5307 & 5407.2.IA Op Manual

CompAir UK Ltd TO VIEW CONTENTS
Page 1
TO VIEW CONTENTS
USING MOUSE.
FROM TO MENU BAR SELECT WINDOW
PULL DOWN TO SHOW BOOKMARK AND CLICK.
ALTERNATIVELY PRESS (F5) ON THE KEYBOARD.
THE INDEX WILL NOW BE SHOWN ON THE LEFT.
SELECT BY CLICKING ON THE PARTICULAR SECTION REQUIRED

IN ADDITION BY CLICKING ON THE (+) MORE INFORMATION WILL BE SHOWN.
ADDITIONALLY IN SOME CIRCUMSTANCES INFORMATION CAN BE OBTAINED BY

CLICKING ON A PARTICULAR SECTION REQUIRED IN THE CONTENTS OR INDEX
PAGE OR A PARTICULAR ILLUSTRATION. THIS FEATURE IS NOT ALWAYS
AVAILABLE.
to view contents.doc
CompAir UK Ltd
OPERATOR HANDBOOK
for
H5307.2.IA & H5407.2.IA
Aircooled Air Compressors
In any correspondence please quote: JOB NUMBER:

MACHINE NUMBERS: (on nameplate)
PUBLICATION NUMBER: 98407/1213/03/07/01
ISSUE DATE: JULY 2001
CUSTOMER ORDER NUMBER:
CompAir UK Ltd. Ranelagh Road IPSWICH ENGLAND IP2 0AQ

Telephone: +44 (0) 1473 602222 Fax: +44 (0) 1473 601704 Parts Fax: +44 (0) 1473 601282 Service +44 (0) 1473 556027
www.CompAir.com e-mail: Ipswich@CompAir.com
CompAir UK Ltd
DECLARATION OF CONFORMITY
CERTIFICATE 'A' CATEGORY 1
98/37/EEC ( Known as the ‘Machinery Directive’ )
BS EN292: ( Safety of Machinery )
BS EN1012-1 ( Compressors - Safety Requirements )
We COMPAIR UK LIMITED
of RANELAGH ROAD, IPSWICH, ENGLAND IP2 0AQ
declare that under our sole responsibility for supply / manufacture, the machinery described below,
Machine Type Rotary Compressor Reciprocating Compressor

Other Pressure Equipment.
Model No. _________________________ Serial No.________________________________
is in conformity with the essential Health and Safety Requirements identified in the above
directives.
This machine/equipment is exempt from 97/23/EC the Pressure Equipment Directive, reference
Article 1 clauses 3.3 & 3.6.
IPSWICH, ENGLAND
Signature and name of responsible person
DATE __________________ ENGINEERING DIRECTOR

Position
Notified Body:
Lloyds Register
European Directive Services UK
Hiramford
Middlemarch Office Village
Coventry.
CV4 4FJ
(Notified Body Reference: 0038)
Conformity assessment procedure: Module H (H1 where appropriate)
Language.
English.
French.
German.
Spanish.
Italian.
Dutch.
conformityPED-A
CompAir UK Ltd
DECLARATION OF INCORPORATION
CERTIFICATE 'C' CATEGORY 1
98/37/EEC ( Known as the ‘Machinery Directive’ )
BS EN292: ( Safety of Machinery )
BS EN1012-1 ( Compressors - Safety Requirements )
We COMPAIR UK LIMITED
of RANELAGH ROAD, IPSWICH, ENGLAND IP2 0AQ
declare that under our sole responsibility for supply / manufacture, the machinery described below,
Machine Type Rotary Compressor Reciprocating Compressor

Other Pressure Equipment.
Model No. _________________________ Serial No. _______________________________
to which this declaration relates is in conformity with the essential Health and Safety Requirements
identified in the above Directives.
This machine/equipment is exempt from 97/23/EC the Pressure Equipment Directive, reference
Article 1 clauses 3.3 & 3.6
STATEMENT
This machinery must not be put into service until the machinery into which it is to be
incorporated has been declared in conformity with the provisions of the above Directives.
IPSWICH, ENGLAND
Signature and name of responsible person
DATE __________________ ENGINEERING DIRECTOR

Position
Notified Body:
Lloyds Register
European Directive Services UK
Hiramford
Middlemarch Office Village
Coventry.
CV4 4FJ
(Notified Body Reference: 0038)
Conformity assessment procedure: Module H (H1 where appropriate)
Language.
English.
French.
German.
Spanish.
Italian.
Dutch.
incorporationPED-C
COMPRESSOR LOG SHEET REF. NO.
COMPRESSOR PRIME MOVER INSTALLED AT OIL GRADE USED:
TYPE: TYPE: CHECK OIL LEVEL
SPEED: B.H.P. CHECK WATER IN/OUT TEMPERATURE
SERIAL NO: DRIVE: DATE INSTALLED: CHECK COOLING FAN BLADES
FINAL FINAL AIR SERVICE
DATE TIME *HOURS STAGE STAGE STAGE PRESSURES PRESSURE PLAN REMARKS SEE SIGNED
RUN TEMP.°C TEMP.°C #(BAR - PSI) #(BAR - PSI) NUMBER OVER FOR MORE
#50/100 1 2 3 4 5
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
5500
6000
6500
7000
7500
8000
8500
9000
9500
10000
10500
11000
11500
12000
12500
*FILL IN HOURS RUN AS DETAILED ON SERVICE PLAN FOR PARTICULAR COMPRESSOR TYPE
# DELETE AS NECESSARY - † FILL IN APPROPRIATE STAGE TRIP TEMPERATURE READING
SERVICE ENGINEER TO SIGN & FILL IN ANY OTHER COMMENTS IN REMARKS COLUMN
SERVICE TELEPHONE +44 (0) 1473 556027 - PARTS +44 (0) 1473 601282
logsheetm.doc
DATE REMARKS DATE REMARKS
logsheetm.doc
CompAir UK Ltd SAFETY SECTION
Page 1
OPERATOR MANUAL - 5000 SERIES AIR

COMPRESSORS
CONTENTS
Page
Ownership Data 2
Foreword 3
Safety Procedures 5
WARNING
The use of replacement parts or lubricating oils not supplied,
recommended or approved by CompAir UK Ltd Ipswich, or the failure to
maintain this equipment in accordance with the maintenance instructions,
may invalidate the WARRANTY, cause equipment failure, create unsafe or
hazardous conditions or result in damage to the equipment.
CompAir UK Ltd Ipswich cannot accept responsibility for damage,

injury or failure caused by these situations.
USE ONLY
CompAir UK Ltd Ipswich
GENUINE PARTS
AND
AUTHORISED SERVICE AGENTS
09/10/02 safety5.doc Page 1

Page 2
OWNERSHIP DATA
TECHNICAL DATA
It is recommended that details taken from the compressor and motor nameplates are recorded below.
Model Type: Motor Serial Number:
Serial Number Motor RPM:
Year: Motor kW:
Maximum Pressure: Motor V. Ph. Hz:
Compressor Lubricant: Motor Bearing Grease:

(if applicable)
Capacity M³/hr - CFM Notes:
CompAir UK Ltd Ipswich CONTACT DETAILS
Contact Name: Sales Telephone: +44 (0) 1473 602222
Address: Notes:
CompAir UK Ltd
Ranelagh Road
Ipswich IP2 0AQ
ENGLAND
Telephone: +44 (0) 1473 602222 Fax: +44 (0) 1473 601704
Contact Names: Parts Telephone: +44 (0) 1473 602222

Parts Fax: +44 (0) 1473 601282
Contact Names: Service: +44 (0) 1473 556027
For any comments or queries about the contents of this MANUAL please write to CompAir UK Ltd.
Ranelagh Road, Ipswich 1P2 0AQ. England marked for the attention of Mr. Dennis Beeton, Technical
Publications Engineer.
Page 2 09/10/02 safety5.doc

Page 3
FOREWORD
CompAir UK Ltd Ipswich H5000 Series compressors are designed and manufactured to give optimum
performance, with long life and reliability.
SPECIAL ATTENTION
The STANDARD BUILD of all CompAir UK Ltd (Ipswich Operations) products are not intended for use in
either Explosive or Potentially Explosive Atmospheres as defined in Directive 95/9/EC.
An Explosive atmosphere is a mixture with air, under atmospheric conditions, of flammable gases, vapours,
hazes or dusts in which, after ignition has occurred, combination propagates to the entire unburned mixture
and may cause a hazard.
A Potential Explosive atmosphere is an atmosphere, which could become explosive due to local
conditions.
This Manual will help you to obtain the best performance from your compressor. It provides the information
required to install, commission and operate the compressor and carry out regular maintenance schedules,
which will ensure the maximum satisfactory service life.
Included within the Manual is a comprehensive Parts List to allow the user to order spare parts for servicing.
Servicing facilities and the supply of genuine replacement parts are provided through a world-wide network
of CompAir Companies and CompAir UK Ltd Distributors, backed by the Service and Parts Departments at
CompAir UK Ltd, Ipswich (UK) tel: +44 (0) 1473 602222. fax: +44 (0) 1473 601704. Customer Service +44
(0) 1473 556027 or Parts fax: +44 (0) 1473 601282.
The information in this Manual was correct at the time of printing but modifications to parts and procedures
may be made without notice which could affect the servicing requirements of the compressor. Before any
servicing or maintenance work is undertaken the user is advised to contact the local CompAir Company or
CompAir UK Ltd Distributor for revised or up-dated information.
In any communication concerning the compressor it is essential to quote the MODEL, SERIAL No.
and any CONTRACT Ref.
It is important this Manual is retained with the compressor for reference and should remain with the
compressor if it is sold or transferred to another user. Ensure that the new user is made fully aware of the
need to study the Safety Section and any Warnings for safe operation given throughout the text.
Protect the environment by using only approved method of disposal of condensates lubricating oil etc.
Please note: a. Throughout the Manual all pressures quoted are gauge pressures.
b. Whilst recyclable materials are used as far as possible, please ensure when
disposing of condensate, spent oil, used filter elements and any discarded parts or
waste material of any kind make sure that there is no pollution to any natural water-
course, drain system and that no burning waste takes place which could cause
pollution of the atmosphere.

Page 4
CAUTION
Use only CompAir UK Ltd Ipswich Genuine Parts when carrying out routine maintenance or repair. The
use of replacement parts or lubricating oils not supplied or recommended by CompAir UK Ltd Ipswich can
lead to expensive failures, which will not be covered by warranty.
Substitution of parts not manufactured or approved by CompAir UK Ltd Ipswich can create a potential
personnel hazard.
This is a High Pressure Compressor, for safe and reliable operation use only
genuine CompAir UK Ltd Ipswich Parts
To ensure continued trouble free operation it is important that periodic servicing is carried out in accordance
with the information given in this manual - refer to the “Maintenance Section”.
Conditions of CompAir UK Ltd Ipswich warranty are stated in our Conditions of Sale. Details of warranty for a
particular unit may be obtained from the local CompAir Company or authorised Distributor.

Page 5
SAFETY PROCEDURES
Page
General.............................................................................. 7
Warnings, Cautions and Notes........................................ 7
General Safety Precautions ............................................. 7
Installation Precautions ................................................... 8
Operational Precautions .................................................. 8
Maintenance and Repair Precautions ............................. 9
Precautions in the Event of Fire..................................... 10

Page 6
SAFETY
• WARRANTY
The Conditions of the CompAir UK Ltd Ipswich Warranty are set out in the Standard Conditions of
Sale.
• MAINTENANCE
To ensure continued trouble free operation of the compressor it is important that periodic maintenance
and servicing are carried out in accordance with the information given in the "Maintenance" section of
this Manual. If any replacement or repair is needed use genuine CompAir UK Ltd Ipswich parts.
∗ WARNING
The use of replacement parts or lubricating oils not supplied or approved by
CompAir UK Ltd Ipswich may lead to failures in service which would not be
covered by warranty.
Any unauthorised modifications or failure to maintain this equipment in accordance with maintenance
instructions may make it unsafe. The use of replacement parts not supplied by CompAir UK Ltd Ipswich
may create hazardous conditions over which CompAir UK Ltd Ipswich has no control.
Such hazardous conditions may lead to accidents that can be life threatening, cause substantial bodily injury
or result in damage to the equipment. CompAir UK Ltd Ipswich can bear no responsibility for equipment
for which unapproved replacement parts are included.
SPECIAL NOTE:
THE FOLLOWING HEALTH AND SAFETY PRECAUTIONS MUST BE READ IN CONJUNCTION WITH
ANY OTHER MANUFACTURERS EQUIPMENT SUPPLIED.

Page 7
SAFETY
1. GENERAL
CompAir UK Ltd Ipswich compressor safety relates

to the document BS EN1012-1 Compressors and
Vacuum Pumps - Safety requirements and the UK RISK OF DANGER
Pressure Systems Health & Safety Regulations S.I.
No. 128.
• Most accidents which occur during the operation

and maintenance of machinery result of failure RISK OF ELECTRIC SHOCK
to observe basic safety rules or precautions.
Recognising a situation that is potentially
hazardous can often prevent an accident.
• When handling, operating or carrying out

maintenance on the unit, personnel must RISK OF HIGH PRESSURE
observe safe engineering practices and all
relevant local regulations. The attention of users
is drawn to the Health and Safety at Work Act
1974, and the regulations of the Institution of
Electrical Engineers.
RISK OF HOT SURFACE
• CompAir UK Ltd cannot anticipate every
possible circumstance, which might represent a
potential hazard. The WARNINGS in this
manual are therefore not all inclusive. If the user
employs an operating procedure, an item of
equipment or a method of working which is not RISK OF GAS EXHAUST
specifically recommended by CompAir UK Ltd
then they must ensure that the unit will not be
damaged or made unsafe and that there is no
risk to persons or property.
• Failure to observe these precautions given

under "Safety Precautions" may be considered CONSULT MANUAL
dangerous practice or misuse of the compressor
3. GENERAL SAFETY PRECAUTIONS
• Read and understand all WARNINGS,
CAUTION AND MANDATORY LABELS on the • When using cleaning solvents, local Health and
unit before operating or carrying out Safety Regulations must be complied with.
maintenance or servicing. Provide good ventilation and use suitable
protection such as a breathing filter mask, safety
2. WARNINGS, CAUTIONS & NOTES glass, protective apron and gloves.
• The following details for this Safety Section • Safety footwear should be compulsory in all
relate to the ESSENTIAL SAFETY workshops. Safety helmets must be worn if there
REQUIREMENTS referred to in Directive is any risk of falling objects.
89/392/EEC, Amended 91/286/EEC.
• If using compressed air for cleaning
purposes, ensure safety regulations are
complied with and appropriate clothing
worn.
• Warnings call for attention to operation
procedures involving specific hazards which • Never direct compressed air onto your skin or at
could cause injury or death and are identified by other people. Never use compressed air to clean
the following:- loose dirt from clothing.

Page 8
3. GENERAL SAFETY PRECAUTIONS (Cont.) be guarded or insulated. Other high temperature

• Before releasing compressed air through a hose pipework should be clearly marked and all
make sure the free end is held securely so that it pipework should be clearly marked.
cannot whip and cause injury.
5. OPERATIONAL PRECAUTIONS
• Avoid injury by using a hoist to lift heavy loads. • Competent personnel under a qualified
Check that all chains, hooks, shackles and supervisor must only operate the compressor.
slings are in good condition and are of the
correct capacity. They must be tested and • Do not operate compressor with any removable
approved according to local safety regulations. inspection cover removed e.g. crankcase doors,
valve covers etc.
• Cables, chains or ropes should never be applied
to lifting eyes. Always use an appropriate
• Never remove or tamper with safety devices,
shackle or hook, properly positioned. Arrange
guards or insulation materials.
lifting cables so that there are no sharp bends.
Use a spreader bar to avoid side loads on
• The compressor must only be operated at the
hooks, eyes and shackles and never leave a
supply voltage and frequency for which it is
heavy load unattended.
designed. Always isolate power before
maintenance or servicing.
• When a load is on a hoist stay clear of the
danger area beneath and around it. Keep lifting
• When mains power is ON, lethal voltages are
acceleration and speed within safe limits.
present in the electrical circuits and extreme
caution is need when essential work is carried
4. INSTALLATION PRECAUTIONS
out on the electrical system. ALWAYS
• Competent personnel under a qualified CONSULT A QUALIFIED ELECTRICIAN
supervisor must only carry out installation work. BEFORE ANY SUCH ESSENTIAL WORK.
• A fused isolator switch must be fitted between • Do not open starter compartment to touch
the main power supply and the compressor. electrical components while voltage is applied
unless it is necessary for measurement, test or
• Precautions must be taken to ensure that no adjustment. Such work should always be
injury is caused to passers-by through loose carried out by a qualified. Electrician with
clothing being sucked into compressor intake. appropriates tools and protection against an
electrical hazard.
• Ensure that the discharge pipe from the
compressor to the user pipework, receiver or • If the unit is equipped with a Remote Control
storage is free to expand and that no flammable device, attach warning notices stating "THIS
material is within the vicinity. If any such material UNIT CAN BE STARTED REMOTELY" in
is close-by take steps to preclude ignition. prominent locations, one on the outside of the
unit, the other inside the control compartment.
• A manual shut-off valve should be fitted in the
discharge line to allow the compressor to be • As a further safeguard, take adequate
isolated. Non return valves cannot be relied precautions that no one is working or checking
upon for isolating parts from a pressure system. the unit before attempting to switch on remotely
A safety valve must be installed between any controlled equipment. Attach a "CHECK THAT
compressor unit and the isolating valve. ALL PERSONNEL ARE CLEAR OF UNIT
BEFORE STARTING" or similar notice.
• A pressure-reliving device must be fitted to
every pressure vessel, or equipment containing • Compressed air and gas piping, together with
air or gas above atmospheric pressure. Never cooling water piping and other parts, with
remove or tamper with safety devices, guards or surface temperature greater than 70°C and may
insulation fitted. In order to limit the risk of be accidentally touched, should be guarded or
Legionnaires Disease, CompAir UK LTD advise insulated.
caution with the use of cooling towers for water
cooling the compressor. Closed circuit or direct
mains cooling is preferred.
• Pipework or other parts with a surface

temperature above 70°C, which may be
accidentally touched in normal operation, must

Page 9
• Wash the area with limewater and avoid

5. OPERATION PRECAUTIONS (Cont.) breathing any fumes. If contamination of the skin
• If there is any indication that the compressor is occurs washes with limewater and seeks
overheating it must be shutdown. (A high air or medical advice.
gas temperature switch is fitted as standard to
guard against operating with excessive Pre-Maintenance Operation
temperature). Beware of burns from hot oil and
water when working on a unit recently shutdown. • 1. Isolate the compressor from the main
electrical supply. Lock the isolator in the OFF
• Do not operate the unit when guards provided position and remove fuses.
for protection for all rotating and reciprocating
parts have been removed for essential
maintenance. Secure guards following any • 2. Attach a label " WORK IN PROGRESS - DO
servicing or repair. NOT APPLY VOLTAGE".
• Local noise regulations must be observed. Ear • 3. Close the isolating valve between the
defenders are suggested by Noise at Work compression unit and user's pipework. Close the
Regulations 1989 when the level is greater than isolating valve in the cooling water inlet pipe.
85 dB A at one meter. Be aware high noise Attach a label "WORK IN PROGRESS - DO
levels can interfere with communication. NOT OPEN".
6. MAINTENANCE & REPAIR PRECAUTIONS

• Competent persons under qualified supervisor • 4. Check that all pressurised gas trapped in the
must carry out maintenance repair and system is released to atmosphere or safely to
modifications. gas storage. Check that all pressure gauges
register zero.
• The compressor will have a preserving oil
applied to interior surfaces (Oil lubricated • 5. Ensure that the cooling water system has
models). Oil free models will have desiccant been drained.
bags in valve covers and distance pieces.
• 6. Check that the drain valve on the delivery
• Handling components such as seals, gaskets
manifold is clear and gas pressure has been
and diaphragms should not present a personnel
released.
hazard. Preservation oils again should not
present a personnel hazard if handled under
normal handling practices. • 7. Check that all interstage drains are open to
ensure any gas trapped between stages has
• Whilst compressors are asbestos free, treat all been released.
damaged gaskets as asbestos - when the
Asbestos at work regulations apply. • Stand clear of all valve covers when removing
the securing screws.
• Viton 'O' seals under normal operating
conditions are safe. • When removing valve covers for valve
replacement, ensure a minimum of two threads
• However, should there be a fire within the is left engaged on the valve cover securing
compressor or these seals are likely to exceed a screws. Lever the valve cover until the 'O' seal is
temperature of 300°C the material will disengaged from the port in the cylinder head.
decompose. Remove the securing screws and take out valve
cover.
• Degraded Viton gives off Hydrogen Fluoride
fumes and if in contact with the skin an acid • Use only lubricating oils and greases
formed causes severe burns. approved by CompAir UK LTD to avoid
potential hazards especially the risk of
• If Viton seals appear charred or gummy do not explosion or fire and the possibility of
touch with unprotected hands: use neoprene or decomposition or generation of hazardous
PVC gloves. gases.
• Always clean oil spills from the surrounding floor

before and after maintenance work.

Page 10
6. MAINTENANCE & REPAIR (Cont.) • Keep the compressor clean at all times.
• Make sure all instructions concerning operation • Protect components and exposed openings by
and maintenance are strictly followed and that covering with a clean cloth or tape during repair
the complete unit, with all accessories and or maintenance work.
safety devices, is kept in good order.
• Protect the motor, intake, electrical and
• The accuracy of pressure gauges and regulation components against the entry of
temperature switches should be regularly moisture e.g. steam cleaning.
checked at least 13 month intervals and
thoroughly examined at least every 48 months. • Precautions must be taken when carrying out
They must be renewed or service exchanged welding or any repair operation which generates
when acceptable tolerances are exceeded. flames or sparks. The adjacent components
must be screened with non-flammable material
• Protection devices should be tested at each and if oil present, the system must first be
regular service interval and replaced or service cleansed thoroughly by steam cleaning.
exchanged if not functioning correctly. The
maximum pressure for safety valves under fault • Condensate (oil and water mixture from
conditions is 1.10 times the set pressure, the set compression process) must be regarded as
pressure being a minimum of 1.05 times the trade effluent and is therefore not suitable for
maximum operating pressure to ensure seat discharge into a surface water sewer, soakaway
tightness. or watercourse.
• Never use a light source with an open flame for PROTECT THE ENVIRONMENT USE APPROVED
inspection. METHODS OF DISPOSAL.
• Before dismantling any part of the compressor 7. PRECAUTIONS IN THE EVENT OF FIRE
be sure that all heavy movable parts are secure.
• Use extreme caution when handling
components that have been subjected to fire or
• After completion of any maintenance or repair very high temperature. Some components may
ensure that no tools, loose items or rags are left
contain fluoroelastomer materials, which
on or inside the compressor.
decompose under these conditions to form
highly corrosive residues. Skin contact can
• Do not use any flammable liquid to clean valves, cause painful and penetrating burns resulting in
filter elements, cooler passages, pipe bores or permanent skin and tissue damage.
any component carrying a flow of air or gas
during normal operation. If chlorinated
hydrocarbon substances are used for cleaning, This is a high pressure Compressor
safety precautions must be taken against toxic use only:
vapours, which may be released. GENUINE
CompAir UK Ltd Ipswich
PARTS
DO NOT USE CARBON TETRACHLORIDE.
• Precautions must be taken against using acids,

alkalis and chemical detergents for cleaning
machined parts. These materials cause irritation
and are corrosive to the skin, eyes, nose and
throat. Avoid splashes and wear suitable
protective clothing and safety glasses. Do not
breathe mists. Ensure water and soap is readily
available.
• When disposing of condensate, old oil, used

filter elements and other parts and waste
material of any kind make sure that there is no
pollution to any drain or natural water course
and that no burning of waste takes place which
could cause pollution of the atmosphere.

CompAir UK Ltd PUBLICATION 98407/1213
Page 1
AMENDMENTS
H-5307.2.IA & H-5407.2.IA HANDBOOK

ISSUE No. MOD NOTE No. M/C SERIAL No. DATE PAGE No’s
1 NEW - NOV 1997 ALL
2 2 - R004949 43
3 3 Renumber pages. JULY 2001
Oil level & filter/restrictor recommendations 11 to 14
4 4 Correct service plans Piston Ring Kits APRIL 2002 17 to 25
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
1213.doc 30/08/02 Page 1

Page 2
Page 2 1213.doc 30/08/02

Page 3
INDEX
PAGE
CERTIFICATE OF CONFORMITY/INCORPORATION. ----------------------------------- ex
COMPRESSOR LOG SHEET. ------------------------------------------------------------------- ex
SAFETY GENERAL -------------------------------------------------------------------------------- ex
AMENDMENTS ---------------------------------------------------------------------------------------1
INDEX ---------------------------------------------------------------------------------------------------3
SECTION 1 GENERAL DESCRIPTION AND OPERATION 5
1.1 GENERAL -------------------------------------------------------------------------5
1.2 RUNNING GEAR ----------------------------------------------------------------5
1.3 VALVES----------------------------------------------------------------------------5
1.4 LUBRICATION -------------------------------------------------------------------5
1.5 GAUGES --------------------------------------------------------------------------6
SECTION 2 LEADING PARTICULARS 7
2.1 UNIT DESIGNATION -----------------------------------------------------------7
2.2 TECHNICAL DATA--------------------------------------------------------------7
2.3 STAGE PRESSURES ----------------------------------------------------------7
2.4 GENERAL -------------------------------------------------------------------------7
2.5 INCLINATION --------------------------------------------------------------------7
2.6 DIMENSIONS --------------------------------------------------------------------7
2.7 SPEEDS ---------------------------------------------------------------------------8
2.8 TEMPERATURES---------------------------------------------------------------8
2.9 LUBRICANTS --------------------------------------------------------------------8
2.10 TORQUE WRENCH SETTINGS CLASS 'A' ------------------------------8
2.11 TORQUE WRENCH SETTINGS CLASS 'B' ------------------------------8
SECTION 3 INSTALLATION 9
3.1 GENERAL -------------------------------------------------------------------------9
3.2 UNPACKING----------------------------------------------------------------------9
3.3 HANDLING ------------------------------------------------------------------------9
3.4 MOUNTING -----------------------------------------------------------------------9
3.5 BELT DRIVE ----------------------------------------------------------------------9
3.6 CONNECTIONS, PIPEWORK AND FITTINGS --------------------------9
3.7 ELECTRICAL -------------------------------------------------------------------- 10
3.8 SITING REQUIREMENTS --------------------------------------------------- 10
SECTION 4 COMMISSIONING 11
4.1 LUBRICATION ------------------------------------------------------------------ 11
4.2 BEFORE STARTING ---------------------------------------------------------- 11
4.3 STARTING-UP PROCEDURE ---------------------------------------------- 11
4.4 OIL REGULATOR SETTING ------------------------------------------------ 12
4.5 MAINTENANCE----------------------------------------------------------------- 12
SECTION 5 OPERATION AND ROUTINE MAINTENANCE 15
5.1 OPERATION AND DAILY MAINTENANCE ---------------------------- 15
5.2 STARTING UP----------------------------------------------------------------- 15
5.3 RUNNING ON LOAD--------------------------------------------------------- 15
5.4 STOPPING --------------------------------------------------------------------- 15
5.5 STANDING IDLE -------------------------------------------------------------- 15
5.6 ROUTINE MAINTENANCE & SERVICE PLANS ---------------------- 16
5.7 BELT ADJUSTMENT--------------------------------------------------------- 25
5.8 RECOMMENDED VEE BELT ALIGNMENT & TENSIONING------ 26
5.9 RECOMMENDED TENSIONING FORCES ---------------------------- 26
5.10 ADJUSTMENT METHOD --------------------------------------------------- 26
5.11 BELT TENSIONING TABLE------------------------------------------------ 27
5.12 METHOD OF BELT TENSIONING,
USING BELT TENSIONING INDICATOR------------------------------- 27
1213.doc 30/08/02 Page 3

Page 4
SECTION 6 DISMANTLING AND REASSEMBLY OF VALVES 29

6.1 GENERAL-------------------------------------------------------------------------- 29
6.2 VALVE REMOVAL HANDLING----------------------------------------------- 29
6.3 FIRST STAGE VALVES -------------------------------------------------------- 31
6.4 SECOND STAGE VALVES---------------------------------------------------- 33
6.5 THIRD STAGE VALVE --------------------------------------------------------- 35
6.6 FOURTH STAGE VALVE ------------------------------------------------------ 37
SECTION 7 FAULT GUIDE 39
7.1 EXCESSIVE STAGE PRESSURES ----------------------------------------- 39
7.2 INSUFFICIENT PRESSURE OR VOLUME-------------------------------- 39
7.3 OVERHEATING ------------------------------------------------------------------ 40
7.4 EXCESSIVE NOISE ------------------------------------------------------------- 40
7.5 EXTENDED RUNNING --------------------------------------------------------- 40
7.6 EXCESSIVE WEAR ------------------------------------------------------------- 40
7.7 FAILURE TO START------------------------------------------------------------ 40
7.8 LOW OIL PRESSURE ---------------------------------------------------------- 40
SECTION 8 PARTS LISTS & DRAWINGS 41
8.1 1ST STAGE VALVES - SUCTION & DELIVERY------------------------- 42
8.2 2ND STAGE VALVES - SUCTION & DELIVERY ------------------------ 42
8.3 3RD STAGE VALVE - CONCENTRIC -------------------------------------- 43
8.4 4TH STAGE VALVE - CONCENTRIC -------------------------------------- 43
8.5 OVERHAUL - MAINTENANCE, JOINT - KITS---------------------------- 43
8.6 BASIC INDUSTRIAL COMPRESSOR ------------------------------5307.2.IA
8.7 BASIC INDUSTRIAL COMPRESSOR ------------------------------5307.2.IA.USA
8.8 BASIC INDUSTRIAL COMPRESSOR ------------------------------5407.2.IA
8.9 BASIC INDUSTRIAL COMPRESSOR ------------------------------5407.2.IA.USA
8.10 CRANKCASE, CRANKSHAFT & CONNECTING RODS-------A30175
8.11 OIL SEAL ASSEMBLY--------------------------------------------------D101501
8.12 1ST & 4TH STAGE CYLINDERS & PISTONS (5407.2.IA) ----E61441
8.13 1ST STAGE CYLINDER & PISTON (5307.2.IA) -----------------E61497
8.14 2ND & 3RD STAGE CYLINDERS & PISTONS -------------------E61442
8.15 3RD STAGE SEPARATOR--------------------------------------------D101509
8.16 1ST STAGE COOLER ASSEMBLY ---------------------------------E61450
8.17 2ND STAGE COOLER ASSEMBLY---------------------------------E61447
8.18 3RD STAGE COOLER ASSEMBLY (5407.2.IA) -----------------E61446
8.19 3RD STAGE COOLER ASSEMBLY (5307.2.IA) -----------------E61494
8.20 4TH STAGE COOLER ASSEMBLY ---------------------------------E61451
8.21 2ND STAGE SUCTION PIPE -----------------------------------------C203453
8.22 3RD STAGE SUCTION PIPE -----------------------------------------C203445
8.23 4TH STAGE SUCTION PIPE -----------------------------------------C203446
8.24 LUBRICATION ASSEMBLY (5407.2.IA)----------------------------E61426
8.25 LUBRICATION ASSEMBLY (5307.2.IA)----------------------------E61498
8.26 FLYWHEEL ASSEMBLY -----------------------------------------------E61421
8.27 SAFETY VALVES --------------------------------------------------------E61449
SECTION 9 ANCILLARY PART PUBLICATIONS 45
Page 4 1213.doc 30/08/02

Page 5
SECTION 1
GENERAL DESCRIPTION AND OPERATION

1.1 5407.2.IA
This compressor is a high pressure, reciprocating ‘V’ configuration, four cylinder machine cooled by
a large pulley driven variable pitch fan.
Air enters via the intake filter and passes to the first stage cylinder where it is compressed before
passing through a heat exchanger to the second stage. On exit from the second stage it flows
round a cooling system positioned in the fan airstream and then into a separator for condensate
removal. On entering the third stage (final stage on 5307.2.IA) the air is further compressed before
passing through the second cooling coil and condensate removal separator. Final compression
takes place in the fourth stage (third stage on 5307.2.IA) before passing through a finned final
cooling system (not on 5307.2.IA).
1.1.1 5307.2.IA
This compressor has the fourth stage piston removed from the 5407.2.IA thus making a three
cylinder compressor working at a final lower pressure.
All stages are protected by safety valves. Final stage safety valve must be fitted in the system
before any restriction occurs, i.e. non-return valve etc.
1.2 RUNNING GEAR
Main bearings are replaceable, but big end and small end bearings are renewable only as a
connecting rod assembly.
1.3 VALVES
First and second stage valves are separate flat plate units for suction and delivery duties whilst the
third and fourth stage utilise integral cylinder head combined suction and delivery valve assemblies.
All valves are easily accessible, for maintenance and replacement when required.
1.4 LUBRICATION
5407.2.IA A cam operated force feed oil pump feeds oil through an oil filter to the bottom of the
final stage liner/plunger and then returns to the crankcase.
5307.2.IA A cam operated force feed oil pump feeds oil through an oil filter to the bottom of the
dummy stage liner/plunger and then returns to the crankcase.
First, second and third stage cylinders, main, big and small end bearings are all oil mist lubricated.
Lubricant returns to the sump for filtration and re-circulation. The specified lubricant must be used
at all times to ensure safe and efficient operation with minimum wear and maximum protection
against corrosion.
Recommendations are the result of extensive research at CompAir UK Ltd Ipswich Works and all
responsibility for the use of any oil other than that recommended is placed on the purchaser and his
oil company.
THE NORMAL GUARANTEE MAY BE INVALIDATED SHOULD A FAILURE BE ATTRIBUTED BY

COMPAIR UK LTD, IPSWICH TO THE USE OF A LUBRICANT NOT RECOMMENDED.
1213.doc 30/08/02 Page 5

Page 6
1.5 GAUGES
Pressure gauges may be fitted to this machine to monitor all stages, and final delivery pressure.
5407.2.IA A tapping in the oil filter body can be connected to a pressure gauge for monitoring
oil pressure when required.
Page 6 1213.doc 30/08/02

Page 7
SECTION 2
LEADING PARTICULARS
2.1 UNIT DESIGNATION
Belt driven, high pressure, air cooled compressor.
2.2 TECHNICAL DATA
5407.2.IA Type.......................................................... Four stage, four cylinder V configuration

5307.2.IA Type.......................................................... Three stage, three cylinder V configuration
Cooling ..................................................................... Fan activated air
Direction of rotation viewed from driving end ............ Anti-clockwise
Type of valves ........................................................... Single and combined, multi ported
2.3 STAGE PRESSURES
5407.2.IA
1st stage (Bar) 2nd stage (Bar) 3rd stage (Bar) Delivery (Bar)
Maximum.........................4.3/4.8 .................20.0/22.1 ...............81.4/90.0 .................350
Minimum:........................4.1/4.6 .................18.7/20.8 ...............61.2/69.6 .................140
Inlet Pressure ........................................................... ..................0.03 Bar g

Safety valve set pressure ......................................... 1st stage .................... 5.86 Bar
........................................................................ 2nd stage .. ................ 26.5 Bar
........................................................................ 3rd stage... ................ 96.5 Bar
........................................................................ Final stage supply...... +5-10%
5307.2.IA
1st stage (Bar) 2nd stage (Bar) Delivery (Bar)
Maximum.........................4.3/4.5 .................17.8/20.0 .................... 80
Minimum:.........................3.9/4.3 .................17.0/19.0 .................... 55
Inlet Pressure ........................................................... 0.03 Bar g

Safety valve set pressure ......................................... 1st stage ................... 5.86 Bar
........................................................................ 2nd stage .. ................ 26.5 Bar
........................................................................ Final stage supply...... +5-10%
Oil Pressure ............................................................. ..................0.7 to 2.7 Bar g (warm)
Oil Pressure ............................................................. ..................3 to 5 Bar g (cold)
Note:- If the oil pressure rises in excess of 7.5 bar g this could indicate a blocked filter.
(see page 12)
2.4 GENERAL
Cooling air flow rate (approx.) at 1800 rpm.............. ..................................... 7000 m3 / Hr

Noise level at 3 metres (approx.) ............................. ..................................... 87 dB (a)
First stage piston displacement................................ ..................................... 39.6 m3 / Hr
2.5 INCLINATION
Maximum permissible inclination of machine

In line with crankshaft............................................... ..................................... 20º
90º to crankshaft ...................................................... ..................................... 30º
2.6 DIMENSIONS
First stage cylinder bore ........................................... ..................................... 92mm

Second stage cylinder bore...................................... ..................................... 50mm
1213.doc 30/08/02 Page 7

Page 8
Third stage cylinder bore .......................................... ..................................... 22mm

Fourth stage cylinder bore........................................ ..................................... 11mm
Stroke ....................................................................... ..................................... 56mm
Final delivery O/D pipe connection (5407.2.IA) ........ ..................................... 8mm
Final delivery pipe connection (5307.2.IA)............... ..................................... 1/4 BSPT
First stage suction connection.................................. ..................................... RP 1
2.7 SPEEDS
Compressor speed (Max.)........................................ ..................................... 1800 rpm

Mean piston speed ................................................... ..................................... 3.35 m/s
2.8 TEMPERATURES (NORMALLY RECOMMENDED)
Ambient and air inlet temperature ............................ ..................................... Min -10ºC

....................................................................... ..................................... Max. 45ºC
NOTE It is extremely difficult to accurately record air temperature by measuring the surface metal
temperature, due to air flow from the fan cooling down the reading. However as a general guide, no
metal surface temperature should exceed 160ºC.
2.9 LUBRICANTS
Recommended oil - synthetic only.................. Reavellite ‘S’ 0 to 45°C. .. Reavellite ‘W’ -15 to 10°C
Sump capacity.............................................. .. ........................................ 4.9 litres
Top Up from minimum.................................... ........................................ 2.7 litres
Recommended grease (for assembly)........... ........................................ Shell Alvania R3
2.10 CLASS A - CRITICAL TORQUE SETTINGS
All figures ± 5%
FOR NON LUBRICATED FASTENERS

ASSEMBLY SIZE LBF/FT NEWTON METRE (Nm)
1st stage valve cover M6 4 5.4
1st stage valve M6 3 4
2nd stage valve cover M6 4 5.4
2nd stage valve M6 3 4
3rd stage valve to cylinder M8 12 16
3rd stage valve M5 4.5 6
4th stage valve to cylinder M8 12 16
4th stage valve M4 2.9 4
Flywheel M10 LH 40 55
Oil pump cam M10 LH 40 55
Oil pump restrictor 1/8" BSP 4 5.4
Balance weight M8 20 27
2.11 CLASS B - ADVISED TORQUE SETTINGS
All figures +5% - 15%

ASSEMBLY SIZE LBF/FT NEWTON METRE (Nm)
All Other Fasteners M6 6 8
M8 15 20
M10 30 40
M12 52 71
Page 8 1213.doc 30/08/02

Page 9
SECTION 3
INSTALLATION
3.1 GENERAL
Compressor must be situated in a level, well ventilated position clear of fumes, heat or high
humidity to ensure efficient performance and also to prevent over temperature problems. If sited in
a large building there should be few problems, provided there is a reasonable air gap between the
front and back of the compressor and any obstructions. If positioned in a small or confined
building, clean cooling air must be directed or ducted towards the compressor fan ensuring that
there is also no air flow short circuit. As all motor power is dissipated in heat to the cooling air, it is
essential that expired cooling air has an unobstructed passage and exit. Another important factor
is that all coolers should be maintained in a clean condition to attain maximum dissipation of
compression heat.
Allow sufficient space around the installation to enable safe maintenance working conditions.
Suitable lifting equipment should be readily available.
Protection from severe weather conditions is desirable.
3.2 UNPACKING
Unless the compressor set is delivered uncrated it is possible that certain components will be
packed within the crate. To avoid the loss of any items please ensure that any such equipment is
located and removed first.
After unpacking, fit any items which were loose and are now required for installation of the set.
3.3 HANDLING
Before attempting to lift the set, ensure that suitable lifting equipment is available. When lifting by
crane or hoist ensure that the lifting lugs are used. Check that the lifting tackle is held clear of any
components such as switches and belt guard etc.
3.4 MOUNTING
For permanent installation seating must be flat, level and designed to support the weight and any
out of balance forces.
3.5 BELT DRIVE
Anti-static banded belts must be used at all times.
Ensure that driving and driven pulley grooves are in line and shafts are parallel before and after
fixing. Tensioning procedures follow normal practice. See 5.7 BELT ADJUSTMENT.
3.6 CONNECTIONS, PIPEWORK AND FITTINGS
3.6.1 All piping and connections must be suitable for the pressures and capacities involved.
3.6.2 Ensure all port protection plugs and blanks are removed and that all pipes, especially
suction piping are free from jointing compound, pipe scale, swarf, dirt or other foreign
matter before final pipe assembly.
3.6.3 A suction filter must always be fitted to prevent damage and excessive wear.
1213.doc 30/08/02 Page 9

Page 10
3.6.4 Safety valves are fitted on all stages as standard equipment. However, safety valves
must also be fitted to the receiver and pipework system to protect from excess pressure
build up.
3.7 ELECTRICAL
The electrical connections to the set must always comply with any local regulations which are
applicable, and be suitable for the loads involved. Wiring must be installed by an electrician
competent to work with hazardous area stipulations.
3.8 SITING REQUIREMENTS
(Diagrams not to scale)
RECOMMENDED INSTALLATION INCORRECT INSTALLATION

COOLING AIR ENTERS, PASSES OVER
MACHINE AND AS HEATED AIR, IT IS COOLING AIR ENTERS, PASSES OVER
EXHAUSTED FROM THE MACHINE. MACHINE AND THEN AS HEATED AIR, RE-
ENVIRONMENT CIRCULATES IN MACHINE ENVIRONMENT.
BAFFLE TO
PREVENT
RECIRCULATING
RECOMMENDED INSTALLATION IN SMALL AREAS
Page 10 1213.doc 30/08/02

Page 11
SECTION 4
COMMISSIONING
WARNING
BEFORE OPERATING THIS EQUIPMENT USERS SHOULD BE MADE AWARE OF AND ENSURE
COMPLIANCE WITH THE HEALTH AND SAFETY REGULATIONS APPROPRIATE TO THIS CLASS OF
WORK. ATTENTION OF UK USERS IS DRAWN TO THE HEALTH AND SAFETY AT WORK ACT, 1974 &
CONTROL OF SUBSTANCES HAZARDOUS TO HEALTH REGULATIONS 1988.
TAMPERING WITH SAFETY VALVES IS DANGEROUS AND ALSO INVALIDATES THE GUARANTEE.
COMMISSIONING OR STARTING A NEW OR OVERHAULED UNIT
SUCTION FILTER
OIL FILLER
4TH STAGE
OIL FILTER
1ST STAGE
SAFETY VALVE 2ND STAGE
SAFETY VALVE
3RD STAGE
SAFETY VALVE
OIL LEVEL
OIL DRAIN GAUGE
4.1 IMPORTANT - LUBRICATION
The recommended lubrication is REAVELLITE, a synthetic oil.
There are some materials, e.g. certain rubbers, paints, plastics and metals, which are not
compatible with synthetic oils. Components on these compressors are synthetic oil compatible but
a problem may exist with ancillary equipment. Consult equipment manufacturer to determine
compatibility.
4.2 BEFORE STARTING
Before attempting to start a new or overhauled unit the operator should be familiar with all
controls and safety devices which are fitted.
4.2.1 Check complete installation, including pipework. Ensure driving belt tension is correct.
See SECTION 5.7
4.2.2 Remove dry type suction filter element, blow over with low pressure air and re-insert in
casing.
1213.doc 30/08/02 Page 11

Page 12
4.2.3 Ensure silencer bore and pipework is clean and blank removed from suction pipe.
4.2.4 Ensure crankcase is filled to 2mm to the TOP level on sight glass with REAVELLITE
synthetic oil. Do not overfill - over lubrication is harmful. Never allow oil level to go below
2mm from bottom of sight glass.
Bearing Cover (1)
MAXIMUM Oil Level

Rotation Arrow 2 mm below here.
MINIMUM Oil Level

2 mm above here.
4.2.5 If machine has been idle for six months or more, remove oil pump bearing cover (1) and
lubricate the bearing before starting up. ENSURE FOURTH STAGE PLUNGER IS
WELL LUBRICATED WITH RECOMMENDED OIL.
4.3 START-UP PROCEDURE
4.3.1 Rotate the compressor at least twice by hand to ascertain free movement. If any
restrictions to movement are discovered the cause must be investigated and corrected
before attempting to start the compressor.
4.3.2 Operate starter and immediately check rotation, check pressure gauge for stage air
flow. Correct rotation, i.e. anti-clockwise when viewed on driving end, it is essential to
achieve cooling air flow through fan to compressor.
4.3.3 Check that all pipework and electrical cables are secure and connections are tight.
Visually check for any oil leaks. Use soapy water when checking for air leaks.
4.3.4 Check oil pressure.
4.3.5 After 30 minutes operation, check valve covers. Intake pipe to valve covers should be
hand warm and outlet pipes hot. Caution must be exercised when checking this.
4.3.6 The set should be run for at least one hour before being put into operational service.
4.3.7 Stop compressor and verify complete blow down, i.e. no residual air pressure remains
in any stage of the stopped machine.
4.3.8 Re-check crankcase oil level and top up if necessary.
Page 12 1213.doc 30/08/02

Page 13
4.4 OIL FILTER - PRESSURE CHECK (Refer to PARTS LIST)
4.4.1 If a pressure gauge is not fitted as standard.
4.4.2 Isolate machine from electric supply and release all pressures from machine, pipework
and receivers.
4.4.3 Remove 1/4" BSP plug (10) from the oil regulator body and fit in its place a 0-16 bar
certified pressure gauge
4.4.3 Reconnect electric supply and run up to working pressure.
4.4.4 Observe gauge reading, this should be between 0.7 to 2.7 Bar. Note:- If starting from
cold the pressure could initially be higher up to 5 Bar.
4.4.5 If the oil pressure rises to 7.5 Bar when warm the indications are the oil filter need
replacing.
and receivers.
By Pass valve
15B
Optional Pressure
Gauge Connection.
Optional Low Oil

Pressure Switch
Connection.
NEW FILTER UNIT ARRANGEMENT
4.4.8 Unscrew filter housing (8) remove old oil filter, fit new, replace filter housing tighten hand
tight.
4.4.10 If the oil pressure remains high after changing the oil filter, the restrictor (15B) is
possibly blocked.
and receivers.
4.4.12 Unscrew filter housing (8) remove oil filter, unscrew restrictor (15B), blow out any
restriction blockage and replace. Note: Do not overtighten, torque to 4 lbf/ft (5.4Nm)
only. Replace oil filter and filter housing, tighten hand tight.
4.4.14 Re-check oil pressure.
1213.doc 30/08/02 Page 13

Page 14
4.4.15 Finally, stop the compressor ensuring all pressure is released and machine is
electrically isolated. Remove oil pressure gauge and replace 1/8" BSP plug if necessary.
OIL IN
FROM PUMP.
EXCESS OIL
OUT TO
CRANKCASE
4.5 MAINTENANCE
4.5.1 After First 15 Hours Running Time
Ensuring that alignment and belt tensioning is correct.
4.5.2 After First 50 Hours Running Time
Change oil in crankcase. Fit new oil filter. When changing oil drain whilst warm then
slowly pour fresh oil into filter neck. Wait 5 minutes, then start the compressor. With
machine still running, loosen vent screw in bottom of oil pump and bleed until bubble
free oil emerges. Stop machine and top-up crankcase. Examine valves. For tightening
torque’s see SECTION 2.
4.5.3 The next oil change will be after 1000 Hours running time
See RSP 5307.2.IA/S, 5307.2.IA/SW, 5407.2.IA/S and 5407.2.IA/SW for more details on
RECOMMENDED SERVICING
Page 14 1213.doc 30/08/02

Page 15
SECTION 5
OPERATION AND ROUTINE MAINTENANCE

5.1 OPERATION AND DAILY MAINTENANCE
Commissioning procedure (SECTION 4) should be used
a) For the first commissioning run;

b) Following overhaul;
c) After standing idle for a long period.
Crankcase oil needs to be changed after a major overhaul. Starting procedure should be
observed after valve overhaul.
Keep exterior of the compressor clean, especially pipe connections and joints, as this will assist in
detecting any leaks. Ensure finned final stage cooler coil is clean at all times.
5.2 STARTING UP
Check crankcase oil level, top up, if necessary, with recommended oil to MAXIMUM mark on
sight glass.
5.2.1 Operate starter and bring onto load. Check machine rotates anti-clockwise when viewed
from the drive end. Oil level will drop in sight glass when machine is running.
5.2.2 Whilst the compressor is running, listen for any noises indicative of mechanical failure.
Stop and investigate if
a) Any uncharacteristic noises commence;

b) Any safety valve opens.
THE CAUSE OF A SAFETY VALVE OPENING MUST BE INVESTIGATED AND RECTIFIED. DO NOT
ATTEMPT TO PREVENT A VALVE OPENING BY TAMPERING WITH ITS SETTING. THIS IS
EXTREMELY DANGEROUS.
5.3 RUNNING ON LOAD
Stop machine at 30 minute intervals (more often in high humidity conditions) to clear condensate,
if an automatic timed drainage system is not fitted.
5.4 STOPPING
Stop compressor from motor control panel.
5.5 STANDING IDLE - INHIBITION PROCEDURE
Condensate drains will automatically be left open.
If machine is to stand idle for more than five weeks (or shorter period if ambient conditions are
unfavourable) it is advisable to carry out recommended inhibition procedure;
5.5.1 Fill to the required level with Shell Ensis 20.
5.5.2 Run the compressor.
5.5.3 Switch off the machine.
1213.doc 30/08/02 Page 15

Page 16
5.5.4 Release separator drain screws.
5.5.5 Remove first and second stage valve covers and valves.
5.5.6 Clean all valves, valve covers and valve chambers, dry with lint free cloth.
5.5.7 Spray valves, valve cover, valve chambers and cylinders with PX.4. Shake valves to
remove excess.
5.5.8 Fit valves, examine ‘O’ rings of valve covers before assembly and replace if necessary.
Tighten valve covers to correct torque setting.
5.5.9 Release third stage suction pipe.
5.5.10 Spray PX.4 into suction side of third stage and rotate machine by hand.
5.5.11 Reassemble third stage suction pipe.
5.5.12 Drain sump of oil.
5.5.13 Seal all openings with threaded plastic plugs.
5.6 MAINTENANCE SCHEDULE
WARNING
BEFORE MAINTENANCE OR DISMANTLING, ISOLATE ALL ELECTRICAL SUPPLY FROM MACHINE

AND ANCILLARY EQUIPMENT. ISOLATE COMPRESSOR FROM STORAGE PIPEWORK AND RELEASE
PRESSURE FROM ALL COMPRESSOR STAGES, PIPEWORK OR STORAGE VESSELS.
THE ATTENTION OF UK USERS IS DRAWN TO THE HEALTH & SAFETY AT WORK ACT 1975 AND
CONTROL OF SUBSTANCES HAZARDOUS TO HEALTH REGULATIONS 1988.
Note: Regular servicing is essential if the design performance of the compressor is to be

maintained. Maintenance intervals will depend on operating conditions and the following
intervals can be used as a guide when the machine is operated under normal
conditions, and may be extended with operating experience. Examination and
monitoring during commissioning will give a good indication of the machines anticipated
maintenance requirements.
Observe the following points:
A. If pressure gauges are fitted, check stages pressures are within stated limits - if not
fitted, check that safety valves are not operating. The stage pressures give an indication
of any valve problems. If a stage pressure increases, investigate the valves in the next
stage. For a lower pressure than required, check valve on that stage. Always stop
machine if a safety valve opens/
B. Check that oil is visible in sight feed unit.
C. Examine for oil or air leaks which must be rectified immediately.
NEVER TIGHTEN ANY FITTING WHEN IT IS UNDER PRESSURE
Note: Valve plates and springs should be replaced at valve inspection periods.
5.6.1 Weekly
Page 16 1213.doc 30/08/02

Page 17
In addition to operational checks, inspect all nuts, screws and fittings for tightness.
Inspect for oil or air leaks, which must be rectified immediately.
5.6.2 Periodically
Remove and renew disposable suction filter, depending on operating conditions i.e.
dusty environment.
5.6.3 RECOMMENDED SERVICE PLAN - 5307.2.IA SYNTHETIC OIL

STANDARD GRADE
INITIAL SERVICE Change oil, oil filter element.

50 HOURS OR
ELAPSED TIME No Part RefRSP
6 MONTHS Off R-5307.2.IA/s.1
REPEAT AT 8000 Change oil (sump capacity 4.9 litres) REAVELLITE 'S' 5 Litre 1 98384/1001
HOURS MAJOR Oil filter element 1 98262/1148
OVERHAUL OR Check belt tension & condition of all ancillaries
ANY
INTERMEDIATE
Check for oil & air leaks
OVERHAUL Check tightness of all fasteners.
AT 500 HOURS Renew suction filter element. No Part RefRSP
OR ELAPSED Off R-5307.2.IA/s.2
TIME Suction filter element. (if fitted) 1 98262/1060
12 MONTHS Check belt tension & condition of all ancillaries
REPEAT AT 1500, Check oil level, top-up if necessary.
2500, 3500, 4500 Check for oil and air leaks
5500, 6500 & 7500
HOURS.
Check tightness of all fasteners.
AT 1000 HOURS Change oil, oil filter element. Renew suction filter element. Service No Part RefRSP
OR ELAPSED 3rd stage valve. Off R-5307.2.IA/s.3
TIME 24 MONTHS Change oil (sump capacity 4.9 litres) REAVELLITE 'S' 5 Litre 1 98384/1001
REPEAT AT 3000, Oil filter element 1 98262/1148
5000 & 7000 Service kit 3rd stage valve 1 98650/1215
HOURS Suction filter element. (if fitted) 1 98262/1060
Check belt tension & condition of all ancillaries
Check for oil and air leaks
Check tightness of all fasteners
Check condition of 3rd & 4th stage cylinder bores.
AT 2000 HOURS Change oil, oil filter element. Service 1st, 2nd & 3rd stage valves. No Part RefRSP
OR ELAPSED Renew suction filter element. Off R-5307.2.IA/s.4
REPEAT AT 6000 Oil filter element 1 98262/1148
HOURS Service kit 3rd stage valve 1 98650/1215
Service kit 2nd stage valve 1 98650/1751
Service kit 1st stage valve 1 98650/1760
'O' ring 1st stage valve covers 2 95602/57
'O' ring 2nd stage valve covers 2 95602/22
Suction filter element. (if fitted) 1 98262/1060
Check unloader valves & seats relap if necessary
Check condition of unloader diaphragms & replace if necessary.
Check condition of all cylinder bores.
Check and clean externally all cooler assemblies particularly the final cooler coil finned
area.
Ensure fan blades are clean, secure and undamaged.
1213.doc 30/08/02 Page 17

Page 18
AT 4000 HOURS Change oil, oil filter element. Renew 1st, 2nd & 3rd stage valves. No
OR ELAPSED Renew 1st, 2nd & 3rd stage piston rings. Renew suction filter Off Part RefRSP
TIME 72 MONTHS element. R-5307.2.IA/s.5
Change oil (sump capacity 4.9 litres) REAVELLITE 'S' 5 Litre 1 98384/1001
Oil filter element 1 98262/1148
3rd stage valve 1 98650/1883
2nd stage suction valve 1 98650/1181
2nd stage delivery valve 1 98650/1182
1st stage suction valve 1 98650/1247
1st stage delivery valve 1 98650/1248
Suction filter element (if fitted) 1 98262/1060
1st stage piston ring set 1 98477/1090
2nd stage piston ring set 1 98477/1091
3rd stage piston ring set 1 98477/1186
Joint Kit 1 98504/1119
Inspect piston ring grooves and piston lands for wear.
Clean out all cooler assemblies including finned area.
AT 8000 HOURS Change oil, oil filter element. Cleanse crankcase, Renew 1st, 2nd &
MAJOR 3rd stage valves. Renew 1st, 2nd & 3rd stage piston rings. Renew
OVERHAUL conn rod assemblies. Renew all gudgeon pins. Renew crankshaft No Part RefRSP
assembly. Renew suction filter. Renew all safety valves. Off R-5307.2.IA/s.6
Suction filter. 1 98262/1075
Joint Kit 1 98504/1119
Conn rod assembly 2 D101485
Crankshaft assembly 1 D101496
B/E bearing spacer 1 98660/1064
Spacer washer 1 98660/1145
Oil seal 1 98505/1009
Gudgeon pin 1st stage 1 C200642
Gudgeon pin 2nd & 3rd stage 1 E2229
Circlips 4 95650/18
Oil pump cam assembly 1 C201452
1st stage safety valve 1 98650/1163-5.9
2nd stage safety valve 1 98650/1163-27
3rd stage safety valve (check contract for correct valve) 1 as fitted
Page 18 1213.doc 30/08/02

Page 19

Cleanse all cooler coils internally & externally specially finned areas.
Hydraulic pressure test all cooler coils.
Cleanse, hydraulic pressure test interstage oil/moisture separators.
Replace or calibrate all pressure gauges
5.6.4 RECOMMENDED SERVICE PLAN 5307.2.IA SYNTHETIC OIL - WINTER GRADE

50 HOURS OR
6 MONTHS Off R-5307.2.IA/sw.1
REPEAT AT 8000 Change oil (sump capacity 4.9 litres) REAVELLITE 'W' 5 Litre 1 98384/1008
OVERHAUL OR
ANY
INTERMEDIATE Check for oil & air leaks
AT 500 HOURS Renew suction filter element No Part RefRSP
OR ELAPSED Off R-5307.2.IA/sw.2
TIME 12 MONTHS Suction filter element. (if fitted) 1 98262/1060
REPEAT AT 1500, Check belt tension & condition of all ancillaries
2500, 3500, 4500, Check oil level, top-up if necessary
5500, 6500 & 7500
HOURS.
AT 1000 HOURS Change oil, oil filter element. Renew suction filter element. No Part RefRSP
OR ELAPSED Service 3rd stage valve. Off R-5307.2.IA/sw.3
TIME 24 MONTHS Change oil (sump capacity 4.9 litres) REAVELLITE 'W' 5 Litre 1 98384/1008
5000 & 7000 Service kit 3rd stage valve 1 98650/1215
HOURS Suction filter element. (if fitted) 1 98262/1060
AT 2000 HOURS Change oil, oil filter element. Service 1st, 2nd & 3rd stage No Part RefRSP
OR ELAPSED valves. Renew suction filter element. Off R-5307.2.IA/sw.4
area.
1213.doc 30/08/02 Page 19

Page 20
AT 4000 HOURS Change oil, oil filter element. Renew 1st, 2nd & 3rd stage valves.
OR ELAPSED Renew 1st, 2nd & 3rd stage piston rings. Renew suction filter No Part RefRSP
TIME 72 MONTHS element. Off R-5307.2.IA/sw.5
Change oil (sump capacity 4.9 litres) REAVELLITE 'W' 5 Litre 1 98384/1008
Joint Kit 1 98504/1119
AT 8000 HOURS Change oil, oil filter element. Cleanse crankcase, Renew 1st, 2nd &
MAJOR 3rd stage valves. Renew 1st, 2nd & 3rd stage piston rings. Renew
OVERHAUL conn rod assemblies. Renew all gudgeon pins. Renew crankshaft No Part RefRSP
assembly. Renew suction filter. Renew all safety valves. Off R-5307.2.IA/sw.6
Joint Kit 1 98504/1119
Oil seal 1 98505/1009
Gudgeon pin 1st stage 1 C200642
Circlips 4 95650/18
3rd stage safety valve (check contract for correct valve) 1 as fitted
Page 20 1213.doc 30/08/02

Page 21

5.6.4 RECOMMENDED SERVICE PLAN 5407.2.IA SYNTHETIC OIL - STANDARD GRADE

50 HOURS OR
ELAPSED TIME No Off Part RefRSP
6 MONTHS R-5407.2.IA/s.1
OVERHAUL OR Check belt tension & condition of all ancillaries
ANY
Check for oil & air leaks
INTERMEDIATE
AT 500 HOURS Renew suction filter element.
OR ELAPSED No Off Part RefRSP
TIME R-5407.2.IA/s.2
12 MONTHS Suction filter element. (if fitted) 1 98262/1060
REPEAT AT 150,0 Check belt tension & condition of all ancillaries
2500, 3500, 4500, Check oil level, top-up if necessary.
5500, 6500 & 7500 Check for oil and air leaks
HOURS.
AT 1000 HOURS Change oil, oil filter element. Renew suction filter element. Service No Off Part RefRSP
OR ELAPSED 3rd & 4th stage valves. R-5407.2.IA/s.3
5000 & 7000 Service kit 4th stage valve 1 98650/1199
AT 2000 HOURS Change oil, oil filter element. Service 1st, 2nd, 3rd & 4th stage
OR ELAPSED valves. Renew 4th stage piston rings. Renew suction filter element. No Off Part RefRSP
TIME 36 MONTHS R-5407.2.IA/s.4
HOURS Oil filter element 1 98262/1148
Service kit 4th stage valve 1 98650/1199
Service kit 3rd stage valve 1 98650/1215
4th stage piston ring set 1 98477/1181
area.
1213.doc 30/08/02 Page 21

Page 22
AT 4000 HOURS Change oil, oil filter element. Renew 1st, 2nd, 3rd & 4th stage
OR ELAPSED valves. Renew 4th stage plunger/liner assembly. Renew 1st, 2nd & No Off Part RefRSP
TIME 72 MONTHS 3rd stage piston rings. Renew suction filter element. R-5407.2.IA/s.5
4th stage valve 1 C201654
4th stage plunger/liner assembly 1 C203410.50
Joint Kit 1 98504/1119
AT 8000 HOURS Change oil, oil filter element. Cleanse crankcase, Renew 1st, 2nd,
MAJOR 3rd & 4th stage valves. Renew 4th stage plunger/liner assembly.
OVERHAUL Renew 1st, 2nd & 3rd stage piston rings. Renew conn rod
assemblies. Renew all gudgeon pins. Renew crankshaft assembly. No Off Part RefRSP
Renew suction filter. Renew all safety valves. R-5407.2.IA/s.6
Joint Kit 1 98504/1119
Oil seal 1 98505/1009
Page 22 1213.doc 30/08/02

Page 23
Gudgeon pin 1st & 4th stage 1 C200642

Circlips 4 95650/18
3rd stage safety valve 1 98650/1164-97
4th stage safety valve (check contract for correct valve) 1 as fitted
5.6.5 RECOMMENDED SERVICE PLAN

5407.2.IA SYNTHETIC OIL - WINTER GRADE

50 HOURS OR
6 MONTHS Off R-5407.2.IA/w.1
REPEAT AT 8000 Change oil (sump capacity 4.9 litres) REAVELLITE 'W' 5 Litre 1 98384/1008
OVERHAUL OR
ANY
INTERMEDIATE Check for oil & air leaks
AT 500 HOURS Renew suction filter element. No Part RefRSP
OR ELAPSED Off R-5407.2.IA/w.2
TIME Suction filter element. (if fitted) 1 98262/1060
12 MONTHS Check belt tension & condition of all ancillaries
REPEAT AT 1500, Check oil level, top-up if necessary.
2500, 3500, 4500, Check for oil and air leaks
5500, 6500 & 7500
HOURS.
AT 1000 HOURS Change oil, oil filter element. Renew suction filter element. No Part RefRSP
OR ELAPSED Service 3rd & 4th stage valves. Off R-5407.2.IA/w.3
5000 & 7000 Service kit 4th stage valve 1 98650/1199
1213.doc 30/08/02 Page 23

Page 24
AT 2000 HOURS Change oil, oil filter element. Service 1st, 2nd, 3rd & 4th stage No Part RefRSP
OR ELAPSED valves. Renew 4th stage piston rings. Renew suction filter element. Off R-5407.2.IA/w.4
HOURS Service kit 4th stage valve 1 98650/1199
Service kit 3rd stage valve 1 98650/1215
4th stage piston ring set 1 98477/1181
area.
AT 4000 HOURS Change oil, oil filter element. Renew 1st, 2nd, 3rd & 4th stage
OR ELAPSED valves. Renew 4th stage plunger/liner assembly. Renew 1st, 2nd & No Part RefRSP
TIME 72 MONTHS 3rd stage piston rings. Renew suction filter element. Off R-5407.2.IA/w.5
Joint Kit 1 98504/1119
Page 24 1213.doc 30/08/02

Page 25
AT 8000 HOURS Change oil, oil filter element. Cleanse crankcase, Renew 1st, 2nd,
MAJOR 3rd & 4th stage valves. Renew 4th stage plunger/liner assembly.
OVERHAUL Renew 1st, 2nd & 3rd stage piston rings. Renew conn rod
assemblies. Renew all gudgeon pins. Renew crankshaft No Part RefRSP
assembly. Renew suction filter. Renew all safety valves. Off R-5407.2.IA/w.6
Joint Kit 1 98504/1119
Oil seal 1 98505/1009
Gudgeon pin 1st & 4th stage 1 C200642
Circlips 4 95650/18
3rd stage safety valve 1 98650/1164-97
4th stage safety valve (check contract for correct valve) 1 as fitted
5.7 BELT ADJUSTMENT
5.7.1 Remove belt guard
5.7.2 Loosen drive motor securing bolts and slide towards the compressor. Examine belt for
wear and replace if necessary. Anti-static banded belts may be used in some
applications. If oily or greasy, clean before replacing on pulleys.
5.7.3 Slide drive unit away from compressor and tension belt to achieve correct deflection
when pressed down at a point midway between pulleys. A pencil type belt tension
indicator will greatly assist in this procedure.
5.7.4 Secure drive unit fixing bolts and replace belt guard.
1213.doc 30/08/02 Page 25

Page 26
5.8 RECOMMENDED VEE BELT ALIGNMENT TENSIONING
TYPICAL BELT DRIVE ALIGNMENT

STRAIGHT EDGE
STRAIGHT EDGE
USE DISTANCE
PIECES
IF REQUIRED
ELECTRIC
COMPRESSOR MOTOR
BELT ADJUSTING SCREWS
It is very important that the driving and driven pulley grooves are in line and both pulley shafts are parallel,
see above, if the pulley faces are not parallel use appropriate size distance pieces to ensure belt grooves are
correctly aligned. Check belt tension by method described on page 27.
5.9 RECOMMENDED TENSIONING FORCES
BELT TENSION INDICATOR

APPLIED TO MID-SPAN.
CENTRE DISTANCE
STRAIGHT EDGE
5.10 ADJUSTMENT METHOD
If the belt tension is incorrect,, correct it by using the adjusting screws provided, using a suitable straight edge
(long enough to span both pulleys) or by use of the second belt, release motor holding down screws enough
to allow the adjustment screws to be free to slide the motor on its adjustment slots without it being loose. Use
method as described on page 2. Note:- When using the adjusting screws it is important to maintain both the
correct belt tension and pulley alignment. Having established the correct deflection and pulley alignment
tighten the motor holding down screws to their correct torque setting
Page 26 1213.doc 30/08/02

Page 27
5.11 BELT TENSIONING TABLE
Belt Force required to deflect belt 16 mm per metre of span

Section
Belt Section Small Pulley Newton Kilogram force
Ø mm (N) (kgf)
SPA 100 to 132 20 to 27 1.5 to 2.7
SPA 140 to 200 27 to 35 2.7 to 3.5
SPZ 67 to 95 10 to 15 1.0 to 1.5
SPZ 100 to 140 15 to 20 1.5 to 2.0
5.12 METHOD OF BELT TENSIONING. USING BELT TENSION INDICATOR.
1. Calculate the deflection distance in mm on a basis of 16 mm per metre of span.

Centre distance (m) X 16 = Deflection (mm). If distance & deflection is
known, go to .2.
2. Set the lower marker ring at the deflection distance required in mm on the lower scale.
3. Set the upper marker ring against the bottom edge of the top tube.
4. Place the belt tension indicator on top of the belt at the centre of span and apply a force
at right angles to the belt deflecting it to the point where the lower marker ring is level with
the adjacent belt, on single belt drives place a straight edge across the two pulleys to act
as a datum.
5. Read off the force value indicated by the top edge of the upper marker ring.
6. Compare this force to kgf value shown in the table above.
7. Tighten or loosen belt tensioner to achieve the correct value.
8. If the measured force falls within the values given, the drive should be satisfactory.
Note:- If a belt tension indicator is not available, a suitably scaled spring balance and rule will
suffice.
10 20 30 40 50 60 14 12 10 8 6 4 2
mm
Deflection in mm Deflection Force in kgf
1213.doc 30/08/02 Page 27

Page 28
Page 28 1213.doc 30/08/02

Page 29
SECTION 6
DISMANTLING AND REASSEMBLY OF VALVES
SERVICING VALVE ASSEMBLIES
Keep a spare oiled and maintained set of valves in store for quick compressor servicing.
6.1 GENERAL
Valves should have a thin carbon layer and be slightly moist with oil.
Valve removal is a simple procedure but the following guidelines should be observed.
6.2 VALVE REMOVAL
6.2.1. FIRST STAGE SUCTION AND DELIVERY VALVES
i) To Remove
Unscrew and remove the four, 10 mm AF nuts securing the suction valve cover/air filter
assembly, and remove from its locating studs. Similarly remove the delivery valve cover.
The suction and delivery valves will now be free in the cylinder head and may be
removed from their seats.
ii) Cleaning And Inspection
Check that the airways are not obstructed or heavily coated with carbon, if de-
carbonising is necessary, blank the valve apertures to prevent loose particles entering
the cylinder. Ensure all loose deposits are removed after cleaning. Inspect the valve
seats for cracks or other damage liable to impair sealing efficiency.
Valve overhaul and inspection is detailed below.
iii) To Assemble
Position the suction and delivery valves in their respective locations within the cylinder
head, the suction valve has a wider top section and a deeper seat recess in the cylinder
head than the delivery valve.
Refit valve covers and securing nuts, evenly torque nuts. After tightening of the valve
cover nuts, there should be a gap of approximately 2mm between the covers and
cylinder head; this indicates that the valves are correctly sealed.
6.2.2 SECOND STAGE SUCTION AND DELIVERY VALVES
Excepting that the second stage suction valve cover is a plain cover, the valve removal
and replacement procedure is identical to that for the first stage valves.
6.2.3 THIRD STAGE SUCTION AND DELIVERY VALVE/CYLINDER HEAD ASSEMBLY
i) To Remove
Disconnect all pipework from the third stage cylinder head. Unscrew the six setscrews
and remove the head. Remove and discard the sealing ‘O’ ring from the cylinder.
1213.doc 30/08/02 Page 29

Page 30

Ensure the ‘O’ ring groove in the cylinder is free from dirt or damage etc., and that the
piston and cylinder wall are free from excessive deposits of carbon. The overhaul
procedure for the cylinder head assembly is detailed below.
iii) To Replace
Ensuring that joint faces are clean, fit a new ‘O’ ring to the cylinder liner top and locate
the head/valve assembly on the studs. Fit the six retaining nuts and evenly torque to
SECTION 2.11. Reconnect all pipework.
6.2.4 FOURTH STAGE SUCTION & DELIVERY VALVE/CYLINDER HEAD ASSEMBLY
The removal and replacement procedure for this assembly is identical to that for the
third stage unit.
Page 30 1213.doc 30/08/02

Page 31
6.3 FIRST STAGE VALVES
FIRST STAGE DELIVERY VALVE FIRST STAGE SUCTION VALVE
1
16
2
15
3
9
14
13
17
5
12
7
18
11
8
19
1213.doc 30/08/02 Page 31

Page 32
6.3.1 FIRST STAGE SUCTION VALVE
i) To Dismantle
Holding base of stud (8) with a suitable Allen key, unscrew and remove nut (1) and
washer (2). Remove seat (3), valve plate (4), spacer (6), springs (5) (2 of) and guard (7)
from stud (8).
The valve components should be degreased using a suitable fluid and stiff brush.
Carbon deposits may be removed by placing components in boiling water, do not
attempt to remove carbon by scraping as this may cause damage to the sealing faces.
The sealing faces of valve plate and seat should be clean and bright over the whole
seat area without any evidence of uneven contact. Renew plate if cracked, indented, not
flat or having a wear groove which exceeds 1/10th of the plate thickness. If the plate or
seat shows severe indentation the complete valve assembly must be renewed.
Inspect the remaining components for cracks, distortion, or other damage liable to
impair valve operation.
iii) To Assemble
Place valve seat (3) on a tubular support similar to item (10) (note that this is not part of
the valve assembly) with peg (9) uppermost. Fit spacer (6) and valve plate (4) engaging
peg (9) with hole in the plate and NOT with the slots. Arrange springs (5) as shown and
place on the valve plate, engaging with pin (9) as for the plate. Centralise the plates and
springs. Taking extreme caution not to disturb springs (5), fit guard (7) engaging
locating pin (9) with corresponding hold in the guard. Holding the valve components
firmly together, pass stud (8) through assembly, lift from the support and fit nut (1) and
washer (2). Tighten nut.
6.3.2 FIRST STAGE DELIVERY VALVE
i) To Dismantle
Unscrew and remove nut (16) and washer (15). Remove guard (14), springs (13) (2 of),
space (12) and delivery plate (17).
(As for the FIRST STAGE SUCTION VALVE, above)
iii) To Assemble
Fit plate (17) to seat (11) engaging locating pin (19) with hole in plate (17) NOT with the
slots. Fit spacer (12). Arrange springs (13) as shown and place on the valve plate,
engaging with the locating pin as for the plate. Centralise the plate and springs. Taking
extreme care not to disturb the springs, fit guard (14), engaging locating pin with
corresponding hole in the guard. Holding the components firmly together, fit nut (16)
and washer (15). Tighten nut.
Page 32 1213.doc 30/08/02

Page 33
6.4 SECOND STAGE VALVES
SECOND STAGE DELIVERY VALVE SECOND STAGE SUCTION VALVE
7 1
8 2
9 3
4
10
11
4
10
6
12
1213.doc 30/08/02 Page 33

Page 34
6.4.1 SECOND STAGE SUCTION VALVE
i) To Dismantle
Unscrew and remove nut (1) and washer (2). Remove seat (3), suction plate (4), and
springs (5) (3 off) from guard (6).
iii) To Assemble
Place valve seat (3) uppermost. Fit plate (4) to the seat, Arrange springs (5) as shown
and place on plate (4). Carefully fit guard (6). Keeping the assembly held firmly together
and fit nut (1) and washer (2). Tighten nut.
6.4.2 SECOND STAGE DELIVERY VALVE
i) To Dismantle
Unscrew and remove nut (7) and washer (8). Remove guard (9), springs (11) (4 of),
delivery plate (10) from valve seat (12).
(As for the SECOND STAGE SUCTION VALVE, above)
iii) To Assemble
To seat (12) place delivery plate (10) in position on the seat. Arrange springs (11) as
shown carefully fit guard (9). Holding the guard in position fit washer (8) and nut (7).
Tighten nut.
Page 34 1213.doc 30/08/02

Page 35
6.5 THIRD STAGE VALVE
12
8
11
9
10
1213.doc 30/08/02 Page 35

Page 36
6.5 THIRD STAGE SUCTION AND DELIVERY VALVE / CYLINDER HEAD ASSEMBLY
i) To Remove
Invert the assembly and remove capscrews (10), which retain base (8) to cylinder head
(1). Remove suction plate (7), springs (6) (2 of) and plate (5). Remove delivery plate (4),
delivery valve springs (12) (2 of) and plate (3). Remove and discard ‘O’ ring (2).
ii) Cleaning and Inspection
iii) To Assemble
Take base (8) and fit plate (7) followed by springs (6) which should be arranged as
shown. Fit suction plate (5).
Invert cylinder head (1), and fit plate (3), followed by springs (12) which should be
arranged as shown. Fit delivery plate (4) and place new ‘O’ ring (2) into the cylinder
head groove. Ensure the delivery plate (4) is centralised.
With a small steel rule, or similar thin-bladed implement, placed across the base (8) to
retain the suction valve components in position, invert the assembly and fit to the
cylinder head. Correct location of the base assured by the offset pins (9) and (11) which
engage with corresponding holes in the cylinder head. Ensure the locating pins are
correctly engaged and keeping downward pressure on the base, carefully withdraw the
rule; check the base is now in full contact with the cylinder head around its
circumference and fit capscrews (10). Evenly tighten the capscrews to SECTION 2.11.
TORQUE SETTING IS CRITICAL. If the base does not correctly engage with the head,
separate the components and repeat the assembly procedure.
Page 36 1213.doc 30/08/02

Page 37
6.6 FOURTH STAGE VALVE
18
17
16
15
14
13
12
11
10
9 4
8
5
6
7
1213.doc 30/08/02 Page 37

Page 38
6.6 FOURTH STAGE SUCTION AND DELIVERY VALVE / CYLINDER HEAD ASSEMBLY
i) To Remove
Invert the head assembly and remove capscrews (6 and 7). Separate valve base (5)
from the valve seat (3) and remove ‘O’ ring (4), suction plate (9), spring (10), shim (11),
spring (12) and plate (13).
Separate delivery valve seat (3) from the cylinder head (1) and remove ‘O’ ring (2),
delivery plate (14), spring (15), shim (16), spring (17) and plate (18).
iii) To Assemble
Place valve base (5) with pegs (8) uppermost. Fit plate (9), spring (10), shim (11),
spring (12) and suction plate (13). Fit ‘O’ ring (4) to its groove.
Fit valve seat (3) to the base, taking care not to disturb the valve components (the offset
locating pins (8) of the base prevent incorrect assembly of the seat).
Place cylinder head (1) with the valve recess uppermost and fit plate (18), spring (17),
shim (16), spring (15) and delivery plate (14), to the recess. Fit ‘O’ ring to its groove.
Keeping base (5) and seat (3) held firmly together, fit this assembly on to the cylinder
head (1), taking care not to disturb the valve components. The offset locating pins
ensure correct alignment of the seat and head. Fit the capscrews (6 and 7)
Evenly tighten the capscrews. TORQUE SETTING IS CRITICAL.
Page 38 1213.doc 30/08/02

Page 39
SECTION 7
FAULT GUIDE
These notes are intended only as a guide to the more common aspects of fault location. In the case of
difficulty, Service Engineers are available to advise and assist.
Before investigating a potential fault, ensure
a) Ambient and air inlet temperature is not too high.

b) Driving unit is in good working order and power supply is adequate.
c) Lubricant(s) are correct.
FAULT SYMPTOM RECOMMENDATION(S)

7.1 EXCESSIVE STAGE 1. Faulty suction or delivery valve(s) Service valve(s) as necessary.
PRESSURE Note: A suction valve fault usually
gives excess pressure in the previous
stage.
2. Pressure gauge not accurate. Check pressure gauge against gauge
of known accuracy.
3. Restriction in pipeline. Existing Installation:
Check setting and function of all
control valves. Clean pipeline filters
and service elements as necessary.
New Installation:
Ensure that protective plugs and
blanks have been removed from ports
and that all control valves are correctly
set. Pipework must be of ample size
with a minimum of bends. Joint
gaskets should be checked for correct
positioning and size.
EXCESSIVE THIRD 1. Fourth stage plunger failure. Remove and examine, replace if
STAGE PRESSURE. necessary.
7.2 INSUFFICIENT 1. Blocked suction filter. Remove and service.
PRESSURE OR
VOLUME
2. Faulty first stage suction valve. Remove and examine.
3. (Air) leakage in pipe system or Locate and rectify.
from machine. (e.g. drain valve open)
(See also: 4. Wear. If general wear is suspected, strip the
1. Excessive Stage machine and examine all working
Pressure) parts.
5. Loss of drive. Check belt drive.
6. Premature opening of final safety Renew valve.
valve.
7. Intake or outlet valve not closing Check and clean valves, replace
properly. main parts as necessary.
1213.doc 30/08/02 Page 39

Page 40
FAULT SYMPTOM RECOMMENDATION(S)

7.3 OVERHEATING 1. Duty higher than recommended Reduce duty to acceptable level.
maximum.
2. Inlet temperature higher than Check that pipework/valves do not
recommended maximum. form a closed loop, i.e. feeding hot
delivered air back into machine inlet.
Check location. Maximum ambient

temperature is 35ºC
3. Insufficient delivered air. Check and clean valves, replace
worn parts as necessary.
(See also: 4. Inlet or delivery valves not Check and clean valves, replace
1. Excessive Stage closing properly. worn parts as necessary.
Pressure and 5. Cylinder fins clogged or dirty. Clean out cylinder fins.
2. Insufficient Pressure) 6. Intercooler and aftercooler tubes Clean tubes with a brush and
dirty. compressed air.
7. Belt drive slipping. Adjust belt drive.
8. Air intake filter. Service air intake filter.
9. Wrong rotation. Reverse motor feed wiring.
THIRD STAGE 10. Possible fourth stage plunger Dismantle and examine fourth stage
OVERHEATING failure. plunger. Replace if necessary.
7.4 EXCESSIVE NOISE 1. Oil level low. Check oil level and replenish.
2. Pulley loose. Tighten pulley.
3. Belt drive worn. Replace banded belts.
4. Vibration in machine. Insecure mounting. Tighten mounting
bolts.
5. Pulley out of line. Inspect and adjust the alignment of the
pulley.
6. 5407 Low oil pressure. Air trapped in oil pump. Vent pump and
oil line.
7. Worn bearings Dismantle, examine and replace, if
necessary.
7.5 EXTENDED RUNNING 1. Speed too low or machine not large If speed cannot be uprated, fit additional
enough. machine or machine with larger
capacity.
Check belt drive.

7.6 EXCESSIVE WEAR 1. Excessive speed and / or pressure. Adjust accordingly.
2. Dirty air and / or suction pipeline. Clean filter element.
3. Excessive side or end thrust. Pulley out of alignment - realign.
Belt too tight / too loose - adjust.

4. Excessive moisture content in air. Check drainage system and regularly
check condition of crankcase oil.
5. Belt wear. Belt too tight / too loose - adjust.
6. Belt slip. Oil or grease on belt - clean or replace
7.7 FAILURE TO START 1. Seizure. If machine does not rotate freely (when
unloaded) this indicates a fault of a
serious nature.
Investigate and check for broken and
damaged components before trying to
restart.
2. Electrical or control fault. Locate and rectify, or consult an
electrician.
7.8 LOW OIL PRESSURE 1. Air trapped in oil pump. Vent pump and oil line.
2. Oil regulator dirty. Dismantle and clean.
3. Fourth stage piston problem. Examine fourth stage plunger and
renew, if necessary.
Page 40 1213.doc 30/08/02

Page 41
PARTS LIST & DRAWINGS

CONTENTS
PAGE
8.1 J 1st STAGE VALVES 42
8.2 K 2nd STAGE VALVES 42
8.3 L 3rd STAGE CONCENTRIC VALVE 43
8.4 M 4th STAGE CONCENTRIC VALVE 43
8.5 N MAINTENANCE KITS 43
8.6 BASIC INDUSTRIAL COMPRESSOR 5307.2.1A
8.7 BASIC INDUSTRIAL COMPRESSOR 5307.2.1A.USA
8.8 BASIC INDUSTRIAL COMPRESSOR 5407.2.1A
8.9 BASIC INDUSTRIAL COMPRESSOR 5407.2.1A.USA
8.10 STG005 CRANKCASE, SEPARATORS, CRANKSHAFT & CONN RODS A30175
8.11 STG006 OIL SEAL ASSEMBLY D101501
8.12 STG010 1st & 4th STAGE CYLINDERS & PISTONS (5407.2.IA) E61441
8.13 STG010 1st CYLINDER & PISTON (5307.2.IA) E61497
8.14 STG015 2nd & 3rd STAGE CYLINDERS & PISTONS E61442
8.15 STG024 3rd STAGE SEPARATOR ASSEMBLY D101509
8.16 STG030 1st STAGE COOLER ASSEMBLY E61450
8.17 STG032 2nd STAGE COOLER ASSEMBLY E61447
8.18 STG034 3rd STAGE COOLER ASSEMBLY (5407.2.IA) E61446
8.19 STG034 3rd STAGE COOLER ASSEMBLY (5307.2.IA) E61494
8.20 STG036 4th STAGE COOLER ASSEMBLY E61451
8.21 STG042 2nd STAGE SUCTION PIPE C203453
8.22 STG044 3rd STAGE SUCTION PIPE C203445
8.23 STG046 4th STAGE SUCTION PIPE C203446
8.24 STG050 LUBRICATION ASSEMBLY(5407.2.IA) E61493
8.25 STG050 LUBRICATION ASSEMBLY(5307.2.IA) E61498
8.26 STG060 FLYWHEEL ASSEMBLY E61421
8.27 STG065 SAFETY VALVES (5407.2.IA) E61449
8.28 STG065 SAFETY VALVES (5307.2.IA) E61645
Note: Standard parts are available where indicated by either a number or letters. The letters indicate
that an item is available as a component of an assembly. Non-listed or individual items of
assemblies where reference numbers are not indicated, are not standard replacement parts
and can only be obtained at the discretion of CompAir UK Ltd Ipswich. The assemblies have
been chosen based on the experience gained by our own Parts and Service Departments.
The right is reserved to modify the contents of this list, without notice, and the information given
is in no way binding on the manufacturers.
1213.doc 30/08/02 Page 41

Page 42
PARTS LIST J - 1st STAGE VALVES
SEE PAGE 31 FOR ILLUSTRATIONS
ITEM No. DESCRIPTION No PER PART No. ASSEMBLY

MACHINE REF.
VALVE COMPLETE - 1st STAGE SUCTION 1 98650/1247 —
OVERHAUL MAINTENANCE KIT 1 98650/1760 NB
J1 NUT 1 — ---
J2 WASHER 1 — —
J3 VALVE SEAT 1 — —
J4 VALVE PLATE 1 — NB
J5 SPRING PLATE 1 — NB
J5/1 SPRING PLATE 1 — NB
J6 LIFT WASHER 1 — NB
J7 VALVE GUARD 1 — —
J8 BOLT 1 — NB
J9 PEG 1 — —
VALVE COMPLETE - 1st STAGE DELIVERY 1 98650/1248 —

OVERHAUL MAINTENANCE KIT 1 98650/1760 NB
VALVE SEAT 1 — —
J10
LIFT WASHER 1 — NB
J11
VALVE PLATE 1 — NB
J12
SPRING PLATE 1 — NB
J13
SPRING PLATE 1 — NB
J13/1
VALVE GUARD 1 — —
J14
WASHER 1 — —
J15
NUT 1 — —
J16
STUD 1 — —
J17
PEG 1 — —
J18
PARTS LIST K - 2nd STAGE VALVES

MACHINE REF.
VALVE COMPLETE - 2nd STAGE SUCTION 1 98650/1181 —
OVERHAUL MAINTENANCE KIT 1 98650/1751 NC
K1 NUT 1 — NC
K2 WASHER 1 — NC
K3 VALVE SEAT 1 — —
K4 VALVE PLATE 1 — NC
K5 LIFT WASHER 1 — NC
K6 SPRING PLATE 3 — NC
K7 VALVE GUARD 1 — —
K8 BOLT 1 — NC
K9 PEG 1 — —
VALVE COMPLETE - 2nd STAGE DELIVERY 1 98650/1182 —

OVERHAUL MAINTENANCE KIT 98650/1751 NC
VALVE SEAT 1 — —
K10
LIFT WASHER 1 — NC
K11
VALVE PLATE 1 — NC
K12
SPRING PLATE 4 — NC
K13
VALVE GUARD 1 — —
K14
WASHER 1 — NC
K15
NUT 1 — NC
K16
STUD 1 — —
K17
PEG 1 — —
K18
Page 42 1213.doc 30/08/02

Page 43
PARTS LIST L - 3rd STAGE CONCENTRIC VALVE

MACHINE REF.
VALVE COMPLETE 1 98650/1883 —
OVERHAUL MAINTENANCE KIT 98650/1215 ND
L1 UPPER BODY 1 — —
L2 'O' RING 1 95602/54 ND
L3 VALVE / BACKING PLATE - Delivery 2 — ND
L4 SPRING PLATE - Delivery 2 — ND
L5 VALVE / BACKING PLATE - Suction 2 — ND
L6 SPRING PLATE - Suction 2 — ND
L7 LOWER BODY 1 — —
L8 PEG 1 — —
L9 'O' RING 1 95602/50 ND
L10 SETSCREW 2 95018/134 ND
PARTS LIST M - 4th STAGE CONCENTRIC VALVE

MACHINE REF.
‡ VALVE COMPLETE 1 C201654 —
OVERHAUL MAINTENANCE KIT 1 98650/1199 NE
M1 ‡ UPPER BODY 1 — —
M2 ‡ 'O' RING 1 95602/16 NE
M3 ‡ VALVE / BACKING PLATE 4 — NE
M4 ‡ VALVE SPRING 4 — NE
M5 ‡ CENTRE PLATE 2 — NE
M6 ‡ MIDDLE BODY 1 — —
M7 ‡ 'O' RING 2 95602/18 NE
M8 ‡ LOWER BODY 1 — —
M9 ‡ PEG 2 — —
M10 ‡ SETSCREW 2 95018/106 NE
‡ ................ Not used on 5307.2.IA
LIST N
MAINTENANCE KITS
ASS/Y DESCRIPTION No PER PARTS ASS/Y

REF. MACHINE No
NA OVERHAUL - MAINTENANCE JOINT KIT 1 98504/1119
NB OVERHAUL - VALVE MAINTENANCE KIT - 1st STAGE 1 98650/1760

NC OVERHAUL - VALVE MAINTENANCE KIT - 2nd STAGE 1 98650/1751
ND OVERHAUL - VALVE MAINTENANCE KIT - 3rd STAGE 1 98650/1215
NE OVERHAUL - VALVE MAINTENANCE KIT - 4th STAGE 1 98650/1199
Note: The maintenance kits may have more items than listed, but this is to allow for a standard kit
being used on all current and past versions of the 5407 and 5307.compressors.
1213.doc 30/08/02 Page 43

Page 44
Page 44 1213.doc 30/08/02

CompAir UK Ltd CRANKCASE A30175
Page 1
CRANKCASE ASSEMBLY - A30175

AIR COMPRESSORS
27 28,29 30 26 25
24
23 1 1a,1b,1c 1c,1e
22
6,6a 19
4,5 18 3 2
15,16
A30175.doc
Page 2

AIR COMPRESSORS
14b 14 14a 19 20,21 17 9 10 8c 8b 8 8a
12
11a
11
13
Torque
Setting
55Nm 1d 7
7a,7b
40lb.ft
Torque
Setting
27Nm
20lb.ft
A30175.doc
Page 3

AIR COMPRESSORS PARTS LIST
REF PART No DESCRIPTION NO OFF
1 A30166.50 Crankcase 1
Kurbelgehäuse
Carter
includes Krukaskast
1a, 1b, 1c, 1d, 1e, 1f Cárter
Carter
1a D54019.8.28 Stud 8
Schaubbolzen
Goujon
Tapeind
Espárrago
Perno
1b PS1113.13 Washer, Shakeproof 8
Unterlegscheibe, Rüttelfest
Rondelle-frein non desserrable
Schokvaste sluitring
Arandela antivibratoria
Rondella dentata
1c 95111.5 Nut 10
Mutter
Ecrou
Moer
Tuerca
Dado
1d 96064.174 Bearing, Roller 1
Rolenlager
Palier ò rouleaux
Rollager
Cojinete de rodillos
Cuscinetto
1e D100171.8.41 Stud 2
Schaubbolzen
Goujon
Tapeind
Espárrago
Perno
1f C203468 Gauge, Level 1
Niveauanzeiger
Indicateur de niveau
Niveaumeter
Indicador de nivel
Indicatore di livello
2 C203470 Pipe, Drain 1
Ablaßrohr
Tuyau de vidange
Aftappijp
Tubo de drenaje
Tubo di Scarico
3 98650.1983 Valve, Oil drain 1
Ölablaßventil
Purgeur d'huile
Olieaftapklep
Válvula, drenaje de aceite
Valvola di scarico olio
A30175.doc
Page 4
4 98660.1155 Seal 1
Dichtung
Joint
Afdichting
Sello
Guarnizone
5 PS1068.4 Plug, Blanking 1
Blindstopfen
Bouchon d'obturation
Blindplug
Tapón obturador
Tappo cieco
6 C203369.100 Cap 2
includes 6a Deckel
Couvercle
Deksel
Tapa
Tappo
6a 95602.78 ‘O’ Ring 2
O-Ring
Joint torique
O-Ring
Aro tórico
O-Ring
7 D101496.50 Crankshaft & Balance Weight - C203386 1
includes 7a, 7b Kurbelwelle - mit Gegengewichten
Vilebrequin - avec contrepoids
Krukas - met contragewichten
Cigüeñal - con contrapesos
Albero a gomiti con contrappesi
7a 95006.155 Bolt 1
Schraube
Boulon
Bout
Perno
Bullone
7b 98422.1009 Locknut 1
Kontermutter
Contre-écrou
Borgmoer
Contratuerca
Dado di serraggio
8 D101488.100 Housing, Bearing 1
includes Lagergehäuse
8a, 8b Logement de palier
Lagerhuis
Alojamiento de cojinete
Alloggiamento del cuscinetto
8a 98076.1126 Bearing, Roller 4
Rollenlager
Papier à rouleaux
Rollager
Cojinete de rodillos
Cuscinetto a rulli
A30175.doc
Page 5
8b 95602.60 Screw, Hexagon Head 4

Sechskantschraube
Vis à tête 6 pans
Zeskantschroef
Tornillo de cabeza hexagonal
Vite a testa esagonale
9 D101485 Rod, Connecting - includes bearings 2
Pleuelstange
Bielle
Drijfstang
Biela de conexión
Biella con cuscinetti
10 C203378 Spacer 1
Distanzring
Entretoise
Afstandring
Espaciador
Distanziale
11 C203391.50 Plunger 1
Kolben
Plonqeur
Plunjer
Embolo
Stantuffo
11a 98650.1010 Circlip 1
Sprengring
Circlip
Borgring
Presilla
12 C201452 Cam 2
Nocke
Came
Nok
Leva
Camma
13 98500.1003 Screw, Hexagon Head - LH Thread 1
Sechskantschraube
Vis à tête 6 pans
Zeskantschroef
Vite a testa esagonale con filettatura sinistra
14 C203394.100 Cover plate 1
includes 14s, 14b Verkleidungsblech
Tôle de carénage
Bekledingsplaat
Placa tapadera
Piastra di copertura
14a C203393 Gasket 1
Dichtungsblech
Joint
Pakking
Junta
Guarnizione
A30175.doc
Page 6
14b 95000.255 Screw, Hexagon Head 6

Sechskantschraube
Vis à tête 6 pans
Zeskantschroef
15 PS1322.6 Seal 2
Dichtung
Joint
Afdichting
Sello
Guarnizione
16 98156.3639 Bush, Reducing 2
Reduzierbuchse
Bague de réduction
Reductiebus
Buje reductor
Boccola di riduzione
17 98086.1001 Eye, lifting 1
Hebeöse
Anneau de levage
Hijsooq
Cáncarmo para levantamiento
Anello di sollevamanto
Blindstopfen
Blindplug
Tapón obturador
Tappo cieco
Blindstopfen
Blindplug
Tapón obturador
Tappo cieco
20 PS1322.4 Seal 1
Dichtung
Joint
Afdichting
Sello
Guarnizione
Blindstopfen
Blindplug
Tapón obturador
Tappo cieco
22 PS1322.8 Seal 1
Dichtung
Joint
Afdichting
Sello
Guarnizione
A30175.doc
Page 7
23 C203396 Pipe 1
Dichtung
Tuyau
Pijp
Tubo
Tubo
24 98262.1166 Filler - Oil 1
Öleinfüllstutzen
Remplisser d'huile
Olievulplug
Rellenador de aceite
Bocchettone olio
25 98315.1127 Hose, Rubber 1
Gummischlauch
Flexible en caoutchouc
Rubber slang
Manquera de caucho
Tubo flessibile, gomma
26 PS1180.3 Clip, Worm drive 2
Schneckengewindeschelle
Attache p. filetage vis sans fin
Slangklem (met wormwiel)
Presilla para tronillo sin fin
Manica
27 PS1295.17 Adapter 1
Adapter
Raccord
Verloopstuk
Adaptador
Adattatore
28 PS1285.7 Sleeve 1
Muffe
Manchon
Verloopstuk
Manquito
29 PS1286.7 Nut, coupling 1

Spanmutter
Ecrou d'accouplement
Moer koppeling
Tuerca, acoplamiento
Dado
30 98156.3102 Elbow 1
Bogenstück
Coude
Kniestuk
Codo
Gomito
Language Support
English
German
French
Dutch
Spanish
Italian
A30175.doc
CompAir UK Ltd OIL SEAL ASSEMBLY D101501
Page 1
OIL SEAL ASSEMBLY D101501

STANDARD COMPRESSORS
Language Support
English
German
French
Dutch
Spanish
Italian

1 D101501 Seal, Shaft 1
Dichtung, Welle
Joint, d'arbre
Asafdichting
Includes Sello de eje
1a, 1b, 1c & 1d Guarnizione albero comprendente
1a D101489 Housing, Seal 1
Gehäuse, Dichtung
Carter d'étanchéte
Afdichtingshuis
Alojamiento de sello
Guarnizione alloggiamento
1b 95605.87 Seal, Oil 1
Dichtung. ÖI
Joint, d'huile
Olieafdichting
Sello de aceite
Paraolio
1c 95602.85 'O' Ring
O-Ring
Joint torigue
O-Ring
Aro tórico
O-Ring
1d 95000.229 Screw, Hexagon Head 4
Sechskanantschraube
Vis à tête 6 pans
Zeskantschroef
D101501.doc
CompAir UK Ltd CYLINDER ASSEMBLY 1ST & 4TH STAGE E61441
Page 1
CYLINDER ASSEMBLY - 1st & 4th STAGE

AIR COMPRESSORS
E61441.doc
Page 2
CYLINDER ASSEMBLY - 1st & 4th STAGE.

1 D101506.50 Piston - 1st Stage 1
Kolben - 1. Stufe
Piston - 1er étage
includes Zuiger - 1e trap
a
1a, 1b,1c Pistón - 1 etapa
Pistone - 1° stadio
1a 98477.1090 Ring kit, Piston - 1st Stage 1
Kolbenring-satz - 1. Stufe
Jeu segment de piston - 1 er stage
Ringenset zuiger - 1e trap
a
Juego anillo pistón – 1 etapa
Kit anelli pistone - 1° stadio
1b C203408 Pin, Gudgeon 1
Kolbenbolzen
Axe de piston
Zuigerpen
Clavija muñðn
Spinotto
1c 95650.19 Circlip 2
Sprengring
Circlip
Borgring
Presilla
Anello di fermo
2 D100259.100 Cylinder - 1st Stage 1
includes Zyinder - 1. Stufe
2a,2b,2c,2d Cylindre - 1er étage
Cilinder - 1 e trap
a
Cilindro – 1 etapa
Cilindro - 2° stadio
2a 95602.90 ‘O’ Ring 1
O-Ring
Joint torique
O-Ring
Aro tórico
O-ring
2b D100171.8.101 Stud 4
Schaubbolzen
Goujon
Tapeind
Espárrago
Perno
2c 95148.14 Washer 4
Unterlegscheibe
Rondelle
Sluitring
Arandela
Rondella
2d 95111.5 Nut 4
Mutter
Ecrou
Moer
Tuerca
Dado
E61441.doc
Page 3
3 A30180.100 Cover Cylinder - 1st Stage 1

Zylinderdeckel - 1. Stufe
Couvercle ducylindre - 1er étage
includes Cilinderdeksel - 1 e trap
a
3a,3b,3c,3d,3e Tapa de cilindro – 1 etapa
3a D100171.6.28 Stud 8
Schaubbolzen
Goujon
Tapeind
Espárrago
Perno
3b 95111.4 Nut 8
Mutter
Ecrou
Moer
Tuerca
Dado
3c 95602.90 ‘O’ Ring 1
O-Ring
Joint torique
O-Ring
Aro tórico
O-Ring
3d D100171.8.150 Stud 6
Schaubbolzen
Goujon
Tapeind
Espárrago
3e 95111.5 Nut 6
Mutter
Ecrou
Moer
Tuerca
Perno
4 C200815.100 Cover, Delivery Valve - 1st Stage 1
Auslaßventildeckel - 1. Stufe
includes Couvercle de soupape de refoulement-1er étage
4a Afdekplaat uitlaatklep - 1e trap
a
Tapa, válvula de reparto – 1 etapa
Copertura valvola - 1° stadio
4a 95602.57 ‘O’ Ring 1
O-Ring
Joint torique
O-Ring
Aro tórico
O-Ring
5 98650.1248 Valve, Delivery - 1st Stage 1
Auslaßventil - 1. Stufe
Soupape de refoulement - 1er etage
Uitlaatklep - 1e trap
a
Válvula de reparto – 1 etapa
Valvola di mandata - 1° stadio
6 C200814.100 Cover, Suction Valve - 1st Stage 1
Einlaßventildeckel - 1. Stufe
includes Couvercle de soupape d'aspiration - 1er étage
6a Afdekplaat zuigklep - 1e trap
a
Topa, válvula de aspiración – 1 etapa
E61441.doc
Page 4
6a 95602.57 ‘O’ Ring 1

O-Ring
Joint torique
O-Ring
Aro tórico
O-Ring
7 98650.1247 Valve, Suction - 1st Stage 1
Einlafßventil - 1. Stufe
Soupape d'aspiration - 1er etage
Zuigklep - le trap
a
Válvula de aspiración – 1 etapa
Valvola di aspirazione - 1° stadio
8 C203410.50 Plunger/Liner Assembly - 4th Stage 1
Laufbuchse/Kolben - 4. Stufe
Ensemble Garniture/Plongeur - 4 ème étage
Voering/Plunjer Montage - 4e trap
a
Forro/Émbollo, Cjto - 4 etapa
Gruppo pistone/camicia del - 4° stadio
8a 98477.1181 Ring kit, Piston - 4th Stage 1
Jeu segment de piston - 4 ème étage
a
Set fasce elastiche per pistone - 4° stadio
8b 95602.15 ‘O’ Ring 4
O-Ring
Joint torique
O-Ring
Aro tórico
O-Ring
8c 95602.18 ‘O’ Ring 1
O-Ring
Joint torique
O-Ring
Aro tórico
O-Ring
9 C201654 Valve 4th Stage 1
Ventil - 4. Stufe
Soupape _-. 4 ème étage
Klep - 4e trap
a
Válvula – 4 etapa
Valvola - 4° stadio
10
11 95406.56 Elbow 1
Bogenstück
Coude
Kniestuk
Codo
Gomito
12 98262.1075 Filter/Silencer - Suction 1
Filter/Schalldämpfer Ansaug
Filtre/Silencieux d'aspiration
Aanzuigfilter/demper
Includes 12a Filtro/Silenciador de aspiración
Filtro di aspirazione
E61441.doc
Page 5
12a 98262.1060 Element, Air Filter 1

Luftfilterpatrone
Elément de filtre à air
Luchfilterelement
Elemento del filtro de aire
Cartuccia del filtro di aspirazione
13 98156.2172 Plug 1
Stopfen
Bouchon
Plug
Tapón
Tappo cieco
Language Support
English
German
French
Dutch
Spanish
Italian
E61441.doc
CompAir UK Ltd CYLINDER ASSEMBLY 1ST STAGE E61497
Page 1
CYLINDER ASSEMBLY - 1st STAGE

AIR COMPRESSORS
E61497.doc
Page 2
CYLINDER ASSEMBLY - 1st STAGE.

1 D101506.50 Piston - 1st Stage 1
Kolben - 1. Stufe
Piston - 1er étage
includes Zuiger - 1e trap
a
1a, 1b,1c Pistón - 1 etapa
Pistone - 1° stadio
1a 98477.1090 Ring kit, Piston - 1st Stage 1
Jeu segment de piston - 1 er stage
a
1b C203408 Pin, Gudgeon 1
Kolbenbolzen
Axe de piston
Zuigerpen
Clavija muñðn
Spinotto
1c 95650.19 Circlip 2
Sprengring
Circlip
Borgring
Presilla
Anello di fermo
2 D100259.100 Cylinder - 1st Stage 1
2a,2b,2c,2d Cylindre - 1er étage
Cilinder - 1 e trap
a
2a 95602.90 ‘O’ Ring 1
O-Ring
Joint torique
O-Ring
Aro tórico
O-ring
2b D100171.8.101 Stud 4
Schaubbolzen
Goujon
Tapeind
Espárrago
Perno
2c 95148.14 Washer 4
Unterlegscheibe
Rondelle
Sluitring
Arandela
Rondella
2d 95111.5 Nut 4
Mutter
Ecrou
Moer
Tuerca
Dado
E61497.doc
Page 3
3 C203803.100 Cover Cylinder - 1st Stage 1

Couvercle ducylindre - 1er étage
a
3a D100171.6.28 Stud 8
Schaubbolzen
Goujon
Tapeind
Espárrago
Perno
3b 95111.4 Nut 8
Mutter
Ecrou
Moer
Tuerca
Dado
3c 95602.90 ‘O’ Ring 1
O-Ring
Joint torique
O-Ring
Aro tórico
O-Ring
3d D100171.8.41 Stud 6
Schaubbolzen
Goujon
Tapeind
Espárrago
3e 95111.5 Nut 6
Mutter
Ecrou
Moer
Tuerca
Perno
4 C200815.100 Cover, Delivery Valve - 1st Stage 1
Auslaßventildeckel - 1. Stufe
includes Couvercle de soupape de refoulement-1er étage
4a Afdekplaat uitlaatklep - 1e trap
a
Tapa, válvula de reparto – 1 etapa
4a 95602.57 ‘O’ Ring 1
O-Ring
Joint torique
O-Ring
Aro tórico
O-Ring
5 98650.1248 Valve, Delivery - 1st Stage 1
Soupape de refoulement - 1er etage
a
6 C200814.100 Cover, Suction Valve - 1st Stage 1
Einlaßventildeckel - 1. Stufe
includes Couvercle de soupape d'aspiration - 1er étage
6a Afdekplaat zuigklep - 1e trap
a
Topa, válvula de aspiración – 1 etapa
E61497.doc
Page 4
6a 95602.57 ‘O’ Ring 1

O-Ring
Joint torique
O-Ring
Aro tórico
O-Ring
7 98650.1247 Valve, Suction - 1st Stage 1
Soupape d'aspiration - 1er etage
Zuigklep - le trap
a
8 95602.15 ‘O’ Ring 4
O-Ring
Joint torique
O-Ring
Aro tórico
O-Ring
9 C203651 Plug 4th Stage 1
Stopfen - 4. Stufe
Bouchon _-. 4 ème étage
Plug - 4e trap
a
Tapón – 4 etapa
Tappo cieco- 4° stadio
10
11 95406.56 Elbow 1
Bogenstück
Coude
Kniestuk
Codo
Gomito
12 98262.1075 Filter/Silencer - Suction 1
Filter/Schalldämpfer Ansaug
Filtre/Silencieux d'aspiration
Aanzuigfilter/demper
Includes 12a Filtro/Silenciador de aspiración
Filtro di aspirazione
12a 98262.1060 Element, Air Filter 1
Luftfilterpatrone
Elément de filtre à air
Luchfilterelement
Elemento del filtro de aire
Cartuccia del filtro di aspirazione
13 C202614 Plug 1
Stopfen
Bouchon
Plug
Tapón
Tappo cieco
14 95650.18 Circlip 1
Sprengring
Circlip
Borgring
Presilla
Anello di fermo
E61497.doc
Page 5
15 98156.2172 Plug, Blanking 1

Blindstopfen
Bouchon d obturation
Blindplug
Tapón obturador
Tappo cieco
Language Support
English
German
French
Dutch
Spanish
Italian
E61497.doc
CompAir UK Ltd CYLINDER ASSEMBLY 2ND & 3RD STAGE E61442
Page 1
CYLINDER ASSEMBLY - 2nd & 3rd STAGE

AIR COMPRESSORS
E61442.doc
Page 2
CYLINDER ASSEMBLY - 2nd & 3rd STAGE.

1 D101507.50 Piston - 2nd Stage/3rd Stage 1
Kolben - 2.Stufe/3.Stufe
Piston - 2ème étage/3ème étage
includes Zuiger - 2e trap/3e trap
a a
1a, 1b,1c & 1d Pistón - 2 etapa/3 etapa
Pistone - 2° stadio/3° stadio
1a 98477.1091 Ring kit, Piston - 2nd Stage 1
Kolbenring-satz - 2.Stufe
Jeu segment de piston - 2ème étage
a
1b 98477.1186 Ring kit, Piston - 3rd Stage 1
Kolbenring-satz - 3.Stufe
Jeu segment de piston - 3ème étage
a
1c C203409 Pin, Gudgeon 1
Kolbenbolzen
Axe de piston
Zuigerpen
Clavija muñðn
Spinotto
1d 95650.19 Circlip 2
Sprengring
Circlip
Borgring
Presilla
Anello di fermo
2 D100119.100 Cylinder - 2nd Stage 1
2a,2b,2c,2d Cylindre - 2ème étage
Cilinder - 2 e trap
a
2a 95602.87 ‘O’ Ring 1
O-Ring
Joint torique
O-Ring
Aro tórico
O-ring
2b D100171.8.91 Stud 4
Schaubbolzen
Goujon
Tapeind
Espárrago
Perno
2c 95148.14 Washer 4
Unterlegscheibe
Rondelle
Sluitring
Arandela
Rondella
E61442.doc
Page 3
2d 95111.5 Nut 4
Mutter
Ecrou
Moer
Tuerca
Dado
3 E60278.100 Cover Cylinder - 2nd Stage 1
Couvercle ducylindre - 2ème étage
a
3a D100171.6.28 Stud 8
Schaubbolzen
Goujon
Tapeind
Espárrago
Perno
3b 95111.4 Nut 8
Mutter
Ecrou
Moer
Tuerca
Dado
3c 95602.56 ‘O’ Ring 1
O-Ring
Joint torique
O-Ring
Aro tórico
O-Ring
3d 95541.160 Pin, Locating 1
Paßstift
Goupille de positionnement
Positioneringspen
Pasador de colocación
Perno di fermo
3e C200525 Liner - 3rd Stage 1
Buchse, Zylinder - 3. Stufe
Garniture de cylindre - 3ème étage
Cilindrevoering - 3 e trap
Forro de cilindro - 3° etapa
Camicia - 3° stadio
4 C200604.100 Cover, Valve - 2nd Stage 2
Ventildeckel - 2. Stufe
includes Couvercle de soupape -2ème étage
4a Ventieldeksel - 2e trap
a
Tapa de válvula – 2 etapa
4a 95602.22 ‘O’ Ring 2
O-Ring
Joint torique
O-Ring
Aro tórico
O-Ring
E61442.doc
Page 4
5 98650.1182 Valve, Delivery - 2nd Stage 1

Soupape de refoulement - 2ème etage
a
6 98650.1181 Valve, Suction - 2nd Stage 1
Soupape d'aspiration - 2ème etage
Zuigklep - 2e trap
a
7 95602.50 ‘O’ Ring 1
O-Ring
Joint torique
O-Ring
Aro tórico
O-Ring
8 98650.1883 Valve 3rd Stage 1
Ventil - 3. Stufe
Soupape _-. 3 ème étage
Klep - 3e trap
a
Válvula – 3 etapa
Valvola - 3° stadio
9 95000.262 Screw, Hexagon Head 6
Sechskantschtaube
Vis à tête 6 pans
Zeskantschroef
Blindstopfen
Blindplug
Tapón oburador
Tappo cieco
13 PS1322.2 Seal 2
Dichtung
Joint
Afdichting
Sello
Guarnizion
Blindstopfen
Blindplug
Tapón oburador
Tappo cieco
15 PS1322.1 Seal 2
Dichtung
Joint
Afdichting
Sello
Guarnizion
E61442.doc
Page 5
16 PS1814.2 Seal 2
Dichtung
Joint
Afdichting
Sello
Guarnizion
Language Support
English
German
French
Dutch
Spanish
Italian
E61442.doc
CompAir UK Ltd SEPARATOR ASSEMBLY D101509
Page 1
SEPARATOR ASSEMBLY D101509

Language Support
English
German
French
Dutch
Spanish
Italian

1 D101509 Moisture Separator - 3rd Stage 1
Kondensatabscheider- 3. Stufe
Séparteur des condensats 3 ème étage
Condensafscheider - 3e trap
Includes Separador de humedad - 3° etapa
1a, 1b, 1c, 1d & 1e Separatore di condensa 3° stadio
1a 95602.78 'O' Ring 1
O-Ring
Joint torigue
O-Ring
Aro tórico
O-Ring
1b 98504.1002 Deflector 1
Deflektor
Déflecteur
Afbuigplaat
Placa deflectora
Deflettore
1c 98152.1143 Ring, Lock 1
Verschlßring
Segment de verrouillage
Sluitring
Anillo de cierre
Ghiera
1d 95000.259 Screw, Hexagon Head 2
Sechskanantschraube
Vis à tête 6 pans
Zeskantschroef
1e PS1454.2 Plug, Blanking 1
Blindstopfen
Blindplug
Tapón obturador
Tappo cieco
D101509.doc
CompAir UK Ltd COOLER ASSEMBLY 1ST STAGE E61450
Page 1
COOLER ASSEMBLY E61450 - 1st STAGE

WITH 1ST STAGE SEPARATOR - 5407.2 COMPRESSORS

1 C201604 Cooler - 1st Stage 1
Kühler - 1. Stufe
Réfrigérant - 1 er étage
Koeler - 1e trap
a
Enfriador - 1 etapa
Refrigeratore - 1° stadio
2 C201200.2 Spacer 1
Distanzring
Eintretoise
Afstandring
Espaciador
Distanziale
Sechskantschraube
Vis à tête 6 pans
Zaskantschroef
Sechskantschraube
Vis à tête 6 pans
Zaskantschroef
5 95111.4 Nut 1
Mutter
Ecrou
Moer
Tuerca
Dado
6 95149.13 Washer 1
Kegelschiebe
Rondelle
Sluitring
Arandela
Rondella
E61450.doc
CompAir UK Ltd COOLER ASSEMBLY 1ST STAGE E61450
Page 2
7 C201109 Bracket, Cooler 1

Halterung, Kühler
Support de réfrigérant
Koelerbeugel
Soporte del enfriador
Munire di supporo refrigeratore
8 C203460 Pipe, Delivery - 1st Stage 1
Druckrohr - 1. Stufe
Tuyau de refoulement - 1er étage
Persleiding - 1e trap
a
Tubo de reparto - 1 etapa
Tubo di mandata - 1° stadio
9 C203461 Pipe, Cooler Outlet - 1st Stage 1
Rohr, Kühlerauslaß - 1. Stufe
Tuyau de sortie du réfrigérant - 1er étage
Uitlaatleiding koeler - 1e trap
a
Tubo de salida del enfriador - 1 etapa
Tubo refrigeratore uscita - 1° stadio
Language Support
English
German
French
Dutch
Spanish
Italian
E61450.doc
CompAir UK Ltd COOLER ASSEMBLY 2ND STAGE E61447
Page 1
COOLER ASSEMBLY E61447 - 2nd STAGE

5407.2 COMPRESSORS
5407.2 COMPRESSORS PARTS LIST

1 E61448 Cooler Coil - 2nd Stage 1
Kühlerspule - 2. Stufe
Bobine de réfrigérant - 2 ème étage
Pijpenwinding Koeler - 2e trap
a
Serpentina refrigeratore - 2 etapa
Bobina refrigeratore - 2° stadio
Sechskantschraube
Vis à tête 6 pans
Zaskantschroef
3 C202609 Strip, Rubber 4
Gummistreifen
Bande en caoutchouc
Gummistrip
Banda de caucho
Nastro in gomma
4 C200576 Clamp, Cooler 4
E61447.doc
CompAir UK Ltd COOLER ASSEMBLY 2ND STAGE E61447
Page 2
Halterung, Kühler
Koelerklamp
Fascetta refrigeratore
5 95141.6 Nut, Hexagonal Self-Locking 4
Sechskantmutter, selbstsichernd
Ecrou 6 pans à auto-verrouillage
Zestantige moer, zelfborgend
Tuerca autobloqueante hexagonal
Dado autobloccante
6 CU41239 Bracket, Cooler 1
Halterung, Kühler
Koelerbeugel
Fascetta staffa
7 PS1742.1 Washer, Taper 1
Kegelschiebe
Rondelle conique
Tapse ring
Arandela cónica
Rondella rastremata
8 95148.14 Washer 1
Kegelschiebe
Rondelle
Sluitring
Arandela
Rondella
Sechskantschraube
Vis à tête 6 pans
Zaskantschroef
10 95006.131 Bolt, Hexagon Head 2
Sechskantschraube
Boulon à tête 6 pans
Zaskantbout
Perno de cabeza hexagonal
Bullone a testa esagonale
11 98660.1189 Washer, Large 2
Unterlegschiebe. groß
Rondelle, grande
Sluitring, groot
Arandela, grande
Rondella grande
Language Support
English
German
French
Dutch
Spanish
Italian
E61447.doc
CompAir UK Ltd COOLER ASSEMBLY 3RD STAGE E61446
Page 1
COOLER ASSEMBLY E61446 - 3rd STAGE

5407.2 COMPRESSORS

1 E61443 Cooler Coil - 3rd Stage 1
a
Sechskantschraube
Vis à tête 6 pans
Zaskantschroef
Sechskantschraube
Zaskantbout
E61446.doc
Page 2
Sechskantschraube
Zaskantbout
Halterung, Kühler
Koelerklamp
Gummistreifen
Bande en caoutchouc
Gummistrip
Banda de caucho
Nastro in gomma
Dado autobloccante
8 98660.1189 Washer, Large 2
Rondelle, grande
Sluitring, groot
Arandela, grande
Rondella grande
Halterung, Kühler
Koelerbeugel
Fascetta staffa
Kegelschiebe
Rondelle conique
Tapse ring
Arandela cónica
Rondella rastremata
11 95148.14 Washer 1
Kegelschiebe
Rondelle
Sluitring
Arandela
Rondella
Sechskantschraube
Vis à tête 6 pans
Zaskantschroef
13 98150.1040 Clamp, Pipe 1
Rohrschelle
Collier de tube
Beugel
Sujetador para tubo
Fascetta tubo
14 95018.170 Capscrew 1
E61446.doc
Page 3
Kopfchelle
Vis à tête
Inbusschroef
Tapa roscada
Vite a testa cilindrica
15 95149.13 Washer 1
Kegelschiebe
Rondelle
Sluitring
Arandela
Rondella
16 95111.4 Nut 1
Mutter
Ecrou
Moer
Tuerca
Dado
Language Support
English
German
French
Dutch
Spanish
Italian
E61446.doc
Page 1
COOLER ASSEMBLY E61494 - 3rd STAGE

WITH FITTING FOR TEMPERATURE SWITCH
5307.2 COMPRESSORS

1 E61494 Cooler Coil - 3rd Stage 1
a
Sechskantschraube
Vis à tête 6 pans
Zaskantschroef
Sechskantschraube
Zaskantbout
E61494.doc
Page 2

Halterung, Kühler
Koelerklamp
Gummistreifen
Bande en caoutchouc
Gummistrip
Banda de caucho
Nastro in gomma
Dado autobloccante
7 98660.1189 Washer, Large 2
Rondelle, grande
Sluitring, groot
Arandela, grande
Rondella grande
Halterung, Kühler
Koelerbeugel
Fascetta staffa
Kegelschiebe
Rondelle conique
Tapse ring
Arandela cónica
Rondella rastremata
10 95148.14 Washer 1
Kegelschiebe
Rondelle
Sluitring
Arandela
Rondella
Sechskantschraube
Vis à tête 6 pans
Zaskantschroef
12 98150.1040 Clamp, Pipe 1
Rohrschelle
Collier de tube
Beugel
Sujetador para tubo
Fascetta tubo
13 95018.170 Capscrew 1
Kopfchelle
Vis à tête
Inbusschroef
Tapa roscada
E61494.doc
Page 3
14 95149.13 Washer 1
Kegelschiebe
Rondelle
Sluitring
Arandela
Rondella
15 95111.4 Nut 1
Mutter
Ecrou
Moer
Tuerca
Dado
Language Support
English
German
French
Dutch
Spanish
Italian
E61494.doc
CompAir UK Ltd COOLER ASSEMBLY 4TH STAGE E61451
Page 1
COOLER ASSEMBLY E61451 - 4th STAGE

INDUSTRIAL COMPRESSORS
E61451.doc
CompAir UK Ltd COOLER ASSEMBLY 4TH STAGE E61451
Page 2
INDUSTRIAL COMPRESSORS PARTS LIST

1 A30181 Cooler Coil - 4th Stage 1
a
Bobina refrigeratore 4° stadio
2 95018.199 Capscrew 1
Kopfschraube
Vis à tête
Inbusschroef
Tapa roscada
Halterung, Kühler
Koelerklamp
4 C200879 Packing 1
Dichtung
Garniture
Pakking
Empaquetadura
5 98241.1049 Tie, Cable 1

Kabelklemme
Etrier de câble
Kabelklem
Amarre de cable
Vincolare, Cavo
6 98156.2809 Coupling, Stud - High Air Temperature Switch 1
Einschraubstutzen - Temperaturschalter
Accouplement de goujon - Thermostat
Inschroefkoppeling - Temperaturschakelaar
Conectador de espárrago - Termostato
7 C201827 Bracket 1
Halterung
Support
Beugel
Soporte
Parentesi
Sechskantschraube
Vis à tête 6 pans
Zaskantschroef
Language Support
English
German
French
Dutch
Spanish
Italian
E61451.doc
CompAir UK Ltd SUCTION PIPE 2ND STAGE C203453
Page 1
SUCTION PIPE ASSEMBLY 2ND STAGE - C203453

5407.2 COMPRESSOR
PARTS LIST
1 98156.2610 Elbow - 90° 1
Bogenstück - 90°
Coude - 90°
Kniestuk - 90°
Codo - 90°
Gomito 90°
2 98617.1020 Tube - Aluminium 1
Rohr -
Tube -
Pijp -
Tubo -
Tubo - alluminio
3 98156.2611 Elbow - 90° 1
Bogenstück - 90°
Coude - 90°
Kniestuk - 90°
Codo - 90°
Gomito 90°
Language Support
English
German
French
Dutch
Spanish
Italian
C203453.doc
CompAir UK Ltd SUCTION PIPE 3RD STAGE C203445
Page 1
SUCTION PIPE ASSEMBLY 3RD STAGE - C203445

5407.2 COMPRESSOR
PARTS LIST
1 98156.2610 Elbow - 90° 1
Bogenstück - 90°
Coude - 90°
Kniestuk - 90°
Codo - 90°
Gomito 90°
Rohr -
Tube -
Pijp -
Tubo -
Tubo - alluminio
3 98156.3653 Elbow - 45° 1
Bogenstück - 45°
Coude - 45°
Kniestuk - 45°
Codo - 45°
Gomito - 45°
Language Support
English
German
French
Dutch
Spanish
Italian
C203445.doc
CompAir UK Ltd SUCTION PIPE 4TH STAGE C203446
Page 1
SUCTION PIPE ASSEMBLY 4TH STAGE - C203446

5407.2 COMPRESSOR
PARTS LIST
1 98156.1801 Coupling 2
Kuppelstück
Accouplement
Koppeling
Acoplamiento

Rohr -
Tube -
Pijp -
Tubo -
Tubo - alluminio
Language Support
English
German
French
Dutch
Spanish
Italian
C203446.doc
CompAir UK Ltd LUBRICATION ASSEMBLY - E61493
Page 1
LUBRICATION ASSEMBLY
INDUSTRIAL COMPRESSORS
E61493.doc
Page 2
INDUSTRIAL COMPRESSORS PARTS LIST
E61493
1 C203458.100 Regulator, Oil 1
Ölregler
Régulateur
Olieregelaar
Regulador de aciete
Regolatore, Olio
1a 98262.1148 Element, Oil Filter 1
Einsatz, Ölfiltre
Elément du filtre á huile
Oliefilterelement
Elemento del filtro de aciete
Cartuccia del filtro olio
1b 95018.174 Capscrew 2
Kopfschraube
Vis à tête
Inbusschroef
Tapa roscada
1c 95602.7 'O' Ring 1
O-Ring
Joint torique
O-Ring
Aro tórico
O-Ring
1d PS1322.2 Seal 1
Dichtung
Joint
Afdichting
Sello
Guarnizione
Blindstopfen
Blindplug
Tapón obturador
Tappo cieco
1f PS1322.1 Seal 1
Dichtung
Joint
Afdichting
Sello
Guarnizione
1g PS1814.2 Plug, Blanking 2
Blindstopfen
Blindplug
Tapón obturador
Tappo cieco
E61493.doc
Page 3
2 C203431 Pump, Oil 1

Ölpumpe
Pompe d'huile
Oliepomp
Includes 2a Bomba de aciete
Pompa dell'olio
2a 95602.40 'O' Ring 2
O-Ring
Joint torique
O-Ring
Aro tórico
O-Ring
3 C203531 Pipe, Oil Feed 1
Ölzufuhr-Rohr
Tuyau d'amenee d'huile
Olieaanvoerpijp
Tubería sumin aciete
Tubo alimentazione olio
4 C203643 Pipe, Oil Return 1
Öl-Rückleitung- Baugruppe
Tuyau de retour d'huile
Olieaterugvoerleiding
Tubería retorno aciete
Tubo ritorno olio
Tubo ritorno olio
6 98660.1152 Seal 3
Dichtung
Joint
Afdichting
Sello
Guarnizione
Language Support
English
German
French
Dutch
Spanish
Italian
E61493.doc
Page 1
5307.2 COMPRESSORS
E61498.doc
Page 2
5307.2 COMPRESSOR PARTS LIST
E61498
1 C203458.100 Regulator, Oil 1
Ölregler
Includes Régulateur
1a, 1b, 1c, 1d, 1e, 1f Olieregelaar
& 1g. Regulador de aciete
Regolatore, Olio
1a 98262.1148 Element, Oil Filter 1
Einsatz, Ölfiltre
Elément du filtre á huile
Oliefilterelement
Elemento del filtro de aciete
Cartuccia del filtro olio
1b 95018.174 Capscrew 2
Kopfschraube
Vis à tête
Inbusschroef
Tapa roscada
1c 95602.7 'O' Ring 1
O-Ring
Joint torique
O-Ring
Aro tórico
O-Ring
1d PS1322.2 Seal 1
Dichtung
Joint
Afdichting
Sello
Guarnizione
Blindstopfen
Blindplug
Tapón obturador
Tappo cieco
1f PS1322.1 Seal 1
Dichtung
Joint
Afdichting
Sello
Guarnizione
1g PS1814.2 Plug, Blanking 2
Blindstopfen
Blindplug
Tapón obturador
Tappo cieco
E61498.doc
Page 3
2 C203431 Pump, Oil 1

Ölpumpe
Pompe d'huile
Oliepomp
Includes 2a Bomba de aciete
Pompa dell'olio
2a 95602.40 'O' Ring 2
O-Ring
Joint torique
O-Ring
Aro tórico
O-Ring
3 C203531 Pipe, Oil Feed 1
Ölzufuhr-Rohr
Tuyau d'amenee d'huile
Olieaanvoerpijp
Tubería sumin aciete
Tubo alimentazione olio
Tubo ritorno olio
Blindstopfen
Blindplug
Tapón obturador
Tappo cieco
6 98660.1152 Seal 5
Dichtung
Joint
Afdichting
Sello
Guarnizione
Language Support
English
German
French
Dutch
Spanish
Italian
E61498.doc
CompAir UK Ltd FLYWHEEL ASSEMBLY 2 X SPA E61421
Page 1
FLYWHEEL ASSEMBLY 2 X SPA E61421

WITH DIRECT DRIVE OPTION
2
2a > 10/98
2b < 10/1998
Note:- GRP (red) and GRN (black) should not be mixed

3-4
on the same fan assembly
5-6
55 nm 40 lb ft
PARTS LIST
1 E61420 Flywheel 1
Schwungrad
Volent
Vliegwiel
Volente
2 98084.1003 Fan, Axial 1
Axiallüfter
Ventilateur, axial
Axiale ventilator
Venilador, axial
2a 98084.1033 Blade, Fan - GRN Black 10
Ventilatorflügel - GRN Schwarz
Pale de ventilateur - GRN Noir
Ventilatrblad - GRN Zwart
Paleta del ventilador - GRN Negro
2b 98084.1005 Blade, Fan - GRP Red 10
Ventilatorflügel - GRP Rot
Pale de ventilateur - GRP Rouge
Ventilatrblad - GRP Rood
Paleta del ventilador - GRP Rojo
3 95179.5 Washer, Spring 6
Federring
Rondelle élastique
Veering
Arandela elastica
4 95018.168 Screw, Caphead 6
Schraube
Vis
Schroefbout
Tornillo
5 98660.1092 Washer, Retaining 1
Sicherungsscheibe
Rondelle de retenue
Borgring
Arandela de retención
6 98500.1003 Screw, Hexagon Head - Left Hand Thread 1
Language Support Sechskantschraube
English Vis à tête 6 pans
German Zestkantschroef
French Tonillo de cabeza hexagonal
Dutch
Spanish
Italian
E61421.doc
CompAir UK Ltd SAFETY VALVES E61449
Page 1
SAFETY VALVES E61449

STANDARD COMPRESSORS PARTS LIST

1 PS1322.2 Seal 3
Dichtung
Joint
Afdichting
Sello
Guarnizion
2 98650.1163-5.9 Valve Safety - 1st Stage 1
Sicherheitsventil - 1. Stufe
Soupape de sécurité - 1 er étage
Veiligheidsklep - 1e trap
a
Válvula de seguridad - 1 etapa
Valvola di sicurezza - 1° stadio
3 98650.1163-27 Valve Safety - 2nd Stage 1
Soupape de sécurité - 2 éme étage
a
4 98650.1164-97 Valve Safety - 3rd Stage 1
a
Language Support
English
German
French
Dutch
Spanish
Italian
E61449.doc
CompAir UK Ltd SAFETY VALVES E61645
Page 1
SAFETY VALVES E61645

PARTS LIST
1 PS1322.2 Seal 3
Dichtung
Joint
Afdichting
Sello
Guarnizion
2 98650.1163-5.9 Valve Safety - 1st Stage 1
Soupape de sécurité - 1 er étage
a
3 98650.1163-27 Valve Safety - 2nd Stage 1
a
4a 98650.1164-69 Valve Safety - Final Stage 1
Working Pressure Sicherheitsventil - Letzt. Stufe
40 - 63 bar Soupape de sécurité - Final étage
4b 98650.1164-76 Veiligheidsklep - Final trap
Working Pressure Válvula de seguridad - Ultimo etapa
63 - 74 bar Valvola di sicurezza - Ultimo stadio
4c 98650.1164-88
Working Pressure
74 - 80 bar
Language Support
English
German
French
Dutch
Spanish
Italian
E61645.doc
Page 45
SECTION 9
ANCILLARY PARTS
AS FITTED
9.1 AIR/GAS CIRCUIT DIAGRAM APP038
9.2 ANTI-VIBRATION MOUNTS APP003
9.3 ELECTRIC MOTOR APP034
9.4 VEE BELT DRIVE APP012H
MOTOR PULLEY 150 PCD
T/L BUSH
VEE BELTS - SPA 2 OFF
9.5 SOLENOID VALVE APP138
9.6 UNLOADER DRAIN SYSTEM APP209
9.7 PRESSURE SWITCH - FINAL APP081 98524.1004
9.8 PRESSURE GAUGES APP070
0 TO 1 BAR
0 TO 6 BAR
0 TO 40 BAR
0 TO 140 BAR
0 TO 600 BAR
0 TO 160 BAR
9.9 SEPARATOR - FINAL APP
9.10 NON RETURN VALVE APP158
9.11 PRESSURE MAINTAINING VALVE APP063 98261.1595
9.12 PRESSURE MAINTAINING VALVE APP064 98261.1597
9.13 LOW OIL PRESSURE SWITCH APP088 98524.1122
9.14 FINAL FILTRATION APP
9.15 CONDENSATE COLLECTION SYSTEM APP044
1213.doc 30/08/02 Page 45

Page 46
Page 46 1213.doc 30/08/02

CompAir UK Ltd PUBLICATION APP038 5407/9 AIR/GAS CIRCUIT DIAGRAM
Page 1
5407 2 & 5409.2

AIR/GAS CIRCUIT DIAGRAM
3RD STAGE 1ST STAGE

COOLER COOLER
INLET
LINK FOR
HIGH AIR 5407.2.NG
TEMPERATURE & 5409.2
SWITCH
APP101
LOW OIL
PRESSURE
SWITCH
APP082 & 088
2ND STAGE
3RD STAGE COOLER
SEPARATOR
1ST STAGE
FINAL COOLER SEPARATOR
NOT FITTED
FINAL SEPARATOR ON 5407.2.NG
APP127, 130 & 135 OR 5409.2
SEE APP208 FOR
RECOMMENDATIONS FINAL DELIVERY
ON SERVICE LIFE 2ND STAGE
SEPARATOR
NON RETURN VALVE

APP158 CONDENSATE
DRAIN
FINAL SEPARATOR &

FILTRATION UNLOADER
APP129, 133, 134, 140, DRAIN VALVE
141, 143, 146, 147, 148, SEE APP209
FINAL
149, 150, 159, 160, & 162. FOR DETAILS
DELIVERY
PRESSURE OPTIONAL FINAL
SEE ABOVE FOR MAINTAINING PRESSURE SWITCH
RECOMMENDATIONS VALVE APP081 & APP083
ON SERVICE LIFE. APP063 & 064
SEE APP207 FOR

RECOMMENDATIONS
ON DRAIN TIMES.
CONDENSATE
COLLECTION SYSTEM
APP044
app038.doc
CompAir UK Ltd PUBLICATION APP038 5407/9 AIR/GAS CIRCUIT DIAGRAM
Page 2
app038.doc
CompAir UK Ltd APP 003 ANTI VIBRATION MOUNTS
Page 1
AVA TYPE
PART NUMBERS VARIOUS
PREVENTIVE MAINTENANCE
1) After installation and initial running in. Record height dimension (H) of each mount.
2) After a week or 100 hours running time recheck and record dimension (H)
3) Check this dimension every 3 to 6 months depending on usage i.e. regular usage every 3
months.
Note: This dimension may only change a small amount during the life of the mount
approximately 1mm.
4) Any oil or paint contact with the rubber mount will affect the life and performance, so keep to a
minimum by regularly cleaning and clearing any contamination from the surrounding area.
5) Under normal working conditions the life expectancy will be 5 to 8 years.
6) Temperatures in excess of 70° C will have an adverse effect on the rubber and will shorten
the life expectancy.
app003.doc
CompAir UK Ltd APP 003 ANTI VIBRATION MOUNTS
Page 2
app003.doc
CompAir UK Ltd PUBLICATION APP034 ELECTRIC MOTOR MAINTENANCE GENERAL
Page 1
ELECTRIC MOTOR MAINTENANCE
WARNING :
Isolate power supply to motor before commencing any routine cleaning or maintenance work.
Routine Cleaning :
Remove the fan cover and ensure that all holes are completely open. Clear any dirt and fluff from behind the
fan and along the ribs of the frame.
Periodic Maintenance :
Remove the cover and the fan which is fitted on the shaft extension.
Slacken and remove bearing cover screws and endshield bolts/studs. The endshields should then be eased
off their spigots.
The rotor can now be withdrawn carefully from the stator.
Having dismantled the motor, maintenance can now be carried out to remove all dirt. Dry, compressed air
under comparatively low pressure is best as a high velocity stream can force dirt into the spaces between
windings, etc.
Grease removing solvents should only be used very sparingly so as not to damage impregnating varnish or
insulation.
Bearings are charged with sufficient grease to last at least two years, provided there is little or no grease
leakage. When replenishing, use only good quality lithium based grease and avoid overfilling the bearing
housing.
Motors should be reassembled in the reverse order from dismantling, taking care not to damage the
windings on insertion of rotor, taking care not to damage the windings on insertion of rotor, remembering to
ease endshields on bearings and spigots. DO NOT USE FORCE.
Before starting, check that the rotor revolves freely. Ensure that the electrical connections are correct and
terminal nuts tight.
Refit any pulley, coupling, sprocket etc. which have been removed, being particularly careful to ensure
correct alignment with the driven part, as misalignment may lead to ultimate bearing failure and shaft
breakage.
app034.doc
CompAir UK PUBLICATION APP034 ELECTRIC MOTOR MAINTENANCE GENERAL
Page 2
APP034.doc
CompAir UK Ltd APP012h - BELT ALIGNMENT & TENSIONING
Page 1
RECOMMENDED VEE BELT ALIGNMENT

& TENSIONING
BELT DRIVE ALIGNMENT
STRAIGHT EDGE
STRAIGHT EDGE
DISTANCE PIECES
5 mm
PRIME
COMPRESSOR MOVER
BELT ADJUSTING SCREW
It is very important that the driving and driven pulley grooves are in line and both pulley shafts are parallel,
see above, if the pulley faces are not parallel use appropriate size distance pieces to ensure belt grooves
are correctly aligned. Check belt tension by method described on following page.
RECOMMENDED TENSIONING FORCES

APPLIED TO MID-SPAN
CENTRE DISTANCE SEE TABLE
STRAIGHT EDGE
ADJUSTMENT METHOD
If the belt tension is incorrect, correct it by using the adjusting screw provided, using a suitable straight
edge (long enough to span both pulleys),.established the correct deflection and pulley alignment.
app012h.doc 22/10/02 Page 1

CompAir UK Ltd APP012h - BELT ALIGNMENT & TENSIONING
Page 2
TABLE
Belt Force required to deflect belt 16 mm per metre of span

Section
Belt Small Pulley Newton Kilogram force
Section Ø mm (N) (kgf)
SPA 100 to 132 20 to 27 1.5 to 2.7
140 to 200 27 to 35 2.7 to 3.5
Method of Belt Tensioning. Using a Belt Tension Indicator.
1. Measure small pulley diameter (motor/engine)
2. Calculate the deflection distance in mm on a basis of 16 mm per metre of span.

Centre distance (metres) X 16 = Deflection (mm). If distance & deflection is known, go to 3.
3. Set the lower marker ring at the deflection distance required in mm on the lower scale.
4. Set the upper marker ring against the bottom edge of the top tube.
5. Place the belt tension indicator on top of the belt at the centre of span and apply a force at
right angles to the belt deflecting it to the point where the lower marker ring is level with the
adjacent belt, on single belt drives place a straight edge across the two pulleys to act as a
datum.
6. Read off the force value indicated by the top edge of the upper marker ring.
7. Compare this force to kgf value shown in the table above.
8. Tighten or loosen belt tensioner to achieve the correct value.
9. If the measured force falls within the values given, the drive should be satisfactory.
Note:- If a belt tension indicator is not available, a suitably scaled spring balance and rule will
suffice.
10 20 30 40 50 60 14 12 10 8 6 4 2
mm
Deflection in mm Deflection Force in kgf
Page 2 app012h.doc 22/10/02

CompAir UK Ltd PUBLICATION APP 138 - 3 WAY SOLENOID VALVES PS2197
Page 1
3 WAY SOLENOID VALVE

PS2197
OPERATION
3 way normally closed energise to open, continuous duty.

On starting the solenoid valve opens (energised) this operates the diaphragms which in turn closes
the valves within the D.D.Vs. (Diaphragm Drain Valves) thus allowing pressure to build up in the
system to the desired pressure. On shutdown the solenoid valve closes (de-energised) this takes the
pressure of diaphragms thus allowing the drains to blow any condensate collected within the stage
separators.
INSTALLATION
Technical Details Current consumption

Part No Voltage Hz Current Inrush Hold
PS2197.1 230 50 AC 26 VA 16 VA
PS2197.2 110 50 AC 26 VA 16 VA
PS2197.3 220 60 AC 26 VA 16 VA
PS2197.4 110 60 AC 26 VA 16 VA
PS2197.5 24 DC - 10 watts
PS2197.6 110 DC - 10 watts
PS2197.7 230 DC - 10 watts
PS2197.8 24 50 AC 26 VA 16 VA
PS2197.9 12 DC - 10 watts
PS2197.10 24 60 AC 26 VA 16 VA
PS2197.11 125 DC 10 watts
PS2197.12 48 50AC 26VA 16VA
Electrical connection Amps pin to DIN 46242

Connector To DIN 43650
Protection IP65
Cable thread size PG9
Coil Class 'H' 180°C insulation
Coil duty Continuous
Voltage tolerance from normal -10% to +10%
Port Size G 1/8"
Orifice Size Ø1.6mm
Maximum working pressure 12 bar g.
Working fluid Air, water, gas, fuel oil & non corrosive liquids.
Ambient temperature range -15°C to +50°C
0 2
app138.doc
CompAir UK Ltd PUBLICATION APP 138 - 3 WAY SOLENOID VALVES PS2197
Page 2
app138.doc
CompAir UK Ltd PUBLICATION APP209
Page 1
UNLOADER DRAIN VALVE ASSEMBLIES
FOR DETAILS OF RECOMMENDED DRAIN TIMES SEE APP207.
OPERATION.
Low pressure air/gas (usually 1st stage) is fed to a solenoid valve which when compressor is running is open,
the air holds the unloader drain valves closed, by means of a diaphragm (B) pushing against the pistons (A).
Located near to separator/filter drains the Unloader Drain Valve (UDV) is designed to drain any condensate
collected during normal operation i.e.
1. When compressor shuts down on Manual Start/Stop operation.

2. When compressor shuts down on Manual Start/Auto Stop operation.
3. When a timed drainage system is used on Auto Start/Stop continuous operation.
MANUAL START/STOP. - MANUAL START/AUTO STOP.
On Shut-Down the solenoid is de-energised, air/gas is shut off, any excess air/gas being vented into the
manifold. The pressure on the diaphragm is released taking the pressure off the pistons allowing the valves
to open, air/gas/condensate is discharged into the manifold and drain pipe for safe disposal or into a
condensate collection vessel if fitted, this must be periodically emptied.
On Start-Up, the solenoid opens. the pressure builds up, the valves close and the cycle repeats itself.
AUTO START/STOP.
For continuous running a timed drainage system should be used, a signal is passed to the solenoid, every 30
minutes from the starter control panel or by means of an optional timer plug, part number 98606.1014,1015
or 1016, this closes the solenoid valve for 5 to 6 seconds duration allowing all condensate collected to be
discharged through the unloader drain valve system. (Note in HIGH AMBIENT/HUMIDITY AREAS it is
recommended the drainage cycle time be more frequent contact CompAir UK Ltd - Customer Service Tel.
+44 (0) 1473 556027 for more information.
The solenoid valve re-opens for normal operation.
app209.doc
Page 2
INLINE UDV ASSEMBLY D101580
3
PORT 'A'
1ST
STAGE
1
PORT 'B'
A 2ND STAGE
B
PORT 'C'
3RD
STAGE
7 PORT 'D' 4TH STAGE

*AN ORIFICE
2 ADAPTER C89347
MAY BE FITTED
5
VALVE CONTROL
4 FROM 1ST STAGE
PRESSURE BY A 3
WAY NC SOLENOID
VALVE PS2197 SEE
APP 138 & AN
OPTIONAL TIMER
6 PLUG 98606.1014,
1015 OR 1016
CONDENSATE DISCHARGE 1" BSPT
PARTS LIST
ITEM PART NUMBER DESCRIPTION NO OFF
1 D101582 VALVE ASSEMBLY 1ST & 2ND STAGE 1
2 D101581 VALVE ASSEMBLY 3RD & 4TH STAGE 1
3 95019.176 CAPSCREW M6 X 60 LG 4
4 95405.861 REDUCING SOCKET 1
5 98650.1163-4.1 SAFETY VALVE 1
6 C203676 MANIFOLD INLINE 4 POSITION 1
7 95602.15 'O' RING 4
8 PS1454.1 BLANKING PLUG IF FITTED (NOT ILLUSTRATED) 1
SPARES KIT
A C203195 PISTON 4
B C203549 DIAPHRAGM 2
CONNECTION DETAILS
COMPRESSOR TYPE PORT 'A' PORT 'B' PORT 'C' PORT 'D'
5407.2 1ST STAGE 2ND STAGE 3RD STAGE 4TH STAGE
5307.2 1ST STAGE 2ND STAGE 3RD STAGE PLUGGED
* AN ADAPTER MAY BE FITTED ON SOME APPLICATIONS TO THE 4TH STAGE DRAIN PORT TO
SLOW DOWN THE DRAIN PROCESS TO PREVENT OVERPRESSURE OF THE CONDENSATE
COLLECTION SYSTEM.
app209.doc
Page 3
2 X 2 UDV ASSEMBLY D101608

PARTS AS D100580 UNLESS AS STATED BELOW
1 PORT 'B'
2ND STAGE
PORT 'A' 1ST

STAGE
2
PORT 'C'
3RD STAGE
PORT 'D' 4TH

STAGE *AN
7 ORIFICE ADAPTER
C89347 MAY BE
FITTED
6 VALVE CONTROL FROM 1ST
STAGE PRESSURE BY A 3
WAY NC SOLENOID VALVE
PS2197 SEE APP 138 & AN
3
OPTIONAL TIMER PLUG
98606.1014, 1015 OR 1016
PARTS LIST
1 D101582 VALVE ASSEMBLY 1ST & 2ND STAGE 1
2 D101581 VALVE ASSEMBLY 3RD & 4TH STAGE 1
3 95019.176 CAPSCREW M6 X 60 LG 4
5 98650.1163-4.1 SAFETY VALVE 1
6 C203677 MANIFOLD 2 x 2 POSITION 1
7 95602.15 'O' RING 4
8 PS1454.1 BLANKING PLUG IF FITTED (NOT ILLUSTRATED) 1
SPARES KIT
A C203195 PISTON 4
CONNECTION DETAILS
COMPRESSOR TYPE PORT 'A' PORT 'B' PORT 'C' PORT 'D'
5407.2 1ST STAGE 2ND STAGE 3RD STAGE 4TH STAGE
5307.2 1ST STAGE 2ND STAGE 3RD STAGE PLUGGED
* AN ADAPTER MAY BE FITTED ON SOME APPLICATIONS TO THE 4TH STAGE DRAIN PORT TO
SLOW DOWN THE DRAIN PROCESS TO PREVENT OVERPRESSURE OF THE CONDENSATE
COLLECTION SYSTEM.
app209.doc
Page 4
2 VALVE UDV ASSEMBLY D101544

SEE D70549 FOR INSTALLATION
2
PORT 'B'
3RD STAGE
1
PORT 'A' 2ND

STAGE
VALVE CONTROL
FROM 1ST STAGE
5 PRESSURE BY A 3
WAY NC SOLENOID
VALVE PS2197 SEE
APP 138 & AN
OPTIONAL TIMER
4
PLUG 98606.1014,
1015 OR 1016.
6
CONDENSATE DISCHARGE 1" BSPT
PARTS LIST
1 C203552 UNLOADER VALVE ASSEMBLY 1
2 95019.176 CAPSCREW M6 X 60 LG 2
3 95602.15 'O' RING 2
5 98650.1163-4.1 SAFETY VALVE 1
6 C203551 MANIFOLD 1
SPARES KIT
A C203195 PISTON 2
CONNECTION DETAILS
COMPRESSOR TYPE PORT 'A' PORT 'B'
5404 2ND STAGE 3RD STAGE
5405 2ND STAGE 3RD STAGE
5405E 2ND STAGE 3RD STAGE
app209.doc
Page 5
2
PORT 'C'
3RD/4TH
STAGE
1 OR PLUGGED
A B
PORT 'B' 2ND/3RD

STAGE
PORT 'A' 2ND

3
STAGE OR
PLUGGED
5
VALVE CONTROL
FROM 1ST STAGE
PRESSURE BY A 3
4 WAY NC SOLENOID
VALVE PS2197 SEE
APP 138 & AN
6 OPTIONAL TIMER
PLUG 98606.1014,
CONDENSATE DISCHARGE 1" BSPT 1015 OR 1016
PARTS LIST
2 95019.176 CAPSCREW M6 X 60 LG 2
3 95602.15 'O' RING 3
5 98650.1163-4.1 SAFETY VALVE 1
SPARES KIT
A C203195 PISTON 3
C C203197 GASKET 1
CONNECTION DETAILS
COMPRESSOR TYPE PORT 'A' PORT 'B' PORT 'C'
5307 2ND STAGE 3RD STAGE -
5404 - 2ND STAGE 3RD STAGE
5406 2ND STAGE 3RD STAGE 4TH STAGE
app209.doc
Page 6
2 PORT 'C'
3RD/4TH STAGE
OR PLUGGED
1
A B
PORT 'B' 2ND/3RD

STAGE
3 PORT 'A' 2ND

STAGE OR
PLUGGED
VALVE CONTROL
5 FROM 1ST STAGE
PRESSURE BY A 3
4 WAY NC SOLENOID
VALVE PS2197 SEE
APP 138 & AN
6 OPTIONAL TIMER
PLUG 98606.1014,
CONDENSATE DISCHARGE 1" BSPT 1015 OR 1016
PARTS LIST
2 95019.176 CAPSCREW M6 X 60 LG 2
3 95602.15 'O' RING 3
5 98650.1287-4.6 SAFETY VALVE 1
SPARES KIT
A C203195 PISTON 3
C C203197 GASKET 1
CONNECTION DETAILS
COMPRESSOR TYPE PORT 'A' PORT 'B' PORT 'C'
app209.doc
CompAir UK Ltd APP 081 PRESSURE SWITCH 98524.1004
Page 1
PRESSURE SWITCH
98524/1004
OPERATION
Located as close as possible to the H.P. delivery line, the pressure switch stops the compressor
when the upper pressure limit is attained and triggers off the start when the lower limit is reached.
The switch transforms a change of pressure into an electrical 'On' or 'Off' signal.
When a pre-set pressure is reached the snap action contact changes state.
INSTALLATION
Pressure switches may be mounted in any convenient position close to the H.P. line, provided it is
not subject to vibration and that the connecting pipe to the receiver does not exceed five metres.
Mount the switch by the lugs provided on the casing.
Where possible the pressure switch operating line should be taken from the receiver to avoid
pressure oscillations.
It is usual to connect 1 and 2 to the compressor electrical control circuit terminals marked pressure
switch'.
Red Pointer
3 1
Green Pointer
4 2
SETTING
Example of pressure setting to 150 bar minimum and 175 bar maximum.
Turn screw (A) to raise the GREEN pointer to its highest point.
Turn screw (B) so that the higher setting (175 bar) coincides with the RED pointer.
Turn screw (A) again to set the lower pressure 150 bar on the GREEN pointer.
NOTE: ALWAYS USE A CALIBRATED PRESSURE GAUGE WHEN SETTING PRESSURE SWITCHES,
AS THE MARKINGS ON SWITCHES ARE FOR INDICATION ONLY.
app081.doc
CompAir UK Ltd APP 081 PRESSURE SWITCH 98524.1004
Page 2
app081.doc
CompAir UK Ltd PUBLICATION APP070 PRESSURE GAUGES GENERAL
Page 1
PRESSURE GAUGES
GENERAL
The pressure gauge should be installed such as to avoid exposure to heat and vibration and to enable easy
observation of the dial indication.
IMPORTANT
It is common practise to install the pressure gauge without an isolating device, so to facilitate calibration or
replacement the system must be de pressurised before any work is carried out.
The pressure gauge is liquid filled to provide better damping from pulsation’s.
INSTALLATION & COMMISSIONING
The tightening and loosening of torque applied to the connection should be by means of the spanner flats
provided on the stem and should not be by means of grasping the case as this may damage the gauge.
No pressure higher than indicated by the working pressure symbol ▼ must be applied to the gauge during
hydrostatic pressure testing of the system. Otherwise the gauge must be isolated or removed during this
operation.
No attempt should be made to remove a pressurised gauge. The pressure system must be totally relieved if
the gauge can not be isolated otherwise.
The remainder of the pressure medium contained in the element may be hazardous or toxic. This should be
considered when handling and storing the removed pressure gauge.
PRESSURE GAUGES IN SERVICE.
Always open isolating devices always gently and never abruptly, as this may generate sudden pressure
surges that may damage the gauge.
The maximum working pressure for which the gauge is suitable, or also the minimum working pressure in
cases of vacuum, is indicated on the dial by corresponding marks ▼. Fluctuating pressure always reduces
the maximum working pressure of the gauge.
Correct zeroing may be inspected by closing the isolating valve and relieving the gauge from pressure. The
pointer must fall within the thickened portion of the zero mark. Unless the gauge temperature is considerably
higher or lower than 20°C, a pointer not returning to zero may indicate serious damage to the gauge.
On-site testing of the pressure gauge is feasible by means of special isolating devices enabling connection of
a test gauge together with a suitable pressure source.
app070.doc
CompAir UK Ltd PUBLICATION APP070 PRESSURE GAUGES GENERAL
Page 2
app070.doc
CompAir UK Ltd PUBLICATION APP158 NON RETURN VALVE 98650.1422/1655
Page 1
NON-RETURN VALVE
Connections 1/2” BSP (G1/2)
CompAir Part Number 98650/1655
TECHNICAL SPECIFICATION
Maximum Working Pressure - 6000 psi

Body material (Stainless Steel)
1
6 4 5 3 7
8 2
Item No. Description No Off

1 Body 1
2 Spindle 1
3 ‘O’ ring collar 1
4 Guide Washer 1
5 Spring 1
6 Locknut 1
7 ‘O’ Ring - PS1205/9 1
8 Retainer Clip 1
Connections 1/4” BSP (G1/4)
CompAir Part Number 98650/1422
TECHNICAL SPECIFICATION
Maximum Working Pressure - 6000 psi

Body material (Chrome plated brass) CZ121
1
6 4 5
3 7 2
Item No. Description No Off

1 Body 1
2 Spindle 1
3 ‘O’ ring collar 1
4 Guide Washer 1
5 Spring 1
6 Locknut 1
7 ‘O’ Ring 1
app158.doc
CompAir UK Ltd PUBLICATION APP158 NON RETURN VALVE 98650.1422/1655
Page 2
App158.doc
CompAir UK Ltd APP 063 PRESSURE MAINTAINING VALVE 98261.1595
Page 1
PRESSURE MAINTAINING VALVE

98261/1595
This valve is fitted to maintain a back pressure through the filters, separators and the compressor. This
ensures that these items of equipment reach their optimum working pressure as soon as possible, to give
long filter life, good oil separation and low oil consumption.
NOTE:- For use at 207 bar g (3000 psi).
ITEM PART NO. DESCRIPTION NO. OFF

1 98261/1568 Adjuster 1
2 98261/1569 Spring cap 1
3 98261/1547 Spring 1
4 98261/1149 Plunger 1
5 98261/1572 Lock nut 1
6 98261/1596 Plunger housing 1
7 *98261/1550 Anti-extrusion Ring 1
8 *98261/1551 Ò` Ring 1
9 98261/1552 Ò` Ring Retainer 1
10 *98261/1054 Bonded seal 1
11 *98261/1153 Piston 1
12 98261/1154 Valve body 1
ex 98261/1664 *Piston/seal Maint. kit 1
CompAir issue 2 24/10/02 app063.doc

Page 2
CompAir issue 2 24/10/02 app063.doc

Page 1
PRESSURE MAINTAINING VALVE

98261/1597
This valve is fitted to maintain a back pressure through the filters, separators and the compressor. This
ensures that these items of equipment reach their optimum working pressure as soon as possible, to give
long filter life, good oil separation and low oil consumption.
NOTE:- For use at 275 bar g (4000 psi).
ITEM PART NO. DESCRIPTION NO. OFF

1 98261/1568 Adjuster 1
2 98261/1147 Spring cap 1
3 98261/1570 Spring 1
4 98261/1149 Plunger 1
5 98261/1572 Lock nut 1
6 98261/1596 Plunger housing 1
7 *98261/1550 Anti-extrusion Ring 1
8 *98261/1551 Ò` Ring 1
9 98261/1552 Ò` Ring Retainer 1
10 *98261/1054 Bonded seal 1
11 *98261/1153 Piston 1
12 98261/1154 Valve body 1
13 98261/1567 Spring stop spacer 1
EX 98261/1664 *Piston/seal Maint. Kit 1
CompAir issue 2 app064.doc

Page 2
CompAir issue 2 app064.doc

CompAir UK Ltd APP 088 LOW OIL PRESSURE SWITCH 98524.1042/1122/1140
Page 1
LOW OIL PRESSURE SWITCH
PART NO: 98524.1042, 98524.1122 & 98524.1140

OPERATION
Located in the crankcase on watercooled & large aircooled compressors, in the oil filter body on aircooled,
the pressure switch stops the compressor when the oil pressure drops to pre-set pressure setting.
PART NO. COMPRESSOR TYPE INLET PRESSURE SETTING
98524/1042 WATERCOOLED Standard 1 bar (15 psi) falling
98524/1122 AIRCOOLED Standard 0.5 bar (7.5 psi) falling
98524/1042 AIRCOOLED GAZPACKS over 0.1 bar 1 bar (15 psi) falling
98524/1042 AIRCOOLED 5450/5470 Standard 1 bar (15 psi) falling
98524/1122 AIRCOOLED GAZPACKS up to 0.1 bar 0.5 bar (7.5 psi) falling
98524/1140 AIRCOOLED GAS Standard 1 bar (15 psi) falling
The switch transforms a change of pressure into an electrical "On" or "Off" signal.
When a pre-set pressure is reached the snap action contact stops the compressor.
INSTALLATION
It is usual to connect 1 (C) and 4 (N/O) to the compressor electrical control circuit terminals marked "Oil
Pressure Switch".
app088.doc
CompAir UK Ltd APP 088 LOW OIL PRESSURE SWITCH 98524.1042/1122/1140
Page 2
app088.doc
CompAir UK Ltd PUBLICATION APP044 CONDENSATE COLLECTION SYSTEM
Page 1
CONDENSATE COLLECTION SYSTEM
(3) Exhaust
SILENCER
98262.1216 (2) Line Filter
ELEMENT 98262.2078
98262.1211 ELEMENT
X 2 ON SOME 98262.2088
JOBS X 2 ON SOME
JOBS
From
OPTIONAL VESSEL
unloader
FULL SWITCH
drainage unit
98524.1131
or separators
(1) Condensate
collection vessel
98478.1002
10 LITRE
(If fitted)
GENERAL DESCRIPTION
This system is designed to separate and collect condensate from the air/gas, which is discharged from the
compressor unloader drain valve system or separators. The condensate is collected in the line filter (2) and
clean air/gas is discharged through an exhaust silencer (3) to atmosphere. The condensate is held in the line
filter body whilst the drain valves are open and the system is under pressure, condensate is allowed to free
drain after the valves close and the pressure is released.
1. The unit is mounted in an elevated position to allow free drainage of the condensate into the
condensate collection vessel (1).
2. The inlet is connected to the outlet of the unloader drain valve unit with a suitable hose.
3. The line filter has a valve which is closed whilst the compressor is running, opens and allows the
condensate to drain into a condensate collection vessel (1) when the compressor is stopped or the
unloader drain valve discharges.
OPERATION & MAINTENANCE
1. Condensate drainage is automatic the amount collected must be monitored and arrangements made for
disposal from the condensate collection vessel. The element in the line filter is replaceable and should
be replaced when heavily contaminated.
2. Periodically the condensate collection vessel should be cleaned out to remove any accumulated sludge.
app044.doc
CompAir UK Ltd PUBLICATION APP044 CONDENSATE COLLECTION SYSTEM
Page 2
CONDENSATE MANUAL DRAIN SYSTEM
(3) Exhaust
SILENCER
98262/1216
ELEMENT
98262/1211
(2) Line Filter

98262/2078
ELEMENT
98262/2088
From
unloader
drainage unit
or separators
3/8" BSP FEMALE

CONDENSATE DRAIN
CONNECTION
app044.doc
WARNING
The use of replacement parts or lubricating oils not supplied, recommended or approved
by CompAir UK Ltd. Ipswich, may lead to failure in service which would not be covered
by the warranty.
Any unauthorised modifications or failures to maintain this equipment is accordance with

the manufacturers maintenance instructions may make it unsafe. The use of replacement
parts not supplied by or recommended by CompAir UK Ltd may create unsafe and
hazardous conditions or result in damage to the equipment over which CompAir UK Ltd
has no control. Such hazardous conditions may lead to accidents that can be life
threatening, cause substantial bodily injury or result in damage to the equipment.
CompAir UK Ltd can bear no responsibility for equipment in which unapproved

replacement parts are included.
GENUINE PARTS
CompAir UK Ltd
Use Reavellite compressor lubricant.

Advantages:
• Longer life.
• Longer time between oil changes.
• Longer valve life.
• Can be used in new or old compressors.
• Reduces carbon build up.
• Reduces oil consumption.
CompAir UK Ltd
Sales, Service and Parts
Ranelagh Road
Ipswich
IP2 0AE
England
Telephone: +44 (0) 1473 602222
Customer Service: +44 (0) 1473 556027
Fax: +44 (0) 1473 601704
Parts Fax: +44 (0) 1473 601282
www.CompAir.com
e-mail: Ipswich@CompAir.com

5307 & 5407.2.IA Op Manual

Uploaded by

Document Informationclick to expand document information

Copyright:

Available Formats

5307 & 5407.2.IA Op Manual

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

5307 & 5407.2.IA Op Manual

Uploaded by

Copyright:

Available Formats

CompAir UK Ltd TO VIEW CONTENTS

ALTERNATIVELY PRESS (F5) ON THE KEYBOARD.

THE INDEX WILL NOW BE SHOWN ON THE LEFT.

SELECT BY CLICKING ON THE PARTICULAR SECTION REQUIRED

ADDITIONALLY IN SOME CIRCUMSTANCES INFORMATION CAN BE OBTAINED BY

In any correspondence please quote: JOB NUMBER:

CompAir UK Ltd. Ranelagh Road IPSWICH ENGLAND IP2 0AQ

of RANELAGH ROAD, IPSWICH, ENGLAND IP2 0AQ

Machine Type Rotary Compressor Reciprocating Compressor

Model No. _________________________ Serial No.________________________________

DATE __________________ ENGINEERING DIRECTOR

Conformity assessment procedure: Module H (H1 where appropriate)

of RANELAGH ROAD, IPSWICH, ENGLAND IP2 0AQ

Machine Type Rotary Compressor Reciprocating Compressor

Model No. _________________________ Serial No. _______________________________

DATE __________________ ENGINEERING DIRECTOR

Conformity assessment procedure: Module H (H1 where appropriate)

OPERATOR MANUAL - 5000 SERIES AIR

CompAir UK Ltd Ipswich cannot accept responsibility for damage,

CompAir UK Ltd Ipswich

09/10/02 safety5.doc Page 1

Model Type: Motor Serial Number:

Serial Number Motor RPM:

Year: Motor kW:

Maximum Pressure: Motor V. Ph. Hz:

Compressor Lubricant: Motor Bearing Grease:

Capacity M³/hr - CFM Notes:

CompAir UK Ltd Ipswich CONTACT DETAILS

Contact Name: Sales Telephone: +44 (0) 1473 602222

Contact Names: Parts Telephone: +44 (0) 1473 602222

Contact Names: Service: +44 (0) 1473 556027

Page 2 09/10/02 safety5.doc

09/10/02 safety5.doc Page 3

Page 4 09/10/02 safety5.doc

09/10/02 safety5.doc Page 5

Page 6 09/10/02 safety5.doc

CompAir UK Ltd Ipswich compressor safety relates

• Most accidents which occur during the operation

• When handling, operating or carrying out

• Failure to observe these precautions given

09/10/02 safety5.doc Page 7

3. GENERAL SAFETY PRECAUTIONS (Cont.) be guarded or insulated. Other high temperature

• Pipework or other parts with a surface

Page 8 09/10/02 safety5.doc

• Wash the area with limewater and avoid

6. MAINTENANCE & REPAIR PRECAUTIONS

• Always clean oil spills from the surrounding floor

09/10/02 safety5.doc Page 9

• Precautions must be taken against using acids,

• When disposing of condensate, old oil, used

Page 10 09/10/02 safety5.doc

H-5307.2.IA & H-5407.2.IA HANDBOOK

1213.doc 30/08/02 Page 1

Page 2 1213.doc 30/08/02

1213.doc 30/08/02 Page 3

SECTION 6 DISMANTLING AND REASSEMBLY OF VALVES 29

Page 4 1213.doc 30/08/02

GENERAL DESCRIPTION AND OPERATION

1.2 RUNNING GEAR

Model No. _ Serial No.________

Model No. _ Serial No. _______