pilotair K25 Datasheet

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INSTRUCTION AND PARTS LIST
MODEL: K25

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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).
For Petrol powered units fitted with electric start capability:
Honda Australia recommends the following specification for
wiring to a battery: Max. Cable length: 1.5 M, Cable size: 8
mm/sq. Over 1.5 M in length requires cable size of 15 mm/sq
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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K25 PUMP

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Pos Component MU Multiplier
1
$33104600
CASING
PZ
1,0
2
$31604730SGL
CYLINDER
PZ
1,0
3
SG61400
HEAD
PZ
1,0
4
SG61200
SHAFT
PZ
1,0
23
9434M01
AIR FILTER ASSEMBLY
PZ
1,0
26
$30400830
FRONT COVER
PZ
1,0
27
$30400860
CASING REAR SUPPORT
PZ
1,0
29
$31003080
FLYWHEEL
PZ
1,0
30
$30300030
BALL BEARING 6205 K8-K28
PZ
2,0
32
$36531150
OIL LIGHT
PZ
1,0
33
$36507050
OIL PLUG
PZ
1,0
34
$30300040
SEAL
PZ
1,0
35
$37400720
SCREW FLYWHEEL
PZ
1,0
36
$37500730
WASHER FLYWHEEL
PZ
1,0
417
$36531140
OIL PLUG
PZ
1,0
900
9434A12
MPK VALVE PLATE K25
PZ
1,0
901
9434B16
MPK PISTON-CONROD K25
PZ
1,0
908
9434E08
MPK AFTERCOOLER K17-18-25
PZ
1,0
909
9434F13
MPK GASKET K25
PZ
1,0
912
9434C15
MPK PISTON RINGS K25
PZ
1,0
921
9434D02
MPK INTERCOOLER K25-28
PZ
1,0
922
9434H05
MPK MAINTEN.PV K25
PZ
1,0

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WARRANTY
Pilot Air Compressors Pty Ltd manufactured goods - 1 Year Warranty and 3 Year Warranty (where
applicable)
February 2012
Pilot Air Compressors Pty Ltd (Pilot Air) warrants to the first purchaser of goods (manufactured by it)
(Product) from Pilot Air and the last purchaser prior to installation that, subject to compliance with the
Conditions of Warranties below that:
1. For a period of 12 months from the date of purchase, the Product will be free from defects due to
defective factory workmanship or materials; and
2. For a period of 12 months from the date of purchase that Pilot Air branded accessories supplied
by Pilot Air will be free from defects due to defective factory workmanship or materials.
3. The compressor pump only (and excluding all other components of the unit) in the following
units:
•TM Series Units
•Classic K Series Units
•Petrol Industrial Series Units
•Three Phase Industrial Series Units
will be free from defects due to defective factory workmanship or materials for a period of 3
years from the date of purchase.
4. The ‘DCR’ and ‘FP’ Series of Rotary Screw type compressors will be free from defects due to
defective factory workmanship or materials for 3,000 working hours in the first 12 months from
the date of purchase. This warranty is extended to a period of 2 years for the air end of the DCR
and FP Series Compressors.
5. Where compressors are powered with either petrol or diesel engines, the engine only is subject
to the warranty provided by the manufacturer of the engine.
6. Non Pilot Air accessories (meaning accessories which are not Pilot Air manufactured and
branded) which are supplied by Pilot Air are not covered by this warranty. Purchasers are
referred to the individual manufacturer’s warranty. Purchasers can request a copy of the
applicable warranties by contacting Pilot Air using the contact details below.

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Conditions of Warranties
a) The warranties specified herein are subject to the following conditions:
b) Pilot Air will not be liable for a breach of any of its warranties unless the Claimant provides proof
of purchase of the Product and makes a written claim to Pilot Air at the address set out below,
either within 30 days after the defect would have become reasonably apparent, or if the defect
was reasonably apparent prior to installation, then the claim must be made prior to installation;
c) The warranties are not transferable;
d) The Product must be installed, operated, maintained and serviced strictly in accordance with the
relevant Pilot Air literature current at the time of installation and must be installed in
conjunction with the components or products specified in the Pilot Air literature. To obtain
copies of such literature go to www.pilotair.com.au or telephone Pilot Air on [phone];
e) If the claimant chooses to rely upon any warranty specified herein the claimant’s sole remedy
under the warranty for breach of the warranty is (at Pilot Air’s option) that Pilot Air will either
supply replacement Product, rectify the affected Product or pay for the cost of the replacement
or rectification of the affected product;
f) In the circumstances where the guarantees under the Australian Consumer Law do not apply in
respect to the purchase of its Products, Pilot Air will not be liable for any losses or damages
(whether direct or indirect) including property damage or personal injury, consequential loss,
economic loss or loss of profits, arising in contract or negligence or howsoever arising. Without
limiting the foregoing, Pilot Air will not be liable for any claims, damages or defects arising from
misuse of the Product, inadequate maintenance and storage of the Product, repairs rendered
necessary or arising from the use of non-genuine Pilot Air parts in the product, normal wear and
tear maintenance of the Product, deterioration of any part of the Product due to normal wear and
tear, work performed on the Product other than by an authorised Pilot Air service technician or
their agent, use of the Product for any purpose other than which it was intended to be used, use
of the Product after essential parts and accessories have been removed, operating the Product
continuously under excessive load, and if the serial/model label has been removed or obscured
on the Product;
g) In circumstances where the guarantees under the Australian Consumer Law do not apply in
respect to the purchase of its Product/s: all warranties, conditions, liabilities and obligations
other than those specified herein are excluded to the fullest extent allowed by law.
h) Parts repaired or replaced under any warranty specified herein are warranted only for the
remaining period of the original warranty period.
i) All defective parts that are the subject of a claim under any warranty specified herein become
the property of Pilot Air.

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j) The warranties specified herein do not apply to the following parts or conditions and cannot be
relied upon in the situation whereby:
i. any Pilot Air product or part has been subject to misuse, negligence, accidental damage,
improper or inadequate use, inadequate maintenance or improper storage or been
operated under unusual conditions or continuously under excessive load;
ii. the defect has been caused by the use of non genuine Pilot Air parts;
iii. the defect or deterioration was due to normal use, fair wear and tear and exposure,
unless due to any defect in material or workmanship;
iv. work was undertaken on any Pilot Air product or part by an unauthorised Pilot Air agent;
v. the serial /model label has been removed from any Pilot Air product or part;
vi. normal maintenance items/parts including valves and piston rings
k) Warranty repairs on all 240 Volt and portable units shall be on a back to base basis that the
Claimant is required to return the Product to the nominated warranty agent as advised by Pilot
Air, provided that such costs are not significant;
l) The replacement or repair of any defective part or correction of operating faults under any
warranty specified herein is to be made only after Pilot Air, or its authorised representative, have
examined the unit to their satisfaction, with their decision being final.
m) In the circumstances where Pilot Air accepts or it is determined by Pilot Air that the claimant
has a valid claim under this warranty, and subject to paragraph (m) below, Pilot Air will bear all
of the claimant's reasonable and proximate expenses incurred as a result of claiming under this
warranty. The claimant is to inform Pilot Air in writing to the address identified below within 21
days from when the claimant first makes a claim under this warranty of all such claims and
expenses and provide it with copies of all receipts and invoices where relevant before any
reimbursement is made by Pilot Air to the claimant. The claimant is responsible for all other
costs of claiming under this warranty.
n) Pilot Air will not be responsible for any courier, transport or freight related costs whatsoever
associated with the return to it of any defective Product that have not first been approved by it.
Pilot Air reserves the right to first inspect any defective Product and decide how, if at all, the
defective Product is to be returned to it. Any unapproved courier, transport or freight related
costs will be to the claimant’s account.

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Important Note:
If you acquire goods from Pilot Air as a consumer according to the Australian Consumer Law, our
goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are
entitled to a replacement or refund for a major failure and for compensation for any other reasonably
foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the
goods fail to be of acceptable quality and the failure does not amount to a major failure.
Any rights a consumer may have under any warranty specified herein are in addition to other rights
and remedies of a consumer under a law in relation to the goods to which these warranties relate.
Nothing in this document shall exclude or modify any legal rights a customer may have under the
Australian Consumer Law or otherwise which cannot be excluded or modified at law.
Contact details if you wish to make a claim under any warranty specified herein:
For more information or to make a claim under any warranty specified herein please telephone Pilot
Air on 1300 667 579 , email Pilot Air via our website: http://www.pilotair.com.au or write to
Pilot Air at:
Pilot Air Compressors Pty Ltd
115 Beaconsfield St
Silverwater NSW 2128
(P O Box 277 Ermington NSW 1700)