Kahlenberg
Instructions, P449 Series, P569-01A, P569-02A
03/23/2010
INSTRUCTIONS FOR INSTALLING
KAHLENBERG P449 SERIES COMPRESSORS
PART NOS. P449-17, P449-18, Compressor Kits
WITH P569-01A and P569-02A Compressor Pump Assemblies
REFERENCES:
Drawing No. 3-6331
Drawing No. 3-6577
Thank you for buying a Kahlenberg P449 Series Intermittent Duty Compressor Kit. This
is an automatic, powerful, and compact accessory for your air horn system and should
give you years of trouble-free performance. Although installation of this compressor kit
is straightforward and simple, we offer the following guidelines to assist you.
WARNING
THIS COMPRESSOR SYSTEM IS RATED FOR INTERMITTENT DUTY ONLY.
PLEASE READ AND UNDERSTAND THESE INSTRUCTIONS INCLUDING
SAFETY PRECAUTIONS ON PAGE 5.
IMPROPER INSTALLATION CAN BE DANGEROUS, AND MAY ALSO
RESULT IN PERMANENT DAMAGE TO THE SYSTEM WHICH IS NOT
COVERED UNDER WARRANTY.
THE FOLLOWING ITEMS ARE INCLUDED IN THIS PACKAGE:
(1) P449 Series Compressor Pump Assembly including air gauge, safety
valve and 1/4” tube fitting installed
(1) 1/4” Nylon Tube, 8’ Length
(1) 5/16” Nylon Tube, 15’ Length
(1) Plastic Package containing (1) 1/8” Nipple, and (1) 5/16” Tube Fitting
(1) Air Tank w/1/4” Drain Cock, 1/8” and 5/16” Tube Fittings Installed
1. Arrange compressor, tank, and air horn in such a way as to keep air line runs as
short as possible. It is best to mount the valve (whether electric or manually
operated) directly to horn with 1/8” N.P.T. nipple, provided. See additional valve
instructions enclosed if you have purchased a Kahlenberg valve. The kit provides
you with 8’ of ¼” SAE J844 brake line tube (for installation between pump and
tank) and 15’ of 5/16” tube (for installation between tank and horn operating
valve). Some custom O.E.M. kits provide longer lengths of tubing. Lengths up to
50’ between the tank and valve may be used and can be purchased from
Kahlenberg or your local industrial supply store. Use ONLY ¼” SAE J844 tube
or equivalent between compressor and tank. Use connectors already installed on
compressor and tank. Cut tube off square with razor or sharp knife and push
firmly into connector. To disconnect, press in on red connector collar and pull
tube out. This provides a simple, airtight flexible connection. See Installation
Drawings 3-6331 attached for additional details.
Page 1 of 5
Kahlenberg
Instructions, P449 Series, P569-01A, P569-02A
03/23/2010
2. The compressor will run HOT. Although the compressor pump includes an
internal thermal disconnect switch which will automatically shut the unit off if it
becomes too hot, as much ventilation as possible is advised. Do not install the
pump in a very small enclosed space.
3. We recommend that the tank be bulkhead mounted with the ¼” N.P.T. Drain
Cock facing down and accessible. Once a year, switch the PT148-005 Pressure
Switch on the compressor to OFF, and open the drain cock on the tank to drain
condensation from the tank, if any. Experience will dictate if the tank should be
drained more or less often. IF ANY PRESSURE IS LEFT IN THE SYSTEM,
BLEED IT OFF SLOWLY BEFORE OPENING DRAIN COCK
COMPLETELY.
4. Wiring connections are made within the PT148-005 Pressure Switch which is prewired to the compressor pump. Simply connect your your positive line voltage to
the RED line connection marked “Line”, and ground to “Line” matching the
BLACK compressor wire. (14 gauge wire minimum, see recommended
wire gauge vs. length of run on the following page). For 24 Volt
Units, the electrical circuit should include a slow burn fuse or breaker rated for
15 amps. For 12 Volt Units, a 25 amp slow burn fuse or breaker should be used.
Refer to the installation drawing included with these instructions for additional
information. We recommend placing a single pole toggle switch in either of these
lines if not connected to a breaker panel, to disconnect the compressor when not
needed during storage periods etc.
5. The pressure switch mounted on the compressor will automatically switch on the
compressor when the pressure in the system is below 120 P.S.I. and turn
compressor off when pressure reaches 150 P.S.I. MAKE SURE THE SWITCH
ON THE SIDE OF THE PRESSURE SWITCH IS SET TO “AUTO”.
6. Upon initial installation of this system, verify that the compressor
pumps strongly to a pressure between 140-150 p.s.i. and shuts off.
You should here an audible “click” when the pressure switch
trips. The time to pump the system from 0 p.s.i. to 150 p.s.i.
should not exceed 5 minutes. If the pumping time exceeds 5
minutes and the system does not reach full pressure, immediately
disconnect power to the unit and see the troubleshooting list
below.
7. If you are installing a Kahlenberg V69-K solenoid valve kit, refer to
instruction sheet #306 for further guidance. (Shipped with valve kit)
Page 2 of 5
Kahlenberg
Instructions, P449 Series, P569-01A, P569-02A
03/23/2010
IMPORTANT!!!
RUN DISTANCE
WIRE GUAGE
Less than 10’
10’ to 35’
35 to 50’
50 to 70’
14 AWG
12 AWG
10 AWG
8 AWG
NOTE: THESE ARE THE WIRE GUAGES NECESSARY FOR
THE ENTIRE WIRING RUN TO YOUR POWER SOURCE
(BATTERY). IF THIS IS NOT DONE, IT WILL RESULT IN A
LOW AMPERAGE CONDITION AND SUBSEQUENT DAMAGE
TO THE COMPRESSOR UNIT.
SEE THE FOLLOWING PAGES FOR TROUBLESHOOTING
AND IMPORTANT SAFETY INFORMATION.
Page 3 of 5
Kahlenberg
Instructions, P449 Series, P569-01A, P569-02A
03/23/2010
TROUBLESHOOTING
IF THE COMPRESSOR DOES NOT SHUT OFF AFTER
APPROXIMATELY 5 MINUTES OR IF IT SHUTS OFF BUT
INTERMITTENTLY TRIES TO START UP (CHUGS),
IMMEDIATELY DISCONNECT POWER AND CHECK THE
FOLLOWING:
• VERIFY THE CURRENT AND WIRE SIZE (SEE ABOVE
SUGGESTED WIRE SIZES) GOING TO THE COMPRESSOR.
NOTE: THE 12-VOLT MOTOR REQUIRES 21 AMPS AT FULL
LOAD.
• CHECK THE SYSTEM FOR AIR LEAKS, AND CHECK THAT
THE DRAIN COCK ON THE TANK IS COMPLETELY CLOSED.
• MAKE SURE THE V-69K SOLENOID VALVE (IF SUPPLIED)
IS ORIENTATED PROPERLY. THE “1” STAMPED ON THE
BRASS BODY OF THE VALVE RECEIVES THE AIR FROM
THE COMPRESSOR/TANK AND THE OUTLET STAMPED
“2” IS CONNECTED TO THE HORN.
• IF THE COMPRESSOR DOES NOT OPERATE AT ALL, VERIFY
CURRENT SUPPLY, AND VERIFY THAT THE LEVER SWITCH
ON THE SIDE OF THE PRESSURE SWITCH (BLACK BOX ON
TOP OF COMPRESSOR PUMP) IS SET TO AUTO.
• CONTACT THE FACTORY IF NEEDED:
SALES/CUSTOMER SERVICE:
PH: 920-793-4507
FX: 920-793-1346
E-MAIL: info@kahlenberg.com
Page 4 of 5
Kahlenberg
Instructions, P449 Series, P569-01A, P569-02A
03/23/2010
IMPORTANT SAFETY INFORMATION
Read and understand the following information and instructions included
with this product before using. This information is for your safety and to
prevent damage to the product.
! CAUTION: To reduce risk of electric shock or electrocution:
1.
2.
3.
4.
Do not disassemble compressor pump. Disassembly or attempted repairs
if accomplished incorrectly can create electrical shock hazard.
Do not use this product in or near an area where it can fall or be pulled
into water or other liquids.
Do not reach for this product if it has fallen into liquid. Disconnect power
immediately.
Never operate this product outdoors in the rain or in a wet area.
! DANGER: To reduce risk of explosion or fire...
1.
2.
3.
4.
Do not use this product in or near explosive atmospheres or where
aerosol (spray) products are being used.
Do not pump anything other than atmospheric air.
Do not pump combustible liquids or vapors with this product or use in or
near an area where flammable or explosive liquids or vapors may exist.
Do not use this product near flames.
! CAUTION: To prevent injury...
1.
2.
3.
4.
5.
6.
Never operate this product if it has been dropped or damaged, or if it has
fallen into water. Return the product to the factory for examination and
repair.
This unit is thermally protected and can restart when the protector resets.
Always disconnect power source before servicing.
Use only in well ventilated areas.
Do not use any tools or attachments without first determining maximum air
pressure for that tool or attachment.
Never point any air nozzle or air sprayer toward another person or any
part of the body.
All electrical products generate heat. To avoid serious burns, never touch
unit during or immediately after operation.
Page 5 of 5
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