Bauer Workshop Manual

Workshop Manual
Table of contents
1.
2.
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Important Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
8
2.1.
Safety notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2.
For spare parts orders please observe: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.
Please do not pollute the environment: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.
Change notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.
Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
3.1.
Torque values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
3.2.
TORQUE SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
3.3.
Tubing and pipe connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
3.4.
LUBRICATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
3.5.
ADHESIVE AND SEALANT CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
3.6.
TESTING AGENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
3.7.
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
4.
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
4.1.
Valve maintenance -- Wear limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
4.2.
Valve maintenance -- general notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23
4.3.
Compressor Blocks IK100 II, IK120 II, BK12.2 II; U/C/M II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
4.4.
COMPRESSOR BLOCK IK12.14 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31
4.5.
COMPRESSOR BLOCK IK150 mod. 9, IK180 mod. 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37
4.6.
COMPRESSOR BLOCK IK18.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41
4.7.
COMPRESSOR BLOCKS IK150 II mod. 10, IK15.1 II mod. 11, IK15.11 II mod. 1, IK180 II mod. 5, IK18.1
II mod. 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
44
4.8.
COMPRESSOR BLOCK K22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
51
4.9.
COMPRESSOR BLOCK K23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
58
4.10.
COMPRESSOR BLOCKS K25, K28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
66
4.11.
KOMPRESSORBLOCK IK22.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
74
4.12.
78
4.13.
80
4.14.
COMPRESSOR BLOCKS IK25.4, IK28.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84
4.15.
COMPRESSOR BLOCK IK25.5, IK28.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
89
5.
Wear and tear assessment of piston rings, pistons and cylinders . . . . . . . . . .
90
5.1.
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
90
5.2.
Blow--By Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
90
5.3.
BlowBy Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
92
Workshop Manual
Table of contents
6.
Cylinders and Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
93
6.1.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
93
6.2.
Wear characteristics on piston rings: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
94
6.3.
Wear characteristics on cylinders: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
95
6.4.
Wear characteristics on pistons: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
95
6.5.
Piston ring gap test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
97
6.6.
Mounting instructions for piston rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
98
7.
8.
9.
Oil quantities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Condensate valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure maintaining valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
99
100
105
Workshop Manual
Table of figures
Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19
Fig. 20
Fig. 21
Fig. 23
Fig. 24
Fig. 25
Fig. 26
Fig. 27
Fig. 28
Fig. 29
Fig. 30
Fig. 31
Fig. 32
Fig. 33
Fig. 34
Fig. 35
Fig. 36
Fig. 37
Fig. 38
Fig. 39
Fig. 40
Fig. 41
Fig. 42
Fig. 43
Fig. 44
Fig. 45
Fig. 46
Fig. 47
Fig. 48
Fig. 49
Stepped piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Taper--Lockt bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve head 1st stage, IK100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve head 1st stage, IK120 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve, 2nd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the intake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unscrewing the cap nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the screw--in pressure plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Securing the intake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve head 3rd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal of 3rd stage pressure valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valves 2nd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valves 3rd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unscrewing the cap nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the screw--in pressure plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve head 4th stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal of 4th stage pressure valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve head and valves, 2nd/3rd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve head and valves, 4th stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve head and valves, 2nd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve head 4th/5th stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal of 4th/5th stage pressure valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve head and valves, 1st stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve head and valves, 2nd/3rd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve head and valves, 2nd stage IK18.1 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve head 4th/5th stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal of 4th/5th stage pressure valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder, 1st/2nd stage with 2nd stage valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve head and valves, 3rd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve head, 1st stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valves, 1st stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2nd stage valve head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2nd stage valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder, 3rd stage and valve head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder and valve head, 4th stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
12
13
20
25
25
26
27
28
28
29
30
30
31
32
32
33
33
34
35
36
38
40
41
42
43
45
46
47
48
49
50
50
52
53
55
57
58
59
60
61
62
62
63
64
66
68
70
Workshop Manual
Table of figures
Fig. 50
Fig. 51
Fig. 52
Fig. 53
Fig. 54
Fig. 55
Fig. 56
Fig. 57
Fig. 58
Fig. 59
Fig. 60
Fig. 61
Fig. 62
Fig. 63
Fig. 64
Fig. 65
Fig. 66
Fig. 67
Fig. 68
Fig. 69
Fig. 70
Fig. 71

Cylinder head 2nd/3rd stage with valve head 2nd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder 1st/2nd stage with 2nd stage valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve head 1st stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve head 2nd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve head and valves, 1st and 2nd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder and valve head 3rd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3rd stage valve head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blowby test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston rings in a stepped cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wear signs of piston rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the piston ring gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure maintaining valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure maintaining valve, 350 bar units /3600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure maintaining valve, 500 bar units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure maintaining valve, 90 bar units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
72
75
76
78
80
81
82
84
84
85
86
87
89
91
93
94
96
98
108
109
110
111
Workshop Manual
1. Preface
This Workshop Manual has been issued for service and repair shops. It describes all dismantling
and assembly procedures required for adjustment and replacement of parts on compressor blocks.
It is presumed that all work is performed by trained specialists. Therefore, all descriptions of basic
procedures have been omitted. The procedures contained in this manual refer to the latest state
of construction of the compressors at date of issue of this manual.
We would like to emphasize that under no circumstances BAUER Kompressoren GmbH will be
held liable for any repair work done by oneself.
For all service and maintenance work please refer to the operating manual applicable for the specific compressor model.
Not contained in this manual are the BAUER scuba diving compressors Varius, Purus, Utilus 10,
Junior and Oceanus. For those, a separate workshop manual is available.
We reserve the right to make changes to all individual items and accessories according to state
of the art requirements in improving performance or as necessitated by safety or commercial restrictions.
Munich,......................January 2003
BAUER--KOMPRESSOREN GmbH
Technical Service Dept.
Technical Documentation Dept.
Workshop Manual
2. Important Notes
2.1.
Safety notes:
Always shut down and decompress the complete system prior to carrying out any work on the
compressor.
Always disconnect electric units from the power supply prior to carrying out any work on the compressor.
Never repair pressure lines by soldering or welding.
Never tighten tube connectors under pressure.
2.2.
For spare parts orders please observe:
For all spare parts orders the following data are required:
Type
Serial no.
Year of manufacturing
The required data are found on the compressor identification plate of from the the compressor
block number stancelled into the crankcase.
2.3.
Please do not pollute the environment:
The condensate from the filters, and the filter cartridges contain oil and must be disposed of according to local regulations.
Workshop Manual
2.4.
Change notice
Change no.
Date of change
January 2003; basic edition
Dear customer
We are happy to give you advice on any questions regarding your BAUER compressor and help
as soon as possible with any arising problems.
You can contact us Mondays to Thursdays from 0800 till 1630, Fridays from 0800 till 1400 on phone
no. (089) 78049--0.
If you call the following extensions directly, it will save you time and repeated dialling.
Do you want to order spare parts?
. Customer service
Phone no: (089) 78049--129 or --149
Fax no: (089) 78049--101
Do you have problems with maintenance or repair work?
. Technical customer service
Phone no: (089) 78049--246 or --176
Fax no: (089) 78049--101
Do you need further information regarding your unit, accessories, prices etc.?
. Sales department
Phone no: (089) 78049--138, --185, --154, --205 or --202
Fax no: (089) 78049--103
Are you interested in any training courses?
Training manager
Phone no: (089) 78049--175
Fax no: (089) 78049--103
Meet us in the internet at: www.bauer--kompressoren.de
Workshop Manual
3. Tables
When doing any repair work please check that at all screws and bolts are tightened with the correct
torque values.
3.1.
Torque values
Unless otherwise specified in text, the following torque values apply.
All valve head screws require torque wrench tightening! The indicated
torque values are valid for bolts in greased condition. Replace self-retaining nuts on reassembly.
Standard Bolts and screws
Thread
Max. torque
Hex and allen head
M6
10 Nm (7 ft.lbs)
Hex and allen head
M 8*
25 Nm* (18 ft.lbs)
Hex and allen head
M 10
45 Nm (32 ft.lbs)
Hex and allen head
M 12
75 Nm (53 ft.lbs)
Hex and allen head
M 14
120 Nm (85 ft.lbs)
Hex and allen head
M 16
200 Nm (141 ft.lbs)
Special screws
Thread
Max. torque
Intake valve 07790
M 14x1
30 Nm (21 ft.lbs)
Intake valve fitting 12841
M 28x1,5
60 Nm (42 ft.lbs)
Pressure valve fitting 14124
M 28x1,5
30 Nm (21 ft.lbs)
Studs (pressure valves --small blocks)
M 8x1
M 8x1,25
15 Nm (11 ft.lbs)
Studs (Intake/pressure valves -- big

blocks)
M 10
35 Nm (25 ft.lbs)

blocks)
M 12
50 Nm (35 ft.lbs)

blocks)
M 14
80 Nm (64 ft.lbs)
Exception: mounting bolts of final pressure safety valve: 10 Nm
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Workshop Manual
Stepped pistons -- antifatigue bolts
Thread
Max. torque
K12.14
M6
10 Nm (7 ft.lbs)
K22.0
M 10
30 Nm (21 ft.lbs)
K23.0, IK23.4
M 10
30 Nm (21 ft.lbs)
K25.0
M 12
35 Nm (25 ft.lbs)
K25.5
M 10
30 Nm (21 ft.lbs)
K28.3
M 10
30 Nm (21 ft.lbs)
K25.9, K25.18
M10
30 Nm (21 ft.lbs)
Fig. 1
1
2
Stepped piston
Antifatique bolt
Dead thread for pulling the upper piston part
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Workshop Manual
Taper--Lockt bushing -- studs
Bushing Type/No.
Max. torque
1008, 1108
5 Nm (3,5 ft.lbs)
1210, 1215
20 Nm (14 ft.lbs)
1310, 1315
20 Nm (14 ft.lbs)
1610, 1615
20 Nm (14 ft.lbs)
2012, 2017
30 Nm (21 ft.lbs)
2517, 2525
45 Nm (32 ft.lbs)
3020, 3030
70 Nm (49 ft.lbs)
It is recommended to secure the studs with one drop of a medium screw fastener, e.g. LOCTITEt
242 / 243.
Fig. 2
1
2
Taper--Lockt bushing
Flywheel
Taper--Lockt bushing
Stud
Thread for jackscrew
3
4
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Workshop Manual
3.2.
TORQUE SEQUENCE
Tighten valve head and cylinder bolts/nuts equally in the sequence shown in Fig. 3.
Be sure to tighten all parts in cold to handwarm condition only.
Fig. 3
Torque sequence
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Workshop Manual
3.3.
Tubing and pipe connections
Leaks at the fittings will be the most commonly

encountered. These may generally br repaired
by tightening the joint. It should be emphasized
that the compression type coupling fittings are
capable of exerting extreme forces on te tubing
and should not be tightened more than is required to seal the joint. To improve the sealing of
the pipe connections and to facilitate the istallation the following should be observed:
Ensure the pipe to be cut at right angles
The pipe should preferably be cut in a pipe

cutting jig.
Debur the inside and outside edge of the

tube after cutting and clean the inside of the
tube to remove even the slightest trace of
cuttings.
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Workshop Manual
Apply a thin layer of lubricant to the thread

(e.g. N19753).
Smear a thin layer of lubricant onto the outside of the olive on asssembly (e.g.
N19753).
Apply a thin layer of lubricant to the thread

of the nut (e.g. N19753).
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Workshop Manual
Install nut and olive as shown
Do not fit the olive the wrong way as it will

not seal.
Fingertighten the nut.
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Workshop Manual
Push the pipe down into the connector until

it bottoms.
Mark the nut and the pipe to determine the

number of turns the nut has been tightened.
Tighten the nut another 1 -- 11/4 turns ensuring the pipe does not rotate. The olive grips
onto the pipe.
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Workshop Manual
Unscrew the nut and check if the collar is
well formed. If not, the nut should be tightened slightly more. The olive can, however
be free to rotate without negative effects on
the sealing ability.
At final installation the nut should only be

tightened to a position ensuring the connection to be tight, i.e. finger--tight + approx. 1/2
turn. After this assembly procedure the nut,
olive, tube and connector should be considererd to be a matched assembly and
must not be interchanged with similar parts.
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Workshop Manual
3.4. LUBRICATION CHART
Usage
Lubricants
Rubber and plastic parts, filter housing

threads
WEICON WP 300 WHITE part no. N19752

or
BAUER special lubricant P/N 072500
Sealing rings
Shaft seal (seal)

Shaft seal (shaft)

Klber SK 01--205
Screws, bolts, threads
WEICON ANTI--SEIZE AS 040 P

part no. N19753 or equivalent compound with
copper or MoS2 additives
For all lubricating oils refer to chapter 2 or lubricating oil list available through BAUER Service Department.
3.5. ADHESIVE AND SEALANT CHART

Usage
Adhesives and Sealants
Screws, Studs
Loctite 2701
Seal for conical threads
Loctite 243
Metal -- metal seals

High temperature connections, e.g. valve
heads, cylinders
Temperature resistant compound, e.g.

WACKER E10, part no. N18247
Paper gaskets
Loctite FAG 2
3.6. TESTING AGENTS

Usage
Testing agents
Tube connectors, tubes
Leakage test spray, part no. FM0089
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Workshop Manual
3.7.
SPECIAL TOOLS
The parts no. are listed in the table on the next page.
1.
2.
5.
4.
3.
9.
10.
6.
11.
8.
7.
14.
15.
18.
16.
13.
12.
Fig. 4
20
Special tools
17.
Workshop Manual
Items printed in bold letters are shown in Fig. 4.
Pos.
Designation
Part no.
1.
Piston ring band 130
65901
Piston ring band 160
65039
Piston ring band 88, small
67976
Piston ring band 88, large
57494
Piston ring band 45
57498
Piston ring band 36
57499
Piston ring sleeve 22
57406
4.
Filter key, Seccant
N29373
5.
Filter key, Seccant
66690
6.
Piston ring pliers 110--160mm
N16721
Piston ring pliers 126/1--100
N4452
Piston ring pliers 126/2--120
N4453
7.
douille de montage 22
57393
8.
57643
9.
64823
10.
Key, cylinder base
N3408
11.
Key, for extraction of jumbo--cartridge
067146
12.
Key, for valve head
82048
13.
tool set for drain tap
067458
14.
Key, insert of intermediate filter
79846
15.
Key for safety valve
57478
16.
Key for pressure maintaining valve
81193
17.
Key for pressure maintaining valve
85154
18.
Filter key, P--Filter system
60074
19.
Test pressure gauge, 0--16 bar
057491
20.
Test pressure gauge, 0--100 bar
057492
21.
Flowmeter 0 -- 50 l/min.
81187--KD
22.
Flowmeter 0 -- 100 l/min.
81218--KD
2.
3.
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Workshop Manual
4. Valves
4.1.
Valve maintenance -- Wear limits
Wear limits for intake and pressure valves:

Wear of intake and pressure valves of air and gas compressors depends on different parameters,
e.g.:
Operating pressure,
Ambient temperature,
Operating temperature,
Lube oil,
Carbonization
Condensate build--up
Intake filter
etc.
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Workshop Manual
4.2.
Valve maintenance -- general notes
Always replace valves as a complete set.

Carefully clean dirty valves. Never use a sharp tool for this purpose. Soak the valves in diesel
oil or petroleum and clean with soft brush. Preferably use an ultrasonic cleaner, if possible.
Use maintenance kitsa)
Lubricate the copper gasket area of the valves before installing with high temperature compound, part no. N19753, or equivalent.
Observe the correct sequence when fitting together again.
Check individual components for excessive wear. If the valve seat and valve disks are dented,
replace the valves.
Valve head screws must be tightened with a torque wrench (see tightening torque values chapter 3.).
Check the valve space in the valve heads for dirt and clean, if necessary, preferably in an ultrasonic cleaner.
Use only satisfactory gaskets and O--rings on reassembly.
After finishing all maintenance work on the valves, turn the compressor manually using the flywheel and check whether all items have been correctly installed.
30 minutes after restarting the compressor unit stop unit, let it cool down to ambient temperature and retighten valve studs and cap nuts. Otherwise valves could work loose due to setting
of the gaskets.
After 3 operating hours retighten all pressure bolts and valve caps of pressure valves with the
correct torque values (refer to special torque value table) to avoid valves working loose due to
setting of the gaskets.
A functional inspection of the valves can be done by checking the intermediate pressures.
Remove and check the valves every 1000 operating hours. (CNG plants 2000 h).
Replace the valves every 2000 operating hours to avoid fatigue failure. (CNG plants 4000 h).
a)
erhltlich ber BAUER--Kundendienst.
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Workshop Manual
4.3.
Compressor Blocks IK100 II, IK120 II, BK12.2 II; U/C/M II
4.3.1.
Changing the valves of the 1st stage, IK100II
Removal
-- Remove pressure line.
-- Remove cap nut (1, Fig. 5) and gasket.
-- Remove stud (2).
-- Remove plug (3) and take out spring washer, o--ring and pressure valve parts (4).
-- Remove allen screws (5), and take off valve head (6).
-- Remove o--Ring and intake valve plate (7).
-- Clean intake and pressure valve (preferably ultra sound bath) and check for damage. Valve
seats and plate valves must not show any signs of wear or damage. Replace damaged parts.
-- Replace damaged parts.
-- Clean cylinder head. Check that the intake and pressure valve bores are in perfect condition.
-- Check with a precision straightedge that the underside of the cylinder head is flat, if necessary
use an emery cloth to smooth out the surface.
Reassembly
-- Replace pressure valve parts (4). Check for correct sequence.
-- Screw in plug (3) with spring washer and tighten (refer to torque table).
-- Grease stud (2) slightly (e.g. N19753), tighten (refer to torque table), mount a new gasket and
counter with cap nut (1) (refer to torque table).
-- Mount new o--ring and intake valve plate (7).
-- Place cylinder head on cylinder, slightly grease allen screw (5) crew in and tighten with correct
torque value (refer to torque table)
-- Replace pressure line.
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Workshop Manual
1
2
5
3
6
Fig. 5
Valve head 1st stage, IK100
4.3.2.
Changing the valves of the 1st stage, IK120II
Intake and pressure valve of the 1st stage are combined in one plate valve under the valve head.
Check that the valve is fitted as shown in Fig. 6.
intake side
pressure side
Top view
Fig. 6
Valve head 1st stage, IK120 II
4.3.3.
Changing the valves of the 2nd stage, (1st stage BK12.2II)
-- Unscrew the intake and pressure lines from the cylinder head (7, Fig. 7).
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Workshop Manual
1
2
3
5
6
Fig. 7
Valve, 2nd stage
-- Remove allen screws fixing cylinder head and completely remove the cylinder head from the
cylinder.
-- Insert two metal pins -- 8 mm diameter , any length -- in the holes in the cylinder head and secure
these in a vice with the cylinder head on top.
-- Unscrew the intake valve body with the special tool (part no. 4555--645, part of the tools set delivered with the unit (Fig. 8).
In order to avoid damaging the special tool or the valve when using the tool, ensure that it is pushed properly and firmly into the valve bore so that it will not tilt
when it is turned.
-- Turn the cylinder head and replace it on the metal pins.

-- Unscrew the cap nut (1) (see Fig. 9).
-- Unscrew stud (2) approx. 5 turns.
-- Unscrew screw--in pressure plug (3), see Fig. 10. Take out the pressure valve parts.
-- Clean intake and pressure valves and check for damage. Valve seats and plate valves must not
show any signs of wear or damage. Replace damaged parts.
-- Check O--ring (4), replace if necessary.
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Workshop Manual
Assembly:
-- Screw the intake valve in with the special tool and tighten.
Valve spring and valve plate must not be jammed.
-- Check valve function. To do so, blow compressed air through the valve in the direction of flow.
-- Secure the intake valve as follows:
Peen the cylinder head aluminium on the screw--in thread of the intake valve in two places opposite one another with a small drift pin, diameter approx. 5 mm (Fig. 19).
-- Insert the pressure valve parts and the O--ring.
Check the pressure valve function and stroke by lifting the valve plate.
-- Screw in the screw--in pressure plug with a pressure pad and tighten.
Ensure that the stud is unscrewed.
Fig. 8
Removing the intake valve
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Workshop Manual
Fig. 9
Unscrewing the cap nut
Fig. 10 Removing the screw--in pressure plug
-- Screw in the stud firmly, fit a new gasket and secure with the cap nut.
-- Put the cylinder head on the cylinder and secure it with the internal hex. screws.
-- Reconnect the intake and pressure lines.
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Workshop Manual
Fig. 11 Securing the intake valve
4.3.4.
Changing the valves of the 3rd stage (2nd stage BK12.2II)
For removal and installation of the 3rd stage intake valve proceed according to 4.4.2. Pressure
valve (5) is merely inserted into valve head (7). It is sealed by O--ring (4) and fixed to the valve head
by stud (3).
Change intake and pressure valves of 3rd stage together, only.
Removal and reinstallation of 3rd stage pressure valve (Fig. 12).

-- Remove acorn nut (1), rewind stud (3) up to three or four turns.
-- Remove internal hex. screw (9) fixing valve head (7), take off valve head cover (8).
-- Put two screwdrivers into the groove of outlet valve body, see Fig. 13. If necessary loosen valve
first by using a 13 mm spanner on the flat surfaces.
-- Lift out pressure valve (5) together with O--ring (4).
Reinstall pressure valve (5) in reverse sequence:
-- Put O--ring (4) into valve head (7). Check O--ring for abrasions.
-- Insert pressure valve (5). Put on valve head cover (8).
-- Fix valve head (7) with internal hex. screws. Torque to correct value, see chapter 20.
-- Screw in and fasten stud (3).
-- Put on gasket (2).
-- Screw on acorn nut (1).
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Workshop Manual
Fig. 12 Valve head 3rd stage
Fig. 13 Removal of 3rd stage pressure valve
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Workshop Manual
4.4.
COMPRESSOR BLOCK IK12.14 II
4.4.1.
Changing the valves of the 1st stage
Intake and pressure valve of the 1st stage are combined in one plate valve under the valve head.
When installing, check that the mark TOP is really at the top. The stamped S indicates the intake
side.
4.4.2.
Changing the valves of the 2nd stage
-- Unscrew the intake and pressure lines from the intake and outlet manifolds (2, Fig. 14).
-- Unscrew 4 allen screws ea. (1) and remove intake and outlet manifolds from cylinder.
-- Discard gaskets (3) and replace by new ones.
-- Clean intake and pressure valves (4) and check for wear and damage.
-- Assembly is performed in the reverse sequence of removal.
3
4
3
2
1
Fig. 14 Valves 2nd stage
4.4.3.
Changing the valves of the 3rd stage
-- Remove internal hex. screws fixing cylinder head and completely remove the cylinder head from
the cylinder.
-- Insert two metal pins -- 8 mm diameter, any length -- in the holes in the cylinder head and secure
-- Unscrew the intake valve body with the special tool (part no. 4555--645, part of the tools set delivered with the unit) (Fig. 16).
31
Workshop Manual
when it is turned.
-- Turn the cylinder head and replace it on the metal pins.
-- Unscrew the cap nut (1, Fig. 15) refer to Fig. 17.
1
2
3
5
6
Fig. 15 Valves 3rd stage
Fig. 16 Removing the intake valve
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Workshop Manual
Fig. 17 Unscrewing the cap nut
-- Unscrew stud (2) approx. 5 turns.

-- Unscrew screw--in pressure plug (3), refer to Fig. 18. Take out the pressure valve parts.
-- Clean intake and pressure valves and check for damage. Valve seats and plate valves must not
show any signs of wear or damage. Replace damaged parts.
Fig. 18 Removing the screw--in pressure plug
-- Check O--ring (4), replace if necessary.

Assembly:
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Workshop Manual
Check valve function. To do so, blow compressed air through the valve in the direction of flow.
-- Secure the intake valve as follows: Peen the cylinder head aluminium on the screw--in thread
of the intake valve in two places opposite one another with a small drift pin, diameter approx.
5 mm (Fig. 19).
-- Insert the pressure valve parts and the O--ring.
Check the pressure valve function and stroke by lifting the valve plate.
-- Screw in the screw--in pressure plug with a pressure pad and tighten.
Ensure that the stud is unscrewed.
-- Screw in the stud firmly, fit a new gasket and secure with the cap nut.
-- Put the cylinder head on the cylinder and secure it with the internal hex. screws, for the correct
torque value.
-- Reconnect the intake and pressure lines.
Fig. 19 Securing the intake valve
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Workshop Manual
4.4.4.
Changing the valves of the 4th stage
For removal and installation of the 3rd stage intake valve proceed according to 4.4.2. Pressure
valve (5) is merely inserted into valve head (7). It is sealed by O--ring (4) and fixed to the valve head
by stud (3).
Change intake and pressure valves of 4th stage together, only.
Removal and reinstallation of 3rd stage pressure valve (Fig. 20).

Fig. 20 Valve head 4th stage

35
Workshop Manual
Fig. 21 Removal of 4th stage pressure valve
-- Fix valve head (7) with internal hex. screws.

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Workshop Manual
4.5.
COMPRESSOR BLOCK IK150 mod. 9, IK180 mod. 4
4.5.1.
Remove and reinstall the valves for replacement as follows (see Fig. 22).
Removal procedure
-- Unscrew and remove cap nut (1).
-- Unscrew stud (3) a number of turns.
-- Check, and if required, replace gasket (2).
-- Remove valve cover nuts (11) and take off valve cover (4).
-- Check O--ring (10) and replace if required.
-- Take off valve cap (5) and remove the valve (6) or (8).
-- Check gasket (7), replace if necessary.
Installation procedure
-- Fit new valve with gasket (7) and position valve cap (5).
-- Fit valve cover (4) with O--ring (10) and fasten with self--retaining nuts (11).
-- Tighten stud (3) using allen key and screw on cap nut (1).
1
2
11
4
10
9
5
6
Fig. 22 Valve head and valves, 1st stage
1 Cap nut
2 Gasket
3 Stud
4 Valve cover
5 Valve cap
6 Discharge valve
7 Valve gasket
8 Inlet valve
9 Valve head
10 O--ring
11 Valve cover nut
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Workshop Manual
4.5.2.
Changing the valves of the 2nd and 3rd stages
Removal procedure
-- Unscrew and remove hex. nut (1). Remove cap holder (2).
-- Insert two screwdrivers into the groove of the valve cap (3) and lift off valve cap with O--ring (4).
-- Check, and if required, replace O--ring (4).
-- Take out valves (5) and (6).
-- Check valve gasket (7) and replace if required.
-- Fit new valve with gasket (7) and position valve cap (3) with O--ring (4).
-- Fit cap holder (2).
The valve cap for the the inlet valve protrudes 2.5 mm (.98 in.) out of the valve head
more than the valve cap for the discharge valve. (Cap holder is designed
accordingly).
-- Screw on hex. nut (1) and tighten with torque wrench.
screwdriver
Fig. 23 Valve head and valves, 2nd/3rd stage

1
2
3
4
5
6
7
8
Hex. nut
Cap holder
Valve cap
O--ring
Discharge valve
Inlet valve
Valve gasket
Valve head
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Workshop Manual
4.5.3.
The valves are located in the valve head of the 4th stage, see Fig. 24. The inlet valve merely comprises a valve disk (6) and a wavy washer (5). The inlet valve seat is machined directly into the cylinder liner (8) of the 4th stage piston. The discharge valve consists of the valve seat (11), valve disk
(12), valve spring (13), and stroke limiter (2).
The procedure for removal and reinstallation of the valves is as follows (refer to Fig. 24).
The valve head comprises the bottom section (7) and the upper section (3). The valve head is secured by means of the valve head screw (14) connecting the cylinder.
Removal procedure
-- Loosen the inlet and discharge pipe on the valve head.
-- Loosen and remove valve head screw (14).
-- Take off valve top section (3) and stroke limiter (2) with O--ring (1). This releases the discharge
valve disk (12) and discharge valve spring (13).
-- Check spring for satisfactory condition and resiliency preferably by comparing with a new spring.
-- Replace spring if necessary.
-- Check O--ring (1) and replace if necessary.
-- Insert two screwdrivers into the extraction groove of the discharge valve seat (11) and lift valve
seat with O--ring (9).
-- Check, and if required, replace O--ring (9) and backing ring (10).
-- Remove wavy washer (5) and inlet valve disk (6).
-- Check inlet valve seat on piston liner (8). If scored, remove piston liner, take out piston, and lap
valve seat.
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Workshop Manual
Fig. 24 Valve head and valves, 4th stage

1 O--ring
2 Stroke limiter
3 Valve head, top section
4 Extraction groove
5 Wavy washer
6 Inlet valve disk
7 Valve head, bottom section
8 Piston liner
9 O--ring
10 Backing ring
11 Discharge valve seat
12 Discharge valve disk
13 Discharge valve spring
14 Valve head screw
-- Turn flywheel on compressor manually until piston protrudes from the cylinder liner (8).
-- Locate the inlet valve disk (6) and the wavy washer (5), both of which are prevented from side
slip by the piston.
-- Insert the discharge valve seat (11) in the bottom section of the valve head (7), taking care to
avoid damage to the inlet valve disk and wavy washer.
-- Place discharge valve spring (13) and discharge valve disk (12) on stroke limiter (2) and locate
this in the top section of the valve head.
-- Screw in valve head screws (14) and tighten down diagonally using a torque wrench.
-- Tighten inlet and discharge pipe couplings.
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Workshop Manual
4.6.
COMPRESSOR BLOCK IK18.1
4.6.1.
See 4.5.1., IK150/180.

4.6.2.
Fig. 25 Valve head and valves, 2nd stage

1
2
3
4
5
6
7
8
Hex. nut
Cap holder
Valve cap
O--ring
Discharge valve
Inlet valve
Valve gasket
Valve head
Removal procedure
41
Workshop Manual
accordingly).
4.6.3.
See 4.5.2., IK150/180.

4.6.4.
Changing the valves of the 4th and 5th stage

Change intake and pressure valves together, only.
Fig. 26 Valve head 4th/5th stage
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Workshop Manual
-- Insert two metal pins -- 8 mm diameter , any length -- in the holes in the cylinder head and secure
-- Unscrew the intake valve body (6) with the special tool (part no. 4555--645, part of the tools set
delivered with the unit).
when it is turned.
Pressure valve (5, Fig. 26) is merely inserted into valve head (7). It is sealed by O--ring (4) and
fixed to the valve head by stud (3).
Remove pressure valve according to Fig. 27 as follows:
-- Put two screwdrivers into the groove of outlet valve body. If necessary loosen valve first by using
a 13 mm spanner on the flat surfaces.
Fig. 27 Removal of 4th/5th stage pressure

valve

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Workshop Manual
4.7.
COMPRESSOR BLOCKS IK150 II mod. 10, IK15.1 II mod. 11, IK15.11 II

mod. 1, IK180 II mod. 5, IK18.1 II mod. 4
4.7.1.
Removal procedure
-- Unscrew and remove nuts (6) and washers (5).
-- Remove valve head assy (1) from studs in cylinder.
-- To remove valve (2), unscrew and remove centre screw (4) and washer (3).
-- Fasten new valve with centre screw (4) and washer (3) tp valve head (1).
-- Place valve head assy on studs in cylinder.
-- Tighten valve head with washers (5) and nuts (6) to correct torque values.
44
Workshop Manual
4
3
6
Fig. 28
1
2
3
4
5
6
Valve head and valves, 1st stage
Valve head
Plate valve
Gasket
Allen screw
Washer
Hex nut
4.7.2.
Changing the valves of the 2nd and 3rd stages (IK18.1 3rd stage, only; 2nd stage
see )
Removal procedure
45
Workshop Manual
accordingly).
-- Screw on hex. nut (1) and tighten with torque wrench. Refer to table in para. D--17.
screwdriver
Fig. 29
1
2
3
4
5
6
7
8
Valve head and valves, 2nd/3rd stage
Hex. nut
Cap holder
Valve cap
O--ring
Discharge valve
Inlet valve
Valve gasket
Valve head
4.7.3.
Changing the valves of the 2nd stage, IK18.1 II
Removal procedure
46
Workshop Manual
accordingly).
-- Screw on hex. nut (1) and tighten with torque wrench. Refer to table in para. LEERER MERKER
Fig. 30
1
2
3
4
5
6
7
8
Valve head and valves, 2nd stage IK18.1 II
Hex. nut
Cap holder
Valve cap
O--ring
Discharge valve
Inlet valve
Valve gasket
Valve head
4.7.4.
Changing the valves of the 4th stage (4th and 5th stage on IK18.1 II)
Change intake and pressure valves together, only.
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Workshop Manual
Removal of the intake valve:
-- Insert two metal pins -- 8 mm diameter, any length -- in the holes in the cylinder head and secure
-- Unscrew the intake valve body with the special tool (part no. 4555--645, part of the tools set delivered with the unit) (Fig. 16).
Fig. 31
Removing the intake valve
when it is turned.
Installation of the intake valve:
Check valve function. To do so, blow compressed air through the valve in the direction of flow.
-- Secure the intake valve as follows: Peen the cylinder head aluminium on the screw--in thread
of the intake valve in two places opposite one another with a small drift pin, diameter approx.
5 mm (Fig. 19).
48
Workshop Manual
Fig. 32
Securing the intake valve
Removal and reinstallation of of the pressure valve (Fig. 20).

49
Workshop Manual
Fig. 33
Valve head 4th/5th stage
Fig. 34
Removal of 4th/5th stage pressure valve
50
Workshop Manual
4.8.
COMPRESSOR BLOCK K22
4.8.1.
The 1st stage valves are located in the valve head of the vertical 1st/2nd stage cylinder, see Fig. 35.
One inlet and one discharge valve are provided.
Removal procedure
-- Take off valve cap (6) and extract the valve.
-- Check valve gasket (8) and replace, if required.
-- Fit new valve with gasket (8) and locate valve cap (6).
-- Fit valve cover (5) with O--ring (11) and fasten with nuts (2).
-- Tighten nuts diagonally using a torque wrench to the correct value.
-- Tighten stud (4) using an allen key and screw on cap nut (1) and gasket (3).
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Workshop Manual

1 Cap nut
2 Valve cover nut
3 Gasket
4 Stud
5 Valve cover
6 Valve cap
7 Discharge valve
8 Valve gasket
9 Inlet valve
10 Valve head
11 Valve cover gasket (O--ring)
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4.8.2.
The 2nd stage valves are located directly on the side of the 1st/2nd stage cylinder, Fig. 36. One
inlet and one discharge valve are provided.
The 2nd stage valves are removed and reinstalled in the same way as for the 1st stage.
Fig. 36 Cylinder, 1st/2nd stage with 2nd stage

valves
1 Cap nut
2 Gasket
3 Stud
4 Valve cover
5 Valve cap
6 Discharge valve
7 Valve gasket
8 Inlet valve
9 Inlet / discharge manifold
11 Valve cover bolt
12 1st/2nd stage cylinder
13 1st/2nd stage piston
14 Gasket
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4.8.3.
The 3rd stage valves are located in the valve head of the 3rd stage, Fig. 37. One inlet and one discharge valve are provided.
Remove and reinstall valves as follows:
Removal procedure
-- Unscrew and remove hex. nuts (1) and remove cap holder (2).
-- Insert two screwdrivers into the groove of the valve cap (3) and lift out valve cap with O--ring (4).
-- Pull out valve.
-- Clean valve and check function.
-- Replace any faulty parts.
-- Fit new valve with gasket (7) and locate valve cap (3) with O--rings (4).
The valve cap of the the inlet valve protrudes 2.5 mm (.098 in.) more out
of the valve head than the valve cap for the discharge valve. The cap
holder is designed accordingly.
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screwdriver
Fig. 37 Valve head and valves, 3rd stage
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Workshop Manual
4.8.4.
The procedure for removal and reinstallation of the valves is as follows:
Removal procedure
-- Insert two screwdrivers into the extraction groove (4) of the discharge valve seat (11) and lift
valve seat with O--ring (9).
valve seat.
slip by the piston.
avoid damaging the inlet valve disk and wavy washer.
this in the top section of the valve head.
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Workshop Manual

1 O--ring
2 Stroke limiter
4 Extraction groove
5 Wavy washer
6 Inlet valve disk
8 Piston liner
9 O--ring
10 Backing ring
14 Valve head screw
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4.9.
COMPRESSOR BLOCK K23
4.9.1.
The 1st stage valves are located in the vertical 1st/2nd stage cylinder, see Fig. 39. Two inlet and
two discharge valves are provided.
Fig. 39 Valve head, 1st stage

1
2
3
4
5
Discharge line
Valve head
Intake port
Cap nut
Valve cover bolts
Remove and reinstall the valves as follows:

Removal procedure (see Fig. 40)
-- Take off valve cap (6) and take out the valve.
-- Check the valve gasket (8) and replace if necessary.
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Workshop Manual
-- Fit valve cover (5) with O--ring (11) and fasten with bolts (2).
-- Tighten bolts diagonally using a torque wrench to the correct value.
-- Tighten stud (4) using an allen key and screw on cap nut (1).
Fig. 40 Valves, 1st stage

1 Cap nut
2 Valve cover bolt
3 Gasket
4 Stud
5 Valve cover
6 Valve cap
7 Discharge valve
8 Valve gasket
9 Inlet valve
10 Valve head
4.9.2.
-- The 2nd stage valves are located directly on the side of the 1st/2nd stage cylinder, Fig. 41. One
inlet and one outlet valve are provided.
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Remove and reinstall the valves as follows:
-- Check gasket (11) and replace if necessary.
-- Remove valve cover bolt (9) and take off valve cover (8).
-- Remove valve cap (4) and take out valve.
-- Check valve gasket (13) and replace if necessary.
-- Fit new valves with gaskets (13) and locate valve cap (4).
-- Fit valve cover (8) with O--ring (7) and fasten with bolts (9). Tighten bolts diagonally using a
torque wrench to the correct value.
-- Tighten stud (10) using an allen key and screw on cap nut (12) with gasket (11).
Fig. 41 2nd stage valve head

1 Discharge line
2 Cap nut
3 Valve cover nut
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Workshop Manual
Fig. 42 2nd stage valves

1 Discharge valve
2 Intake valve
3 O--ring
4 Valve cap
5 Manifold
6 Allen screw
7 O--ring
8 Valve cover
9 Nut
10 Stud
11 Gasket
12 Cap nut
13 Valve gasket
4.9.3.
The 3rd stage valves are located in the horizontally positioned 3rd stage valve head. One inlet and
one outlet valve are provided.
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Fig. 43 Cylinder, 3rd stage and valve

1 Intake line
head
2
3
Discharge line
Securing nuts for
press pad
screwdriver
The valves are removed and reinstalled as follows (Fig. 44):
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Workshop Manual
Removal procedure
-- Unscrew and remove hex. nut (1) and remove cap holder (2).
-- Pull out valves (5) and (6).
-- Check valve gaskets (7) and replace if required.
-- Check O--rings (4) and replace if required.
-- Fit new valves with gaskets (7) and locate valve caps (3) with O--rings (4).
-- Screw on hex. nut (1) and tighten with torque wrench. Refer to table in D--LEERER MERKER
4.9.4.
The 4th stage valves are located in the 4th stage valve head, Fig. 45.
The inlet valve merely comprises a valve disk (6, Fig. 46) and a wavy washer (5). The inlet valve
seat is machined directly into the cylinder liner (8) of the 4th stage piston. The discharge valve consists of the valve seat (11), valve disk (12), valve spring (13), and stroke limiter (2).
Fig. 45 Cylinder and valve head, 4th stage
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The procedure for removal and reinstallation of the valves is as follows (see Fig. 46):
Removal procedure
-- Loosen the inlet and discharge pipe on the valve head (1 and 2, Fig. 45).
-- Loosen and remove valve head screw (3, Fig. 45; 14, Fig. 46).

1 O--ring
2 Stroke limiter
4 Extraction groove
5 Wavy washer
6 Inlet valve disk
8 Piston liner
9 O--ring
10 Backing ring
14 Valve head screw
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Workshop Manual
-- Insert two screwdrivers into the extraction groove (4) of the discharge valve seat (11) and lift
valve seat with O--ring (9).
valve seat.
Turn flywheel on compressor manually until piston protrudes from the cylinder liner (8).
Locate the inlet valve disk (6) and the wavy washer (5), both of which are prevented from side slip
by the piston.
Insert the discharge valve seat (11) in the bottom section of the valve head (7), taking care to avoid
damage to the inlet valve disk and wavy washer.
Place discharge valve spring (13) and discharge valve disk (12) on stroke limiter (2) and locate this
in the top section of the valve head. Position the top section of the valve head on the bottom section.
Screw in valve head screws (14) and tighten down diagonally using a torque wrench.
Tighten inlet and discharge pipe couplings.
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4.10. COMPRESSOR BLOCKS K25, K28
4.10.1. Changing the valves of the 1st stage
The 1st stage valves are located in the valve head of the 1st/2nd stage vertical cylinder, see Fig. 47.
One inlet and one outlet valve are provided.

1 Cap nut
2 Valve cover nut
3 Gasket
4 Stud
5 Valve cover
6 Valve cap
7 Discharge valve
8 Valve gasket
9 Inlet valve
10 Valve head
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Removal procedure
Tighten nuts diagonally using a torque wrench to the correct value.
Tighten stud (4) using an allen key and screw on cap nut (1) and gasket (3).
4.10.2. Changing the valves of the 2nd stage
The 2nd stage valves are located directly on the side of the 1st/2nd stage cylinder, Fig. 48. One
inlet and one outlet valve are provided.
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1 Discharge valve
2 Intake valve
3 O--ring
4 Valve cap
5 Manifold
6 Allen screw
7 O--ring
8 Valve cover
9 Nut
10 Stud
11 Gasket
12 Cap nut
13 Valve gasket
The 2nd stage valves are removed and reinstalled as follows:

Removal procedure
-- Remove cap nut (12).
-- Check gasket (11) and replace if necessary.
-- Remove nuts (9) and take off valve cover.
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-- Remove valve cap (4) and take out valve.
-- Check valve gasket (13) and replace if necessary.
-- Fit valve cover (8) with O--ring (7) and fasten with nuts (9). Tighten nuts diagonally using a torque
wrench to the correct value. Refer to table in chapter D--LEERER MERKER
4.10.3. Changing the valves of the 3rd stage
The 3rd stage valves are located in the 3rd stage valve head, Fig. 49. Two inlet and two outlet
valves are provided.
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1 Hex. nut
2 Lock washer
3 Stud
4 Valve cover
5 Valve cap
6 O--ring
7 Discharge valve
8 Gasket
9 Valve head gasket
10 Inlet valve
11 Valve head
12 Groove
Removal procedure
-- Unscrew and remove hex. nuts (1).
-- Loosen studs (3) a couple of turns.
-- Remove six allen screws (not shown) from valve head cover and remove valve cover (4).
-- Insert two screwdrivers into groove (12) of the valve cap (5) and lift out valve cap with O--ring
(6).
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Inspection
-- Clean valves and check function.
-- Fit valve cover (4) and secure with six allen screws.
The valve cap of the the inlet valve protrudes 3 mm (0.118 in.) more out
of the valve head than the valve cap for the discharge valve. Make sure
that studs are turned out far enough before installing valve cover.
-- Tighten studs (3) by hand.
-- Screw on hex. nut (1) and tighten with torque wrench while holding studs in position with a screwdriver.
4.10.4. Changing the valves of the 4th stage
The valve head comprises the bottom section (7) and the upper section (3). The valve head is secured to the cylinder by means of the valve head screw (14).
The procedure for removal and reinstallation of the valves is as follows:
Removal procedure
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Workshop Manual
-- Insert two screwdrivers into the extraction groove of the discharge valve seat (11) and lift valve
seat with O--ring (9).
-- Check inlet valve seat on piston liner (8). If scored, remove piston liner, take out piston and lap
valve seat.

1 O--ring
2 Stroke limiter
4 Extraction groove
5 Wavy washer
6 Inlet valve disk
8 Piston liner
9 O--ring
10 Backing ring
14 Valve head screw
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Workshop Manual
slip by the piston.
avoid damaging the inlet valve disk and wavy washer.
this in the top section of the valve head. Place the top section of the valve head on the bottom
section.
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4.11. KOMPRESSORBLOCK IK22.2
The 1st stage valves are located in the valve head of the 1st stage. One inlet and one discharge
valve are provided.
Removal procedure
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Workshop Manual

1 Cap nut
2 Valve cover nut
3 Gasket
4 Stud
5 Valve cover
6 Valve cap
7 Discharge valve
8 Valve gasket
9 Inlet valve
10 Valve head
-- Tighten nuts diagonally using a torque wrench to the correct value.
-- Tighten stud (4) using an allen key and screw on cap nut (1) and gasket (3).
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Workshop Manual
The 2nd stage valves are located in the valve head of the 2nd stage cylinder. One inlet and one
discharge valve are provided (Fig. 52).

1 Cap nut
2 Gasket
3 Stud
4 Valve cover
5 Valve cap
6 Discharge valve
7 Valve gasket
8 Inlet valve
11 Valve cover bolt
Removal procedure
-- Remove valve cover bolts (11) and take off valve cover (4).
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Workshop Manual
4.12. COMPRESSOR BLOCK IK22.5
The valves of the 1st stage are located in the valve head of the first (vertical) stage. One inlet and
one discharge valve are provided. For removal and reinstallation of the valves, see 4.11.1.
The valves of the 2nd stage are located in the valve head of the 2nd stage cylinder (left). One inlet
and one discharge valve are provided. Use the same procedure as for the valves of the 1st stage.
Refer to 4.11.1.
The 3rd stage valves are located in the valve head of the 3rd stage. One inlet and one discharge
valve are provided (Fig. 53).
screwdriver

1
2
3
4
5
6
7
8
Hex. nut
Cap holder
Valve cap
O--ring
Discharge valve
Intake valve
Valve gasket
Valve head
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Workshop Manual
Removal procedure
-- Unscrew and remove hex. nuts (1) and remove cap holder (2).
Inspection
-- Check valve gaskets (7) and replace if required.
-- Check O--rings (4) and replace if required.
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4.13. COMPRESSOR BLOCK IK23.4
The 1st stage valves are located in the valve head on the two horizontal 1st stage cylinders. One
inlet and discharge valve are provided for each cylinder.
For removal and reinstallation of the valves, see 4.11.1.
The 2nd stage valves are located directly on the side of the vertical 2nd/3rd stage cylinder. One
inlet and one discharge valve are provided (Fig. 54).
Fig. 54 Cylinder head 2nd/3rd stage with valve head 2nd stage
1 Pressure line
2 Cap nut
3 Valve cover nut

-- Check and if required replace gasket (11).
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-- Fit valve cover (8) with O--ring (7) and fasten with bolts (9). Tighten bolts diagonally using a
torque wrench to the correct value.
Fig. 55 Cylinder 1st/2nd stage with 2nd stage valves

1 Discharge valve
2 Intake valve
3 O--ring
4 Valve cap
6 Allen screw
7 O--ring
8 Valve cover
9 Valve cover nut
10 Stud
11 Gasket
12 Cap nut
13 Valve gasket
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The 3rd stage valves are located in the valve head of the 3rd stage. Two inlet and two discharge
valves are provided.

1 Hex. nut
2 Lock washer
3 Stud
4 Valve cover
5 Valve cap
6 O--ring
7 Discharge valve
8 Gasket
9 Valve head gasket
10 Inlet valve
11 Valve head
12 Groove
Removal procedure
-- Loosen studs (3) a couple of turns.
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Workshop Manual
-- Remove six allen screws (not shown) from valve head cover and remove valve cover (4).
(6).
Inspection
The valve cap of the the inlet valve protrudes 3 mm (0.118 in.) more out
of the valve head than the valve cap for the discharge valve. Make sure
-- Fit valve cap (4)
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Workshop Manual
4.14. COMPRESSOR BLOCKS IK25.4, IK28.2
4.14.1. Changing the valves of the 1st and 2nd stage
The valves are located in the valve heads of the two horizontally positioned cylinders and in the
vertical cylinder of the 2nd stage (Fig. 58). Two inlet and two discharge valves are provided.
Remove and reinstall the valves for replacement as follows (see Fig. 57 and Fig. 59).
Fig. 57 Valve head 1st stage
Fig. 58 Valve head 2nd stage
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Workshop Manual
Removal procedure
Fig. 59 Valve head and valves, 1st and 2nd stage

1 Cap nut
2 Valve cover bolt
3 Gasket
4 Stud
5 Valve cover
6 Valve cap
7 Discharge valve
8 Valve gasket
9 Inlet valve
10 Valve head
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Workshop Manual
-- Tighten stud (4) using an allen key and screw on cap nut (1).
The 3rd stage valves are located in the valve head of the 3rd stage. Two inlet and two discharge
valves are provided (Fig. 60).
Fig. 60 Cylinder and valve head 3rd stage

1
2
3
4
Intake line
Discharge line
Mounting nuts for cap holder
Valve head bolts
Remove and reinstall the valves for replacement as follows (see Fig. 60 and Fig. 61).
Removal procedure
-- Remove connecting pipe (1, Fig. 60) between valve head inlet and intermediate separator, 2nd
stage.
-- Remove connecting pipe (2) between valve head outlet and after--cooler.
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Workshop Manual
-- Loosen studs (3, Fig. 61) a couple of turns.
-- Remove six allen bolts (4, Fig. 60) from valve head cover and remove valve cover (4, Fig. 61).
(6).

1 Hex. nut
2 Lock washer
3 Stud
4 Valve cover
5 Valve cap
6 O--ring
7 Discharge valve
8 Gasket
9 Valve head gasket
10 Inlet valve
11 Valve head
12 Groove
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Inspection
The valve cap of the inlet valve protrudes 3 mm (0.118 in.) more out of
the valve head than the valve cap for the discharge valve. Make sure
-- Fit valve cover (4) with six allen bolts.
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4.15. COMPRESSOR BLOCK IK25.5, IK28.3
4.15.1. Changing the valves of the 1st and 2nd stage
The valves are located in the valve heads of the two horizontally positioned 1st stage cylinders and
in the vertical cylinder of the 2nd stage. Two inlet and two discharge valves are provided.
For removal and reinstallation of the valves refer to 4.14.1.
The 3rd stage valves are located directly on the side of the 2nd/3rd stage stepped cylinder. One
inlet valve (1, Fig. 62) and one discharge valve (2) are provided. For removal and reinstallation of
the valves refer to 4.13.2.
Fig. 62 3rd stage valve head
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5.
Wear and tear assessment of piston rings, pistons

and cylinders
5.1.
Procedure
After approximately 4000 hours (8000 operating hours for CNG stations) pistons and cylinders
should be checked by performing a blow--by test.
What is Blow--By?
Blow--by is defined as the leakage from the compression chambers of each compression stage
into the crankcase caused by wear and tear of piston rings and cylinders.
On BAUER compressors it is measured with a flowmeter* in liters/minute and a backpressure
of 200 bar. Test point is the crankcase venting outlet. The blow--by test is a simple method to determine the degree of wear of cylinders and pistons without having to dismantle the cylinders.
If during this test increased values outside the specified tolerances should be encountered, it can
be assumed that the piston rings and cylinders are excessively worn out. Consequently, those cylinders and piston rings have then to be exchanged. The blow--by values for the different compressor
models are listed in the table in 5.3.
Initially, perform the blow--by test for the complete compressosr block. If the blow--by is too high,
check each single stage to finally find out the faulty cylinder. Start the tests with the last stage. The
portion per stage is 1/3rd for three stage blocks, 1/4th for 4 stage blocks, and 1/5th for 5 stage blocks
of the the values according to the blow--by table.
5.2.
Blow--By Test
Blow--By Test Procedure (Fig. 63)

-- Warm up compressor for 15 min.
-- Adjust pressure maintaining valve to 200 bar 10%.
-- Disconnect vent line from crankcase vent opening and connect flowmeter.
-- Perform test (t = 2 min.)
-- Compare measured value with blow--by table
-- Remove flowmeter and reconnect vent line to 1st stage valve head
-- If measured value is above the indicated max. value in the table, replace piston rings of all stages
and, if required cylinders and the free--floating piston of the last stage.
* available through BAUER service dept.; 0--50 l/min :part no. 81187--KD; 0--100 l/min :part no. 81188 --KD
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Workshop Manual
Fig. 63
Blowby test
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Workshop Manual
5.3.
BlowBy Table
Flowmeter *: 50 l/min; atm.; 20C ambient temperature

Note: the lower the blow--By, the better run in are cylinder and piston rings
Compressor block model
Modification no.
Blow--By
Pressure
maintaining valve
(state of construction)
[ltr./min]
UTILUS II
CAPITANO II
MARINER II
K100
IK100 II
K120
IK120 II
K14
IK12.14 II
K15
K150
IK150 II
IK15.11
K180
IK180 II
K18.1
IK18.1 II
2
3
3,5
3,7
4
04
04
04
03
04
03
04
08
01
06
09
10
01
04
05
03
04
04
09
01
02
01
set pressure
[bar] 10%
standard
max.
18
18
25
10
18
10
25
25
44
30
30
25
25
30
30
90
65
20
20
25
45
60
25
25
35
15
25
15
35
40
60
45
45
40
40
45
45
130
100
35
35
40
70
90
200
200
200
200
200
200
200
200
200
200
200
200
200
200
200
200
200
200
200
200
200
200
For all booster compressor blocks the Blow--By is depending from the intake pressure (please contact the BAUER service dept.)
* available through BAUER technical service
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6. Cylinders and Pistons
6.1.
General
Before starting to dismantle cylinders, necessarily perform a blow--by
test.
If blow--by values are o.k. it is not necessary to remove the cylinders.
When repairing pistons and piston rings, observe correct order of piston rings at reassembly. Refer
to parts list.
When mounting the piston rings, also check that the TOP sign on the rings points upwards, with
exception of the lower tapered rings on compressor blocks with stepped pistons. Those are
mounted with the TOP sign pointing downwards. The TOP sign should always be towards the
compression chamber (Fig. 64).
TOP
TOP
Fig. 64 Piston rings in a stepped cylinder
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Workshop Manual
6.2.
Wear characteristics on piston rings:
The piston ring wear should always be looked at in connection with the cylinder wear, only.
Visible scratches and grooves on the surface
Silvery shining toeing on complete surface (tapered rings)
Significant reduced thickness (compared to new rings)
Piston rings gummed up in the piston grooves
Piston ring ends deteriorated (ground off)
Uneven wear (toeing)
Worn out piston grooves
Broken rings
Angular view, magnified approx. 100

times; the real angle is less than 1.
Fig. 65 Wear signs of piston rings
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Workshop Manual
6.3.
Wear characteristics on cylinders:
The cylinder wear should always be looked at in connection with the piston ring wear, only.
Visible scratches, grooves >0,1 mm, signs of seizing
Dark grey / brown discolouration
Cracks
Damaged threads
Hone image not visible
6.4.
Wear characteristics on pistons:
Aluminium and cast iron pistons

The piston wear should always be looked at in connection with the piston ring and cylinder wear,
only.
Visible scratches and grooves, signs of seizing
Dark grey / brown discolouration
Polished surface on the lathe turn image
Worn out piston pin bore
Worn out piston pin
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Workshop Manual
new
Fig. 66 Cylinder wear
96
acceptable
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Workshop Manual
6.5.
Piston ring gap test

The piston ring gap test should only be considered as a secundary
means of determining the piston and cylinder wear.
-- Remove the piston with piston rings.

-- Remove the piston rings from the piston.
-- Insert the piston rings in the corresponding cylinder approx. 10 mm (3/8) from the top edge.
Check the piston ring gap with feeler gauge part no. N20889, see Fig. 67.
-- Change the piston rings if permissible values are exceeded.
-- Dismantle pistons with piston rings.
-- Remove piston rings from pistons.
Max. allowable piston ring gap
Cylinder-- (mm)
Gap min. (mm)
Gap max. (mm)
215
1,35
1,60
185
1,20
1,45
170
1,10
1,30
160
1,05
1,25
150
1,00
1,20
140
0,95
1,15
130
0,90
1,15
50
0,50
0,70
45
0,45
0,65
36
0,40
0,55
28
0,37
0,45
24
0,35
0,45
22
0,33
0,40
18
0,30
0,40
16
0,30
0,35
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Workshop Manual
Fig. 67 Checking the piston ring gap
6.6.
Mounting instructions for piston rings
Change piston rings only as a complete set. Observe correct order and orientation.
For dismantling or mounting of piston rings with larger diameters use respective piston ring
pliers. Refer to special tools table.
Remove preservation compound from new rings.
Lubricate rings and inside of cylinders well with compressor oil.
Mount ring gaps with 180 offset to each other.
TOP marks of the rings should point towards the compression camber.
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7. Oil quantities
Compressor model
Oil Max.
Oil Min.
Top--up quantity
Oil filter
[ltr.]
[ltr.]
[ltr.]
[ltr.]
U--10, JUNIOR,
0,35
0,28
~ 0,07
--
JUNIOR II
--
OCEANUS
UTILUS
01,30
01,75
01,10
01,50
~ 0,20
~ 0,25
---
CAPITANO
--
MARINER
--
UTILUS II
02,90
02,40
~ 0,50
intern
CAPITANO II
intern
MARINER II
intern
IK 100, IK120
IK100 II, IK120 II
02,80
02,90
02,40
02,40
~ 0,40
~ 0,50
-Intern
IK12.14 II
Intern
K14, K14.11
K15, K16,
02,80
04,40
02,20
04,10
~ 0,60
~ 0,30
---
K150, K180,
--
K18.1
--
IK150 II, IK180 II
06,00
04,40
~ 1,60
Intern
IK18.1 II
Intern
IK22.0, IK22.5
IK23.0, IK23.4
IK25.0, IK25.4,
08,50
10,50
34,00
06,75
08,30
25,00
~ 1,75
~ 2,20
~ 9,00
~ 0,50
~ 0,50
~ 1,00
IK25.5, IK25.9
IK25.18, IK28.0,
IK28.2, IK28.3,
2, 3, 3,5
01,70
01,35
~ 0,35
--
3,7
--
06,00
04,50
~ 1,50
~ 0,5
The exact oil quantities have to be checked with oil dipstick or oil sight gauge, depending on the
compressor model.
For recommended compressor oils refer to oil list.
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8. Condensate valves
General information
The automatic condensate drain unit ensures regular and reliable drainage of the condensate produced due to the recooling after compression process. It will also increase the lifetime of the filter
cartridges in the purifying systems many times over.
Furthermore, a correctly adjusted condensate drain unit will reduce premature wear of the free
floating piston of the final stages and dynamic pressure load on the final separator pressure
vessels.
We recommend:
Check automatic condensate drain units every 500 operating hours at least annually for correct
function (by means of intermediate pressure gauges*)
Every 1000 operating hours at least every 2 years replace inner parts (e.g. gaskets, sealing
rings, o--rings, valve seats, pistons) -- use maintenance kits*.
Dismantle defective condensate drain valves according to drawing and clean parts, preferably
in ultrasonic cleaning bath.
Replace parts subject to wear and tear.
If heavily damaged parts are encountered (e.g. damaged threads) replace complete drain valve.
After maintenance work readjust pressure loss (np) and drain interval and drain time (nt).
For all final separators a np of max. 50% of the operating pressure is recommended.
The nt of the automatic condensate drain unit has to be set according to the compressed medium (refer to operating manual).
* BAUER parts service / technical service
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Workshop Manual
Condensate drain valves, normally open type
25
55
5
50
60
70
35
40
10
45
15
20
65
30
Disassembly:
-- Remove hex nut and electric coil
-- Remove allen screws (50) and solenoid valve (5)
-- Remove o--ring (10).
-- Screw allen screw (50) some turns into piston (20).
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Workshop Manual
-- Pull piston (20) out of housing (25).
-- Remove allen screw (65) and lower housing (45).
-- Remove valve seat (35) and o--rings (40) and (70). Clean parts, preferably in ultrasonic cleaning
bath. Replace worn parts. If possible, use maintenance kits*. If heavily damaged parts are encountered (e.g. damaged threads) replace complete drain valve.
Assembly:
-- Assemble parts in the reverse order of disassembly
-- Tighten all screws with torque wrench (refer to torque table)
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Workshop Manual
Condensate drain valves, normally closed type
25
70
65
60
80
40
45
10
15
35
50
20
30
55
75
Disassembly:
-- Remove hex nut and electric coil
-- Remove allen screws (60) and solenoid valve (5)
-- Remove o--ring (10).
-- Screw allen screw (60) some turns into piston (20).
-- Pull piston (20) out of housing (25).
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Workshop Manual
-- Remove allen screws (75) and lower housing (55).
-- Remove valve seat (40) and o--rings (80) and (45), Piston (35) and spring (50). Clean parts, preferably in ultrasonic cleaning bath. Replace worn parts. If possible, use maintenance kits*. If
heavily damaged parts are encountered (e.g. damaged threads) replace complete drain valve.
Assembly:
-- Assemble parts in the reverse order of disassembly
-- Tighten all screws with torque wrench (refer to torque table)
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Workshop Manual
9. Pressure maintaining valves
General information
The pressure maintaining valves ensure a correct and reliable operation of the air and gas compressors and of the air and gas processing systems.
Furthermore, they will reduce dynamic pressure load on the purifier pressure vessels.
We recommend to check the pressure maintaining valves every 500 operating hours at least
annually for correct function.
Every 1000 operating hours at least every 2 years replace inner parts (e.g. gaskets, sealing
rings, o--rings, valve seats, pistons) -- use maintenance kits*.
Dismantle defective pressure maintaining valves according to sectional drawings and clean
parts, preferably in ultrasonic cleaning bath.
Replace parts subject to wear and tear.
If heavily damaged parts are encountered (e.g. damaged threads) replace complete valve.
After maintenance work readjust opening pressure -- refer to tables on next page.
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Workshop Manual
Pressure setting for pressure maintaining valves
Medium pressure units
Operating pressure of unit
Adjusted opening pressure
30 bar
20 bar
40 bar
25 bar
50 bar
30 bar
60 bar
40 bar
70 bar
45 bar
90 bar
55 bar
For other compressor unit final pressure setting, we recommend to adjust the opening pressure to
60% of the compressor unit operating pressure.
High pressure units
Operating pressure of unit
Adjusted opening pressure
150 bar
100 bar
200 bar
150 bar
300 bar
170 bar
350 bar
180 bar
400 bar
200 bar
500 bar
300 bar
For other compressor unit final pressure setting, we recommend to adjust the opening pressure to
60% of the compressor unit operating pressure.
Adjustment of the pressure maintaining valves
How to determine the opening pressure of the pressure maintaining valve:
As long as the pressure built up by the compressor is below the adjusted opening pressure of the
pressure maintaining valve, the final pressure indication remains at zero. But, the pressure building
up in front of the pressure maintaining valve can be read from the pressure gauge mounted at the
filter system venting valve. When the pressure maintaining valve opens, the final pressure gauge
will begin to show the rising pressure. At this moment, read the opening pressure from the pressure
gauge at the filter system.
This method is not possible on units without filter system (mostly medium pressure units). In this
case, a test pressure gauge (see high pressure accessories catalog) has to be mounted at the test
connector of the final separator.
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Workshop Manual
Pressure maintaining valves
Type
Part no.
Operating pressure
outlet
056705
400 bar
10 mm
057351
350 bar
1/4 NPT
060510
400 bar
12 mm
062516
150 bar
8 mm
063838--KD
350 bar
8 mm
065469--KD
350 bar
8 mm
068275
500 bar
8 mm
068385
350 bar
10 mm
071043--KD
150 bar
8 mm
071386
500 bar
6 mm
075330
350 bar
8 mm
075413--KD
350 bar
8 mm
090062--KD
350 bar
8 mm
80751
350 bar
80760
350 bar
80804
350 bar
80815
350 bar
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Workshop Manual
Type 1
Compressor units up to 350 bar, max. 650 l/min.
The opening pressure is adjustable with screw (1, Fig. 68). First loosen counter--nut (2) and turn
out stud (3) several turns.
Turning cw increases pressure
Turning ccw reduces pressure
Fig. 68 Pressure maintaining valve
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Workshop Manual
Type 2
The opening pressure is adjustable with screw (1, Fig. 69). First turn out stud (2) several turns.
Fig. 69 Pressure maintaining valve, 350 bar units /3600
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Workshop Manual
Type 3
The opening pressure is adjustable with screw (1, Fig. 70). First turn out stud (2) several turns.
Fig. 70 Pressure maintaining valve, 500 bar units
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Workshop Manual
Type 4
Remove cover (1).

The opening pressure is adjustable with key (2, Fig. 71).
Fig. 71 Pressure maintaining valve, 90 bar units
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Workshop Manual
112
Lubricating oil list

1.
GENERAL
After extensive tests with many different kinds of lubricants, we have decided to authorize the following brands of oil for use in BAUER
compressors under the given operating conditions.
This list is up to date at the time of printing and will be reviewed continuously. Should your list or your instruction manual be older,
please request the latest edition from BAUER Customer Services. When using any of the oils listed below, please follow the oil
change intervals and the oil filling level described for the equivalent BAUER compressor oil in the instruction manual of your unit.
Oil type
Brand
name
Type
Designation
Special Compressor oil

Part no. N28355
b) c)

Part no. N22138
a)

Part no. N26303
Mobil
Ambient
temperature
Use
S
M
b)
b)
Rarus 829
Breathing
air
Nitrox
+
+
---
I
Industrial
air
+
----
G
Helium,
Argon
+
+
-+
+
--+
C
CNG
--+
--
GI
Nitrogen
+
--+
+5 ...+45 C
+
+
+
+
Oil type
S
synthetic oil
mineral oil
Application
A
approved for breathing air application with BAUER air purification systems
approved for nitrox application with BAUER membrane unit
suitable for industrial air compressor units
suitable for gas compressor units for dry and highly pure gases
suitable for compressed natural gas compressors (CNG filling stations)
GI
suitable for gas compressor units for nitrogen
a)
oil change every 1000 operating hours
b)
oil change every 2000 operating hours
c)
oil change every 1000 operating hours in case of nitrox application
Suitability
= suitable
= partly suitable
--
= not suitable
Oil list /06/06
BAUER KOMPRESSOREN GmbH

Postfach 710260 D--81452 Mnchen Tel. 089/78049--0 Fax 089/78049167
Lubricating oil list

2.
TYPE OF OIL
Due to the thermal load on the compressor only high quality oil should be used. You are recommended to restrict oils to those which
have been approved by us and are listed in the instruction manual or in the lubricating list on page 1.
Our compressor units are delivered ex works with lubricating oil filled into the crankcase or as consignment, depending
on the model, as follows:
Breathing air compressor units:
BAUER Special Compressor oil, part no. N28355
Nitrox compressor units:
Industrial air and gas compressor units:
CNG compressor units:
For operation under difficult conditions, such as continuous running and/or high ambient temperatures, we only recommend the
BAUER special synthetic compressor oils acc. to the list on the previous page. These have proved excellent quality under ambient
temperatures between +5 C and +45 C. For lower temperatures a compressor heating device is required which is capable of pre-heating the unit up to +5 C.
For operation under less severe conditions, and for intermittent operation, i.e. when the compressor is not used for longer periods
between the operating periods, we also recommend the use of the mineral oil acc. to the list on the previous page. This oil is suitable
for ambient temperatures between +5 C and +45 C. Here also, a pre--heating device will be required if ambient temperatures should
fall below +5 C.
2.1.
Changing the Oil Type
CAUTION
To avoid severe damage to the compressor unit when changing to another oil
type, the following measures should be strictly adhered to.
--
Drain mineral oil while still warm.
--
Check valves, coolers, separators, purifiers and all pneumatic tubes and hoses for deposits.
If deposits are present, perform the following steps:

--
Remove deposits or change valves, coolers, separators, purifiers and all pneumatic tubes and hoses.
--
Change oil filter, if applicable.
--
Fill compressor with the new oil.
--
After approx. 100 operating hours, replace oil filter again (if applicable). and change oil.
--
Top up with same oil type.
3.
OIL CHANGE
Mineral oil
every 1000 operating hours, at least annually
Synthetic oil
every 2000 operating hours, at least every two years
Oil change volume
see compressor unit operating manual
BAUER compressor oil is available in the following quantities:

Oil quantity b
Oil type '
Synthetic oil N28355
Synthetic oil N26303
Mineral oil N22138
0.5 ltr. bottle
Best.--Nr. N28355--0,5
not available
Best.--Nr. N22138--0,5
1 ltr. bottle
part no. N28355--1
part no. N26303--1
part no. N22138--1
5 ltr. container
part no. N28355--5
part no. N26303--5
part no. N22138--5
20 ltr. container
part no. N28355--20
part no. N26303 --20
part no. N22138--20
BAUER KOMPRESSOREN GmbH

Postfach 710260 D--81452 Mnchen Tel. 089/78049--0 Fax 089/78049167

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Workshop Manual

For spare parts orders please observe: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Please do not pollute the environment: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tubing and pipe connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADHESIVE AND SEALANT CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valve maintenance -- Wear limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valve maintenance -- general notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Compressor Blocks IK100 II, IK120 II, BK12.2 II; U/C/M II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COMPRESSOR BLOCK IK12.14 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COMPRESSOR BLOCK IK150 mod. 9, IK180 mod. 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COMPRESSOR BLOCK IK18.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COMPRESSOR BLOCK K22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COMPRESSOR BLOCK K23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COMPRESSOR BLOCKS K25, K28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COMPRESSOR BLOCK IK22.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COMPRESSOR BLOCK IK23.4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COMPRESSOR BLOCKS IK25.4, IK28.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COMPRESSOR BLOCK IK25.5, IK28.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wear and tear assessment of piston rings, pistons and cylinders . . . . . . . . . .

Cylinders and Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wear characteristics on piston rings: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wear characteristics on cylinders: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wear characteristics on pistons: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Piston ring gap test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting instructions for piston rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valve head and valves, 4th stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

For spare parts orders please observe:

Please do not pollute the environment:

January 2003; basic edition

Meet us in the internet at: www.bauer--kompressoren.de

Standard Bolts and screws

Hex and allen head

Hex and allen head

25 Nm* (18 ft.lbs)

Hex and allen head

Hex and allen head

Hex and allen head

120 Nm (85 ft.lbs)

Hex and allen head

200 Nm (141 ft.lbs)

Intake valve 07790

Intake valve fitting 12841

Pressure valve fitting 14124

Studs (pressure valves --small blocks)

Studs (Intake/pressure valves -- big

Studs (Intake/pressure valves -- big

Studs (Intake/pressure valves -- big

Exception: mounting bolts of final pressure safety valve: 10 Nm

Tubing and pipe connections

Leaks at the fittings will be the most commonly

The pipe should preferably be cut in a pipe

Debur the inside and outside edge of the

Apply a thin layer of lubricant to the thread

Apply a thin layer of lubricant to the thread

Install nut and olive as shown

Do not fit the olive the wrong way as it will

Fingertighten the nut.

Push the pipe down into the connector until

Mark the nut and the pipe to determine the