SERVICE MANUAL E

Model: K 1000 --- 2 --- G / H 35

Part No.: 1.2617.1
Serial No.: ...............................................

Index: 090801
GL---Nr.: K1000---2---G---1.2617.1---02

Manufacturer:

KAESER KOMPRESSOREN GmbH

D---96410 Coburg : Postfach 2143 : Tel. (09561) 640---0 : Fax.(09561) 640---130
.     *  + 

 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 --- 2
1.5 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 2
1.6 Safety Valve Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 2
1.7 Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 2
1.8 Recommended Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 3
1.9 Dimensional Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 3

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

2.1 Explanation of Symbols and References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 5
2.2 General Notes on Accident Prevention Regulations . . . . . . . . . . . . . . . . . . . . . . . 2 --- 5
2.3 Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 6
2.4 General References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 6
2.5 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 7
2.6 Environmental Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 7

3 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 8
3.1 Correct Use of the Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 8
3.2 Incorrect Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 8
3.3 Compressed Air Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 8
3.4 Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 8

4 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 9
4.1 Transport Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 9
4.2 Transport with a Lift Truck or Fork ---lift Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 9
4.3 Transport Using a Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 9
4.4 Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 10
4.5 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 10

5 Construction and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 11

5.1 Principle of Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 11
5.2 Short Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 11
5.3 Components of the Base---Mounted Reciprocating Compressor . . . . . . . . . . . . 5 --- 12

6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 13
6.1 Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 13
6.2 Fitting the Antivibration Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 13
6.3 Connection of the Compressed Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 14
6.4 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 14
6.5 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 15
6.6 Pipe and Instrument Flow Diagram (P & I Diagram) . . . . . . . . . . . . . . . . . . . . . . . 6 --- 15
6.7 Compulsory Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 18

i
 Table of Contents
Chapter --- Page

6.7.1 Motor overload protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 18

6.7.2 Pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 18
6.7.3 Unloaded starting valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 18
6.7.4 Nonreturn valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 18
6.7.5 Working pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 18

7 Putting into Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 19

7.1 Points to be Observed before Putting into Operation . . . . . . . . . . . . . . . . . . . . . . 7 --- 19
7.2 Direction of Rotation Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 19

8 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 20
8.1 Starting and Stopping the Compressor Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 20
8.2 Faultfinding and Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 20
8.2.1 Compressor does not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 20
8.2.2 Compressor starts with difficulty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 20
8.2.3 Compressor overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 20
8.2.4 Compressor runs continuously, discharge pressure not reached . . . . . . . . . . . 8 --- 21
8.2.5 Whistling noises at the cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 21
8.2.6 Safety valve blowing off prematurely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 21
8.2.7 Oil consumption of compressor too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 22
8.2.8 Compressor unit squealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 22

9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 23
9.1 Observe the Following during all Maintenance and Repair Work: . . . . . . . . . . . 9 --- 23
9.2 Regular Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 24
9.3 Checking the Oil Level and Topping Up (Compressor Block) . . . . . . . . . . . . . . . 9 --- 25
9.4 Oil Change (Compressor Block) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 25
9.5 Clean or Renew the Dirt Trap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 26
9.6 Checking the V---Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 27
9.7 Tensioning the V---belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 28
9.8 V---Belt Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 28
9.9 Clean or Renew the Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 29
9.10 Checking the Safety Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 29
9.11 Maintenance of the Motor Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 30
9.12 Cleaning or Changing the Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 30
9.12.1 Cleaning the solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 31
9.12.2 Changing the solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 31
9.13 Check or Renew the Cylinder Heads and Valves (Compressor Block) . . . . . . . 9 --- 32

10 Spare Parts and After Sales Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 33

10.1 Service Parts and Expendable Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 33
10.2 Ordering Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 33

11 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 34
11.1 Maintenance Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 34

ii
 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235 kg
Drawings:
Dimensional drawing . . . . . . . . . . . . . . . . . . . . . . . . K1.2617.0.00
Electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ---
P & I flow diagram . . . . . . . . . . . . . . . FKKK1000---2G---00044.00
(Pipework and Instrument flow diagram)

1.2 Sound Pressure Level

Operational state of the compressor package
Full load, the compressor package runs at: rated speed, rated pressure, rated capacity.

Setting up conditions:
Free field measurement.
Statement of sound pressure level:
Measurement to DIN 45635 (measurement of noise on machines, compressors)
- 1 m distance
- 1.6 m height
- Related point of measurement: in all directions
Highest sound pressure value . . . . . . . . . . . . . . . . . . . . . . . . . . 81 dB (A).

1.3 Compressor Block

Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K 1000 --- 2
Theoretical inlet capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1050 l/min
Free air delivered at 12 bar gauge working pressure . . . . . 835 l/min
Maximum gauge working pressure . . . . . . . . . . . . . . . . . . . . . 35 bar
Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 960 min ---1
Oil capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 l
Oil top ---up quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,65 l

1 --- 1
 Technical Specification

1.4 Drive Motor

Three---phase motor 400 / 690 V
Rated power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 kW
Rated speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3000 min ---1
Enclosure protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IP 54
Max. switching frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 per hour

1.5 Power Supply

Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 / N / PE
Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Hz

Possible starting systems

Star--Delta 7' at 400 V power supply

Maximum rated current IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 A
Maximum mains fusing (slow or gl) . . . . . . . . . . . . . . . . . . . . . 25 A
Supply cable core cross---section (multicore) . . . . . . . . . . 4 x 10 mm2
Direct-- online ' at 400 V power supply
Maximum rated current IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 A
Maximum mains fusing (slow or gl) . . . . . . . . . . . . . . . . . . . . . 63 A
Supply cable core cross---section (multicore) . . . . . . . . . . 4 x 16 mm2
Direct-- online 7 at 690 V power supply
Maximum rated current IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 A
Maximum mains fusing (slow or gl) . . . . . . . . . . . . . . . . . . . . . 35 A
Supply cable core cross---section (multicore) . . . . . . . . . . . 4 x 6 mm2

1.6 Safety Valve Settings

2SHQLQJ SUHVVXUHV
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 Oils

Under normal operating conditions (see chapter 1.7), fill with engine oil of viscosity VG 30
to DIN 51 562.
Recommended HD engine oils to DIN 51 506

Oil company Type of oil

AGIP AGIP MOTOR OIL HD 30

AGIP DIESEL GD 30 GAMMA 30

ANTAR MILANTAR 2 B SAE 30

ARAL ARAL Kowal motor oil SAE 30

AVIA AVIA MOTOR OIL HD 30

BP BP Vanellus --- T SAE 30

BP Energol HD---S SAE 30

DEA DEA Regis SAE 30

DEUTZ DEUTZ OEL SG HD---B 30

ELF ELF PERFORMANCE 2 B SAE 30

ESSO ESSO LUBE HDX PLUS + 30

PURFINA PURFINA MOTOR OIL SAE 30

RENOLIN RENOLIN HD 30

MOBIL OIL Mobil Delvac 1130

Mobil HD 30
Mobil Delvac 1230

SHELL Shell Rimula X Monograde 30

TOTAL TOTAL Rubia H 30

TOTAL Super HD 30

1.9 Dimensional Drawing

(see following page)

1 --- 3
 Safety

2 Safety Regulations

Read this service manual carefully and observe cautionary references before putting this
compressor into operation and before carrying out any maintenance.

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.

Explanation of the warning label on the compressor unit:

Warning:
Do not touch hot surfaces.

2.2 General Notes on Accident Prevention Regulations

European Standards must be complied with when carrying out installation, operation,
maintenance and repair of compressor units.
Valid national regulations and standards must be complied with for those European Stan-
dards that are not yet incorporated into national legislation.
Users of compressor units located outside the jurisdiction of European Standards are ob-
liged to comply with the valid safety and accident prevention regulations concerning the
compressor unit in the country of use.
If necessary, corresponding measures must be taken to ensure compliance with national
regulations before the compressor is put into operation.
We also recommend observation of the following:
- Allow no open flame and flying sparks in the place of installation.
- During any necessary welding near compressors ensure that sparks or high tempera-
tures cannot cause fire or explosion.
- Ensure that the inlet air to the compressor is clean and free of damaging components.
- 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 --- 5
 Safety

- The oil change must be carried out according to the service manual, or at least once
annually.

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 I N (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 General References

Attention! The compressor unit may only be put into operation with the necess-
ary safety devices (see chapter 6.7).

If the compressor unit is operated as a component part of another ma-

chine it may only be put into operation together with that complete ma-
chine when the complete machine has been subjected to safety tests
and conforms to the provisions of the accident prevention regulations,
such as apply to protective devices for danger sources such as noise,
temperature, etc.

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 unit

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

Before work is carried out on the electrical system, carry out the fol-
lowing measures in the sequence shown.

2 --- 6
 Safety

1. Switch off all phases

2. Ensure the unit cannot be switched on again

3. Check that no voltage is present

Discharge or shut off pipework under pressure if not stated otherwise

in the service manual.

Attention! Any alterations or reconstruction carried out without consultation with

and without the previous consent of KAESER will invalidate the war-
ranty.

2.5 Spare Parts

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

2.6 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
 General

3 General

Attention! The service manual must always be available at the compressor ’s

place of use.

3.1 Correct Use of the Compressor

The compressor 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.
This compressor package may only be used for industrial purposes.

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.

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 --- 8
 Transport

4 Transport

4.1 Transport Instructions

Never transport the compressor other than vertically to prevent damage to the compressor
block.
See chapter 1.3 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 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 --- 9
 Transport

4.4 Packaging
A decisive factor concerning the type of packaging is the transport route.
The packaging conforms to the packaging regulations laid down by the German Federal
Association of Wood, Pallet and Export packaging (HPE) and by the German Machinery
and Plant Association (VDMA), if not otherwise contractually agreed.

4.5 Storage
Always store the compressor, whether packaged or not, in an enclosed, dry space.
The ambient temperature may not exceeds the limits of --- 25 •C and + 60 •C.

4 --- 10
 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.

5 --- 11
 Construction and Operation

5.3 Components of the Base ---Mounted Reciprocating Compressor

7 10 11 3 8 9 5 2 1 4 6

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

5 --- 12
 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 4.3.

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

4
2 3

1 Antivibration mount 4 Spring washer

2 Oblong hole 5 Hexagonal nut
3 Washer

6 --- 13
 Installation

 Lift up the compressor package with a lifting belt. Observe the instructions in chapter 4.3.
 Fit the antivibration mounts (1) with washer (3), spring washer (4) and hexagonal bolt
(5) to the feet of the compressor package.

6.3 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.

1
1

1 Compressed air discharge connection

6.4 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 I N (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 --- 14
 Installation

6.5 Control
A controller conforming to EN 60 204 must be provided for the connection to the power
supply.
The compressor is fitted with a solenoid valve (230 V) that allows an unloaded start via a
controller in direct ---on ---line or via a star---delta starter.
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 valve must be activated by the controller. The
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 to be arranged on the compressor as shown in the accompanying P & I
flow diagram.

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

(see following pages)

6 --- 15
 Installation

6.7 Compulsory Safety Equipment

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

6.7.1 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.

6.7.2 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.

6.7.3 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

- 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.

- 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.

6.7.4 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.

6.7.5 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 --- 18
 Putting into Operation

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 compressor unit restarts automatically after a power failure pro-

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

- It is expected that the operator employs safe working methods and that all valid and, if
necessary, all local operating and safety regulations are complied with when operating
the compressor unit.
- The user of this compressor unit is responsible for its safe operating condition.
- Do not operate this compressor unit in spaces where high dust pollution, poisonous or
inflammable vapours or gases could exist.
- Do not connect the compressor unit to a supply voltage other than that stated on the
nameplate.
- Do not install the compressor unit 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).
- 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

- 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 --- 19
 Operation

8 Operation

8.1 Starting and Stopping the Compressor Unit

Switch the compressor unit on and off with the main power supply switch.
Starting the compressor unit
 Switch on the main power supply switch (see chapter 2.3).
Attention! Check for correct direction of rotation when starting the compressor
unit (see chapter 7.2).

Stopping the compressor unit

 Switch off the main power supply switch.

8.2 Faultfinding and Removal

General safety regulations (see chapter 2) and local safety regulations
must be complied with during faultfinding and removal procedures.

Starting after a defect:

See chapter 7 ‘Putting into Operation’.
Explanation of symbols for the following fault diagnosis:
% 1 --- have checked by a specialist.
% 2 --- contact KAESER customer service department.

8.2.1 Compressor does not start

Possible cause: Remedy:

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

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
9.12.1/9.12.2)

Damaged bearings Renew the bearings or fit an exchange

compressor

Piston seized Change the piston and cylinder

(no oil or wrong oil) (see chapter 9.13)

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).

8 --- 20
 Operation

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 9.9); % 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 9.13).

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.

8.2.5 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.

Maladjusted. Setting 1 bar above max. gauge working

pressure (see chapter 1.1) of the compres-
sor 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 --- 21
 Operation

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 rings and cylinder; % 2.

Piston rings worn or damaged after only a Renew 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).

8.2.8 Compressor unit squealing

Possible cause Remedy

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

(see chapter 9.6)

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

8 --- 22
 Maintenance

9 Maintenance

9.1 Observe the Following during all Maintenance and Repair Work:

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 unit

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

Before any maintenance work is carried out on the compressor unit

break the power supply by operating and locking out the main isolat-
ing device (mains supply switch or mains plug, see chapter 2.3) to
prevent an accidental compressor start.

If work is to be done on the pressurised pipework of the compressor

unit the pipework must be vented beforehand (vent the air receiver).

Before starting the compressor again ensure that no maintenance per-

sonnel are working on the compressor unit and that all covers are
fitted.

To start the compressor unit (see chapter 8.1).

Attention! Always check and tighten all screwed fittings that were removed or
loosened during maintenance and repair work.

Dispose of all used materials and parts accumulating during oper-

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

9 --- 23
 Maintenance

9.2 Regular Maintenance

Period Work to be done See chapter

daily check the oil level in the compressor block 9.3

24 hours after first put- check the V---belt tension 9.6

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

change the compressor oil 9.4

500 hours or at least change the compressor oil * 9.4

anually
check and clean the dirt trap 9.5

check the V---belt tension 9.6

check the safety valve 9.10

clean the solenoid valve 9.12.1

2000 hours renew the solenoid valve 9.12.2

3000 hours check the cylinder head and valves for correct 9.13
function

10000 hours carry out a general overhaul of the compressor 9.13

renew the motor bearings 9.11

* The maintenance interval can vary according to model, installation, cut ---in frequency and
the ambient conditions.
We recommend that a record is kept of all maintenance work.
A sample maintenance record is provided in chapter 11.1.

9 --- 24
 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.

max.
2
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.

9.4 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 the first 50 service hours approximately.

Change the oil after every further 500 service hours or at least annually.

9 --- 25
 Maintenance

If, under unsuitable operating conditions, condensed water is observed in the oil, recognis-
able by the milky colour in the oil level sight glass (2), carry out an oil change immediately.
See chapter 1.8 for suitable oils.

2
3

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).

9.5 Clean or Renew the Dirt Trap

The dirt trap prevents contamination of the solenoid valve and the air inlet chamber.
If problems occur during off load running or during unloaded start, clean the dirt trap.
It must be cleaned at the latest after 500 service hours.

9 --- 26
 Maintenance

1 2

1 Plug
2 Strainer

 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.

9.6 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 --- 27
 Maintenance

9.7 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.

1 Hexagonal nut

9.8 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 9.6).

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 --- 28
 Maintenance

9.9 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 2

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.

9.10 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.

9 --- 29
 Maintenance

To prevent the valve seat from sticking, open the safety valve every 500 service hours or at
least annually.

4 2

1
3

1 Interstage safety valve

2 Knurled ring
3 Safety valve on the aftercooler
4 Ring

Attention! Always wear ear muffs during the safety valve check because of the
extremely loud noise caused when the valve opens.
 Shut down the compressor unit under load (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.

Safety valve 1
 Turn the knurled ring (2) on the safety valve (1) anticlockwise until air blows off.
Safety valve 2
 Pull the ring (4) on the safety valve (3) until the valve opens and then release the ring
again.
Attention! A defective safety valve must be renewed complete.

Attention! Adjustment of the safety valve setting and removal of the seal is for-
bidden and invalidates all liability.

9.11 Maintenance of the Motor Bearings

- The motor bearings are permanently greased.
- Under normal operating conditions, with ambient temperatures around 25 •C, the
motor bearings should be renewed approximately every 10 000 service hours.
- 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.
- 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.

9.12 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 --- 30
 Maintenance

9.12.1 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.

2 3 4 5 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.

9.12.2 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.

9 --- 31
 Maintenance

1 Pipe fitting
2 Cable

 Open the pipe fitting (1).

 Remove the electrical cable (2) 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 9.12.1 item 9).

 Fit the solenoid valve and gasket into the piping.

9.13 Check or Renew the Cylinder Heads and Valves (Compressor Block)
Check the cylinder heads and the valves for correct function after 3000 service hours.

Attention! If faults are obvious on the cylinder head or the valves, these parts
must be repaired or renewed by KAESER Service.

Have the compressor generally overhauled by KAESER Service after 10000 service hours.

9 --- 32
 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 2607 6.1408.0

Solenoid valve 1 off 7.0318.0

Solenoid valve 1 off 7.1360.0

Lubricating oil 1 litre 9.0910.0

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.

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 Appendix

11 Appendix

11.1 Maintenance Record

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

Date Description of work Operating hours Signature

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