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Komptec GmbH. KT-90A User Manual

 

Page 50 of 52

 

v1.0a; 8 May 2016

 

Num.  Qty 

Bezeichnung 

Description 

Désignation 

Ordering # 

047 

Ölabstreifring mit O-Ring 

Wiper ring with O-ring  

Segment  racleur  avec  joint 
torique

 

910470 

048 

Rohrverschraubung Auslaß

 

 

Exhaust threaded elbow joint  

Raccord vissé échappement

 

910290 

049 

Zylinderkopfschrauben 

Cylinder head bolts  

Vis de tête de cylindre

 

910490 

050 

Ventileinsatz

 

 

Valve seat  

Boisseau

 

910500 

051 

Einlaßventil

 

 

Intake valve  

Soupape d'admission

 

910510 

052 

Einlaßventilfeder

 

 

Intake valve spring  

Ressort soupape d'admission

  

910520 

053 

Auslaßventil

 

 

Exhaust valve  

Soupape d'échappement

 

910530 

054 

Auslaßventilfeder

 

 

Exhaust valve spring  

Ressort soupape d'échappement

 

910540 

055 

O - Ring Zylinder-Zylinderkopf

  

Cylinder - cylinder head O-ring  

Joint  torique  cylindre  tête  de 
cylindre

 

910550 

056 

O  -  Ring  Zylinderkopf-Ven-
tileinsatz

 

 

Cylinder - valve seat O-ring 

Joint torique tête de cylindre bois-
seau

 

910560 

 

E

 

 

 

Verdichterstufe

 

 
3rd Compressor stage 

 

 
3ème étage du compresseur

 

 

057 

Kolben 3.Stufe

 

Piston - 3rd stage  

Piston 3ème étage

 

910570 

058 

Kolbenbolzen

 

Piston pin  

Axe de piston

 

910580 

059 

Sicherungsfeder 

für 

Kol-

benbolzen

 

Piston pin snap ring  

Ressort d'arrêt pour axe de piston

 

910400 

060 

Kolbenring mit O-Ring

 

Gasket with O-ring  

Joint  d'étanchéité  avec  joint 
torique

 

910600 

061 

Zylinder

  

Cylinder  

Cylindre

 

910610 

063 

O-Ring Gehäuse-Zylinder

 

Housing - cylinder head O-ring  

Joint torique cylindre carter

 

910440 

064 

Zylinderdeckel

 

Cylinder cover 

 

Couvercle de cylindre

 

910640 

065 

Ölabstreifring mit O-Ring 

Wiper ring with O-ring  

Segment  racleur  avec  joint 
torique

 

910650 

066 

Rohrverschraubung Einlaß 

Intake threaded elbow joint  

Raccord vissé admission

 

910460 

067 

Rohrverschraubung Auslaß 

Exhaust threaded elbow joint  

Raccord vissé échappement

 

910670 

068 

Zylinderkopfschrauben 

Cylinder head bolts  

Vis de tête de cylindre

 

910490 

069 

Ventileinsatz

  

Valve seat  

Boisseau

 

910690 

070 

Einlaßventil

  

Intake valve  

Soupape d'admission

 

910700 

071 

Einlaßventilfeder

 

 

Intake valve spring  

Ressort soupape d'admission

 

910710 

072 

Auslaßventil

 

 

Exhaust valve  

Soupape d'échappement

 

910720 

073 

Auslaßventilfeder

 

 

Exhaust valve spring  

Ressort soupape d'échappement

 

910730 

074 

O - Ring Zylinder-Zylinderkopf

 

 

Cylinder - cylinder head O-ring  

Joint  torique  cylindre  tête  de 
cylindre

 

910740 

075 

O  -  Ring  Zylinderkopf-Ven-
tileinsatz 

Cylinder - valve seat O-ring  

Joint torique tête de cylindre bois-
seau

 

910750 

 

F

 

 

 
Ölfüllstutzen 

und 

Gehäusedruckausgleich

 

 

 
Oil filler tube and housing pres-
sure equalization 

 

Tube de remplissage d'huile et 
système d'équilibrage de pres-
sion du carter

 

 

077 

Ölfüllrohr

 

Oil filler neck  

Tube de remplissage d'huile

 

910760 

078 

Steckverbinder gerade

 

Connector, straight 

Connecteur, droit

 

910780 

079 

Entlüftungsschlauch

 

Ventilation tubing  

Tube souple de mise à l'air libre 

910790 

080 

Peilstab

 

dipstick  

jauge d'huile

 

910800 

081 

Gummiring

 

Rubber ring  

Anneau de plastique

 

910810 

 

G

 

 

 
Zwischenkühler, 

Nachkühler 

und Überdruckventile

 

Intercooler  and  aftercooler 
Safety valves

 

Radiateur  intermédiaire,  radia-
teur  postérieu  et  Clapets  de 
surpression

 

 

082 

Zwischenkühler 1. zu 2. Stufe 

 

Intercooler 1st to 2nd stage  

Radiateur  intermédiaire  1er  au 
2ème étage 

 

910820 

083 

Zwischenkühler 2. zu 3.  

Intercooler 2nd to 3rd stage  

Radiateur intermédiaire 2ème au 
3ème 

 

910830 

084 

Nachkühler 3. Stufe 

 

Aftercooler 3rd stage 

 

Radiateur  postérieur  du  3ème 
étage

 

910840 

085 

Überdruckventil  1.  Stufe  10-16 
bar 

Safety valve 1st stage 10-16 bar   Clapet  de  surpression  1er  étage 

10 - 16 bar

 

910850 

086 

Kondensatabscheider 

condensate separator 

séparateur de condensat

 

910860 

087 

Steckverbinder, winklig

 

Connector, angle 

Connecteur, angle

 

910870 

090 

Überdruckventil 2. Stufe 30-60bar 

Safety valve 2nd stage 30-60bar   Clapet  de  surpression  2ème 

étage 30 - 60 bar

 

910900 

091 

Rohrverschraubung  

Threaded elbow joint  

Raccord vissé 

 

910910 

092 

Verbindungsrohr Filter

 

Connecting pipe Filter

 

Tube de filtrante

 

910920 

 

H

 

 

 
Antrieb und Kühlventilator

 

 
Engine and cooling fan 

 

 
Moteur et ventilateur

 

 

095 

Keilriemenscheibe 

 

Flywheel disk  

Poulie de la courroie trapézoïdale 

 

910950 

096 

Inbusschraube 

Allen stud screw  

Vis sans tête

 

910960 

097 

Paßfeder

  

Adjustment spring  

Ressort d'ajustage

 

910970 

Summary of Contents for KT-90A

Page 1: ...Komptec GmbH KT 90A User Manual v1 0a 8 May 2016 Page 1 of 52 KT 90A HIGH PRESSURE AIR COMPRESSOR User Manual...

Page 2: ...Examples of training topics 10 1 12 Symbols Used 10 2 Product Description 12 2 1 Intended Use 12 2 2 Construction 12 2 2 1 Air Filter 12 2 3 Optional Equipment 13 2 3 1 Block Heater for operation belo...

Page 3: ...ng Hose 27 8 2 Adjusting and Setting 28 8 2 1 Operation 28 8 2 1 1 Starting the Motor 28 8 2 1 2 pressure buildup 29 8 2 1 3 To Fill the pressure cylinder 29 8 2 1 4 Condensate Drain 30 8 2 1 5 Turnin...

Page 4: ...Komptec GmbH KT 90A User Manual Page 4 of 52 v1 0a 8 May 2016...

Page 5: ...s than 5 C run for 5 minutes with output open with no pressure vessel attached then turn off Open Condensate Screws and drain condensate Close Output Fill Valve Attach Pressure Vessel to be filled Tur...

Page 6: ...rized to work on the compressor must have read the operating instruc tions The compressor has been built according to state of the art and recognized safety regulations Nevertheless it can be hazardou...

Page 7: ...O WARRANTY ORAL OR WRITTEN EXPRESED OR IMPLIED OTHER THAN THE ABOVE WARRANTY IS MADE WITH REGARD TO THIS KOMPTEC PROD UCT KOMTEC DISCLAIMS ANY IMPLIED WARRANTY OF MERCHATABIL ITY OR FITNESS FOR A PART...

Page 8: ...sure the manual is given to other users or subsequent owners in the event of resale keep the manual in good condition and ensure its contents remain undamaged do not remove tear or re write any part o...

Page 9: ...operator Any failure to comply with the safety instructions in this manual or on the compressor can result in injury or death Read the KOMPTEC Instruction Manual All compressor operators mainte nance...

Page 10: ...e operating elements Explanation of the operating instructions for the operating personnel Special experience of the operator in handling the compressor The use of input materials tools and auxiliary...

Page 11: ...of 52 v1 0a 8 May 2016 Danger Specifications or instructions and prohibitions to prevent personal injury or substantial property damage Mark for performing an action by the operator Enumeration Hint U...

Page 12: ...perating instructions and comply with the inspection and maintenance schedules The KT90A is tailored to the specific requirements of filling air tanks Its construction has been designed for this purpo...

Page 13: ...acked and must be used within for 24 months of their seal date Once the cartridge is removed from its vacuum pack and put into service it has a one year life independent of compressor usage 2 3 Option...

Page 14: ...lter is incorpo rated in the housing for the KT 90A In the gasoline version of the KT 90 an intake filter must be mounted in the lid of the com pressor when used for com pressing breathing air The int...

Page 15: ...mpressor and per form maintenance and repairs the personnel are regularly instructed in all applicable questions regarding occupa tional safety and environmental protection and knows the operating ins...

Page 16: ...ly identified Only authorized personnel should operate the compressor Make sure that training must be performed by an experienced person Work on electrical equipment of the compressor may only be perf...

Page 17: ...work Cleaning of flexible hoses connections and fittings at the beginning of maintenance is important Aggressive or flammable cleaning agents should not be used Before cleaning the compressor cover al...

Page 18: ...Hazard statements for dealing with the filter and pressure vessels Never remove reservoir cap or pipe connection parts under pressure The KT 90A has a container filter for dynamic load This pressure v...

Page 19: ...er from heat generated by the exhaust of the Internal Combustion Engine Wait 30 minutes after switching off the engine before carrying out maintenance work Danger derived from the noise emitted by the...

Page 20: ...DIN EN ISO 13857 2008 DIN EN 1012 1 2010 DIN EN 60204 1 2006 Angewendete nationale Normen und technische Spezifikationen AD 2000 Merkbl tter TRG 400 Technische Regeln Druckgase Abs F llanlagen TRG 401...

Page 21: ...on Stroke 17 mm Piston Speed 0 5 m sec Intermediate pressure 1st stage 7 bar Intermediate pressure 2nd stage 45 bar 5 3 compressor oil Compressor oil capacity 300 ml Oil type CL751 Komptec 5 4 Connect...

Page 22: ...2 Air Intake Hose 3 1st Compressor Stage 4 Intercooler 5 1st Stage Pressure Relief Valve 6 2nd Compressor Stage 7 Intercooler 8 2nd Stage Pressure Relief Valve 9 3rd Compressor Stage 10 Aftercooler 11...

Page 23: ...ed to its destination and assembled on site If required the compressor is preserved and packed Transport damage must be reported immediately For transportation if necessary appropriate lifting tools a...

Page 24: ...that near the intake point are no motor vehicles with the engine running l Physical Do not operate near open flames fumes 6 3 Placement Place the unit on a firm surface Place the unit horizontally Sp...

Page 25: ...pressor with the filling valve open for a few minutes To prevent fire hazards and to ensure adequate ventilation place the compressor in operation in at least 0 5m from buildings and other equip ment...

Page 26: ...rst start that all tools and foreign objects were removed from the compressor For three phase motors check the motor rotation direction prior to operation Also read the chapter General safety instruct...

Page 27: ...only be used according to its intended use Also read the chapter General safety instructions 8 1 Description of the controls 8 1 1 Compressor 1 Filter Unit 2 Condensate drain pipe 3 Drain Screw 4 Fil...

Page 28: ...ed Only approved and current air receivers and air tanks DOT T V etc should be filled Only compressed air containers and bottles that are approved for the in tended operating pressure filling pressure...

Page 29: ...a 8 May 2016 After being moved Following this warm up period proceed with item 2 above 8 2 1 2 pressure buildup 1 Build up pressure to 100 bar 8 2 1 3 To Fill the pressure cylinder 1 Open filling valv...

Page 30: ...ter and compressor oil Cloth and condensate must be disposed of in accordance with local laws and regulations to ensure ap propriate places Opening the condensate drain plug too quickly may cause icin...

Page 31: ...compressor disassemble the in take filter and add a few drops of oil so that a light film of lubricant is aspirated and penetrates the interior of the compressor Stop the compressor and refit the inta...

Page 32: ...ve Action Compressor does not reach pres sure Leaking pipe or condensate drain Retighten cylinder connection or drain screws Cartridge defective Check Reduced air deliver Dirty intake filter Clean int...

Page 33: ...e Check fuses Engine failure Replace motor Fuses blow when engine turned on Wrong size fuses Replace fuses Short circuit in electrical sys tem Have it checked by a specialist Compressor becomes noisy...

Page 34: ...work on the electrical equipment of the compressor may be basically carried out only by trained electrical specialists All non recycled fuels lubricants and additives must be disposed of in an environ...

Page 35: ...hange O rings on the cylinder cover Clean the filter unit Check safety valve check exhaust Check all operation and leaks Change intake filter Replace piston rings Check tightness of all cooler and con...

Page 36: ...Komptec GmbH KT 90A User Manual Page 36 of 52 v1 0a 8 May 2016 10 2 Filter changing log Date Hours Sum Date Hours Sum...

Page 37: ...the compressor when refilling the oil If the compressor is operated with too little or too much oil this can cause serious damage to the compressor Only use the recommended oil section 4 3 because ot...

Page 38: ...3 Unscrew the air filter cover Use an appropriate tool such as an Allen wrench 4 Extraction Tool for fil ter cartridge screw 5 Remove filter cartridge 6 Insert new filter cartridge 7 Check O rings for...

Page 39: ...4 Carefully put the Com pressor on its side 5 Open oil drain plug with 6mm Allen key 6 Screw in oil drain pipe 7 Place a container under neath 8 Raise compressor slowly 9 Raise compressor slowly 10 Un...

Page 40: ...Komptec GmbH KT 90A User Manual Page 40 of 52 v1 0a 8 May 2016 10 3 4 Final pressure gauge check 1 The end of the pressure gauge must be located in the unpressurized state to the 0 position...

Page 41: ...Komptec GmbH KT 90A User Manual Page 41 of 52 v1 0a 8 May 2016 86 87 87 79 87 80 77 79 Figure 1 Exploded View 2016 KompTec GmbH...

Page 42: ...Komptec GmbH KT 90A User Manual Page 42 of 52 v1 0a 8 May 2016 Figure 2 Crankshaft with Pistons 2016 KompTec GmbH...

Page 43: ...Komptec GmbH KT 90A User Manual Page 43 of 52 v1 0a 8 May 2016 Figure 3 First Stage 2016 KompTec GmbH...

Page 44: ...Komptec GmbH KT 90A User Manual Page 44 of 52 v1 0a 8 May 2016 86 87 Figure 4 Second Stage 2016 KompTec GmbH...

Page 45: ...Komptec GmbH KT 90A User Manual Page 45 of 52 v1 0a 8 May 2016 Figure 5 Third Stage 2016 KompTec GmbH...

Page 46: ...Komptec GmbH KT 90A User Manual Page 46 of 52 v1 0a 8 May 2016 78 80 5 77 79 0 79 87 0 6 87 87 0 81 0 78 Figure 6 Crankcase 2016 KompTec GmbH...

Page 47: ...Komptec GmbH KT 90A User Manual Page 47 of 52 v1 0a 8 May 2016 Figure 7 Filter Housing 2016 KompTec GmbH...

Page 48: ...stage 2 me tage du compres seur E 3 Verdichterstufe 3rd compressor stage 3 me tage du compres seur F lf llstutzen und Geh use Druckausgleich Oil filler tube and housing pressure equalization Tube de...

Page 49: ...1er tage 910190 020 1 Kolbenbolzen Piston pin Axe de piston 910200 021 2 Sicherungsringe f r Kol benbolzen Piston pin snap ring Anneaux d arr t pour axe de pis ton 910210 022 1 Kolbenring mit O Ring...

Page 50: ...ilfeder Intake valve spring Ressort soupape d admission 910710 072 1 Ausla ventil Exhaust valve Soupape d chappement 910720 073 1 Ausla ventilfeder Exhaust valve spring Ressort soupape d chappement 91...

Page 51: ...ch Adapter cooling fan Ventilateur 911010 102 1 Pa feder Adjustment spring Ressort d ajustage 911020 104 1 Senkschraube Sink bolt 911040 105 3 Sechskantschrauben Hex screws Vis t te hexagonale 911050...

Page 52: ...c Kompressoren Technik GmbH Gutenbergring 3 63110 Rodgau Telefon 49 0 6106 2661787 Telefax 49 0 6106 2662829 Email kontakt komptec de Service Komptec Kompressoren Technik GmbH Gutenbergring 3 63110 Ro...

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