1. Introduction
This manual provides essential information for the safe and efficient operation, maintenance, and troubleshooting of your Kaishan KS40 3-cylinder industrial piston air compressor. Please read this manual thoroughly before operating the unit.
Figure 1: Kaishan KS40 Industrial Piston Air Compressor
2. Safety Information
Always observe the following safety precautions to prevent injury and damage to the equipment:
- Ensure the compressor is placed on a stable, level surface.
- Verify the power source matches the compressor's voltage requirements (380V/3ph/50Hz).
- Do not operate the compressor in explosive atmospheres or near flammable materials.
- Wear appropriate personal protective equipment (PPE), including eye and ear protection.
- Never direct compressed air at people or animals.
- Before performing any maintenance, disconnect the compressor from the power supply and relieve all air pressure.
- Regularly inspect all hoses, fittings, and connections for wear or damage.
- Keep children and unauthorized personnel away from the operating compressor.
3. Product Overview and Key Components
The Kaishan KS40 air compressor is designed for industrial applications, featuring a robust piston design and efficient operation. Key components include:
- Piston Assembly: Utilizes superior piston rings for durability and sealing.
- Valve: Feather valve adopted for higher efficiency.
- Air Filter: Core made of imported filter paper for effective filtering and moisture absorption.
- Electromagnetic Switch: From famous brands like Schneider.
- Motor: High-efficiency three-phase electric motor (e.g., 380V/3ph/50Hz, 3kW).
- Pulley: Patented fan wheels for improved cooling.
- Air Tank: Storage for compressed air (e.g., 175L capacity).
- Pressure Gauge: For monitoring working pressure.
Figure 2: Key Components of the KS Series Air Compressor
Figure 3: Motor Specification Label
4. Specifications
| Feature | Specification |
|---|---|
| Model Number | KS40 |
| Brand Name | Kaishan |
| Type | Piston |
| Configuration | Portable |
| Power Source | AC Power |
| Lubrication Style | Oil-less |
| Mute | No |
| Voltage | 380V/3ph/50Hz |
| Working Pressure | 8 bar (182 Psi/0.8Mpa) |
| Power | 3 kW |
| Capacity | 400 L/min |
| Air Tank Capacity | 175 L |
| Rotary Speed | 860 r/min |
| Cooling Method | Air Cooling |
| Transmission Way | Belt Driven |
| Dimension (L*W*H) | 1400*510*1120 mm |
| Weight | 230 kg |
| Certification | CE |
| Warranty | 1 Year (on core components: Motor, Pump) |
| Applicable Industries | Manufacturing Plant, Machinery Repair Shops, Retail, Construction work |
5. Setup Instructions
- Unpacking: Carefully remove the compressor from its packaging. Inspect for any shipping damage.
- Placement: Position the compressor on a firm, level surface in a well-ventilated area. Ensure adequate clearance around the unit for air circulation and maintenance.
- Electrical Connection: Connect the compressor to a suitable 380V/3ph/50Hz power supply. Ensure the electrical circuit is properly grounded and protected by a circuit breaker of appropriate rating. Consult a qualified electrician if unsure.
- Initial Inspection: Before first use, check all visible connections, bolts, and belts for tightness. Ensure the air filter is securely in place.
- Drain Valve: Ensure the drain valve on the air tank is closed before operation.
6. Operating Instructions
- Starting the Compressor:
- Ensure all connections are secure and the drain valve is closed.
- Turn on the main power switch to the compressor.
- The compressor will start to build pressure in the air tank. Monitor the pressure gauge.
- The compressor will automatically shut off once the maximum working pressure (8 bar) is reached.
- Using Compressed Air:
- Connect your air tools or equipment to the compressor's air outlet.
- Adjust the pressure regulator (if equipped) to the desired working pressure for your tools.
- The compressor will cycle on and off automatically to maintain pressure as air is consumed.
- Stopping the Compressor:
- Turn off the main power switch.
- Slowly open the drain valve on the air tank to release all remaining air pressure. This is crucial for safety and to prevent moisture buildup.
- Disconnect any air tools.
7. Maintenance
Regular maintenance ensures the longevity and efficient operation of your air compressor. Always disconnect power and relieve pressure before maintenance.
- Daily:
- Drain moisture from the air tank by opening the drain valve.
- Check for any unusual noises or vibrations during operation.
- Weekly:
- Inspect the air filter for dirt and debris. Clean or replace if necessary.
- Check all fasteners and connections for tightness.
- Inspect drive belts for wear and proper tension.
- Monthly / Every 100 Hours:
- Inspect the safety valve for proper operation.
- Clean the exterior of the compressor, especially cooling fins, to ensure efficient air cooling.
- Annual / Every 500 Hours:
- Have a qualified technician inspect the air tank for corrosion or damage.
- Replace the air filter element.
Note: This model is specified as "OIL-LESS", meaning it does not require oil changes for the compressor pump. However, always refer to the specific manufacturer guidelines for any lubrication requirements for other moving parts like motor bearings.
8. Troubleshooting
| Problem | Possible Cause | Solution |
|---|---|---|
| Compressor does not start | No power, tripped circuit breaker, faulty switch, motor overload. | Check power connection, reset breaker, inspect switch, allow motor to cool. |
| Compressor runs continuously | Air leak, faulty pressure switch, worn piston rings. | Check for leaks, inspect/replace pressure switch, consult service for piston rings. |
| Low air pressure/output | Clogged air filter, air leak, worn piston rings, incorrect pressure regulator setting. | Clean/replace air filter, check for leaks, adjust regulator, consult service. |
| Excessive noise or vibration | Loose components, worn bearings, unbalanced pulley. | Tighten fasteners, consult service for internal component inspection. |
| Moisture in air line | Tank not drained regularly, high humidity. | Drain tank daily, consider an inline air dryer for sensitive applications. |
9. User Tips
- For optimal performance, ensure the compressor is always used within its specified working pressure range.
- Regularly check the air filter to prevent dust and debris from entering the compressor, which can reduce efficiency and lifespan.
- When storing the compressor for extended periods, ensure the air tank is completely drained and the unit is disconnected from power.
- Spare parts, such as filter elements, are available. Contact your authorized dealer or the manufacturer for specific needs.
10. Warranty and Support
The Kaishan KS40 air compressor comes with a 1-year warranty on core components (Motor, Pump). For warranty claims, technical support, or spare parts, please contact your authorized dealer or the manufacturer directly.
Manufacturer Information:
- Brand: Kaishan
- Place of Origin: Zhejiang, China
- Company Address (Trading): Room 102, Building 3, No. 12, Bailing Middle Road, Qujiang District, Quzhou, Zhejiang, China.
Figure 4: Product Certifications
11. About Kaishan Group
Founded in 1956, Kaishan Group is a large state-level enterprise, a provincial civilized unit, and a state-level contract-abiding and trustworthy unit. Kaishan Group is recognized as the first enterprise to win the title of "China's Famous Trademark" in the national industry and is also the first enterprise to win the title of "National Inspection-free Products" in the compressor industry.
Figure 5: Kaishan Group Facilities
