Pilotair K100 Datenblatt

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INSTRUCTION AND PARTS LIST

MODEL: K100

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USER GUIDE

Congratulations on the purchase of a PILOT air compressor. This

unit has been designed to provide reliable and trouble free usage

in servicing your compressed air requirements.

Please take a moment to familiarise yourself with the

information contained in the following sections of this guide

before attempting to operate this unit.

LOCATION OF UNIT

For optimum efficiency locate unit in a clean, dry and cool

environment with good ventilation. Avoid placing obstacles

either on or around unit to facilitate maximum air flow and

cooling.

CHECK OIL LEVEL BEFORE USE IN CASE OF LOSSES

INCURRED DURING SHIPPING

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OPERATION

ELECTRIC UNITS

Ensure ON/OFF switch is located on the pressure switch is in an

OFF position (down), before inserting power plug into appropriate

power point and applying power.

Unit can then be switched on using the ON/OFF switch. The

pressure switch will automatically start and stop the compressor

when the air receiver drops below or reaches factory set cut-in

and cut-out pressures respectively.

ALWAYS SWITCH UNIT ON AND OFF VIA

PRESSURE SWITCH TO ENSURE THE UNIT

DOES NOT START AGAINST HIGH PRESSURE

TO PREVENT DAMAGE TO UNIT OR PERSONS DO NOT

ATTEMPT TO MODIFY, BYPASS OR REMOVE PRESSURE

SWITCH OR SAFETY VALVE IN ANY WAY.

“TM” OR “K” SERIES ARE DESIGNED TO OPERATE TO

A MAXIMUM PRESSURE OF 10 BAR.

The air receiver is equipped with a safety valve to release

pressure in the event of a pressure switch cut-out failure. To

prevent damage to the unit, do not attempt to modify, bypass or

remove the pressure switch or safety valve in anyway.

The motor features a manual overload protection (where fitted).

In poor power conditions or motor over temperature conditions,

this overload protector will cut power to the motor. To reset,

wait for the motor to cool then press reset button. If problems

persist, check for power ratings, faulty power or poor

connections.

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PETROL /DIESEL DRIVEN UNITS

Please refer to OEM documentation in reference to care and

operation of your petrol/diesel engine.

This unit has been designed to “idle down” to minimum operating

speeds when factory set cut-out pressures are reached. This

saves both fuel consumption and wear on moving parts. When

pressure drops to set cut-in pressures the unit will automatically

resume pumping at normal operating speeds.

To facilitate easy starting of the unit and to ensure no damage to

the electric starter (where fitted) always open the “EASY START”

valve until the unit is operating and then close for normal

operation. This valve is located on the motor/pump platform

(models K25P,K30P) or in the discharge pipe from the pump to

the air receiver (other models).

SAFETY

Pressure vessels (air receivers) are a type of plant,

and as such, MAY be required to be registered with

the relevant statutory authority in your state.

Regulations regarding plant registration vary from

state to state. Check with your relevant government

authority about plant registration.

Compressed air can be dangerous. Never point

compressed air tools or equipment towards another

person.

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After use, drain all residual air pressure or engage

outlet tap to prevent accidental discharge by children.

Keep clear of compressor pump during and after

operation. Heat build up in the pump may cause burns

to unwary.

Never operate the unit without factory fitted belt

guard.(belt drive models) or pump shroud (direct drive

models).

Never operate the unit with damaged or exposed

electrical wiring.

Do not alter, adjust or remove any components on the

unit without technical support from Pilot Air or an

authorised Pilot Air agent

Whenever transporting an air compressor, ensure all

air is drained from the air receiver. There should be NO

residual air pressure in the air receiver.

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MAINTENANCE INSTRUCTIONS

•Check that fuses or circuit breakers correspond to motor rating. In

case of 415-Volt units, check rotation as indicated by arrow

attached to unit. On 240-Volt units, avoid using extension leads as

they could cause voltage drop and power loss to motor. If extension

is to be used, please follow the table below.

TABLE 1.

KW HP VOLTS RECOMMENDED WIRE SIZE

1.65 2.25 240 HEAVY DUTY, 1.5MM SQUARE WIRE (MAX LENGTH 20 M)

2.20 3.00 240 HEAVY DUTY, 1.5MM SQUARE WIRE (MAX LENGTH 10 M)

•Oil level should be at the centre of the oil sight glass on the

compressor pump. Do not overfill as this could cause excessive oil

being expelled from the crank case breather.

•Oil is to be replaced every 1000 working hours or on a six (6)

monthly basis. Recommended oil:

•PILOT PCO-40G or equivalent (Stationary models).

•PILOT PCO-30G or equivalent (Portable models).

Note: In humid and/or very low duty cycle environments,

condensate may collect in the sump. Under these conditions, it is a

requirement that the operator drain the residual water from the

sump on a regular basis and/or change the oil more frequently than

recommended above.

•Whenever transporting an air compressor, ensure all air is drained

from the air receiver. There should be NO residual air pressure in

the air receiver.

•Routine maintenance should be performed on at least a six (6)

monthly basis.

•Condensation must be drained from air receiver at least weekly.

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•Unit must be kept clean to allow proper cooling to take effect.

Special care should be taken to clean the crankcase breather in

order to allow proper crankcase breathing.

•Whenever attempting to carry out any maintenance to compressors,

isolate power and release all pressure from receiver.

•For information regarding spare parts and/or service, please always

quote model and serial number.

•PLEASE KEEP THIS INFORMATION NEAR MACHINE, SO IT CAN BE

READ BY ANYONE ATTEMPTING PREVENTATIVE MAINTENANCE.

DO NOT BOLT COMPRESSOR DIRECTLY ONTO FLOOR. THIS MAY CAUSE

CRACKS IN THE AIR RECEIVER. IF THE COMPRESSOR MUST BE BOLTED,

ENSURE RUBBER VIBRATION PADS ARE IN PLACE AND FASTEN, LEAVING

A GAP BETWEEN BOLT HEAD OR NUT AND COMPRESSOR FOOT TO AVOID

ANY METAL TO METAL CONTACT.

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COMPRESSOR COMPONENT DESCRIPTIONS

•PRESSURE SWITCH (240V & 415V models only): This switch is

located on the top of the air receiver and functions as a manual

on/off switch in addition to automatically stopping and starting the

compressor at factory pre-set pressures (electric models only).

•PRESSURE GAUGE: The Pressure Gauge is located on the air

receiver and indicates the pressure held in both PSI and KPA.

•SAFETY VALVE: The Safety Valve is located on the air receiver and

is designed to release pressure in the event of a pressure switch

failure.

•OVERLOAD PROTECTION: Electric models are fitted with an

overload protector, to protect the motor in the event of an over

temperature condition. These reset buttons are located either on

the pressure switch or the motor itself.

•CHECK VALVE (240V & 415V models only): The Check Valve is

located at the junction of the pump discharge pipe and the air

receiver. The check valve prevents air pressure returning from the

air receiver to the pump.

•EASY START VALVE: (Petrol/Diesel models only) The Easy Start

Valve is located on the check valve for portable units and on the

compressor platform for stationary units. This valve should be

opened for ease of starting of the engine and closed when running

for normal operation.

•RECEIVER DRAIN: The Receiver Drain is located at the underside of

the air receiver and is used for draining condensate from the

receiver.

•OIL SIGHT GLASS: The Oil Sight Glass is located on the side of the

compressor pump (opposite the flywheel) and is used for examining

the oil level of the unit.

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K100 PUMP

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Pos Component MU Multiplier

$33106000

CASING

1,0

$31604010

CYLINDER

2,0

SP61400

HEAD

2,0

SP61200

SHAFT

1,0

SP81000

AIR FILTER K50-K100-NB

2,0

$30406060

FRONT COVER

1,0

$30406050

CASING REAR SUPPORT

1,0

$31003760

FLYWHEEL

1,0

$30306020

BALL BEARING 6211 K100

2,0

#012031000

OIL LIGHT

1,0

$36507100

OIL PLUG

1,0

$30306030

SEAL

1,0

$37406090

SCREW FLYWHEEL

1,0

$37501980

WASHER FLYWHEEL

1,0

110

9049020

RELIEF VALVE

2,0

417

$36531140

OIL PLUG

1,0

418

$36504590

PLUG OIL FILLING 3/4"

1,0

900

9434A17

MPK VALVE PLATE (LF)

1,0

900

9434A24

MPK VALVE PLATE (RG)

1,0

901

9434B21

MPK PISTON-CONROD K100

2,0

908

9434E18

MPK AFTERCOOLER K100

1,0

909

9434F18

MPK GASKET K100

1,0

912

9434C20

MPK PISTON RINGS K100

2,0

921

9434D04

MPK INTERCOOLER K50-100

2,0

922

9434H08

MPK MAINTEN.PV K50-100

1,0

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