Komptec KT-90E User Manual
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Komptec KT-90E User Manual

High pressure air compressor 60hz
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KT-70E/KT-90E/KT-70SE
H
P
A
C
IGH
RESSURE
IR
OMPRESSOR
User Manual
(60Hz Version)
KT-70E / KT-90E / KT-70SE User Manual
Page 1 of 59
24 April 2018

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Summary of Contents for Komptec KT-90E

  • Page 1 KT-70E/KT-90E/KT-70SE RESSURE OMPRESSOR User Manual (60Hz Version) KT-70E / KT-90E / KT-70SE User Manual Page 1 of 59 24 April 2018...

  • Page 2: Table Of Contents

    Principle; Intended Use ..................... 18 3.2.2. Responsibility ......................18 3.2.3. Personnel selection and qualification; fundamental obligations ......... 19 3.2.4. Safety instructions for certain operating phases ............19 KT-70E / KT-90E / KT-70SE User Manual Page 2 of 59 24 April 2018...
  • Page 3 Waste Disposal ......................36 Troubleshooting ........................37 9.1. Tabular overview of possible malfunctions and suggestions to help eliminate the fault..37 9.1.1. List of Faults ......................37 KT-70E / KT-90E / KT-70SE User Manual Page 3 of 59 24 April 2018...
  • Page 4 Figure E. Third Stage Cylinder ..................... 51 Figure F. Oil filler tube and housing pressure equalization ............52 Figure G. Filter Housing ....................... 53 Figure H. Casing ........................... 54 KT-70E / KT-90E / KT-70SE User Manual Page 4 of 59 24 April 2018...

  • Page 5: Introduction

    • If the compressor will be out of use for an extended period, run the compressor with both condensate fill valves open for a minimum of 1 minute. KT-70E / KT-90E / KT-70SE User Manual Page 5 of 59 24 April 2018...
  • Page 6 • Once a year or every 500 operating hours change the crankcase oil. • Check the oil level before each use. ATTENTION in case of malfunction, depressurize compressor and remove power KT-70E / KT-90E / KT-70SE User Manual Page 6 of 59 24 April 2018...

  • Page 7: Foreword

    1.2. Foreword Dear Customer, Thank you for choosing the KT-70E / KT-90E / KT-70SE This manual is an aid to successful and safe operation of the compressor. These materials are only for information purposes. Changes may be made without prior notice. Please refer to the manual for compliance to regulations, for accident prevention and environmental protection.

  • Page 8: Warranty

    1.4. Warranty We warranty to the original owner of the KT-70E / KT-90E purchased from Komptec as new will be free from manufacturing defects in materials and workmanship under normal use within a period of (1) one year from date of purchase for an end user, or (90) ninety days for a commercial user, provided it is operated and maintained according to instruc- tions and the user manual.

  • Page 9: Required Operator Training

    • In the event of damage caused by not complying with the above listed points, Komptec GmbH is not liable. The warranty and liability claims or general terms and conditions of Komptec GmbH are not changed by the guidelines listed above.

  • Page 10: Customer Service

    (e.g. acquired during training courses run by the manufacturer). 1.9. Customer service For technical information about Komptec’s products and their systematic application, please contact customer service. Should you have any questions about our products, please call our customer service de- partment.

  • Page 11: Examples Of Training Topics

    1.12. Symbols Used In the manual, the following terms and symbols for particularly important information are used: information Special information regarding the economical use of the machine KT-70E / KT-90E / KT-70SE User Manual Page 11 of 59 24 April 2018...
  • Page 12 Specifications or instructions and prohibitions to prevent personal injury or substantial property damage Mark for performing an action by the operator ● Enumeration Hint Useful hints and tips for the operator KT-70E / KT-90E / KT-70SE User Manual Page 12 of 59 24 April 2018...

  • Page 13: Product Description

    The 2.5 CFM KT-70E and KT-70SE are tailored to the specific requirements of filling air tanks of up to 20L. The 3.2 CFM KT-90E is suited for filling air tanks of up to 45L. Their construction has been designed for this purpose.

  • Page 14: Construction

    • On-off switch 2.3. Optional Equipment The KT-70E and KT-90E are offered as one of three configurations, based on the intended use, and the user’s budget. • Base Configuration: (Base Option) The base configuration groups together the pres- sure gauge, safety valve, and DIN connector on the end of the fill hose. After filling, pressure is relieved in the fill hose as part of the process of draining the condensate, by opening the final condensate drain.

  • Page 15: Automatic Shut-Off

    (Not available with KT-70SE) 2.3.4. Automatic Condensate Drain. If configured, the Automatic Condensate Drain (ACD) will bleed off the condensate into a separate container on a defined interval. KT-70E / KT-90E / KT-70SE User Manual Page 15 of 59 24 April 2018...

  • Page 16: Functional Description

    1 m above the compressor. port. See optional filling unit description in sec. 8.1.2 KT-70E / KT-90E / KT-70SE User Manual Page 16 of 59 24 April 2018...

  • Page 17: Pneumatic Air Flow

    This avoids the creation of a high velocity path thru the filter material. Con- stant air velocity permits optimum effectiveness of and utilization of the molecular sieve material KT-70E / KT-90E / KT-70SE User Manual Page 17 of 59 24 April 2018...

  • Page 18: General Safety

    3.1. Obligation of diligence To ensure maximum working efficiency, Komptec has constructed the compressor with carefully selected components and materials. The compressor is tested prior to delivery. Continued compressor efficiency over time will also depend on proper use and mainte- nance as per the instructions contained in this manual.

  • Page 19: Personnel Selection And Qualification; Fundamental Obligations

    In case of malfunction, the compressor must be shut down immediately and secured! Faults must be eliminated immediately! Before switching on / starting the compressor, make sure that nobody can be endangered by the compressor. KT-70E / KT-90E / KT-70SE User Manual Page 19 of 59 24 April 2018...
  • Page 20 Necklaces, bracelets and rings can be a source of danger Workplace lighting must be adequate for the work in progress. Insufficient or excessive lighting can generate risks. KT-70E / KT-90E / KT-70SE User Manual Page 20 of 59 24 April 2018...

  • Page 21: Notes On Special Types Of Hazard

    Hazard statements for dealing with the filter and pressure vessels Never remove reservoir cap or pipe connection parts under pressure. The KT-70E / KT-90E has a container (filter) for dynamic load. This pressure vessel may be operated under varying operating pressure. The pressure may vary between the atmos- pheric and the maximum operating pressure.
  • Page 22 Risk from contact with the drive belt Risk from contact with the cooling fan Danger of contact with the hose should the hose break during cylinder refill. KT-70E / KT-90E / KT-70SE User Manual Page 22 of 59 24 April 2018...

  • Page 23: Eg-Konformitätserklärung

    Daten und den bestimmungsgemäßen Gebrauch haben, die Maschine also wesentlich verän- dern, machen diese Konformitätserklärung ungültig! Rodgau, Januar 2015 Ort, Datum (Unterschrift) Michael Wittmann, Technische Betriebsleitung KT-70E / KT-90E / KT-70SE User Manual Page 23 of 59 24 April 2018...

  • Page 24: Technical Specifications

    81 dB (A) Note. The 115V 2HP motor is rated at 15A, however measured inrush current exceeds 20A, requir- ing the use of a 30A service. KT-70E / KT-90E / KT-70SE User Manual Page 24 of 59 24 April 2018...
  • Page 25 Power 6.5 HP Rotation Left For further details, refer to the Motor’s operating manual Noise level 86 dB (A) Note, supplier for Gasoline Engine may vary. KT-70E / KT-90E / KT-70SE User Manual Page 25 of 59 24 April 2018...

  • Page 26: Pneumatic Flow Diagram - Base Configuration

    12. Condensation Absorber 13. Active Coal Granulate 14. Felt Disk 15. Moisture Absorption Granulate 16. Filling Armature 17. Safety Valve 18. Intermediate Condensate Collector and Drain KT-70E / KT-90E / KT-70SE User Manual Page 26 of 59 24 April 2018...

  • Page 27: Transport And Installation

    0.5 m. Outdoor Installation: Provide aggregate on firm surface and up horizontally Make sure that near the intake point are no motor vehicles with the engine running. KT-70E / KT-90E / KT-70SE User Manual Page 27 of 59 24 April 2018...

  • Page 28: Placement

    0.5m from buildings and other equip- ment. Do not bring any flammable materials are Nourish the compres- sor. Superstructures or operation in crates or the like is not permitted. KT-70E / KT-90E / KT-70SE User Manual Page 28 of 59 24 April 2018...

  • Page 29: Start-Up

    The oil level should be at the middle mark on the dipstick, or higher. Check filter system for damage and completeness. Insert the filter car- tridge. All protective devices must be correctly fitted. KT-70E / KT-90E / KT-70SE User Manual Page 29 of 59 24 April 2018...

  • Page 30: Operation

    Configurations 1 and 2 1 Fill Hose Connection 2 Safety Valve 3 Minimum Pressure Valve 4 Auto Shut-Off KT-70SE 1. Fill Valve 2. Safety Valve 3. Bleed Screw KT-70E / KT-90E / KT-70SE User Manual Page 30 of 59 24 April 2018...

  • Page 31: Filling Hose

    200 bar or DIN 300 bar 2 Bleed Valve 3 Fill Valve 4 Gauge KT-70SE Fill Hose connects to output of Fill Valve and has a Quick Disconnect fitting KT-70E / KT-90E / KT-70SE User Manual Page 31 of 59 24 April 2018...

  • Page 32: Adjusting And Setting

    Carry out the instructions as described in Chapter 7.2 Connect the Spark Plug and add gasoline (for gas motor version) Note the speed of the gas motor is set by Komptec and is not adjustable Pay attention to the condition of the cylinders, pressure vessels and valves! Cylinders and pressure vessels which have defects, which can endanger third parties may be endangered, shall not be filled.

  • Page 33: Pressure Buildup

    Units with Minimum Pres- (on compressor, on hose or monitored !! sure Valves should open fill- on target cylinder) ing valve prior to pressure reaching MPV setting KT-70E / KT-90E / KT-70SE User Manual Page 33 of 59 24 April 2018...

  • Page 34: Condensate Drain

    Auto Shut-Off, compressor will stop when target pressure is reached 1. Upon reaching the set air 2. The compressor stops. pressure, switch to “O” or “OFF” KT-70E / KT-90E / KT-70SE User Manual Page 34 of 59 24 April 2018...

  • Page 35: Complete The Filling Process

    8.3. Filter • ONLY the filter cartridges provided by Komptec may be used! • Filter part numbers are listed in section 10.1 • Modifying the filter system in any way is prohibited! •...

  • Page 36: Extended Storage

    Deteriorated or obsolete ma- chines are also classified as special waste. Waste oil must be disposed of in compliance with local ordinances. KT-70E / KT-90E / KT-70SE User Manual Page 36 of 59 24 April 2018...

  • Page 37: Troubleshooting

    Verify gasket on intermediate drain screw did not create block- age. KT-70E / KT-90E / KT-70SE User Manual Page 37 of 59 24 April 2018...
  • Page 38 Compressor becomes noisy v-belt not tightened Tighten belts Gas motor does not start See manual for Gas Motor Contact the manufacturer for issues not listed. KT-70E / KT-90E / KT-70SE User Manual Page 38 of 59 24 April 2018...

  • Page 39: Maintenance

    10.1. Consumable Parts Description Item Number Air Filter – Breathing Air K310100 Air Filter – Non-Breathing Air, for Construction or Air Gunners K319100 Oil, CL751, 1 liter K320400 KT-70E / KT-90E / KT-70SE User Manual Page 39 of 59 24 April 2018...

  • Page 40: Maintenance Plan

    Date Signature Oil change 10.4.3 Change O-rings on the filter Change O-rings on the cylinder cover Clean the filter unit Check safety valve 10.4.5 check exhaust KT-70E / KT-90E / KT-70SE User Manual Page 40 of 59 24 April 2018...
  • Page 41 10.4.3 Change O-rings on the filter Change the filter Clean the filter unit Check the safety valve Check exhaust Check all operation and check for leaks KT-70E / KT-90E / KT-70SE User Manual Page 41 of 59 24 April 2018...

  • Page 42: Filter Changing Log. Please Top Off The Crankcase Oil Each Time The Air Filter Is Changed

    10.3. Filter changing log. Please top off the crankcase oil each time the air filter is changed. Date Hours Date Hours KT-70E / KT-90E / KT-70SE User Manual Page 42 of 59 24 April 2018...

  • Page 43: Maintenance Work

    Such syringes are readily available from medical supply stores, or on-line. Measuring 50ml of oil with this technique both lets you know how much oil was added, and prevents spilling oil onto the compressor. KT-70E / KT-90E / KT-70SE User Manual Page 43 of 59 24 April 2018...

  • Page 44: Filter Change. Please Top Off The Crankcase Oil Each Time The Air Filter Is Changed

    8. Clean the thread on the filter 9. Tighten the filter cover by damage, replace if nec- lid and and lubricate with hand essary silicone grease. KT-70E / KT-90E / KT-70SE User Manual Page 44 of 59 24 April 2018...

  • Page 45: Oil Change

    8. Raise compressor slowly 11. Drain oil into collection 15. Check oil level with the basin dipstick. 12. Remove oil drain pipe 13. Replace oil drain plug KT-70E / KT-90E / KT-70SE User Manual Page 45 of 59 24 April 2018...

  • Page 46: Final Pressure Gauge Check

    “on” button to override the auto shut off. 10.4.6. Other Maintenance Notes • When replacing heads on the compressor cylinders, re-torque the bolts to a torque of 10nm. KT-70E / KT-90E / KT-70SE User Manual Page 46 of 59 24 April 2018...

  • Page 47: Break-Out Drawings

    11. Break-out Drawings Figure 4. Exploded View KT-70E / KT-90E / KT-70SE User Manual 24 April 2018 Page 47 of 59...
  • Page 48 Figure E. Crankshaft with Piston Rods KT-70E / KT-90E / KT-70SE User Manual 24 April 2018 Page 48 of 59...
  • Page 49 Figure F. First Stage Cylinder KT-70E / KT-90E / KT-70SE User Manual Page 49 of 59 24 April 2018...
  • Page 50 Figure 7. Second Stage Cylinder KT-70E / KT-90E / KT-70SE User Manual Page 50 of 59 24 April 2018...
  • Page 51 Figure 8. Third Stage Cylinder KT-70E / KT-90E / KT-70SE User Manual Page 51 of 59 24 April 2018...
  • Page 52 Figure 9. Oil filler tube and housing pressure equalization KT-70E / KT-90E / KT-70SE User Manual Page 52 of 59 24 April 2018...
  • Page 53 Figure 10. Filter Housing KT-70E / KT-90E / KT-70SE User Manual Page 53 of 59 24 April 2018...
  • Page 54 Figure K. Casing KT-70E / KT-90E / KT-70SE User Manual Page 54 of 59 24 April 2018...
  • Page 55 2nd compressor stage 3rd compressor stage Oil filler tube and housing pressure equalization Intercooler, aftercooler and Safety valves Engine and cooling fan. See figure B Casing KT-70E / KT-90E / KT-70SE User Manual Page 55 of 59 24 April 2018...
  • Page 56 Exhaust valve 910530 Exhaust valve spring 910540 Cylinder - cylinder head O-ring 910550 Cylinder - valve seat O-ring 910560 3rd Compressor stage Piston - 3rd stage 910570 KT-70E / KT-90E / KT-70SE User Manual Page 56 of 59 24 April 2018...
  • Page 57 Nuts M6 x 10 113a Washer Screw M6 x 10 stiffening profile handle Side panel motor Cover motor Screw M8 x 80 119a Washer Screw M5 x 10 KT-70E / KT-90E / KT-70SE User Manual Page 57 of 59 24 April 2018...
  • Page 58 Screw M8 x 10 121a Washer Attention! Not all parts are available separately. Please contact Customer Service for information on parts sets that are supported. KT-70E / KT-90E / KT-70SE User Manual Page 58 of 60 24 April 2018...
  • Page 59 Telefax: + 49 (0) 6106 2662829 Email: kontakt@komptec.de Service: Komptec Kompressoren Technik GmbH Gutenbergring 3 63110 Rodgau Telefon: + 49 (0) 6106 2661787 Telefax: + 49 (0) 6106 2662829 Email: technik@komptec.de KT-70E / KT-90E / KT-70SE User Manual Page 59 of 59 24 April 2018...

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Kt-70seKt-70e

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