re-
ciprocating compressors in the application where incidental food contact may occur
with the discharge air. This lubricant meets the requirements of the FDA Regulation 21
CRF §178.3570 and is USDA H---1 approved. FG---150 is approved for canning, food
packing, meat and poultry processing and other applications where incidental food
contact may occur.
SPECIALTY KAESER LUBRICANTS

(Refer to product information to determine suitability.)
SIGMA DESCRIPTION MAXIMUM RECOMMENDED

LUBRICANT CHANGE INTERVAL*
First Oil Change Subsequent Oil

Change
FG---150 ISO 46 Food Grade 500 Hours 1,000 Hours

Synthetic Lubricant
* Oil changes may need to be more frequent depending on ambient conditions.

When high ambient temperatures or dirty conditions are present, oil changes may be
necessary every 500 hours (1,000 hours for synthetic) or even shorter intervals. Oil
change intervals required should be determined through periodic oil analysis.
KAESER synthetic lubricant should be stored in a protected location to prevent contamina-
tion. Do not re---use drums; flush and send to reconditioner.
Although the KAESER synthetic is not highly flammable, it will burn. While KAESER syn-
thetic compressor oil is less flammable than equal viscosity mineral oils, it cannot be classi-
fied as a fire---resistant fluid. It has a flash point above 460F. Since the user has total con-
trol over the conditions of the compressor lubricant, he assumes total responsibility for its
safe usage.
Material Safety Data Sheets are available for each lubricant from your KAESER authorized
distributors.
- Compatibility:
FG---150 is similar to mineral oil in its compatibility with paints, seals, gaskets and
hoses. The typical precautions are required when changing over from mineral oil to
KAESER synthetic hydrocarbon based lubricant.
Never mix lubricants of different types or brands.
When switching from mineral oil to a synthetic oil, the plant’s system materials must be
re---evaluated. Certain plastics are not compatible with synthetic oils. The following is a par-
tial list of acceptable and not recommended materials:
1 --- 4
ACCEPTABLE NOT RECOMMENDED
Viton Celcon PVC

High Nitrile Buna N Neoprene ABS
Teflon SBR Rubber
Epoxy Paint Low Nitrile Buna N
Oil Resistant Alkyd Acrylic Paint
Nylon Lacquer
Delrin Polystyrene
Attention! Polycarbonate bowls can be etched by any synthetic lubricant.

We recommend replacement with metal bowls, or the addition of metal
guards.
1.11 Cooling Water Specification

Max. cooling water outlet temperature . . . . . . . . . . . . . . . . . . . 95 EF
Cooling water volume flow at at = 41 F . . . . . . . . . . . . . . . . 12 gal/min
Cooling water pressure loss at at = 41 F . . . . . . . . . . . . . 7.25 psig
1.12 Cooling Water Quality

Attention! The following minimum demands on cooling water quality must be ful-
filled to prevent build -- up of scale, clogging and/or other cooler con-
tamination:
- pH value 7 to 10
- Carbonate hardness (CH) { 1.8 mval/l (corresponds to 89.5 ppm CaCo3) for an acid
capacity up to pH 4.3
- Overall hardness (OH) { 14.0 mval/l
- Chloride content (CI) { 200 mg/l corresponds to 5.6 mval/l
- Ferrite content (FE) { 0.2 mg/l
- Silicic acid (SiO2) { 200 mg/l
- Sulfate content (SO4) { 200 mg/l
- Overall salinity (OS) { 1000 mg/l
- Phosphate content (PO4) { 15 mg/l
- Appearance as clear as possible, colorless, without sediments
- Alga growth not permissible
- Solid matter insoluble depositable solid matter { 0.1 mm particle size
Corresponding cooling water treatment measures and filter devices must be implemented
and are stipulated.
The addresses of companies specialized in the examination of cooling water and who
supply suitable equipment for the treatment of cooling water can be obtained from
KAESER COMPRESSORS on request.
1.13 Dimensional Drawing

(see following page)
1 --- 5
Safety
2 Safety Regulations
Read this service manual carefully and observe cautionary references before putting the
compressor unit into operation and before carrying out any maintenance on the unit.
2.1 Explanation of Symbols and References

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

paid to directives, regulations, instructions and the correct sequence
of work so that damage and/or destruction of the compressor block is
prevented.
This symbol identifies environmental care measures.
This symbol indicates operations and actions to be carried out by the

operator or service technician.
- This bullet identifies listings.
This warning label identifies hot surfaces:

DO NOT TOUCH!
2.2 General References

Work on power driven systems may only be carried out by trained or
specialized personnel.
Prior to working on electrical systems of the compressor always per-

form the following steps in the sequence shown.
1. Lock the main disconnect in the ”off” position in accordance with

applicable lock out/ tag out procedures (example: OSHA CFR 29
§ 1910.147) to ensure the compressor does not restart.
2. Ensure the unit cannot be switched on again
3. Check that no voltage is present
4. Lock the isolation shut-- off valve in the ”closed” position and vent
all compressed air trapped between the compressor and the isolation
shut-- off valve in accordance with applicable lock out/ tag out proce-
dures (example: OSHA CFR 29 § 1910.147).
Attention! Any alterations or reconstruction carried out without the previous writ-
ten consent of KAESER COMPRESSORS Inc. will invalidate the war-
ranty.
2 --- 8
Safety
2.3 Additional Safety Precautions

Attention! Comply with the following:
- Do not allow open flame and flying sparks at the installation site.
- Take necessary precaution when welding on or near the compressor unit to ensure
that sparks or high temperatures cannot cause fire or explosion.
- Ensure that the compressor unit is supplied only with clean uncontaminated air.
- Do not allow the maximum ambient temperature to be exceeded (see chapter 1.9),
unless special measures have been agreed upon between the manufacturer and the
customer.
- Perform oil changes according to the service manual or at least once annually (see
chapter 9.2).
- Do not mix cooling oils of different types.
- Use only cooling oils recommended by the manufacturer (see chapter 1.10).
2.4 Electrical Power Supply

Attention! The main power supply and overcurrent protection must be installed
by a qualified electrician in accordance with NEC, OSHA and any appli-
cable local codes.
Compressor units must be installed with a lockable main disconnect

and fuses or other short-- circuit and ground fault protection device.
For fuse and wire recommendations, see chapter 1.4
Please note that the conductors, fuses and procedure are Kaeser’s
recommendations. These recommendations do not supersede other
applicable codes.
2.5 Spare Parts

Safe and reliable operation of the compressor unit is guaranteed only with KAESER original
spare parts and KAESER SIGMA compressor oil.
2.6 Compressed Air System

If a compressed air system is extended or changed, verify that the blowoff pressure and
capacities of the safety valves on the air receiver tanks and in the system match the rating
of all the compressor units installed.
2.7 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 care regula-
tions.
Maintenance materials/wear items/replacement parts

Dispose of all used materials and parts accumulating during opera-
tion, maintenance and repair of the compressor unit according to envi-
ronmental care regulations!
2 --- 9
General
3 General
3.1 Proper Use of the Compressor

The compressor unit is intended solely for the purpose of generating compressed air. Any
other use is considered improper. The manufacturer cannot accept liability for any damage
caused by such improper use; the user alone is liable for any risks incurred.
Proper use of the compressor also includes compliance with the installation, removal, ap-
plication, operational and maintenance instructions laid down by the manufacturer.
3.2 Improper Use

Never direct compressed air toward persons. Compressed air is a con-
centrated form of energy and as such dangerous to life.
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.
3.3 Copyright
KAESER COMPRESSORS, INC.
All rights reserved. No part of this manual may be reproduced in any form without
permission of KAESER COMPRESSORS, INC.
3 --- 10
Transport
4 Transport
4.1 Transport Instructions

Always use a fork lift truck, a lift truck or lifting equipment when transporting the com-
pressor unit to avoid damage to cabinet and framework.
See chapter 1.1 for details of the weight.
4.2 Transport with a Lift Truck or Fork ---lift Truck

Always mount the compressor on a suitable transport medium (pallet) when transporting
with a fork ---lift truck or lift truck.
Attention! Never drive directly underneath the compressor and lift.
4.3 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 beneath hanging loads.
Do not exceed the maximum permissible lifting weight of the lifting ap-
pliance.
Attention! Do not excert any side forces on the compressor unit when transport-
ing with lifting equipment.
4 --- 11
Transport
4.4 Storage
Always store the compressor, whether packaged or not, in an enclosed dry location.
The ambient temperature may not exceed the limits of --- 13 F and + 140 F.
4 --- 12
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 5.4).
5.1 Principle of Compression

This booster compressor is an air cooled, oil lubricated compressor using the principle of
single stage compression.
Compressed air from an air system is drawn in through the inlet port (1) and the collector
pipe (3) to the compression chamber of the compressor block (2). This compressed 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 center. After the piston has reached the bottom dead cen-
ter position the compressed air is boosted 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 boosted compressed air flows via an aftercooler pipe (4) to the compressed air outlet (5).
5.2 Brief Description

The compressor block is driven by an electric motor (9) via V---belts. The three cylinders
are arranged as single cylinders in the form of a W. Cooling fins on the cylinders and cylin-
der heads dissipate the heat of compression.
The crankshaft in the compressor block is supported by ball and roller bearings; the con-
rod is fitted with plain bearings. The cylinder liners, pistons, crankshaft and conrods are
automatically splash lubricated.
A solenoid valve (closed when de---energised) is fitted between the compressed air inlet
and the compressor block. A pneumatic unloading valve (13) at the compressed air inlet is
coupled to a pneumatic valve (14) at the compressed air outlet for the purpose of venting
the compressor. Also, a drain valve that drains the water out of the pressurised system is
coupled to the pneumatic unloading valve (13).
An oil pump is provided to force the oil through an oil filter (23). The clean oil is then re-
turned to the crankcase.
The compressor is stopped and started within preset pressure limits by a pressure switch
(24) (see chapter 1.6).
5 --- 13
5.3 DUAL Control
p
max
Pressure
p
min
1 2 3 4 5
Full load t1 t2
Motor power
Idle
Standstill
Time
In DUAL Control the compressor normally runs at full -- load, idle, or standstill.
Operation is controlled by a pressure switch within set limits between full -- load and idle.
If the compressor runs for longer than a preset time period, (1) to (2) e.g. t1 = 6 min, in
idle, the electric motor switches off completely (2). When the cut ---in point p min (3) is
reached the motor will restart automatically. The pressure now rises to the cut ---out point
p max (4) and the compressor runs in idle. Should, however, the pressure drop within a
shorter time period (4) to (5) e.g. t2 = 3 min again to p min (5), the compressor will automat-
ically switch from idle to full---load.
Attention! If pressure ratio > 3 the booster package must be allowed to go to idle
every $# mdcein2 minutes for at least $# mdcaus2 minutes.
5 --- 14
5.4 Components of the Base ---Mounted Booster Package
30*
29
3~
22 20
21 23
26 16 19 6 11 29 24
31* 9 25 3 2 7 10 8 28
5 --- 15
31* 32* 33*
Z
12
5 --- 16
27 27
Z
18
15
1
4 17 14 13
1 Air inlet connection with air filter* 18 Oil filter with oil pump
2 Compressor block 19 Dirt trap(oil circulation)
3 Collector pipe 20 Oil temperature gauge switch
4 Aftercooler(watercooled) 21 Pressure gauge(oil pressure)
5 Compressed air outlet with 22 Pressure gauge(inlet pressure)
high temperature switch 23 Pressure gauge(boost pressure)
6 Oil return line 24 Pressure switch(inlet pressure)
7 Oil collection bottle 25 Air filter
8 Safety valve 26 Check valve
9 Electric motor 27 Cooling water inlet / outlet
10 Oil filler 28 Safety valve(air aftercooler)
(crankcase venting and oil filter) 29 Terminal box
11 Oil level sensor and sight glass 30* Starter control box
12 Oil drain plug 31* Air pressure switch
13 Dirt trap(compressed air inlet) 32* Check vave
14 Solenoid valve(deenergized closed) 33* Discharge hose
15 Pneumatic unloading valve(compressed
air inlet) * Supplied with separate package
16 Pneumatic unloading valve(compressed Connection supplied by custome
air outlet) (see chapter 11.1)
17 Condensate drain
5 --- 17
Installation
6 Installation
6.1 Installation Instructions

To ensure sufficient cooling of the compressor unit the specified minimum compressor
location size, minimum distance to the walls and minimum size of the ventilation inlet and
exhaust openings must be complied with (see chapter 1.9).
The cooling air flow of the compressor unit is not greatly influenced in smaller locations
even if 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 compressor unit is only guaranteed if the ambient temperature re-
mains within the limits stated in chapter 1.9).
Exhaust 31.5*
opening
* Recommended
minimum door
width to allow
entry of
compressor
19.7
Inlet opening
Dimensions in inches
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 4.3.
The compressor package can tip because of its high point of gravity
and its own weight.
5
2
1 Antivibration mount 4 Spring washer

2 Oblong hole 5 Hexagonal nut
3 Washer
Lift up the compressor package with a lifting belt. Observe the instructions in chapter 4.3.
6 --- 18
Installation
Fit the antivibration mounts (1) with washer (3), spring washer (4) and hexagonal bolt
(5) to the feet of the compressor package.
6.3 Compulsory Safety and Regulating Equipment
Attention! Safety and regulating equipment is supplied in a separate package

and must be installed by the user to ensure safe operation of the
booster unit.
6.3.1 Starter control box

The control box contents the control equipment of the booster unit like motor starter, over-
load relay and KAESER CONTROL. The starter control box has to be connected to the
booster package according to the wiring diagram in chapter 11.
6.3.2 Pressure switch

The pressure switch must be fitted for the regulation of the compressed air demand. This
pressure switch is normally fitted on the corresponding air receiver and regulates the
booster between the cut ---out and cut ---in pressures.
6.3.3 Flexible hose

The flexible hose is used to connect the booster package with an existing air system (air
receiver or pipework).
6.3.4 Check valve

To prevent the compressed air from flowing back into the compressor block, the check
valve must be fitted between the booster package and the air receiver.
Attention! The size of the check valve depends upon the maximum working pres-
sure (see chapter 1.3) and the cross-- section of the connection to the
air system (see dimensional diagram) from the compressor.
6.3.5 Air inlet filter

To ensure that the booster package is used only with clean air the air filter has to be fitted
to the air inlet connection.
6 --- 19
Installation
6.4 Typical Installation
safety starter control box

relief valve main discon-
nect switch
high pres-
sure
high switch
pres-
sure shut---
air sy- off
stem flexible valve
hose
existing
air fil- air sy-
ter stem
check
valve
high pressure booster package
tank with drain
trap
Terminal box
6.5 Connection of the Compressed Air Supply

The booster package is connected to an existing air system by a flexible hose.
A shut off valve must be connected between the air system and the inlet of the booster
compressor.
The discharge outlet has to be connected to the consumers via a flexible hose or pipework
with check valve.
The location of the compressed air inlet and outlet connections is shown in chapter 6.4.
6.5.1 Air connection to low pressure air main 1

The pipe connection from the the low pressure air main to the booster package must be
made with a swan’s neck. The prefilter, an absolute necessity, prevents dust and con-
densate from being sucked into the booster. A flexible hose must be used to connect the
prefilter to the booster package.
6 --- 20
Installation
1
2
4 3
3
B
A
A To the low pressure consumers

B To the booster package via flexible hose
1 Air main pipe (low pressure)
2 Swan’s neck outlet
3 Hose
4 Prefilter
5 Connection to low pressure compressed air network

= Compressed air inlet to booster B
6.5.2 Connection to high pressure network 2

The connection from the booster package to the high pressure network must be made
with a flexible hose.
1 Compressed air connection to the high pressure network
6 --- 21
Installation
6.6 Cooling Water Connection

Oxygen free copper heat exchanger pipes (OF Cu) are mounted in the coolers as stan-
dard.
Attention! Suitable working materials must be used for the feed and discharge
pipes to the heat exchanger, whereby the electrochemical series of the
metals must be taken into account.
The water system is designed for a nominal pressure of 145 psig.

The size and position of the connecting ports for the cooling water and the direction of flow
are determined in the dimensional drawing (see chapter 1.13).
6.7 Electrical Connection

The main power supply and overcurrent protection must be installed
by a qualified electrician in accordance with NEC, OSHA and any appli-
cable local codes.
For fuse and wire recommendations, see chapter 1.4.
The control box is wired ready for connection to the main supplies. Feed the supply cable
with cores marked L1, L2, L3 and PE through the cable inlet in the base frame of the con-
trol box and connect to the terminals marked L1, L2, L3 and PE in this box.
Attention! Maximum dual element time -- delay fuses are selected according to
1996 N.E.C. Article 240 -- 6, 430 -- 52 and Tables 430 -- 148 & 150.
Select multi-- strand copper core wire at 40C ambient temperature

according to 1996 N.E.C. 110 -- 14(c), 220 -- 3, 310 -- 15, Table 310 -- 16,
430 -- 6, 430 -- 22 and Tables 430 -- 148 & 150.
Wire temperature rating:
1.25 x FLA wire correction factor

(see chapter 1.4) temperature rating for 40C
100A 60C 0.82
> 100A 75C 0.88
6.7.1 Motor connection
2 4 6 Starter Control Box

Motor starter (delta contactor)
W U2 V2
2
Compressor motor terminal
U1 V1 W
1
Starter Control Box

6 4 2 Motor overload relay
6 --- 22
Installation
6.7.2 Solenoid valve connection
6 --- 23
Installation
6.8 The Controller

A controller that conforms to EN 60204 must be used for the mains power supply connec-
tion.
The base---mounted compressor is provided with a 115 V solenoid valve that must keep
the pneumatic venting valve closed when deenergized. The solenoid valve may open only
when the pressure at the compressed air inlet is equal to or higher than the cut ---in pres-
sure set on the pressure switch (see chapter 1.6).
The following components are wired in a terminal box fitted to the compressor (see wiring
diagram in chapter 11.1):
Six cables are fed to the terminal box (1).
1, 2 , 3, --- three PTC sensors are connected in series (if a sensor malfunctions or the
maximum temperature setting is exceeded the compressor package is
shut down)
4 --- oil pressure switch (17.5 psig)
5 --- inlet pressure monitoring switch
6 --- inlet pressure valve (solenoid valve at compressed air inlet)
Two cables are fed out of the terminal box (1) .
1 --- one cable for the three PTC sensors
1 --- one cable (oil pressure switch, inlet pressure monitoring switch,
inlet pressure valve)
The motor and the cables fed from the terminal box are to be wired into the controller. The
following points must be taken into account:
--- the oil pressure switch (14.5 psig) must be bridged during the motor run up phase and
must shut down the compressor if the pressure is less than 14.5 psig
--- The inlet pressure monitoring switch must start the compressor package if the
pressure exceeds pON and switch into idle if the pressure is less than pOFF
(see chapter 1.6).
Attention! The inlet pressure monitoring switch is set at the factory (see chapter
1.6) and may not be changed.
If, however, a lower final pressure is required and the inlet pressure is
less than that set on the inlet pressure monitoring switch then the set-
ting (see chapter 7.6) can be changed.
The ratio between inlet pressure and final pressure may not exceed
1:4.5.
If the pressure in the inlet line falls below pOFF during the load phase then the com-
pressor package is switched into idle by the pressure switch.
If the pressure in the inlet line falls below pOFF during the idle phase then the com-
pressor package switches first to load when the pressure has reached pON .
6 --- 24
Installation
Inlet pressure monitoring Air system pressure Compressor

switch switch
MDR 43/16
(user)
p > p ON p < p min runs up
p > p ON p > p max switches to---> idle
p < p OFF p > p min < p max switches to---> idle*
p < pON p < p min switches to or stays in idle *
* It would be practical to cater for this problem in the controller and indicate it with the
help of a signal.
p ON --- cut ---in pressure of the inlet pressure monitoring switch (e.g. 135 psig)
p OFF --- cut ---out pressure of the inlet pressure monitoring switch (e.g. 128 psig)
p min --- cut ---in pressure of the air system pressure switch (user) (e.g. 610 psig)
p max --- cut ---out pressure of the air system pressure switch (user) (e.g. 650 psig)
--- The PTC sensor must shut down the compressor package if the temperature exceeds
374 F , i.e. even if only one sensor registers a temperature excess (this is why they are
connected in series). The wiring used to connect the PTC sensors must be open circuit
protected.
--- The adjustable temperature gauge switch (2) is provided with dry contacts that
can be used in the controller.
The components are fitted to the compressor as shown in the accompanying P & I flow
diagram.
2
3
4
1 Terminalbox
2 Discharge temperature gauge
3 Pressure gauge (Oil pressure)
4 Pressure gauge (Pre ---pressure)
5 Pressure gauge (Discharge pressure)
6.9 Pipe and Instrument Flow Diagram (P & I Diagram)

(see following pages)
6 --- 25
Putting into Operation
7 Putting into Operation
7.1 Points to be Observed before Putting into Operation

Every compressor unit is given a test run at the factory and carefully checked before ship-
ment. The test run confirms that the compressor unit conforms to the specification data
and runs perfectly. However, independent of the checks made at the factory, the com-
pressor unit could be damaged during transport. For this reason, we recommend that the
compressor unit is examined for such possible damage. Observe the compressor unit
carefully during the first hours of operation for any possible malfunction.
Attention! Important functional components in the compressor unit (such as
check valve, safety relief valve and solenoid valve) are adjusted and
fitted to factory standards and specifications. Alterations to these com-
ponents are not allowed without prior written authorization from the
manufacturer.
Do not disassemble the check valve, safety relief valve and solenoid
valve. They are heavily spring loaded.
7.2 Points to be Observed before Starting the Compressor Unit

ANY NON -- OBSERVANCE OF THIS OR OTHER REFERENCES (WARN-
ING; ATTENTION; DANGER) CAN LEAD TO ACCIDENTS CAUSING IN-
JURY TO PERSONS OR DAMAGE TO EQUIPMENT.
The compressor unit starts automatically after a power failure provid-

ing the line pressure is lower than the setting on the air pressure
switch.
Do not operate the compressor without belt guards or open doors as

injury to persons could occur from the drive belts and electrical equip-
ment.
Remove all packaging materials, tools and transport securing devices on and in the
compressor unit.
- It is expected that the user employs safe working techniques and that all lawful operat-
ing and safety regulations are followed when operating this compressor unit.
- The operator of this compressor unit is responsible for its safe operating condition.
- Do not operate this compressor unit in locations where heavy dust conditions, poison-
ous or inflammable gases could exist.
- Do not connect the compressor unit to a supply voltage other than that stated on the
nameplate.
- Install the compressor unit in a location not subject to freezing temperatures. The air
temperature requirements at the air intake must be complied with (see chapter 1.9).
- During installation of the compressor unit, ensure that a distance of at least 19.7 ” is
kept between the air intake of the unit and any wall.
Lock the main disconnect in the ”off” position in accordance with ap-
plicable lock out/tag out procedures (example: OSHA CFR 29
§ 1910.147) to ensure the compressor does not restart.
Check all screws on the electrical connections for tightness and

tighten if necessary (carry out this check again after 50 hours of oper-
ation).
7 --- 28
7.3 Direction of Rotation Check

- Check the direction of rotation of the compressor block by switching the compressor
unit 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.
7.4 Motor Overload Relay Adjustment

§ 1910.147) to ensure the compressor does not restart. See
chapter 2.2 for the main disconnect switch.
The relay is set to the standard adjustment at the factory.

Compressor motor: Wye -- delta start
In the Wye---delta configuration the phase current is fed through the motor overload relay.
This phase current is 0.58 times the nominal motor current.
For the nominal motor current see motor nameplate.
Adjustment:
The value can be set to a maximum of 10% higher than the calculated phase current to
prevent the overload relay from tripping under voltage fluctuations.
When the fault is removed the compressor can be started again by pressing the reset but-
ton on the overload protection trip.
7.5 Setting the Idle Timer Relay for Dual Control

The idle timer is situated in the control cabinet (range of adjustment 0.5 to 10 minutes).
The idle time interval should be set so that the maximum number of starts of the motor
(see chapter 1.5) is not exceeded.
7 --- 29
7.6 Setting the Air Pressure Switch

1 Cover
2 Handwheel
3 Locking Pin
4 Screw
Unscrew the screws (4) to the right and left of the cover (1).
Remove the cover (1) of the pressure switch.
To increase the cut-- out pressure:
Turn the handwheel (2) clockwise.
To decrease the cut-- out pressure:
Turn the handwheel (2) counter clockwise.
To increase the pressure differential between the cut-- in and cut-- out pressure:
Remove the locking pin (3).
Depress the handwheel (2) and turn counter clockwise.
Insert the locking pin (3).
To decrease the pressure differential between the cut-- in and cut-- out pressure:
Remove the locking pin (3).
Depress the handwheel (2) and turn clockwise.
Insert the locking pin (3).
Put the cover (1) back on after every adjustment of the pressure switch
and before starting the compressor unit.
Put the cover (1) back on.
7 --- 30
7.7 Setting the Inlet Pressure Switch

See chapter 1.6 for the factory setting of the pressure switch and the pressure diagram.
Attention! The pressure setting can only be changed with the pressure switch
fitted and under pressure.
Attention! Do not set the maximum cut-- out pressure higher than the maximum
gauge working pressure (see chapter 1.1).
1
3
5
1 Cover 4 Adjusting screw ” D p ”

2 Pressure switch nameplate 5 Screw
3 Adjusting screw ” P ”
Shut down the compressor unit (see chapter 8.1).
Unscrew the screws (5) to the right and left of the cover (1).
Remove the cover (1) of the pressure switch.
To increase the cut-- out pressure:
Turn the adjusting screw ‘‘P” (3) clockwise using a screwdriver. The red pin on the
pressure scale indicates the pressure.
Screw the plug back into the cover of the pressure switch.
To decrease the cut-- out pressure:
Turn the adjusting screw ‘‘P” (3) counterclockwise using a screwdriver. The red pin on
the pressure scale indicates the pressure.
Screw the plug back into the cover of the pressure switch.
To increase the pressure difference between the cut-- in and cut-- out pressures:
Turn the adjusting screw ‘‘ap” (4) clockwise. The black pin on the differential pressure
scale moves in the ‘‘max’’ direction.
7 --- 31
To decrease the pressure difference between the cut-- in and cut-- out pressures:
Turn the adjusting screw ‘‘ap” (4) counterclockwise. The black pin on the differential
pressure scale moves in the ‘‘min’’ direction.
Replace the cover of the pressure switch.
Replace the cover after every adjustment of the pressure switch and
before starting the compressor unit.
7.7.1 Cut-- in frequency of the compressor unit from ‘‘standstill” to ‘‘load”

The cut ---in frequency of the compressor unit from ”standstill” to ”load” can be changed
within a limited range by changing the pressure difference between the cut ---in and cut ---
out pressures (switching difference). To change the cut ---in frequency the pressure switch
must be adjusted (see chapter 7.6).
Attention! See chapter 1.5 for the maximum cut-- in frequency from ‘‘standstill” to
‘‘load” per hour.
- Increasing the switching difference causes a decrease in the cut ---in frequency.
- Decreasing the switching difference causes an increase in the cut ---in frequency.
7 --- 32
Operation
8 Operation
8.1 Starting and Stopping the Compressor Unit
Starting the compressor unit

Switch on the main disconnect switch (see chapter 2.2).
Turn the control switch in the controller to the ”Start” position.
Attention! Check for correct direction of rotation when starting the compressor
unit (see chapter 7.3).
Stopping the compressor unit
Attention! Do not stop the compressor unit with the main disconnect switch.
Always start and stop the compressor unit with the control switch in
the controller.
Turn the control switch in the controller to the ”Stop” position.

Switch off the main disconnect switch.
See chapter 2.2 for the main disconnect switch.
8.2 KAESER CONTROL Safety System

The compressor unit is supervised by the KAESER CONTROL safety system.
The green LED (1) illuminates when the unit is ready for operation and during operation. It
is not illuminated during an alarm.
If an alarm occurs the red LED’s for the supervisory functions (2), (3) and (4) illuminate.
.$(6(5 &21752/
1
2 0RWRU
3 7HPSHUDWXUH
4 2LO 3UHVVXUH
5 7HPSHUDWXUH
Supervisory functions with indication and shutdown:

2 Overload protection cut-- out for the compressor motor
If an overload occurs, the motor overload relay shuts down the compressor unit (see
chapter 7.4).
When the malfunction is corrected reset the compressor unit.

Turn the control switch to the ‘‘0’’ position.
Press the reset button of the overload protection switch.
Turn the control switch to the ‘‘1’’ position.
8 --- 33
Operation
3 Shutdown by high temperature in the cylinder head

The PTC sensor must shut down the compressor package if the temperature exceeds
374 F , i.e. even if only one sensor registers a temperature excess (this is why they are
connected in series). The wiring used to connect the PTC sensors must be open circuit
protected.
When the malfunction is corrected, reset the compressor unit by turning the control
switch from ”I” to ”0”.
4 Shutdown by oil pressure switch
The compressor unit is shut down if the oil pressure in the crankcase is excessive or is
insufficient.
5 Temperature gauge switch for detection of excess discharge temperature
If a temperature fault occurs the compressor unit is shut down by the temperature
gauge switch. (see chapter 8.4)
The compressor is started again after the fault has been removed.
8.3 Shutdown of the Compressor Package by Safety Devices

Shutdown by inlet pressure monitoring switch
--- The compressor package is shut down if the inlet pressure is insufficient (less than p off).
8.4 Temperature gauge with switch

The compressed air temperature is sensed directly at the discharge port of the oil separa-
tor. If it reaches 175 F, the switch inside the temperature gauge will cause the indicator
light at the KAESER CONTROL (see chapter 8.2) to come on and also shut the compressor
down.
Search for and correct the malfunction.
Possible malfunctions:
- Low oil
- Cooling system fault
- Ambient temperature too high or too low
Then restart the compressor unit (see chapter 8.1).
8.5 Trouble Shooting: Possible cause --- Remedy

General safety regulations (see chapter 2) and local safety regulations
must be complied with during trouble shooting and repair procedures.
Starting after a repair (or malfunction):

See chapter 7 ‘Putting into Operation’.
Explanation of symbols for the following fault diagnosis:
% 1 --- have checked by a specialist.
% 2 --- contact your authorized KAESER distributor.
8 --- 34
Operation
8.5.1 Compressor does not start
Possible cause: Remedy:
No motor power supply, fuses blown. Replace the fuses; % 1.
8.5.2 Compressor starts with difficulty
Solenoid valve not opening Check the electrical connection, clean or

change the valve (see chap-
ters LEERER MERKER/LEERER MERKER)
Damaged bearings Replace the bearings or fit an exchange

compressor
Pistons seized Change the piston and cylinder

(no oil or wrong oil) (see chapter 9.18)
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 9.4)
8.5.3 Compressor overheating
Ambient temperature too high Lower the ambient temperature (see chap-
(over 105 F). ter 1.9).
Wrong direction of rotation Change over L1 and L2 terminals (see

(observe the direction arrow). chapter 7.3); % 1.
The fan cannot draw in air freely. Ensure that inlet air is available for the fan.
Valve plate leaking, varnished or the reed Check, clean or replace valve plate; % 1
valves are broken. und % 2.
8.5.4 Compressor runs continuously, discharge pressure not reached
Valve plate gasket defective or wrongly Fit new gaskets

fitted
Valve plate valves varnished or defective Clean or replace the valves

(see chapter 9.18)
Pressure losses within the unit Brush soapy water on piping and fittings,
seal leaks or replace leaking parts
Air demand higher than the capacity of the Increase the size of the compressed air
compressor supply
Solenoid valve blowing off constantly, coil Check the solenoid valve, clean the valve or
burned out or defective actuation replace the coil
8 --- 35
Operation
8.5.5 Whistling noises at the cylinder head
Loose cylinder head bolts or defective gas- Tighten the bolts or replace the gaskets;
kets. % 1 and % 2.
8.5.6 Safety valve blowing off prematurely
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. Replace the safety valve; % 1.
Wrong set point. Set 10---15 psig above max. working pres-
sure (see chapter 1.1) of the compressor
unit; % 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.
8.5.7 Oil consumption of compressor too high
Viscosity of oil too low. Fill with correct oil

(see chapter 1.10); % 1.
Defective crankcase venting system. Clean the crankcase venting system or re-
place the filter; % 1.
Piston rings worn or damaged. Replace piston rings and cylinder; % 2.
Piston rings worn or damaged after only a Replace piston rings 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).
8.5.8 Compressor unit squealing
Possible cause Remedy
V---belt slipping Tension the V---belt

(see chapter 9.12)
Lip seal ring on the compressor pump shaft Oil the sealing ring
running dry
8 --- 36
Maintenance
9 Maintenance
9.1 Observe the following rules during all maintenance and servicing work:
Work on power driven equipment may only be carried out by trained or
specialized personnel. Follow all applicable OSHA and local safety
regulations.
The compressor unit restarts automatically after a power failure if the

line pressure is lower than the pressure setting on the air pressure
switch.
Lock the main disconnect switch in the ”off” position in accordance

with applicable lock out/tag out procedures (example: OSHA CFR 29
§ 1910.147) to ensure the compressor does not restart (see chapter 2.4
for main disconnect switch).
Ensure that no maintenance personnel is working on the compressor

unit, that all panels are latched back on again and all maintenance
doors are closed before restarting the compressor unit.
To start the compressor unit see chapter 8.1.
Attention! Always tighten down any screw connection that has been loosened
during maintenance work.
Ensure that waste operational and maintenance materials, replaced

parts, etc. are disposed of according to environmental care regula-
tions!
9 --- 37
Maintenance
9.2 Regular Maintenance
Period Work to be done See chapter
daily check the oil level in the compressor block 9.4
2 and 24 hours after check the V---belt tension 9.12

first putting into opera-
tion and after changing
the V---belt
50 hours after first put- check all electrical screw connections for tight- 7.2
ting into operation ness and tighten if necessary
carry out a compressor oil and oil filter change 9.5
Proper interval varies carry out a compressor oil and oil filter change * 9.5
(see chapter 1.10) or at
least annually
500 hours or at least check and clean the air filter * 9.7
annually
check and clean the oil filter * 9.6
check and clean the dirt trap * 9.9
check the V---belt tension 9.12
check the safety valve 9.15
check and clean the check valve * 9.8
clean or replace the dirt trap in the air after coo- 9.9
ler
1000 h change the oil filter in the crankcase venting 9.6

system
Check the aftercooler for contamination 9.19
2000 hours replace the solenoid valve 9.17
3000 hours check the cylinder head, piston rings and valves 9.18
for signs of excessive wear
10000 hours carry out a general overhaul of the compressor 9.18
replace the motor bearings 9.16
* The maintenance period can vary depending on the cycle rate and environmental
conditions.
For severe duty (i. e. ambient temperature over 90 F, relative humidity over 90 %, or dirty
environment) the maintenance periods should be cut in half.
We highly recommend that a record is kept of the maintenance work done (see
chapter 11.2).
9 --- 38
Maintenance
9.3 Regular Maintenance of the Automatic Condensate Separator
Period Work to be done See chapter
Monthly Check the function of the unit by operating the See manual
test switch for the auto-
matic con-
Annually Change the diaphragm, valve core and gaskets densate se-
parator
9.4 Oil Level Check and Top Off (Compressor Block)

Check the oil level daily through the oil sight glass when the compressor unit is shut down.
Attention! If the oil level has sunk to the lower mark, top off the oil immediately
according to the oil recommendations (see chapter 1.10).
Never top off to a level exceeding the maximum oil mark on the oil
level sight glass.
When topping off the oil always use a strainer or pour the oil directly
from the new oil can.
max.
min.
1 Oil filler with crankcase venting

2 Oil level sight glass
Shut down the compressor (see chapter 8.1).
Remove the crankcase venting plug (1) from the oil filler.
Attention! Let oil settle a few minutes before filling to the maximum oil level mark.
The oil must flow through the crankcase first.
Top off the oil to the maximum mark. See chapter 1.3 for the quantity of oil required for
topping off from the minimum mark to the maximum mark.
Replace the crankcase venting plug in the oil filler.
9 --- 39
Maintenance
9.5 Oil Change (Compressor Block)

Oil change must be carried out with warm to the touch condition of the compressor unit
(Oil temperature approx. 104 F).
Danger of scalding with hot oil

Danger of burns from hot components
Change the oil after approximately the first 100 service hours.
For oil change requirements see chapter 1.10.
If, under unsuitable operating conditions, condensed water is observed in the oil, recogniz-
able by the milky color in the oil level sight glass (2), carry out an oil change immediately.
See chapter 1.10 for suitable oils.
3
1
4 max.
5 min.
1 Crankcase venting with oil filter

2 Oil level sight glass
3 Oil drain plug
4 Hose
5 Oil collecting canister
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.
Attention! When topping off the oil always use a strainer or pour the oil directly
from the new oil can.
Flush out the crankcase with a small quantity of new oil.

Screw the oil drain plug back into the crankcase.
Fill up with new oil (see chapter 9.4).
9 --- 40
Maintenance
9.6 Changing the oil filter

A constant oil mist is created by the pressure in the crankcase. Because this oil mist
should not be allowed to escape to the open air the crankcase is vented via an oil filter (5)
that retains the oil.
If the booster unit runs continuously, the oil accumulating in the crankcase venting system
can increase to the point where it can no longer return to the crankcase.
This oil is routed into an oil canister (3) via a hose (2) and must then be poured back into
the crankcase.
Attention! Do not run the booster unit without the oil filtered crankcase venting
system.
The oil filter (5) must be changed at every 500 service hours oil change interval.
7
1
2 6
3
6
1 Crankcase venting with oil filter 5 Oil filter

2 Hose 6 O ---ring
3 Oil collecting canister 7 Spring
4 Venting cap
Unscrew the hose (2) from the crankcase venting plug (1).
Unscrew the venting cap (4) from the crankcase venting plug (1).
Take out the oil filter (5).
Dispose of the oil filter in accordance with environmental care regula-

tions.
Screw the venting cap (4) back into the crankcase venting plug (1), check the pres-
sure setting spring (7) for correct seating.
Screw the crankcase venting plug (1) back into the oil filler.
Screw the hose (2) back onto the crankcase venting plug (1).
9 --- 41
Maintenance
9.7 Cleaning or Replacing the Air Filter

The filter cartridge (3) of the air filter (1) consists of oil wetted knitted coconut fibre.
Do not exceed a maintenance interval of 500 service hours. Replace the complete air filter
if the cartridge is heavily contaminated or has been cleaned often.
1
3
1 Air filter
2 Air inlet
3 Filter cartridge
4 Snap fastener
Unscrew the air filter (1) from the collector pipe.

Unhook the snap fastener (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! Make sure that the air inlet in the filter cap (2) is facing downwards
when screwing on the air filter .
Screw on the air filter (1), fit the cap.
Attention! Replace the complete air filter if the cartridge is heavily contaminated
or has been cleaned often.
9 --- 42
Maintenance
9.8 Cleaning or Replacing the Check Valve

The check valve is fitted between the collector pipe and the air filter. It vents the collector
pipe during idle mode.
Check and, if necessary, clean the check valve every 500 service hours or at least once
annually.
2
1
6
5
4
3
1 Check valve 4 Valve seat
2 End plug 5 Spring
3 Valve piston 6 Sealing ring
9.9 Clean or Renew the Dirt Trap in the Air After Cooler
The dirt trap prevents clogging of the unloading valve.
The dirt trap must be cleaned at the latest after 500 service hours.
3
1 Relief valve
2 Thread joint
3 Reducing nipple
Shut down the compressor package (see chapter 8.1).
Unscrew the fitting (2).
Screw out the reducing nipple (3) together with the unloading valve (1).
centrated form of energy and is as such dangerous to life. Always
wear personnel protective equipment.
9 --- 43
Maintenance
Remove the strainer together with the reducing nipple (3) and clean by blowing out
with compressed air.
Attention! If the strainer is very dirty or has been cleaned often it should be
replaced.
Fit the strainer and the reducing nipple (3).
9.10 Cleaning or Replacing the Dirt Trap

The dirt trap prevents contamination of the solenoid valve and the air inlet chamber.
If problems occur during idle or during unloaded start, clean the dirt trap.
It must be cleaned every 500 service hours.
1 Plug
2 Strainer
Unscrew the plug (1).

centrated form of energy and is as such dangerous to life. Always
wear personnel protective equipment.
Remove the strainer (2) and clean by blowing out.
replaced.
Screw the strainer (2) and plug (1) back in again.
9 --- 44
Maintenance
9.10.1 Check and clean the dirt trap on the crankcase

The dirt trap prevents clogging of the oil pump.
The dirt trap must be cleaned if the compressor malfunctions during idle or during un-
loaded starts. It must be cleaned at the latest after 500 service hours.
1 Plug
2 Strainer
Unscrew the screw plug (1).
Attention! If the dirt trap is cleaned with diesel fuel this must be done in the open
air. The appropriate regulations concerning the handling of combust-
ible fuels must be observed.
Remove the strainer (2).

Wash out the strainer (2) with diesel fuel or by blowing out with compressed air.
replaced.
Screw the strainer (2) and the plug (1) back again.
9 --- 45
Maintenance
9.11 Changing the Oil Filter on the Crankcase
Attention! Change the oil filter after approximately the first 50 service hours
Danger of scalding with hot oil

Danger of burns from hot components
The oil filter must be changed after every oil change see chapter 1.10 .
Changing the oil filter
Shut down the compressor package (see chapter 8.1).
Isolate and lock out the mains supply to the compressor package
(main switch or mains plug) to prevent an accidental start.
Close the user’s shut ---off valve between the compressor package and the air main.
The compressor’s oil circulation system vents automatically.
The pressure gauge must indicate 0 bar.
1 Oil filter cartridge

2 Turn in this direction to remove the oil filter
Twist the used or contaminated oil filter cartridge counter clockwise to remove and
catch escaping oil in a suitable container.
Dispose of the old oil filter and any used, accumulated oil according to
environmental care regulations!
Clean the face of the combination block with a lint free cloth.
Lightly oil the gasket of the new filter cartridge before screwing into position.
Screw in the new filter cartridge clockwise by hand until the gasket fits tightly.
Attention! Do not use a tool as this may cause damage to the oil filter cartridge
and the gasket.
Check the oil level (see chapter 9.4).

Open the isolation shut ---off valve between the compressor package and the main air
system.
9 --- 46
Maintenance
Carry out a trial run.
§ 1910.147) to ensure the compressor does not restart. See chap-
ter 2.2 for the main disconnect switch.
Carry out a visual check for leaks.
9.12 Checking V---belt Tension

Check V---belt tension after 24 and then every 500 service hours.
Check the position of the locating pin (3).
The V---belts are automatically tensioned within a certain range by a tensioning device.
If the V---belts have stretched so much that the marking pin is located at the upper end of
the slot (3) the V---belts must be tightened again.
1
2
1 Hexagonal nut
2 Hexagonal nut
3 Marking pin
9.13 Adjusting the V---belt tension

Shut down the booster (see chapter 8.1).
Break and lock out the power supply by operating the main disconnect
device (main disconnect or mains plug) to prevent an accidental start.
Unscrew the hex nut (1).

Turn the hex nut (2) until the locating pin (3) has reached the lower end of the slot
again.
Tighten the hex nut (1).
9 --- 47
Maintenance
9.14 V---belt change

Shut down the booster (see chapter 8.1).
Break and lock out the power supply by operating the main disconnect
device (main disconnect or mains plug) to prevent an accidental start.
Remove the belt guard.

Screw the hex nut (2, see chapter 9.12) of the swing frame adjustment downwards.
Turn the hex nut (1, see chapter 9.12) clockwise until the V---belts are no longer under
tension.
Take off the V---belts
Attention! Replacement belts must be of exactly the same length (as a set) and
100% impervious to oil. For this reason, we recommend that only orig-
inal KAESER V-- belts are used.
V-- belts may only be replaced in sets.
Lay the new V---belts over the motor and compressor pulleys without forcing them.
Unscrew the hex nut (1, see chapter 9.12) until the V---belts are under tension.
Tension the V---belts (see chapter 9.12).
Replace the belt guard again.
Check the V---belt tension after the first two and then 24 service hours and tension
again, if necessary (see chapter9.12), as experience shows that the belts stretch most
during this period.
9.15 Testing the Safety Relief Valve

If the maximum permissible working pressure is exceeded, the safety valve (2) opens and
blows off the excess air to protect the compressor unit and the users connected to the air
system.
To prevent the valve seat from sticking, activate the safety valve every 500 service hours or
at least annually.
1 Ring
2 Safety valve
Safety relief valve is hot!
Attention! Always wear ear and eye protection during the safety valve check.
During this procedure hot, pressurized air is released with a loud
noise.
9 --- 48
Maintenance
Turn the knurled ring (1) on the safety valve (2) counterclockwise with the booster
package running under full load until air blows off.
Attention! A defective safety valve must be replaced complete.
Adjustment of the safety valve setting and removal of the seal is for-
bidden and invalidates all liability.
9.16 Maintenance of the Motor Bearings

- The motor bearings are sealed and lubricated for the lifetime of the bearing.
- Under normal operating conditions, with ambient temperatures around 77F, the
motor bearings should be replaced approximately every 10 000 service hours.
- The wear on the bearings increases with higher ambient temperatures. With very high
ambient temperatures of around 95F replace the bearings approximately every 6000
hours.
- Change the motor bearings every 3 years independent of service hours.
Attention! The bearings must be changed by your authorized KAESER distributor

when the above maintenance is due.
9.17 Renewing the Solenoid Valve

If the solenoid valve starts to leak the cause is generally a dirty piston or solenoid core. For
reasons of operational reliability the solenoid valve must be renewed after 2000 service
hours.
Shut down the compressor package (see chapter 8.1)
1 Hexagonal nut
2 Control line
3 Plug for solenoid valve
Attention! Isolate the compressor package from the air main (close the shut-- off
valve in the inlet end) if the solenoid valve located in the compressed
air inlet is changed.
9 --- 49
Maintenance
Unscrew the hexagonal nut (1).

Isolate the solenoid valve from the electrical cable (2) by removing the plug to the
valve.
Unscrew the control lines (2) from the solenoid valve.
Take off the solenoid valve.
Fit the new solenoid valve.
Tighten down the hexagonal nut (1).
Screw the control lines (2) back onto the solenoid valve.
Plug in the electrical cable again.
Attention! Open the shut-- off valve to the air main.
9.18 Check or Replace the Cylinder Heads and Valves (Compressor Block)
Check the cylinder heads, piston rings and the valves for signs of excessive wear after
3000 service hours.
Attention! If wear is obvious on the cylinder head, piston rings or the valves,
these parts must be repaired or replaced by KAESER Service.
Have the compressor generally overhauled by your authorized KAESER distributor after
10000 service hours.
Attention! The cylinder heads, pistons and piston rings should be inspected for
excessive wear.
To determine the level of piston ring wear, measure the ring end gap:
Gap Required action

0.008” to 0.016” Wear normal inspect at next normal interval
over 0.02” Replace rings and inspect piston and cylinder
The cylinder head and valves should be inspected and cleaned of all varnish, carbon de-
posits, corrosion or rust.
Attention! If excessive rust or corrosion are present, contact your local KAESER
distributor for corrective actions.
9.19 Cleaning the AfterCooler --- Leakage check

Cleaning:
Check the after/oil cooler every 1000 service hours for contamination.
Heavy contamination could lead to excessive temperature in the oil circulation system.
If the operating temperature of the compressor unit lies 20F above the average mean an-
nual temperature the coolers must be cleaned by an authorized KAESER distributor.
Leakage check:
Check the after/oil cooler annually for leaks.
Special attention must be paid to aging and corrosion of the cooler materials under long
term operating conditions. As the pressure of the oil and the oily compressed air lies above
that of the cooling water, oil could be forced into the water system should a leak occur.
Attention! If a cooler should leak, shut down the compressor unit immediately
and remove the cause of the leak.
9 --- 50
Spare Parts and After Sales Service
10 Spare Parts and After Sales Service
10.1 Service Parts and Maintenance Parts
Name Qty. Part number
Set of V---belts 1 6.2544.0
Oil filter Crankcase venting) 1 9.2147.0
Oil filter (Crankcase) 1 6.1901.1
Air filter 1 6.0175.0
Solenoid valve (inlet) 1 7.6062.00010
Fredericksburg, VA 22404
Tel. (540) 898 -- 5500
Fax (540) 898 -- 5520
Model Year Voltage
Serial---No. HP FLA
Serial---No. Phase Hz/RPM
Displ. cfm MWP psig
Tank gals Pre---pressure psig
10.2 Ordering Spare Parts

When ordering spare parts always state (see nameplate):
--- Compressor model
--- Serial Number
--- Year of manufacture
Important for all orders and inquiries:

Enter the data from the nameplate of the compressor unit in the nameplate shown
above.
Attention! Always order original spare parts from the compressor manufacturer
to avoid lower quality spare parts in your compressor unit.
We want to point out that maintenance parts, spare parts and accessories not supplied by
us are also not tested and authorized by us. The use of such products could change de-
sign characteristics of the compressor unit negatively and might therefore affect the safety
of the unit.
The use of such parts or accessories releases KAESER COMPRESSORS from all liabilities
and warranties for consequential damage caused by such parts or accessories.
10 --- 51
Appendix
11 Appendix
11.1 Electrical Diagram

(see following page)
11 --- 52
Appendix
11.2 Maintenance Schedule
Model No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Serial No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Date Description of work Operating hours Signature
11 --- 73

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SERVICE MANUAL USE

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

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

2 Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 8

5 Construction and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 13

7 Putting into Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 28

10 Spare Parts and After Sales Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 51

1.1 Booster Unit

1.2 Noise Level Data

1.3 Compressor Block

1.4 Electrical Connection

Select multi-- strand copper core wire at 40C ambient temperature

1.5 Drive Motor

1.6 Air Pressure Switch Setting

Cut ---out pressure psig

1.7 Inlet Pressure Switch Setting

MDR 43/16 Possible setting range

1.8 Safety Relief Valve Setting

1.9 Installation Requirements

1.10 Oil Recommendations

RECOMMENDED KAESER LUBRICANTS

SIGMA DESCRIPTION MAXIMUM RECOMMENDED

First Oil Change Subsequent Oil

M---150 ISO 100 Semi---Synthetic 50 Hours 1,000 Hours

* Oil changes may need to be more frequent depending on ambient conditions.

- S---150 lubricant is recommended for compressors operating in ambient temperatures

SPECIALTY KAESER LUBRICANTS

SIGMA DESCRIPTION MAXIMUM RECOMMENDED

First Oil Change Subsequent Oil

FG---150 ISO 46 Food Grade 500 Hours 1,000 Hours

* Oil changes may need to be more frequent depending on ambient conditions.

ACCEPTABLE NOT RECOMMENDED

Viton Celcon PVC

Attention! Polycarbonate bowls can be etched by any synthetic lubricant.

1.11 Cooling Water Specification

1.12 Cooling Water Quality

1.13 Dimensional Drawing

2.1 Explanation of Symbols and References

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

This symbol identifies environmental care measures.

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

- This bullet identifies listings.

This warning label identifies hot surfaces:

2.2 General References

Prior to working on electrical systems of the compressor always per-

1. Lock the main disconnect in the ”off” position in accordance with

2. Ensure the unit cannot be switched on again

3. Check that no voltage is present

2.3 Additional Safety Precautions

2.4 Electrical Power Supply

Compressor units must be installed with a lockable main disconnect

For fuse and wire recommendations, see chapter 1.4

2.5 Spare Parts

2.6 Compressed Air System

2.7 Environmental Protection

Maintenance materials/wear items/replacement parts

3.1 Proper Use of the Compressor

3.2 Improper Use

Never use compressed air for breathing purposes and production

4.1 Transport Instructions

4.2 Transport with a Lift Truck or Fork ---lift Truck

Attention! Never drive directly underneath the compressor and lift.

4.3 Transport Using a Crane

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

Select multi-- strand copper core wire at 40C ambient temperature

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

Select multi-- strand copper core wire at 40C ambient temperature

Put the cover (1) back on.

Replace the cover of the pressure switch.

Turn the control switch in the controller to the ”Stop” position.