Compair 5336 5436 Mk2 Operator Manual

Com Air UK Ltd

!"#$%&

OPE RA TO R MA NUAL fo r H5336.2, & H5436.2

Wat er- co o le d Hig h Pressu re Re ciproc ati ng A ir C om pre sso rs.

In any correspondence please quote:JOB NUMBER:

MACHINE NUMBERS: PUBLICATION NUMBER: ISSUEDATE:

(on nameplate) 98407/1176 iss2 OCTOBER2000

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: [email protected]

CompAir UK Ltd

DECLARATION OF CONFORMITY 98/37/EEC BS EN292: 1991 BS EN1012-1: 1997

(Machinery Directive) (Safety of Machinery) (Compressors and Vacuum Pumps – 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

Model No. _________________________

Reciprocating Compressor Serial No.___ _____________________________

is in conformity with the essential Health and Safety Requirements identified in the above directives.

IPSWICH, ENGLAND Signature and name of responsible person

DATE

__________________

PRODUCT MANAGER

Position

DECLARATION DE CONFORMITE - 98/37/EEC, BS EN292:1991, BS EN1012-1:1997 Nous,

COMPAIR UK LIMITED

de


déclarons que sous notre seule responsabilité quant à sa fourniture / fabrication, le matérial décrit cidessous,

Type de machine Compresseur rotif No de modèle _________________________

Compresseur alternatif à pistons No de série __________________________________

est conforme aux exigences essentielles d’hygiène et sécurité établies aux Directives ci-dessus.

IPSWICH, ENGLAND

Signature et nom de la personne responsable

DATE_ ___________________

_______________________ Position

Deutsch

Español

Nederlands

!

KONFORMIT ÄTSBESCHEINIGUNG - 98/37/EEC, BS EN292:1991, BS EN1012-1:1997

COMPAIR UK LIMITED

Wir mit Sitz in

RANELAGH ROAD, IPSWICH, ENGLAND IP2 0 AQ

erklären unsere volle Haftung für Lieferung / Erzeugung der folgenden gelisteten Maschinen,

Maschinenart

Kolbenkompressor

Modellnr. __________________________________

Seriennr.__________________________________________

gemäß den Gesundheits-und Sicherheitsanforderungen der oben genannten Richtlinien.

IPSWICH, ENGLAND Unterschrift und Name der verantworlichen Person

DATUM Position

DECLARACIÓN DE CONFORMIDAD - 98/37/EEC, BS EN292:1991, BS EN1012-1:1997

COMPAIR UK LIMITED con domicilio en


declara, bajo su exclusiva responsabilidad por el suministro o fabricación, que la maquinaria descrita a continuación

Tipo demáquina

Compresorrotativo

Nº de modelo ______________________________

Compresoralternativo Nº de serie ________________________________________

cumple las principales normas de seguridad e higiene estipuladas en las directivas mencionadas anteriormente.

IPSWICH, ENGLAND Nombre y firma de la persona responsable

FECHA ______________________

_______________________ Cargo

VERKLARING VAN CONFORMITEIT - 98/37/EEC, BS EN292:1991, BS EN1012-1:1997 Wij

COMPAIR UK LIMITED

Van


verklaren onder onze volle aansprakelijkheid voor de levering / vervaardiging dat de hierna beschreven machinerie,

Soorm t achine Type nr ___________________________________

Zuigercompressor Serie nr ___________________________________________

voldoet aan de essentiële Vereisten voor Gezondheid en Veilgheid als geïdentificeerd in de hiervoor vermelde directieven.

IPSWICH, ENGLAND Handtekening en naam van de verantwoordelijk persoon

DATUM _____________________

_______________________ Functie

CompAir UK Ltd

DECLARATION OF INCORPORATION 98/37/EEC BS EN292: 1991 BS EN1012-1: 1997

(Machinery Directive) (Safety of Machinery) (Compressors an vacuum pumps – Safety Requirements)

We

COMPAIR UK LIMITED

of


declare that under our sole responsibility for supply / manufacture, the machinery described below,

Machine Type

Rotary Compressor

Reciprocating Compressor

Model No. _________________________

Serial No. _______________________________

to which this declaration relates is in conformity with the essential Health and Safety Requirements identified in the above Directives.

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 __________________

______________ PRODUCTS MANAGER Position

DECLARATION DE INCORPORATION –98/37/EEC, BS EN292:1991, BS EN1012-1:1997 Nous,

COMPAIR UK LIMITED

de

RANELAGH ROAD, IPSWICH, ANGLETERRE IP2 0AQ

déclarons que sous notre seule responsabilité quant à sa fourniture / fabrication, le matériel décrit ci-dessous,

Type de machine Compresseur rotatif No de modèle ______________________

Compresseur à pistons No de série ______________________________

concerné par la présente déclaration, est conforme aux exigences essentielles d’hygiène et sécurité identifiées dans les Directives susmentionnées.

Cet équipement ne doit être mis en service que lorsque l’équipement dans lequel il doit être intégré a été certifié conforme aux dispositions des Directives susmentionnées. IPSWICH, ANGLETERRE Signature et nom du responsable

DATE __________________

__________________________________ Poste

Deutsch

Español

!

EINBEZIEHUNGSERKLÄRUNG - 98/37/EEC, BS EN292:1991, BS EN1012-1:1997 Wir

COMPAIR UK LIMITED

aus


erklären daß unter unserer alleinigen Verantwortung für Lieferung/Herstellung die unten aufgeführte Maschine.

Maschinentyp:

Kreiskolbenverdichter

Hubkolbenverdichter

Modell-Nr.___ ______________________________

Serien-Nr. _________________________________________

auf die sich diese Erklärung bezieht, den grundlegenden Arbeitsschutzbedingungen in oben genannten Direktiven entspricht.

ERKLÄRUNG Diese Maschine darf nicht in Betrieb genommen werden, solenge die Konformität der Maschinen, in die sie einbezogen werden soll, mit den Auflagen der oben genannten Directiven nicht erklärt w orden ist. IPSWICH, ENGLAND Unterschrift und Name der Verantworlichen Person

DATUM_______________________ Position

COMPAIR UK LIMITED con domicilio en


declara, bajo su exclusiva responsabilidad por el suministro o fabricación, que la maquinaria descrita a continuación Tipodemáquina

Compresorrotativo

Nº de modelo ______________________________

Compresoralternativo Nº de serie ________________________________________

a la que se refiere esta declaración, cumple las principales normas de seguridad e higiene estipuladas en las directivas mencionadas anteriormente.

DECLARACIÓN Esta máquina no podrá ponerse en marcha hasta que haya quedado demostrado que la máquina a la que va incorporada cumple las disposiciones estipuladas en l as directivas mencionadas anteriormente.

IPSWICH, ENGLAND Nombre y firma de la persona responsable

FECHA _______________________

_______________________ cargo

Nederlands

!

VERKLARING VAN SAMENVOEGING - 98/37/EEC, BS EN292:1991, BS EN1012-1:1997 Wij

COMPAIR UK LIMITED

te


verklaren dat, onder onze volledige verantwoordelijkheid ten aanzien val levering/fabricage van de hieronder beschreven machine. Typemachine

Roterendecompressor

Model nr __________________________________

Zuigcompressor Serie nr ___________________________________________

waarop deze verklaring betrekking heeft in overeenstemming is met de essentiële gezondheids-en veiligheidsvoorschriften, zoals beschreven in de bovengenoemde.

VERKLARING Deze machine mag pas in werking worden geseld als verklaatd is dat de machine waarmee het wordt samengevoegd in overeenstemming is met de bepalingen van de bovengenoemde richtlijnen.

IPSWICH, ENGLAND Handtekening en naam van de verantwoordelijke persoon

DATUM ______________________

______________________ functie

COMPRESSOR LOG SHEET COMPRESSOR

PRIMEMOVER

TYPE: SPEED: SERIALNO: DATE

TYPE: B.H.P. DRIVE: TIME

*HOURS STAGE RUN TEMP.°C #50/100 500 1000 1500

FINAL STAGE TEMP.°C

INSTALLEDAT

REF. NO.

OILGRADEUSED: CHL EOE CIL VKEL CHECW KATEIR N/OUTTEMPERATURE DATEINST ALLED: CHECKCOOLINGFANBLADES FINAL AIR SERVICE STAGE PRESSURES PRESSURE PLAN REMARKS SEE SIGNED #(BAR - PSI) #(BAR - PSI) NUMBER OVER FOR MORE 1 2 3 4 5

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 NECESSAR Y - † FILL IN APPROPRIATE STAGE TRI P 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

DAT E

logsheetm.doc

REM ARKS

DAT E

REM ARKS

CompAir UK Ltd SAFETY SECTION Page 1

OPERATOR MANUAL - 5000 SERIES AIR COMPRESSORS CONTENTS Page OwnersD hiapta

2

Foreword

3

SafePtyrocedures

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

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OWNERSHIP DATA TECHNICAL DATA It is recommended that details taken from the compressor and motor nameplates are recorded below.

ModeTl ype:

MotoS r eriaN l umber:

SeriaNl umber

MotoRr PM:

Year:

Motor kW:

MaximumPressure:

MotorVP . hH . z:

CompressorLubricant:

MotorBearingGrease: (if applicable)

CapacityM³/hC -r FM

Notes:

CompAir UK Ltd Ipswich CONTACT DETAILS ContactName:

SalesTelephone:+44(0)1473602222

Address: CompAir UK Ltd Ranelagh Road Ipswich IP2 0AQ ENGLAND Telephone: +44 (0) 1473 602222

Notes:

Fax: +44 (0) 1473 601704

ContactNames:

PartsTelephone:+44(0)1473602222 Parts Fax: +44 (0) 1473 601282

ContactNames:

Service:+44(0)1473556027

For any comments or queries about the contents of this MANUAL please write to CompAir UK Ltd. Ranelagh Road, Ipswich 1P2 0 AQ. England marked for the attention of Mr. Dennis Be eton, Technical Publications Engineer.

Page 2

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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. Plea se no te:

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 watercourse, drain system and that no burning waste takes place which could cause pollution of the atmosphere.

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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 4

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SAFETY PROCEDURES

Page Ge n er al ....... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... 7 War n in g s, C au tio n s an d No tes ........................................ 7 Gen er al Saf ety Pre ca u ti o n s ............................................. 7 Ins ta ll ati o n Pr ec au ti o n s ................................................... 8 Op er ati o n al Pr ec au ti o n s .................................................. 8 Main ten anc e and Repair Prec aut io ns ............................. 9 Pre ca ut io n s in th e Ev en t o f Fir e ..................................... 10

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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 re placement parts or lubricating oils not su pplied or approved by CompAir UK Ltd Ipswich m ay le ad to fa ilure s in service which would not be cov ere d by warranty.

Any unauthorised modifications or failure to maintain this equipment in accordance with maintenance instructions may make it unsafe. The use of re placement part s not su pplied by Comp Air UK Ltd Ipswich may crea te ha za rdous co nditions ov er which CompA ir UK Ltd I pswic h 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. CompA ir UK Ltd I pswic h 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 M ANUFACTURERS EQUIPMENT SUPPLIED.

Page 6

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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 Pressure Systems Health & Safety Regulations S.I. No. 128. •

•

RIS K OF DANGER

Most accidents which occur during theofoperation and maintenance of machinery result failure to observe basic safety rules or precautions. Recognising a situation that is potentially hazardous can often prevent an accident.

RISK OF ELECTRIC SHOCK

When handling, operating or carrying out maintenance on the unit, personnel must 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 HIGH PRESSURE

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 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.

•

RIS K OF GA S EXHAUST

Failure to observe these precautions given under "Safety Precautions" may be considered dangerous practice or misuse of the compressor

CONSULT MANUAL

3. •

2. •

•

Read and understand all WARNINGS, CAUTION AND MANDATORY LABELS on the unit before operating or carrying out maintenance or servicing.

•

When using cleaning solvents, local Health and Safety Regulations must be complied with. Provide good ventilation and use suitable protection such as a breathing filter mask, safety glass, protective apron and gloves.

•

Safety footwear should be compulsory in all

WARNINGS, C AUTIONS & NOTES The following details for this Safety Section relate to the ESSENTIAL SAFETY REQUIREMENTS referred to in Directive 89/392/EEC, Amended 91/286/EEC.

Warnings call for attention to operation procedures involving specific hazards which could cause injury or death and are identified by the following:-

GENERAL SAFETY PRECAUTIONS

workshops. is any risk ofSafety fallinghelmets objects. must be worn if there •

If using compressed air for cleaning purposes, ensure safety regulations are complied with and appropriate clothing worn.

•

Never direct compressed air onto your skin or at other people. Never use compressed air to clean loose dirt from clothing.

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3.

GENERAL SAFETY PRECAUTIONS (Cont.)

•

Before releasing compressed air through a hose make sure the free end is held securely so that it cannot whip and cause injury.

•

Avoid injury by using a hoist to lift heavy loads. Check that all chains, hooks, shackles and slings are in good condition and are of the correct capacity. They must be tested and approved according to local safety regulations.

•

•

Cables, chains or ropes should never be applied to lifting eyes. Always use an appropriate shackle or hook, properly positioned. Arrange lifting cables so that there are no sharp bends. Use a spreader bar to avoid side loads on hooks, eyes and shackles and never leave a heavy load unattended. When a load is on a hoist stay clear of the danger area beneath and around it. Keep lifting acceleration and speed within safe limits.

4.

Competent personnel under a qualified supervisor must only carry out installation work.

•

A fused isolator switch must be fitted between the main power supply and the compressor.

•

•

•

•

5. •

Do not operate compressor with any removable inspection cover removed e.g. crankcase doors, valve covers etc.

•

Never remove or tamper with safety devices, guards or insulation materials.

•

The compressor must only be operated at the supply voltage and frequency for which it is designed. Always isolate power before maintenance or servicing.

•

When mains power is ON, lethal voltages are present in the electrical circuits and extreme caution is need when essential work is carried out on the electrical system. ALWAYS CONSULT A QUALIFIE D ELECTRICIAN BEFORE ANY SUCH ESSEN TIAL WORK .

•

Do not open starter compartment to touch electrical components while voltage is applied unless it is necessary for measurement, test or

Precautions must taken to ensure no injury is caused tobe passers-by throughthat loose clothing being sucked into compressor intake. Ensure that the discharge pipe from the compressor to the user pipework, receiver or storage is free to expand and that no flammable material is within the vicinity. If any such material is close-by take steps to preclude ignition. A manual shut-off valve should be fitted in the discharge line to allow the compressor to be isolated. Non return valves cannot be relied upon for isolating parts from a pressure system. A safety valve must be installed between any compressor unit and the isolating valve. A pressure-reliving device must be fitted to every pressure vessel, or equipment containing air or gas above atmospheric pressure. Never remove or tamper with safety devices, guards or insulation fitted. In order to limit the risk of Legionnaires Disease, CompAir UK LTD advise 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 8

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OPERATIONAL PRECAUTIONS Competent personnel under a qualified supervisor must only operate the compressor.

•

INSTALLATION PR ECAUTIONS

•

•

be guarded or insulated. Other high temperature pipework should be clearly marked and all pipework should be clearly marked.

adjustment. Such work should always be carried out by a qualified. Electrician with appropriates tools and protection against an electrical hazard. •

If the unit is equipped with a Remote Control device, attach warning notices stating "THIS UNIT CAN BE STARTED REMOTE LY" in prominent locations, one on the outside of the unit, the other inside the control compartment.

•

As a further safeguard, take adequate precautions that no one is working or checking the unit before attempting to switch on remotely controlled equipment. Attach a " CHEC K THAT ALL PERSONNEL ARE CLEAR OF UNIT BEFORE STARTING" or similar notice.

•

Compressed air and gas piping, together with cooling water piping and other parts, with surface temperature greater than 70°C and may be accidentally touched, should be guarded or insulated.

CompAir UK Ltd SAFETY SECTION Page 9 •

5. •

•

•

6.

OPERATION PRECAUTIONS (Cont.) If there is any indication that the compressor is overheating it must be shutdown. (A high air or gas temperature switch is fitted as standard to guard against operating with excessive 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 position and remove fuses.

•

2. Attach a label " WORK IN PROGRESS NOT APPLY VOLTAGE" .

•

3. Close the isolating valve between the compression unit and user's pipework. Close the isolating valve in the cooling water inlet pipe. Attach a label "WORK IN PROGRESS - DO NOT OPE N" .

•

4. Check that all pressurised gas trapped in the system is released to atmosphere or safely to gas storage. Check that all pressure gauges register zero.

•

5. Ensure that the cooling water system has been drained.

•

6. Check that the drain valve on the delivery manifold is clear and gas pressure has been released.

•

Whilst compressors are asbestos free, treat all damaged gaskets as asbestos - when the Asbestos at work regulations apply.

7. Check that all interstage drains are open to ensure any gas trapped between stages has been released.

•

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 is left engaged on the valve cover securing screws. Lever the valve cover until the 'O' seal is disengaged from the port in the cylinder head. Remove the securing screws and take out valve cover.

•

Use only lubricating o ils and greases approved by Comp Air UK LTD to avoid potent ial hazards especially the risk of explosion or fire and the possibility of decompo sition or generation of haz ardous gases .

•

Always clean oil spills from the surrounding floor before and after maintenance work.

Do not operate the unit when guards provided for protection for all rotating and reciprocating parts have been removed for essential maintenance. Secure guards following any servicing or repair. Local noise regulations must be observed. Ear defenders are suggested by Noise at Work Regulations 1989 when the level is greater than 85 dB A at one meter. Be aware high noise levels can interfere with communication.

MAINTENANCE & REPAIR PRECAUTIONS Competent persons under qualified supervisor must carry out maintenance repair and modifications.

•

The compressor will have a preserving oil applied to interior surfaces (Oil lubricated models). Oil free models will have desiccant bags in valve covers and distance pieces.

•

•

Handling components such as seals, gaskets and diaphragms should not present a personnel hazard. Preservation oils again should not present a personnel hazard if handled under normal handling practices.

•

However, should there be a fire within the compressor or these seals are likely to exceed a temperature of 300°C the material will decompose.

•

Degraded Viton gives off Hydrogen Fluoride fumes and if in contact with the skin an acid formed causes severe burns.

•

Pre-Maintenance Operation •

•

•

Wash the area with limewater and avoid breathing any fumes. If contamination of the skin occurs washes with limewater and seeks medical advice.

If Viton seals appear charred or gummy do not touch with unprotected hands: use neoprene or PVC gloves.

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6.

MAINTENANCE & REPAIR (Cont.)

•

Make sure all instructions concerning operation and maintenance are strictly followed and that the complete unit, with all accessories and safety devices, is kept in good order.

•

The accuracy of pressure gauges and temperature switches should be regularly checked at least 13 month intervals and thoroughly examined at least every 48 months. They must be renewed or service exchanged when acceptable tolerances are exceeded.

•

Protection devices should be tested at each regular service interval and replaced or service exchanged if not functioning correctly. The maximum pressure for safety valves under fault conditions is 1.10 times the set pressure, the set pressure being a minimum of 1.05 times the maximum operating pressure to ensure seat tightness.

•

Keep the compressor clean at all times.

•

Protect components and exposed openings by covering with a clean cloth or tape during repair or maintenance work.

•

Protect the motor, intake, electrical and regulation components against the entry of moisture e.g. steam cleaning.

•

Precautions must be taken when carrying out welding or any repair operation which generates flames or sparks. The adjacent components must be screened with non-flammable material and if oil present, the system must first be cleansed thoroughly by steam cleaning.

•

Condensate (oil and water mixture from compression process) must be regarded as trade effluent and is therefore not suitable for discharge into a surface water sewer, soakaway or watercourse.

•

Never use a light source with an open flame for inspection.

PROTECT THE ENVIRONMENT USE METHODS OF DISPOSAL .

•

Before dismantling any part of the compressor be sure that all heavy movable parts are secure.

7.

•

After completion of any maintenance or repair ensure that no loose items or rags are left on or inside thetools, compressor.

•

Do not use any flammable liquid to clean valves, filter elements, cooler passages, pipe bores or any component carrying a flow of air or gas during normal operation. If chlorinated hydrocarbon substances are used for cleaning, safety precautions must be taken against toxic vapours, which may be released.

DO NOT USE CARB

ON 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.

Page1 0

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•

APPROVED

PRECAUTIONS IN THE EVENT OF FIRE Use extreme caution when handling components that have been subjected to fire or very high temperature. Some components may contain fluoroelastomer materials, which decompose under these conditions to form highly corrosive residues. Skin contact can cause painful and penetrating burns resulting in permanent skin and tissue damage.

This is a high

pressure Compressor use only:

GENUINE CompAir UK Ltd Ipswich PARTS

CompAir UK Ltd PUBLICATION 98407.1176 Page 1

HISTORY RECORD H5336.2, 5436.2 COMPRESSORS ISSUE No

MOD Note No

M/CSERIALNoCHANGE.-REASON

DATE

PAGENo

1 2 3 4 5 6 7

NEW NONE NONE

NEW NONE - ADD H5436.N2.B2 DETAILS TO MANUAL & PARTS LIST DELETEDH5436.2.N2.B2NOW98407.1307

1999 FEB OCT 2000 NOV2001

ALL VARIOUS VARIOUS

8

1176.doc

Page 1


Page 2 1176.doc


CONTENTS PAGE CERTIFICATEOFCONFORMITY/INCORPORATION. COMPRESSOLROS GHEET. SAFEGTEYNERAL AMENDMENTS INDEX

SECTION 1 1.1 1.2 1.3 1.4 1.5 1.6

SECTION 2 2.1 2.2 2.3

SECTION 3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9

SECTION 4 4.1 4.2 4.3 4.4 4.5

SECTION 5 5.1 5.2 5.3 5.4

ex ex ex 1 3

LEADING PARTICULARS UNIT DESIGNATION------------------------------------------------------------------------5 TECHNICAL DATA - GENERAL ---------------------------------------------------------5 PRESSURE AND TEMPERATURE ACCEPTANCE LEVELS-- ------------------6 RUNNING CLEARANCES -----------------------------------------------------------------7 CRITICAL TORQUE WRENCH SETTINGS--- ----------------------------------------8 NON-CRITICAL TOR QUE WREN CH SE TTINGS -----------------------------------8

GENERAL DESCRIPTION GENERAL DETAILS ------------------------------------------------------------------------9 SYNTHETIC OILS --------------------------------------------------------------------------10 COMPATIBILITY OF MATERIALS WITH SYNTHETIC TYPE OILS -----------11

INSTALLATION HANDLING OF UNIT-- ---------------------------------------------------------------------13 LOCATION------------------------------------------------------------------------------------13 MOUNTING-----------------------------------------------------------------------------------14 CONNECTIONS, PIPEWORK AND FITTINGS--------------------------------------14 DRIVE RECOMMENDATIONS ----------------------------------------------------------14 COOLING -------------------------------------------------------------------------------------15 ELECTRICAL CONNECTIONS----------------------------------------------------------15 CONTROL FOR AUTO STOP/START-------------------------------------------------16 RECOMMENDED ANCILLARIES SUMMARY---------------------------------------16

COMMISSIONING OR RECOMMISSIONING BEFORE STARTING---- -------------------------------------------------------------------17 START-UP PROCEDURE ----------------------------------------------------------------18 AFTER THE FIRST 15 HOURS RUNNING TIME-----------------------------------18 AFTER THE FIRST 100 H OURS RUNNING TIME ---------------------------------18 CHANGING OVER FROM MINERAL TO SYNTHETIC LUBRICANT----------19

OPERATION & ROUTINE MAINTENANCE OPERATION AND DAILY MAINTENANCE ------------------------------------------21 MAINTENANCE PERIODS ---------------------------------------------------------------22 VALVE MAINTENANCE PERIODS-----------------------------------------------------23 MAINTENANCE DETAILS ----------------------------------------------------------------23

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SECTION 6 6.1 6.2 6.3

SECTION 7 7.1 7.2 7.3 7.4 7.5 7.6 7.7

SECTION 8

VALVE SERVICING GENERAL ------------------------------------------------------------------------------------ 27 CLEANING AND INSPECTION ALL STA GES -------------------------------------- 27 VALVE REM OVAL AN D DIS MANTLING --------------------------------------------- 27

FAULT GUIDE EXCESSIVE PRESSURE ---------------------------------------------------------------- 31 INSUFFICIENT PR ESSURE OR VOL UME ------------------------------------------ 31 OVERHEATING----------------------------------------------------------------------------- 32 EXCESSIVE NOISE ----------------------------------------------------------------------- 32 EXCESSIVE WEAR- ----------------------------------------------------------------------- 32 EXTENDED RUNNING ------------------------------------------------------------------- 32 FAILURE TO START ---------------------------------------------------------------------- 32

RECOMMENDED SERVICE PLANS--- -----------------------------33 RSP5436M - H5436.2 - Mineral Oil -------------- ------------------------------------- ex 1 RSP5436S - H5436.2 - Synthetic Oil ------------------------------------------------- ex 2 RSP5336M - H5336.2 - Mineral Oil -------------- ------------------------------------- ex 3 RSP5336S - H5336.2 - Synthetic Oil ------------------------------------------------- ex 4

SECTION 9

ILLUSTRATED LIST OF PARTS -------------------------------------35 98407/1176PL

SECTION 10

ANCILLARY EQUIPMENT ---------------------------------------------37

COMPRESSOR CROSS REFERENCE CHART NEW DESIGNATION H5336.2 H5346.2

Page 4 1176.doc

OLD DESIGNATION C5336MK2 C5436MK2


SECTION 1

LEADING PARTICULARS 1.1

UNIT DESIGNATION Flange mounted, motor driven machine ----------------------------------------------- H5336.2, & H5436.2 V-belt driven machine, electric or internal combustion engine powered-------------------------------------------------------------- H5336.2, & H5436.2

1. 2

TECHNICAL DATA - GENERAL Type acting, stage H5336, vee Type ----------------------------------------------------------------Single ---------------------------------------------------------- Single acting, threethree stage H5436, 90° 90° Booster Type ----------------------------------------------------------------- Single acting, four stage, H5436, 90° vee Cooling--------------- --------------------------------------------------------------------------------------------- Water Direction or rotation, viewed from drive end -------------------------------------------------- Anti-clockwise Number of valves------------------------------------------- One combined suction and delivery per stage Type of valve -------------------------------------------------------------------------------------- Flat plate, low lift Mounting----------------------------------------------------------------------Three point, anti-vibration mounts Lifting points ----------------------------------------------------------------------------------------------------- Three

TEMPERATURES: Minimum ambient temperature -------------------------------------------------------------------------------- 0°C Maximum compressor air intake temperature------------ ------------------------------------------------ 45°C Maximum ambient for radiator sets (Contact CompAir UK Ltd for lubricant/duty restric tions) ------------------------------------------ 30\40°C Maximum water inlet temperature--------------------------------------------------------------------------- 37°C Temperature rise across machine -------------------------------------------------------------------10°C\1 2°C

SPEEDS: Maximum speed---------------------------------------------------------------------------------------1500 rev/min Minimum speed----------- ------------------------------------------------------------------------------ 725 rev/min

PRESSURES:

H5336.2

H5436.2

Minimum working pressure ------------------------------------------- ---------------- 40 bar -----------140 bar Maximum working pressure ------------------------------------------ ---------------- 85 bar -----------350 bar Maximum water pressure --------------------------------------------- ----------------- 5 bar ------------- 5 bar Oil pressure----------------- -------------------------------------------------------------------- all 2.0-2.75 bar # Contact CompAir UK Ltd for more details.

LUBRICATION: Crankcase oil capacity ---------------------------------------------------------------------------------- all 45 litres Recommended grease (for assembly) -------------------------------------------------- all Shell Alvania R3

Recommended oil (Synthetic).

--------------------------------------------------------------- Reavellite

Recommended oil ------------------------- Mineral .See duty restrictions --------------- Mobil Rarus 427 ¤ Oil rec o m m en d at io n s ar e b as ed on n o rm al c o n d it io n s . If d iff ic u lty is ex p er i en c ed a c h an g e m ay be advisable - refe r to Com pAir UK Ltd.

COOLING: Water ---------------------------------------------------------------------------- Mains or water pump circulation Cooling water flow @ 15°C ------------------------------------------------------------------------------ 75 l/h/kw

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Page 5


INTERNALDIMENSIONS:

H5336.2

Piston stroke -------------------------------------------------------------First stage cylinder bore ----------------------------------------------Second stage cylinder bore (1st stage on SP1)----- ------------Third stage cylinder bore (2nd stage on SP1) -------------------Fourth stage cylinder bore (3rd stage on SP1)---------------- ---

H5436.2

--------------------75 mm ----------- 75 mm -------------------185 mm --------- 185 mm --------------------95 mm ----------- 95mm -------------------- 45mm------------ 45mm ----------------------N/A ------------- 22mm

CONNECTIONS: First stage suction ---------------------------------------------------------------------- Special flange adaptor Rp3 Final delivery H5436.2---------------------------------------------------------------------------------------------- Rp½ Final delivery H5336.2---------------------------------------------------------------------------------------------- Rp¾ Water inlet ------------------------------------------------------------------------------------------------------------- Rp1 Water outlet ----------------------------------------------------------------------------------------------------------- Rp1

WATER TEST PRESSURES: First stage cooler ------------------------------------------------------------------------------------------------10.3 bar Second Stage cooler---------------------------------------------------------------------------------------------- 55 bar Third stage cooler ------------------------------------------------------------------------------------------------285 bar Fourth stage cooler-----------------------------------------------------------------------------------------------690 bar Water Jacket------------ ------------------------------------------------------------------------------------------10.3 bar

UNIT WEIGHT (APPROX.): Bare machine----------------------------------------------------------------------------------------------------1070 kgs Crankcase---------------- ----------------------------------------------------------------------------------------- 230 kgs Cooler body ------------------------------------------------------------------------------------------------------- 180 kgs

1. 3

PRESSURE AND TEMPERATURE ACCEPTANCE LEVELS

Pressures: M/cType H5336.2:

H5436.2:

O il 2.02.7 2.02.7 2.0 2.7 2.02.7 2.02.7 2.0-2.7 2.0-2.7 2.0-2.7 2.0-2.7

First 2.5-2.9 2.6-3.0 2.73.1 2.753.2 2.753.2 2.7-3.1 2.7-3.1 2.7-3.1 2.7-3.1

Stages (bar) Second 12.8-13.9 13.5-15.2 14.215.9 14.816.5 15.717.4 16.3-17.9 16.5-18.2 16.7-18.4 17.0-18.7

Third 27.5 41.3 55 69 85 66.1-74.1 73.0-81.3 79.9-88.9 86.8-96.5

4thDelivery N/A N/A N/A N/A N/A 137.8 206.8 257.7 344.7

Temperatures: Maximum stage----------------- --------------------------------------------------------------------------------------------- 215°C Final Delivery (Max) ----------------------------------------------------------------------------------------------------------70°C These te mperatures must not be exceeded except under certain reduced operating conditions, detai ls of which can be obtained fr om Com pAir Distributors or from Com pAir UK Ltd Custom er Service De partm ent. NOTE: THE MAXIMUM OPERATING TEMP ERATURES AR E IMPORTANT TO THE LIFE AND SAFETY OF THE MACHINE.

Page 6 1176.doc


1.4

RUNNING CLEARANCES (MILLIMETRES)

ParDt escription

Stage

Piston (Plunger) Vertical Clearance

1

Piston Ring Gaps

1

(Measured in unworn portion of cylinder/liner)

H5436.2 Peek 450 Piston Ring Axial Width Clearance (Measured between groove & top face of ring with ring in normal running position).

H5436.2 Peek 450 Piston Ring Groove Width

2 3 4 1 2 3 4 1 2

H5436.2 Piston/Plunger Diameter Above Top Ring

H5436.2 Cylinder/LinerDiameter

CrossheadDiametricalClearance Small End Bearing Diametrical Clearance In Conn Rod In Piston BigEndBearingDiametricalClearance SmallEndBearingEndFloat MainBearingDiametricalClearance CrankshaftEndFloat CouplingFaceDistanceforDirectCoupledSets

3 4

AsFitted (mm)

Max. Permissible (mm)

2 3 4 Taper Scraper Taper Scraper Plain Plain Taper Scraper Taper Scraper Plain Plain Taper Scraper Taper Scraper Plain Plain 1 1 2

0./0.9 0.4/0.9 0.45/1.0 0.35/1.46 0.2/0.45 0.2/0.45 0.1/0.23 0.1/0.23 0.05/0.18 0.2/0.4 0.04/0.09 0.05/0.10 0.02/0.08 0.05/0.10 0.03/0.09 0.03/0.07 4.80/4.83 8.01/7.99 3.23/3.20 4.83/4.80 2.05/2.01 2.05/2.01 184.77/184.74 184.54/184.49 94.91/94.88

0.9 0.9 1.0 1.46 1.63 1.43 1.47 1.27 1.32 1.32 0.29 0.30 0.28 0.30 0.29 0.20 4.91 8.09 3.31 4.91 2.13 2.13 184.69 184.44 94.83

3 4 1 2 3 4 3 4

44.93/44.90 21.955/21.945 185.05/185.00 95.04/95.00 45.03/45.00 22.01/22.00 0.06/0.13 0.06/0.13

44.85 21.9 185.11 95.10 45.09 22.07 0.19 0.19

1 2,3,4 1 2,3,4 1,2,3,4 1 2,3,4

0.01/0.05 Needle Roller -0.003/0.013 0.025/0.044 0.066/0.12 0.15/0.64 0.15/0.55 0.05/0.14 0.66/0.23 2.0/6.0

0.1 0.03 0.09 0.24 1.0 1.0 0.2 0.75 6

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Page 7


1. 5

CRITICALTORQUE WRENCHSETTINGS

PartDescription

S iz e

Big end bearing bolts 1st & 2nd stage cooler covers 3rd stage cooler covers 1st stage valve cover 2nd stage valve cover 3rd stage valve cover 4th stage valve cover* 4thstagevalvecover(5436Honly)* 1st stage cylinder to crankcase 2nd stage cylinder to crankcase 3rd&4thstagecrossheadtocrankcase 3rd&4thstagecylinderstocrossheadguide Flywheel bolt 3rd stage piston to crosshead

NOTE:

M16 M10 M16 M12 M12 M20 M20 M20

NoOff 8

Lbs/Ft

10 6 6 4 4 4

203 54 236 41 41 95 108 122

150 40 174 30 30 70 80 90

4 4 6 8

95 95 95 95

70 70 70 70

17

M12 M12 M12 M12 ¾"UNF M8

Newtonmetre(Nm)

1 1

162

120

27

20

1. Under no circumstances are any deviations from the above figures allowed unless authorised in writing by CompAir UK Ltd. 2. All figures are subjected to a tolerance of ±5%. 3. Figures are for NON-LUBRICATED fastenings. * To be tightened sequentially in 27 Nm steps.

1. 6

NON-CRITICAL TORQUE WRENCH SETTINGS

PartDescription

Size

D/Emainbearinghousingtocrankcase O/Emainbearinghousingtocrankcase cover O/E Crankcase door Cooler body cylinders to Bursting disc cover Cooler door stage 1st valve stage 2nd valve stage 3rd valve stage valve 4th Motor bell housing Motor bracket to crankcase pump Oil Cylinder lubricator NOTE:

1. 2. 3.

Page 8 1176.doc

M12 M12 M8 M10 M12 M10 M10 M10 M8 M6 M5 M12 M16 M8 3/8"

NoOff 8 10

NewtonMetre(Nm) 95 95

10 24 6 4 26 1 1 1 1 10 5 3 4

27 54 95 54 27 21 11 6 3 95 162 27 35

Lbs/Ft 70 70 20 40 70 40 20 16 8 5 2 70 120 20 26

Under no circumstances are any deviations from the above figures allowed unless authorised in writing by CompAir UK Ltd. All figures are subjected to a tolerance of +5% -15%. Figures are for NON-LUBRICATED fastenings.


SECTION 2

GENERAL DESCRIPTION 2.1 GENERAL Pressure gauges

Lifting eyes rd 3 stage safety valve st 1 stage safety valve Stage temperature gauges

th

4 stage cylinder rd

3 stage cylinder

Final stage non-return valve th 4 stage safety valve Suction/inlet filter silencer st 1 stage cylinder

Coolant drains Oil filler

Oil pump Final separator drain valve

th

4 stage cylinder lubricator Oil level gauge Oil drain plug

H5436.2 ILLUSTRATED These compressors have four stages H5436.2, single acting, 90°-vee configuration, which provides complete primary balance. Air enters the machine through a filter/silencer and is compressed by the first stage piston, after which it passes through cooler tubes to the second stage for further compression. Cooled again, the process is repeated through the third stage (final stage on H5336.2 after further cooling, the air is delivered at the designed pressure to the system), After which it is cooled again before entering the final stage for compression. After further cooling, the air is delivered at the designed pressure to the system. Cooling is by water through the jackets and passages either from the mains or by a radiator cooled, self-contained system. Seawater cooling is used for marine applications. Drive is by either flange mounted motor or v-belt transmission from a suitable power source, such as electric motor or internal combustion engine. Cylinders are bolted to the crankcase in a 90°-vee formation and the second, third and fourth stage cylinders are fitted with liners. Main bearing bushes, big end bearing halves and small end bearings are all replaceable. First and second stage pistons are conventional, whilst the third has an integral piston and crosshead assembly. The fourth stage has a floating solid plunger fitted to a crosshead. All are fitted with piston rings. On the H5336.2 is different a dummy piston being fitted in place of the fourth stage. Multi-stage coolers are fitted after each compression stage and maintained through access doors. First, second and third stage coolers are fixed, whilst the fourth stage has a withdrawable tubestack (not on H5336.2 this is blanked off). All stage valves are of the flat plate, low lift, multi-ported type and combine both suction and delivery functions. Ease of access, only one valve cover per cylinder and good flow characteristics are a feature of this reliable valve design. 1176.doc

Page 9


System Description - Lubrication A forced lubrication system is utilised, conveying oil to the big end and main bearings via a filter and crankshaft passages. The connecting rods are drilled to supply small end bearing/bushes. Oil is forced through the bearing clearance and thrown off the rotating crankshaft to ensure an adequate supply to cylinders, pistons and crossheads. Return flow oil is drawn through a strainer and excess pressure regulated by a spring-loaded relief valve. Oil pressure is gauge indicated. The H5436.2 4th stage cylinder being fed from the crankcase oil pump via a non-return valve. The crankcase is filled through the filler on the crankcase and the oil level is indicated in a sight glass on the crankcase end. Lubricating oil to the recommended specification must be used at all times to ensure safe and efficient operation with minimum wear and protection against moist air corrosion. Recommendations are the result of extended research at CompAir UK Ltd and all responsibility for the use of oil other than that recommended is placed on the purchaser and his oil supplier.

THE NORMAL GUARANTEE MAY BE INVALIDATED SHOULD A FAILURE BE ATTRIBUTED, BY CompAir UK Ltd, TO THE USE OF A LUBRICANT NOT RECOMMENDED. OIL FLOW DIAGRAM H5436.2 ILLUSTRATED

OIL PUMP

25 MICRON FILTER

RELIEF VALVE

OIL BYPASS VALVE

4TH STAGE CYLINDER 5436 ONLY

O/E MAIN BEARING

D/E MAIN BEARING

ONLY OPENS IF FILTER BLOCKS CRANK SHAFT

STRAINER

OIL FILLER

SUMP BIG END BEARING

SMALL END BEARING

Page 101176.doc

PRESSURE GAUGE

LOW OIL PRESSURE


System Description - Controls For starting purposes, automatic or manual unloaders/drains are fitted to all stages. Automatic unloaders provide initial venting when starting and close as the compressor attains operational speed, opening again for condensate draining when the machine is shut down. A timer may be incorporated in the unloading circuit to effect timed drainage (compatible with environmental and operating conditions). High humidity requires more frequent draining. Pressure safety valves are fitted at each stage. Oil and air pressure gauges for each stage are mounted on a common panel. Low oil pressure and high temperature switches are standard equipment. A bursting disc is fitted to prevent excessive pressure build up in the water passages. Excessive pressure will rupture specified pressure disc to relieve internal pressure.

2.2

SYNTHETIC OILS

These are oils which are arrived at by chemical synthesis from petroleum feed stocks, although in some cases would be from vegetable and mineral oils, rather than by straight run distillation of crude.

Advantages 1.

Carbon deposits are significantly reduced compared with mineral type oils, thus extending, by 1½ to 3 times, the maintenance periods normally expected for high pressure valves.

2.

Oil change periods can be increased by 2 to 3 times normally expected.

3.

Wear rates are reduced.

4.

These oils being produced to close tolerances have properties, and hence obtain performance, which are consistent from batch to batch.

5.

Oil carry-over reduced by up to 35%.

Disadvantages 1.

There are some materials, e.g. certain rubbers, paints, plastics and metals that are not compatible with synthetic oils (see: Compatibility of Materials Chart). Components on the 500 series compressors are compatible with synthetic lubricants but a problem may exist with auxiliary equipment, so consult their manufacturer to determine compatibility. The following synthetic type oils are approved:REAVELLITE ANDEROL 555

These oils are approved for use in the 5000 series compressors, having been evaluated for performance and compatibility with materials used in their construction. The above oils have been found to give better and more consistent valve life on high pressure valves (i.e. third and fourth stages). REAVELLITE is non-toxic and suitable for use in breathing air compressors.

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Page 11


2.3

COMPATIBILITY OF MATERIALS WITH SYNTHETIC TYPE OILS Acceptable A. SEAL MATERIALS

Fluorocarbon (Teflon, FEP) Fluorosilicone Rubber Silicone Rubber ¤ Nitrile Rubber (Buna-N-NBR) Polysulfide (Thiokol)

Marginal † Nitrile Rubber (Buna-N- NBR) Polyurethane Ethylene-Propylene Terpolymer Epichlorohydrin

NoR t ecommended Polychloroprene (Neoprene) Natural Rubber Styrene-Butadiene Rubber (SBR, Buna-S) Butyl Rubber Chlorosulfonated Polyethylene Polyacrylate Rubber × Nitrile Rubber (Buna-N-NBR)

B. PAINT Epoxy Baked Phenolic Two Component Urethane Moisture cured Urethane

Alkyds (baked finish preferred) Phenolic Single Component Urethane Industrial Latex

Acrylic Latex (household type) Vinyl (PVC) Varnish Lacquer

Urethane Polyethylene Polypropylene Polycarbonate Acrylate & Methacrylate

Polystyrene Polyvinyl Chloride ABS (acrylonitrile/butadiene/styrene

Cadmium

Zinc

C. PLASTICS Nylon Fluorocarbon (Teflon) Polyacetal Polysulfone

D. METALS Steel and alloys Aluminium and alloys ‡ Copper and Alloys Tin Nickel Inconel, Monel

¤ High nitrile content (<36% acrylonitrile) × Low nitrile content (>30% acrylonitrile) †medium nitrile content (30-36% acrylonitrile) ‡Minimising exposure to copper will extend the life of any oil

Page 121176.doc


SECTION 3

INSTALLATION 3.1 HANDLING OF UNIT When using the compressor and motor eyebolts as the slinging attachment, it is essential that a spreader be used. The lift should always be made vertical; as inclined loading drastically reduced the eyebolt strength. Suitable shackles should be used for this operation.

3.2 LOCATION Compressor should be installed in a cool, level, well-ventilated position, clear of fumes, heat or high humidity, to ensure efficient performance and also to prevent temperature problems. Should circumstances necessitate installation in an unsuitable atmosphere, clean cool air must be piped to the compressor via a suction filter to eliminate ingress of abrasive or foreign matter. Suction ducting, when fitted, must be structurally rigid to withstand pulsating suction effects. It is imperative that the radiator fan works in a cool, clean, direct airflow and that there is a reasonable air gap around the radiator or it is fixed into a wall. As a large percentage of the compressor cooling water heat is dissipated via the radiator to the inducted air stream, it is essential that expired cooling air has an unobstructed passage and exit and does not, under any circumstances, re-circulate in the immediate compressor environment. If more than one compressor set is installed, each must have its own direct air flow and in small buildings and enclosures the radiator(s) should be sealed to an outside wall by means of a duct of a sufficient area for the ventilation required. Allow sufficient space around the installation to enable safe maintenance working conditions. Protection from severe weather conditions is desirable. Maximum allowable ambient cooling air temperature for radiator cooled sets is dependant on many variables e.g. pressure speed and type of oil. Contact UK Ltd to ascertain allowable temperature for operating conditions.

RECOMMENDED INSTALLATION COOLING AIR ENTERS, PASSES OVER MACHINE AND AS HEATED AIR, IT IS EXHAUSTED FROM THE MACHINEENVIRONMENT.

INCORRECTI NSTALLATION COOLING AIR ENTERS, PASSES OVER MACHINE AND THEN AS HEATED AIR, RE-CIRCULATES INMACHINEENVIRONMENT.

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Page 13


3. 3

MOUNTING Under normal circumstances a special foundation is unnecessary but verification must be obtained that the support floor is structurally adequate as well as flat and level. If installed adjacent to vibrating machinery it may be necessary to bolt down the isolation pads but when tightening, ensure the isolation pads are not distorted. If bedplate mounted, ensure floor is level and even surfaced, to prevent distortion.

3.4

CONNECTIONS, PIPEWORK AND FITTINGS Full consideration mustand be capacities given to system layout. Checkmounted, piping and connections are suitable for pressures and asand thepipework compressor is flexibly (must allow 75mm all round movement) adjacent pipework and electrical cables must be flexible. Pipework adjoining the compressor should consist of short flexible sections to facilitate maintenance removal of pipework and absorb any vibration. It is essential that all pipework is made and installed so that it is not constrained or distorted when connected to the compressor. Wherever possible use 90° bends with 8" (0.2m) radius, not elbows. This will help to provide the discharge pipework with the necessary flexibility to allow for thermal expansion. Before completing pipework assembly, ensure all port protection plugs and blanks are removed and suction pipe sections are clear of jointing compound, scale, swarf, dirt or other foreign substance. The system must be suitably braced to prevent vibration and coupling strain on the compressor. Flexible suction piping should be suitable to withstand suction collapse. If suction delivery is from an air main prevent transfer of liquid from the main to the compressor pipe by connecting the latter to the top of the main pipe. Separators and drain traps of adequate capacity should be fitted in an easily accessible low section of the pipework system to prevent condensate or oil carry over build up. These must be drained regularly. The delivery line should incorporate non-return valves, especially for large capacity systems or where two or more compressors are linked to common main. Unloading and control gear piping must be as short as possible. CompAir UK Ltd compressors incorporate safety valves at all stages as standard equipment. However, they must also be fitted to the receiver and pipework system to protect it from excess pressure build up.

3.5

DRIVE RECOMMENDATIONS (DIRECT OR V-BELT TRANSMISSION) Details of drive arrangements and non isolation pad mountings are available from CompAir UK Ltd, Ipswich. An overload device must always be fitted to motors. Manufacturers terminal box wiring instructions must be observed. An hours run meter fitted to the motor starter is recom mended for efficient maintenance scheduling.

Belt Drive: It is very important that the driving and driven pulley grooves are in line and both pulley shafts parallel. V-belt tensioning procedures follow normal BS.3790, 1981 practice. See Section 5.4.5 page 22 for more details on belt tensioning and alignment.

Page 141176.doc


Direct Drive: Ensure compressor and drive motor is correctly aligned as the flexible couplings are for vibration duties only and not as non-alignment couplings. See Section 5.4.4 page 22 for more details.

3.6 COOLING Satisfactory compressor operation depends on correct cooling, which requires positive circulation of cool, clean water, free from suspended particles. Seawater may be used for marine applications. It is recommended that a filter be fitted in the inlet water line (mains). Maximum permitted water pressure within the compressor is 5 bar equivalent to 52 metres of water head. Cooling water flow rate is determined by temperature rise across the machine adjusted on site to 10°C to 12°C. Maximum recommended water inlet temperature is 37°C. It is recommended that temperature gauges be fitted to water inlet and outlet pipes to monitor water temperatures (mains). Water flow rate at 15°C inlet temperature will be 75 l/h/kW approximately (mains). Prevent overcooling by shutting off flow water when compressor is not running (mains). Thermostatic water temperature control, a regulating valve, or orifice in the water inlet pipe will govern the flow. The latter should only be installed where there is a constant water pressure (mains). A CompAir UK Ltd automatic water valve can be fitted to govern water supply when stopping or starting the compressor (mains). Water flow arrangements should be fail-safe to ensure that compressor can only run on full load for short periods without water flow (mains). During freezing weather conditions, cooling water should be drained from the system if the compressor is not being used (mains) or anti-freeze added to radiator sets in manufacturers specified quantities (radiator).

3.7 ELECTRICAL CONNECTIONS Ensure compressor is installed to comply with local electricity authority stipulations and that necessary electrical work is carried out by a competent electrical engineer. Check electrical requirements for machine with manufacturer before commencing installation wiring.

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Page 15


3.8 CONTROL CIRCUIT FOR AUTO STOP/START KEY R. T.. SV. HTS.

RELAY. TIMER. SOLENOID VALVE HIGH TEMPERATURE CUT OUT SWITCH. LOPS. LOW OIL PRESSURE CUT OUT SWITCH.

MPS. MAIN PRESSURE SWITCH

OPERATION START ON LOW PRESSURE SIGNAL FROM MPS. ON REACHING HIGH PRESSURE COMPRESSOR STOPS, UNLOADS & DRAINS. IF IT RUNS FOR 30 MINUTES WITHOUT STOPPING, DRAINS OPEN FOR 5/6 SECONDS.

10 SEC. DELAY ON. INSTANT OFF. MAIN COIL. INSTANT ON. DE-ENERGISES 5 SEC. EVERY 30 MIN. RE-ZEROS ON RE-ENERGISING. HOURS RUN METER. FOR WATER PUMP MOTOR IF FITTED. FOR DELIVERY UNLOADERS/DRAINS SUCTION UNLOADERS (H5236 ONLY)

3. 9

Page 161176.doc

RECOMMENDED ANCILLARIES SUMMARY 1. 2.

Flexible pipe fitted on final delivery. Overload trips.

3.

Water inlet and outlet thermometers.

4.

Water flow control.

5.

Separators and drain traps.

6.

Non-return valves.


SECTION 4

COMMISSIONING OR RECOMMISSIONING WARNING: BEFORE OPERATING THIS EQUIPMENT USERS SHOULD BE MADE AWARE OF AND ENSURE COMPLIANCE WITH THE HEALTH & SAFETY REGULATIONS APPROPRIATE TO THIS CLASS OF WORK. ATTENTION OF U.K. USERS IS DRAWN TO THE HEALTH & SAFETY AT WORK ACT, 1974 & CONTROL OF SUBSTANCES HAZARDOUS TO HEALTH REGULATIONS 1988. TAMPERING WITH SAFETY VALVES IS D ANGEROUS AND ALSO INVALIDATES THE GU ARANTEE

4.1 BEFORE STARTING Low oil ressure switch

Remove protective blank

Remove priming plug Oil filler Oil pump Oil level gauge

High air/gas temperature switches

Drain Plug

Before starting up ensure one is familiar with safety devices and type of control.

NOTE: Low oil pressure and high air temperat

ure switches are preset and should n ot be adjusted. H533 6.2, & H543 6.2 : 3rd st age (2 nd stage on H533 6.2)air temp erature protectio n s witc h is preset a nd sh ould n ot be adjusted. 1176.doc

Page 17


On H5336.2 & H5436.2 ensure suction filter is in good condition. Make sure that protective blank fitted to the first stage suction is removed. Check that silencer bore and any suction pipework is clean before reassembling. Check that the inside of the crankcase is clean and filled with the correct grade of oil until oil level sight glass is at maximum level. It is important to maintain oil level between upper and lower limits.

Important: Do not overfill. H5336.2, & H5436.2 must be run-in on mineral oil only. See later section for operation on synthetic oil. Remove the plug from the outer end cover, immediately above the main lubrication pump and prime the pump suction port with the recommended oil. Replace the plug. Turn over the machine at least one revolution by hand, to ensure freedom of movement. Replace all items, which have been removed.

NOTE:

4. 2

It i s not n ecessar y to remov e any inhibitor oil whic h may h ave be en applied before despatch, unless there are specifi c instruc tions attached to the m achine stating otherwise.

START-UP PROCEDURE If automatic drainage/unloading is provided - set to hand control unload the compressor by operating the drains. If no hand switch is fitted, disconnect solenoid valve electric supply to achieve this. Check radiator is topped up on radiator sets or water is flowing in mains water installations. Operate starter. Check immediately that rotation is counterclockwise looking on driving end. Check oil pressure is above 2 bar. Compressor must not be run for more than 30 seconds with no oil pressure. Check there are no uncharacteristic noises. Run for 30 minutes unloaded. Stop and isolate the compressor and release all pressures. Check that outer surface of the compressor is cool. Remove crankcase doors and check that bearings and running gear are not over-heating. Replace doors, ensuring joints are corrected seated. Reconnect solenoid valve electric supply. Start the compressor and bring slowly onto load. Build up to full pressure within 30 minutes. If appropriate, set the machine for automatic operation. Check and adjust the control equipment settings, if applicable. For example, final air delivery pressure switch. Continue to check that machine is functioning correctly and not over-heating. If thermostats are fitted check temperatures are within normal limits. Observe stage pressures and temperatures are normal. Check for air, water or oil leaks.

Page 181176.doc


WARNING: Do not try to

correct lea ks w hen items are pressurised.

Ensure that automatic controls (if applicable) are operating correctly. If machine is manually controlled open all condensate drains at 30-minute intervals. Adjust cooling water flow to give 11°C rise across machine. Run at full load for one and a half hours and record compressor rpm, oil pressure and stage pressures at 30-minute intervals.

4.3

AFTER THE FIRST 15 HOURS RUNNING TIME Check alignment and belt tensioning (if applicable) is correct.

4.4

AFTER THE FIRST 100 HOURS RUNNING TIME H5336.2, & H5436.2 At 100 hours:desired to use syn

1 Check motor drive belt te nsion (if fitted) 2 Check water pump drive belt tension (if fitted) 3 Drain sump, replace oil filter & refill sump with Mineral oil If it is thetic lubricant, foll ow directions as in late r section.

FOR FURTHER MAINTENANCE PERIODS REFER TO LATER SECTION.

4.5

CHANGING OV ER FROM MINERAL TO S YNTHETIC L UBRICANT H5336.2, & H5436.2 Basically all compressor components in contact with the lubricant should be as clean as it is practical before changing over. This is necessitated by the excellent solvency of synthetic oils that tend to loosen and remove existing deposits. 1.

Drain the old mineral lubricant completely whilst the oil is warm from crankcase sump.

2.

Remove from crankcase sump all deposits and/or sludge,

3.

Renewoilfilter.

4.

5. 6.

7.

Inspect suction and delivery valves. If they are covered by carbon and/or heavy lacquer deposits, Remove and thoroughly clean. Replace all items removed, renew any damaged seals or gaskets. Fill crankcase sump with Reavellite synthetic oil until oil level sight glasses are filled to upper level. Run compressor following starting procedures.

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Page 201176.doc


SECTION 5

OPERATION AND ROUTINE MAINTENANCE 5.1

OPERATING AND DAILY MAINTENANCE

The commissioning procedure should be used:(A) For the first commissioning run; (B) Following overhaul; (C) After standing idle for a long period. The the compressor, especially pipe connections and joints, kepteasily cleanseen. at all times. If oil exterior film andof condensate are wiped away regularly, any leaks that occurshould will bebe more It is good practice to monitor and record stage pressures. This information gives a good indication of machine operation and can give advanced warning of a malfunction. The readings vary with ambient conditions but pressure readings are usually within plus or minus 4%. A useful visual indication can be obtained if the gauge glass is marked.

Starting Up: Before starting up ensure one is familiar with the safety devices and types of control. Check oil level in crankcase and top up, if necessary, using recommended oil until oil level sight glass is on maximum. Check v-belts are in good condition and correctly tensioned. (See later section). Ensure there is adequate water in the cooling system (radiator sets) or supply from mains. Check stop valves fitted in main and control pipework are set correctly. Check main isolator is on. Ensure fault circuits are re-set. For automatic starting control the machine should already be unloaded ready for starting. Operate main control/motor starter. For automatically controlled machines the machine should function according to the type of control.

Running on Load: Check gauges are indicating normal pressures. Temperature rise of water flowing through the machine should be 10°C to 12°C. This should be checked once the machine has settled. Check that machine is running correctly; for example no excessive vibration or noise.

Stopping: Machine will stop automatically when pressure falls to set point on final pressure switch. Manual or emergency stops may be made by use of stop button on starter panel.

Standing Idle: Condensate drains will be left automatically open. 1176.doc

Page 21


For ambient temperatures below 0°C protect machine by draining off cooling water system, unless protected by anti-freeze. After one week standing idle, turn the machine over by hand before starting to ensure it turns freely. If the compressor is to stand idle for more than four weeks or shorter period if ambient conditions are unfavourable, it is advised to consult CompAir UK Ltd for correct inhibition procedure.

5.2 MAINTENANCE PERIODS SEE SECTION 8 FOR RECOMMENDED SERVICE PLANS The optimum period between servicing will depend upon the operating conditions. Regular servicing is essential if the design performance of the compressor is to be maintained.

Periodically: In addition to operational checks, check all nuts, screws and fittings for tightness and inspect for air, oil or water leaks, which should be rectified immediately, Examine oil in crankcase and ensure that it is not contaminated with condensate. Depending on the degree of contamination, the oil may appear emulsified (creamy in colour) especially if the recommended lubricant is not used. If emulsification takes place the oil must be changed and the crankcase cleaned. This condition is usually visible through the oil level indicator and must be rectified immediately. Trace cause of contamination, rectify, fit new oil filter and refill crankcase sump with recommended oil. If moisture forms without emulsification, as two separate liquids, condensate may be drained from below the oil by means of the drain plug. The oil level should be replenished accordingly with clean oil. Crankcase oil contamination is often accompanied by increase in sight glass level, due to oil being supported by condensate fluid.

Initial Running & After Major Overhaul: H5336.2, & H5436.2 Mineral Oil Run in on mineral oil. At 100 hours: - 1 Check motor drive belt tension (if fitted) 2 Check water pump drive belt tension (if fitted) 3 Drain sump, replace oil filter & refill sump with mineral oil

H5336.2, & H5436.2 Synthetic Oil Run in on mineral oil. At 100 hours: - 1 Check motor drive belt tension (if fitted) 2 Check water pump drive belt tension (if fitted) 3 Drain sump, replace oil filter, clean & refill sump with synthetic oil 4 Clean suction and delivery valves

Daily

N. B. This compressor mu st not be run on minera l oil. 1 Checkoillevelinsump 2 Check oil level in mechanical lubricator (if fitted) 3 Check stage pressure gauge readings

Weekly 1

Check oil flow rate in lubricator flow indicators (if fitted)

2

Check bursting disc for signs of cracking

A co mp lete overhaul is recom mend ed every 3 years if 80 00 (Mineral) or 9000 (Synthetic) runnin hours are not rea ched. After a minor service run co mpressor briefly to confirm s atisfa ctory op era tion. After a major service re comm ission the compressor as per comm issioning proc edure.

Page 221176.doc

g


5.3 VALVE MA INTENANCE PE RIODS Compressor Valve Inspection: The periods quoted in the table for valve inspection are based on our experience and average usage. When operating these compressors under adverse running conditions, such as high ambient temperatures and pressures, more frequent inspection may be necessary for the final stage. For compressors being used on light duties, i.e. low pressure, low speed and non-arduous ambient conditions, assessing valve condition on initial running periods and extending them to suit may often increase the period between valve inspections.

5.4

MAINTENANCE DETAILS 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 v essels.

THE ATTENTION OF U.K. USERS IS DRAWN TO THE HEALTH & S AFETY AT WORK ACT, 1974 AND CONTROL OF SUBSTANCES HAZARDOUS TO HEALTH REGULATIONS 1988. 5.4.1

Pressure Gauges: Relate pressure readings against a gauge of known accuracy and if faulty, renew.

5.4.2

Bursting Disc: Should a rupture occur, stop compressor immediately and turn off cooling water supply. Rectify cause of excess pressure before fitting a new bursting disc. Fluctuating water pressure can cause such failure and if pulsing water supply is unavoidable, renew bursting disc more frequently than scheduled.

USE ONLY GENUINE COMPAIR BURSTING DISC AS REPLACEMENT 5.4.3

Corrosion R od: If severe electrolytic action is encountered inspect rod more frequently than specified in maintenance cycle.

5.4.4

Direct Drive: Ensure compressor and drive motor is correctly aligned as the flexible couplings are for vibration duties only and not as non-alignment couplings. Note that direct-coupled sets with bell type housing (see below) are self-aligning.

DIRECT DRIVE CHECKING FOR FREE PLAY AND WEAR. After the first 500 hours and every 2000 hours, more frequently on arduous duties such as more than 6 starts per hour on auto stop/start operation, check the following:Ensuring compressor is isolated from mains supply, remove inspection cover (1) from bell housing (3) to expose drive components (5, 6 & 7), then by gripping the motor half coupling (5) firmly check for free movement by rotating backwards and forwards. The amount of free movement should be minimal 0.5 to 1.0 mm, excessive movement i.e. 3 to 4 mm or more should be investigated and the rubber coupling (6) replaced (complete set) as necessary.

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Page 23


1

2

10 3 9

4 5

8 6 7

5.4.5

Belt Drive Tensioning: Recommended Practice for Installation Tension in Belt Drives: It is necessary to be able to measure the belt tensions with sufficient accuracy to avoid belt slip or overloaded bearings or to meet particularly arduous conditions. Measure the length of the span in millimetres. At the centre of the span apply a force with a spring scale in a direction perpendicular to the span, until the belt is deflected from the normal by an amount equal to 0.015 mm for every millimetre of span length. For example, the deflection for a span of 1 metre would be 1000 mm x 0.015 mm or 15 mm. In all cases it is essential that the pulley centres be fixed and that the larger pulley be then rotated at least four times before making the measurement. On a multiple belt drive it is essential that a matched set of belts be used and the above procedure be carried out on each belt. A measured forced below the lower value in the table indicates under tensioning, whilst a measured force above the higher value indicates over tensioning. However, when starting up a drive with new belts, the drive should be tensioned to the higher value since the tension falls rapidly in the early stages of running in. All belts should be watched carefully during the running in period after initial start-up. Retensioning should be carried out by the above procedure, when necessary.

BELT DRIVE ALIGNMENT STRAIGHT EDGE

STRAIGHT EDGE DISTANCE PIECES

ELECTRIC MOTOR COMPRESSOR

ELECTRIC MOTOR

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 later. Page 241176.doc


CENTRE DISTANCE

BELT TENSION INDICATOR APPLIED TO MID-SPAN

STRAIGHT EDGE

RECOMMENDED TENSIONING FORCES 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.

BELT DEFLECTION MEASUREMENT

Required Deflection Force "P" at Centre of Span for Compressor Speed Ranges (Newtons) Above follows current BS3790 practice.

725-1230 Small Pulley Diameter (mm)

160 - 265 265 and above

Speed (rpm) 1300-1500

35.0 - 50.0 N 52.5 - 64.0 N

29.5 - 34.0 N 52.0 - 57.0 N

SELECTION TABLE Belt Section SPB

Force required to deflect belt 15 mm per metre of span Small Pulley Newton Kilogram force Ø mm (N) (kgf) 160to224 236to315

35to50 50to65

3.5to5.1 5.1to6.6

Method of Belt Tensioning. Using a Belt Tension Indicator. 1.

Calculate the deflection distance in mm on a basis of 15 mm per metre of span. Centre distance (m) X 15 = 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.

1176.doc

Page 25


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 tensio n indicator is not available, a suitably scaled spring balance and rule will suffice.

BELT TENSION INDICATOR

DEFLECTION IN MM

Page 261176.doc

DEFLECTION FORCE IN kgf


SECTION 6

VALVE SERVICING 6. 1

GENERAL Keep a spare oiled and maintained set of valves in store for quick compressor servicing. Valves should have only a thin carbon layer and be slightly moist with oil. Valve removal is a simple procedure but the following guidelines should be observed. NOTE: Unless replace ment o f the springs and plates is intended, the order in which these com ponents are re mov ed should b e care fully noted so th at the va lves may be rea ssembled w ith the same seating faces in contact.

6.2

CLEANING AND INSPECTION - ALL STAGES The valve components should be degreased using a suitable solvent and stiff brush. Carbon deposits may be removed scraping with a soft, blunt instrument, e.g. a piece of wood. WARNI NG: - Gr eat ca re should be taken when remov ing carbon deposits to ensure that the seat ing faces; of the above co mpon ents are not damaged. These faces should be clean and bright over their whole area, with no evidence of uneven contact. Renew any plates which are indented, cracked, warped, or have wear grooves which exceed 1\10th of the plate thickness. If the seats show severe wear or indentations the complete valve assembly must be renewed. The remaining components should be checked for cracks, distortion or other damage liable to impair valves operation.

6.3

VALVE REMOVAL AND DISMANTLING Valve removal is as follows for all stages: (Special tools, which are available from CompAir UK Ltd, will assist in valve removal). Remove valve covers nuts. Using forcing screws, to remove valve covers. Using the special valve lifting tools, remove valve assemblies. Remove central nut from valve unit. Carefully separate upper and lower bodies and with unit on a level surface, lift off upper body. Remove valve plates and springs, noting very carefully their relative positions to the body and each other if they are to be re-used.

Cleaning Valve Units: Completely clean all documents. Always renew valve plates and springs in complete sets. The seating faces of each valve plate and body half should be clean and bright with all round, even contact and be free from indentations. Any item with indentations will require renewal. Reassemble valve plates and springs exactly as dismantled. NEVER reverse plates/springs as this will lead to rapid failure.

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Page 27


First Stage Valve Reassembly (Diagram 'M' Page 24 IN PARTS LIST) 1.

Place upper body (M12) face downward on suitable metal ring, or protected open vice jaws with locating pegs uppermost.

2.

Place spring plates (M3) to locate over pegs (M9) with bridging strip resting between pegs and springs facing upwards.

3.

Place valve plate (M2) onto spring plate, located as above, ensuring concentricity on centre hole.

4.

Place middle life washer (M7) over centre hole.

5.

Place valve plate (M6) onto locating pegs (M8).

6.

Put lower lift washer (M5) onto locating pegs.

7.

Place valve spring plates (M4) onto locating pegs with springs pointing downwards.

8.

Place lower body (M1) onto assembly, ensuring inner and outer pegs engage correctly. If assembly has been carried out correctly upper and lower body faces will contact.

9.

Place nut (M11) on stud and tighten to recommended torque.

10.

Test for correct operation by ensuring free movement of suction and delivery valve plates.

11.

Ensure Ò` ring is secure in slot in upper valve body.

Second Stage Valve Reassembly (Diagram 'N' Page 2 IN PARTS LIST) 1.

Place upper body (N9) face downward on suitable metal ring or protected open vice jaws with locating peg uppermost.

2.

Place valve plate (N5) to locate over peg.

3.

Place three spring plates onto valve plate, locating them on peg, springs facing downwards.

4.

Follow this with valve backing plate (N2). Place delivery valve springs (N3) onto valve/backing plate having first positioned them as follows:Assemble the delivery plate springs (N3) in pairs, rotating one spring in each pair until the inner and outer circumferences are matched perfectly. Hold the two pairs of springs together with the concave faces facing each other and then rotate one pair until their edges touch all round the circumference and there is a constant gap around the inner edge.

Page 281176.doc

5.

Place the second backing plateonto (N2)assembly. on spring plates and then after concentricity placevalve lower body (N1) If all components areensuring located correctly upper and lower bodies will contact.

6.

Screw on nut (N9) and tighten to recommended torque.

7.


8.

Ensure ‘O’ ring is secure in slot in upper valve body.


Third Stage Valve Reassembly (Diagram 'P' Page 29 IN PARTS LIST) 1.

Using suitable metal ring or open protected vice jaws, place upper valve body, (P6) face downwards.

2.

Insert valve plate (P5) followed by three spring rings (P4) bowed two against one as shown.

3.

Follow with valve backing plate (P2) and then four spring plates (P3) bowed in pairs.

4.

Follow up with the second valve backing plate (P2) and when satisfied all components are correctly aligned, place lower body (P1) and centre stud through assembly.

5.

Press together and ensure edges of upper and lower body contact then place washer (P8) over stud, screw on nut (P9) and tighten to recommended torque.

6.


7.

Ensure Ò` ring is secure in slot in upper valve body.

Fourth Stage Valve Reassembly (Diagram 'Q' Page 31 IN PARTS LIST) 1.

Place upper body (Q6) face downward on suitable metal ring or protected vice jaws.

2.

Insert bowed spring plates (Q3) in pairs into valve body recess.

3.

Place valve plate (Q2) on top of spring plates (Q3) and then locate plate (Q5) over hole in centre of upper valve body (Q6).

4.

Insert spring (Q4) centrally over stud in lower valve body (Q1), ensuring that smaller diameter end of spring is inserted into valve body.

5.

Using steel rule or similar thin flat object, depress bowed springs into upper valve body (Q6), and holding spring (Q4) onto lower valve body (Q1), assemble so that stud passes through hole in upper valve body (Q6).

6.

Ensure both valve bodies contact, screw nut (Q8) onto stud and tighten to recommended torque.

7.

See that Ò` ring is secure in slot in face of upper valve body.

Valve Reassembly into Compressor: Ensure valve pocket is clean before replacing valve assembly. When fitting new valve it should be lapped into its pocket using fine Carborundum paste and finishing with metal polish. Ensure com plete clea nliness before fitting. Ensure valve beds properly as a slight misfit will entail the loss of a large amount of air. Check valve cover for cleanliness before reassembly. Renew Ò` rings lightly greasing before fitting. There should be at least a 2-mm gap between the top of cylinder and bottom of valve cover.

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Page 29


Page 301176.doc


SECTION 7

FAULT GUIDE These suggestions are a guide to the more common aspects of fault location. It is assumed that:1. 2. 3. 4. 5. 6.

Cooling water inlet temperature is correct. Temperature rise across machine is within limits. Cooling water flow rate is correct. Driving unit is efficient and power supply adequate. Correct uncontaminated lubricant. Lubrication system is fully operational.

NOTE:- Safe ty valve opening ind icates excessive pressu re a nd und er NO CI RCUMSTANCES mu st a safety valve be screwed dow n to a cco mm odate excessive pressu re. THI S IS DANGEROUS. If safety valve opens or appears fa ulty, shut dow n com pressor imm edia tely and investigate .

Fault

ProbableCause

7.1 Excessive Pressure

Faulty suction or delivery valve(s)

Recommendation(s) Service valve(s) as necessary.

Pressure gauge inaccurate.

Check gauge against instrument of known accuracy.

Pipeline restriction

Existing Installation:

NOTE: A faulty suction valve gives excess pressure in previous stage.

Check functioning and setting of all control valves. Clean pipeline filters and service elements.

New Installation: Ensure all protective plugs are removed from ports and control valves are set correctly. Ascertain pipework is of adequate dimensions with minimum of bends. Check joint gaskets for correct positioning and size.

7.2 Insufficient Pressure or Volume.

Final delivery pressure control fault, i.e. air governor (relay) or pressure switch.

Automatic Control: Inspect control equipment for malfunction, rectify as necessary.

Blockedsuctionfilter.

Remove and service.

First stage suction valve fault.

Remove, examine and rectify.

Air leakage from machine\system.

Locate and rectify. Check drain valves.

Wear.

If general wear is suspected, strip machine, examine components and renew as necessary.

Loss of drive.

Check coupling, v-belt drive and tension.

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Page 31


Fault

ProbableCause

7.3 Overheating

Abovemaximum recommended operation. Reduced cooling efficiency.

7.4 Excessive Noise

Machine set up or pipework system vibration.

7.5 E xcessive Wear

Excessive speed and\or pressure. Dirty air and\or suction pipeline.

7.6 Extended Running

7.7 FailuretoStart

Excessive moisture content in air cylinder. Insufficient speed or machine capacity too low. Seizure

Electrical or control fault.

Page 321176.doc

Recommendation(s) Reduce operation level. Examine cooler(s) for partial blockage. Examine machine seating, ascertain pipework system is firmly secured, check clearances and alignment of couplings and tension of v-belts. Operation within limits. Examine filters and renew elements. Clean out suction pipeline. Check drainage system and crankcase oil for contamination. Up-rate machines if possible or install parallel unit or larger replacement. Check v-belts. Failure to turn freely when unloaded indicates a serious fault. Examine and ensure there are no broken or damaged components, before attempting to re-start. Trace and rectify.


SECTION 8

RECOMMENDED SERVICE PLANS RSP5436M - H5436.2 - MINERAL OIL ----------------------------- EX1 RSP5436S - H5436.2 - SYNTHETIC OIL -------------------------- EX2 RSP5336M - H5336.2 - MINERAL OIL ----------------------------- EX3 RSP5336S - H5336.2 - SYNTHETIC OIL -------------------------- EX4

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Page 341176.doc

CompAir UK Ltd

RECOMMENDED SERVICEPLAN - 5336 Mk2-M

Page 1

INITIAL SERVICE 100 HOURS OR ELA PSED TIM E 6 MONTHS

MINERAL OIL - SUBJECT TO OPERATING RESTRICTIONS IMPORTANT - DAILY & BEFORE STARTING Check oil level top up if necessary Change oil & oil filter element. Cleanse crankcase. Repeat after MAJOR OVERHAUL (8000) hours or any intermediate overhaul. ONfof Change oil (total capacity 45 litres) - Mineral oil 25 litres. Change oil filter Check belt tension/drive couplings & condition of all ancillaries Check for oil & air leaks Check tightness of all fasteners

2 1

AT 1000 HOURS OR ELA PSED TIM E 12 MONTHS REPE AT A T 5000 & 7000 HOURS

Change 3rd stage valv es. R outinecsuction heckofdfilter rive&element. ancillarieClean s.

AT 2000 HOURS OR ELA PSED TIM E 24 MONTHS

Change oil & oil filter element. Cleanse crankcase. Change suction filter element. Clean 1st, 2nd & 3rd stage valves. Service diaphragm drain valves. Check condition of sacrificialnode. NO off

NoOff

Changesuctionfilterelement ‘O’ Ring 3rd stage valve cover upper ‘O’ Ring 3rd stage valve cover lower Back-up ring 3rd stage valve cover lower ‘O’ Ring 3rd stage valve 1 Check belt tension/drive coupling & condition of all ancillaries Check for oil & air leaks Check tightness of all fasteners Check condition of 3rd stage cylinder bore & clean air passages.

Change oil (total capacity 45 litres) - Mineral oil 25 litres. Change oil filter Changesuctionfilterelement.

1

Part Ref RSP5336/2/m.1

98384/1022 98262/1009


98262/1063 1 98504/1108 1 98504/1107 1 98504/1113 95604/24

2 1 1


98384/1022 98262/1009 98262/1063

‘O’ringkitvalvemaintenance 1 98504/1001 Servicekitdiaphragmdrainvalves 3 98650/1535 Check belt tension/drive couplings & condition of all ancillaries Check for oil & air leaks Check tightness of all fasteners Check condition of 1st, 2nd & 3rd stage cylinder bores & clean air passages. AT 3000 HOURS OR ELA PSED TIM E 36 MONTHS

Service 3rd stage valve. Change suction filter element. Replacesacrificiaal node

Part Ref NoOff

RSP5336/2/m.4

Changesuctionfilterelement. 1 98262/1063 ‘O’ Ring 3rd stage valve cover upper 1 98504/1108 ‘O’ Ring 3rd stage valve cover lower 1 98504/1107 Back-up ring 3rd stage valve cover lower 1 98504/1113 Servicekit3rdstagevalve 1 98650/1059 Sacrificialanode(corrosionrod). 2 98163/1002 Check belt tension/drive couplings & condition of all ancillaries Check for oil & air leaks Check tightness of all fasteners Check condition of 3rd stage cylinder bore & clean air passages. Check Non-Return Valve

53362m.doc

CompAir UK Ltd


Page 2

AT 4000 HOURS OR ELA PSED TI ME 48 MONTHS

Change oil & oil filter. Cleanse crankcase. Service 1st & 2nd stage valves. Replace bursting discs. Service diaphragm dravianlves. N Ooff Change oil (total capacity 45 litres) - Mineral oil 25 litres. Change oil filter Changesuctionfilterelement. ‘O’ringkitvalvemaintenance 1ststagevalveservicekit 2ndstagevalveservicekit Servicekitdiaphragmdrainvalves


2

98384/1022 1 98262/1009 1 98262/1063 1 98504/1001 1 98650/1518 1 98650/1533 3 98650/1535

Service burstingdisc 2 C201556/100 Check kit tightness of all fasteners Check belt tension/drive couplings & condition of all ancillaries. Check condition of sacrificial anode (corrosion rod) Check condition of 1st & 2nd stage cylinder bores & clean air passages. AT 6000 HOURS OR ELA PSED TI ME 60 MONTHS

Change suction filter element. Replace 3rd stage valve. Replace sacrificial anode. Routine check drive & ancillaries

Part Ref No Off

Changesuctionfilterelement. 1 ‘O’ ring 3rd stage valve cover upper ‘O’ ring 3rd stage valve cover lower Back-up ring 3rd stage valve cover lower 3rd stage valve 1 Sacrificial anode 2 Check tightness of all fasteners Check belt tension/drive couplings & condition of all ancillaries. Check condition of 3rd stage cylinder bore & clean air passages.

RSP5336/2/m.6

98262/1063 1 98504/1108 1 98650/1107 1 98504/1113 98650/1049 98163/1002

53362m.doc

CompAir UK Ltd


Page 3

AT 8000 HOURS MAJOR OVERHAUL

Replace all valves, piston rings, gudgeon pins, bearings etc. Check condition of 1st, 2nd & 3rd stage cylinder bores. Clean all water jackets, hydraulic test all coolers. recalibrate all pressure gauges replace if faulty. Replace drive belts/coupling rubbers. Function test all ancillaries. Check condition of suction filter internals, clean or replace as necessary. O Nfof Change oil (sump capacity 45 litres)Mineral oil25 litres. Change oil filter. Changesuctionfilterelement.

2 1 1


98384/1022 98262/1009 98262/1063

Joint kit 1 98504/1002 1st stage valve 1 98650/1519 2nd stage valve 1 98650/1039 3rd stage valve 1 98650/1049 Servicekitdiaphragmdrainvalves 3 98650/1535 Servicekitburstingdisc 2 C201556/100 Sacrificialanode(corrosionrod) 2 98163/1002 Check cylinder bores for wear Inspect all piston ring grooves and piston lands for wear Deglaze all liners/bores when fitting new piston rings. 1ststagepistonringset 1 98477/1085 2ndstagepistonringset 1 98477/1086 3rdstagepistonringset 1 98477/1087 1st stage gudgeon pin 1 C85727/1 2nd,3rd&dummystagegudgeonpin 3 C85727/2 2nd,3rd&dummystagegudgeonpincirclips 6 95650/25 1ststagegudgeonpincirclips 2 95650/30 1st stage S/E bush 1 C200016 2nd,3rd&dummystageS/Ebearings 3 96072/74 Check crankshaft journals & oil seal diameter for wear 1st,2nd,3rd&dummystageB/Ebearings 4 C201109 CrankshaftD/Eoilseal 1 95605/135 Main bearing bush 2 C85736/2 Thrust washer 2 98074/1004 1ststagesafetyvalve 1 98650/1020-3.8 2ndstagesafetyvalve 1 98650/1021-24 3rdstagesafetyvalve 1 98650/1022-100 Surgevesselsafetyvalve 1 98650/1011 Re-calibrate/renew or check high temperature switch settings Re-calibrate/renew or check pressure gauges Cleanse all separators, cooler covers & cooler assemblies Hydraulically test all cooler assemblies Check oil pump & drive Check tightness of all fasteners after initial run Check condition of all other ancillaries.

53362m.doc

CompAir UK Ltd

RECOMMENDED SERVICE PLAN - 5336 Mk2-S

Page 1

INITIAL SERVICE 100 HOURS OR ELA PSED TIM E 6 MONTHS



SYNTHETIC OIL - STANDARD GRADE IMPORTANT - DAILY & BEFORE STARTING Check oil level top up if necessary Change oil & oil filter element. Cleanse crankcase. Repeat after MAJOR OVERHAUL (9000) hours or any intermediate overhaul.

Part Ref ONfo f

Change oil (total capacity 45 litres) - REAVELLITE ‘S’ 20 litres. +REAVELLITE‘S’5Litres Change oil filter Check belt tension/drive couplings & condition of all ancillaries Check for oil & air leaks

2 1 1

Check tightness of all fasteners

Change suction filter element. Clean 3rd stage valv es. Routinecheckofdrive&ancillaries.

RSP5336/2/s.1

98384/1002 98384.1001 98262/1009

Part Ref NoOff

Changesuctionfilterelement ‘O’ Ring 3rd stage valve cover upper ‘O’ Ring 3rd stage valve cover lower Back-up ring 3rd stage valve cover lower ‘O’ Ring 3rd stage valve 1 Check belt tension/drive coupling & condition of all ancillaries Check for oil & air leaks Check tightness of all fasteners Check condition of 3rd stage cylinder bore & clean air passages.

Change oil & oil filter element. Cleanse crankcase. Change suction filter element. Clean 1st, 2nd & 3rd stage valves. Service diaphragm drain valves. Check condition of sacrificialnode. Change oil (total capacity 45 litres) - REAVELLITE ‘S’ 20 litres. +REAVELLITE‘S’5Litres

1

RSP5336/2/s.2

98262/1063 1 98504/1108 1 98504/1107 1 98504/1113 95604/24

Part Ref NO off 2 1

RSP5336/2/s.3

98384/1002 98384.1001

Change oil filter 1 98262/1009 Changesuctionfilterelement. 1 98262/1063 ‘O’ringkitvalvemaintenance 1 98504/1001 Servicekitdiaphragmdrainvalves 3 98650/1535 Check belt tension/drive couplings & condition of all ancillaries Check for oil & air leaks Check tightness of all fasteners Check condition of 1st, 2nd & 3rd stage cylinder bores & clean air passages. AT 4500 HOURS OR ELA PSED TIM E 36 MONTHS

Service 3rd stage valve. Change suction filter element. Replacesacrificiaal node Changesuctionfilterelement. ‘O’ Ring 3rd stage valve cover upper ‘O’ Ring 3rd stage valve cover lower Back-up ring 3rd stage valve cover lower Servicekit3rdstagevalve Sacrificialanode(corrosionrod). Check belt tension/drive couplings & condition of all ancillaries

Part Ref NoOff

RSP5336/2/s.4

1

98262/1063 1 98504/1108 1 98504/1107 1 98504/1113 1 98650/1059 2 98163/1002

Check for oil & air leaks Check tightness of all fasteners Check condition of 3rd stage cylinder bore & clean air passages. Check Non-Return Valve

53362SS.doc

CompAir UK Ltd


Page 2


Change oil & oil filter. Cleanse crankcase. Service 1st & 2nd stage valves. Replace bursting discs. Service diaphragm dravianlves. N Ooff Change oil (total capacity 45 litres) - REAVELLITE ‘S’ 20 litres. +REAVELLITE‘S’5Litres Change oil filter Changesuctionfilterelement. ‘O’ringkitvalvemaintenance 1ststagevalveservicekit 2ndstagevalveservicekit

Part Ref RSP5336/2/s.5

2 1 1 1 1 1 1

98384/1002 98384.1001 98262/1009 98262/1063 98504/1001 98650/1518 98650/1533

Service kit diaphragm 98650/1535 Servicekit bursting disc drainvalves 23 C201556/100 Check tightness of all fasteners Check belt tension/drive couplings & condition of all ancillaries. Check condition of sacrificial anode (corrosion rod) Check condition of 1st & 2nd stage cylinder bores & clean air passages. AT 7500 HOURS OR ELA PSED TI ME 60 MONTHS

Change suction filter element. Replace 3rd stage valve. Replace sacrificial anode. Routine check drive & ancillaries

Part Ref No Off

Changesuctionfilterelement. 1 ‘O’ ring 3rd stage valve cover upper ‘O’ ring 3rd stage valve cover lower Back-up ring 3rd stage valve cover lower 3rd stage valve 1 Sacrificial anode 2 Check tightness of all fasteners Check belt tension/drive couplings & condition of all ancillaries. Check condition of 3rd stage cylinder bore & clean air passages.

RSP5336/2/s.6

98262/1063 1 98504/1108 1 98650/1107 1 98504/1113 98650/1049 98163/1002

53362SS.doc

CompAir UK Ltd


Page 3


Replace all valves, piston rings, gudgeon pins, bearings etc. Check condition of 1st, 2nd & 3rd stage cylinder bores. Clean all water jackets, hydraulic test all coolers. re-calibrate all pressure gauges replace if faulty. Replace drive belts/coupling rubbers. Function test all ancillaries. Check condition of suction filter internals, clean or replace as necessary. O Nfof Change oil (sump capacity 45 litres) REAVELLITE ‘S’ 20 litres. +REAVELLITE‘S’5Litres Change oil filter.

2 1 1

Part Ref RSP5336/2/s.8

98384/1002 98384.1001 98262/1009

Changesuctionfilterelement. 1 98262/1063 Joint kit 1 98504/1002 1st stage valve 1 98650/1519 2nd stage valve 1 98650/1039 3rd stage valve 1 98650/1049 Servicekitdiaphragmdrainvalves 3 98650/1535 Servicekitburstingdisc 2 C201556/100 Sacrificialanode(corrosionrod) 2 98163/1002 Check cylinder bores for wear Inspect all piston ring grooves and piston lands for wear Deglaze all liners/bores when fitting new piston rings. 1ststagepistonringset 1 98477/1085 2ndstagepistonringset 1 98477/1086 3rdstagepistonringset 1 98477/1087 1st stage gudgeon pin 1 C85727/1 2nd,3rd&dummystagegudgeonpin 3 C85727/2 2nd,3rd&dummystagegudgeonpincirclips 6 95650/25 1ststagegudgeonpincirclips 2 95650/30 1st stage S/E bush 1 C200016 2nd,3rd&dummystageS/Ebearings 3 96072/74 Check crankshaft journals & oil seal diameter for wear 1st,2nd,3rd&dummystageB/Ebearings 4 C201109 Crankshaft D/E oil seal 1 95605/135 Main bearing bush 2 C85736/2 Thrust washer 2 98074/1004 1ststagesafetyvalve 1 98650/1020-3.8 2ndstagesafety valve 1 98650/1021-21 3rdstagesafetyvalve 1 98650/1022-100 Surgevesselsafetyvalve 1 98650/1011 Re-calibrate/renew or check high temperature switch settings Re-calibrate/renew or check pressure gauges Cleanse all separators, cooler covers & cooler assemblies Hydraulically test all cooler assemblies Check oil pump & drive Check tightness of all fasteners after initial run Check condition of all other ancillaries.

53362SS.doc

CompAir UK Ltd


Page 1

MINERAL OIL - RESTRICTED DUTIES ONLY IMPORTANT - DAILY & BEFORE STARTING Check oil level top up if necessary INITIAL SERVICE 100 HOURS OR ELAPSED. TIME 6 MONTHS

Change oil & oil filter element. Cleanse crankcase. Repeat after MAJOR OVERHAUL (8000) hours or any intermediate overhaul. Change oil (total capacity 45 litres) - Mineral oil 25 litres. Change oil filter Check belt tension/drive couplings & condition of all ancillaries Check for oil & air leaks Check tightness of all fasteners

Part Ref RSP5436/m.1

ONfo f 2 1

AT 1000 HOURS OR ELA PSED TIM E 12 MONTHS REPE AT A T 5000 & 7000 HOURS

Change suction filter element. Clean 3rd & 4th stage valves. Routinecheckofdrive&ancillaries. NoOff


Change oil & oil filter. Cleanse crankcase. Change suction filter element. Clean 1st & 2nd stage valves. Service 4th stage

98384/1022 98262/1009

Part Ref

RSP5436/m.2

Changesuctionfilterelement 1 98262/1063 ‘O’ Ring 3rd stage valve cover upper 1 98504/1108 ‘O’ Ring 3rd stage valve cover lower 1 98504/1107 Back-up ring 3rd stage valve cover lower 1 98504/1113 ‘O’ Ring 3rd stage valve 1 95604/24 ‘O’ Ring 4th stage valve cover upper 1 98504/1110 ‘O’ Ring 4th stage valve cover lower 1 98504/1109 Back-up ring 4th stage valve cover lower 1 98504/1091 ‘O’ Ring 4th stage valve 1 95604/20 Check belt tension/drive couplings & condition of all ancillaries Check for oil & air leaks Check tightness of all fasteners Check condition of 3rd & 4th stage cylinder bores & clean air passages..


valve. Service diaphragm drain valves. Check condition of sacrificial anode.

No Off

Change oil (total capacity 45 litres) - Mineral oil 25 litres. 2 98384/1022 Change oil filter 1 98262/1009 Changesuctionfilterelement. 1 98262/1063 ‘O’ringkitvalvemaintenance 1 98504/1001 Servicekit4thstagevalve 1 98650/1832 Servicekitdiaphragmdrainvalves 4 98650/1535 Check belt tension/drive couplings & condition of all ancillaries Check for oil & air leaks Check tightness of all fasteners Check condition of 1st, 2nd & 4th stage cylinder bores & clean air passages. AT 3000 HOURS OR ELA PSED TIM E 36 MONTHS

Service 3rd stage valve. Change suction filter element. Replacesacrificiaal node Changesuctionfilterelement. ‘O’ Ring 3rd stage valve cover upper ‘O’ Ring 3rd stage valve cover lower Back-up ring 3rd stage valve cover lower

Part Ref NoOff 1

RSP5436/m.4

98262/1063 1 98504/1108 1 98504/1107 1 98504/1113

Servicekit3rdstagevalve 1 98650/1059 Sacrificialanode(corrosionrod). 2 98163/1002 Check belt tension/drive couplings & condition of all ancillaries Check for oil & air leaks Check tightness of all fasteners Check condition of 3rd stage cylinder bore & clean air passages. Check and clean final delivery cooler coil assembly and pipework if fitted

54362m.doc

CompAir UK Ltd


Page 2


Change oil & oil filter. Cleanse crankcase. Service 1st & 2nd stage valves. Replace 4th stage valve. Replace 4th stage piston rings. Replace bursting discs. Service diaphragm drain valves. Change oil (total capacity 45 litres) - Mineral oil 25 litres. Change oil filter ‘O’ringkitvalvemaintenance 1ststagevalveservicekit 2ndstagevalveservicekit 4th stage valve

Part Ref No Off 2 1 1 1 1 1

RSP5436/m.5

98384/1022 98262/1009 98504/1001 98650/1518 98650/1533 98650/1794

4th stage piston rings 2 98477/1143 Servicekitdiaphragmdrainvalves 4 98650/1535 Servicekitburstingdisc 2 C201556/100 Check tightness of all fasteners Check belt tension/drive couplings & condition of all ancillaries. Check condition of sacrificial anode (corrosion rod) Check condition of 1st & 2nd stage cylinder bores & clean air passages. Deglaze liner bore when fitting new piston rings. AT 6000 HOURS OR ELA PSED TI ME 60 MONTHS

Change oil & oil filter. Cleanse crankcase. Change suction filter element. Replace 3rd stage valve. Service 4th stage valve. Replace sacrificial anode. Routine check drive & ancillaries

Part Ref O Nfof

RSP5436/m.6

Change oil (total capacity 45 litres) - Mineral oil 25 litres. 2 98384/1022 Change oil filter 1 98262/1009 Changesuctionfilterelement. 1 98262/1063 ‘O’ ring 3rd stage valve cover upper 1 98504/1108 ‘O’ ring 3rd stage valve cover lower 1 98650/1107 Back-up ring 3rd stage valve cover lower 1 98504/1113 3rd stage valve 1 98650/1049 ‘O’ ring 4th stage valve cover upper 1 98504/1109 ‘O’ ring 4th stage valve cover lower 1 98650/1110 Back-up ring 4th stage valve cover lower 1 98504/1091 Servicekit4thstagevalve 1 98650/1832 Sacrificial anode 2 98163/1002 Check tightness of all fasteners Check belt tension/drive couplings & condition of all ancillaries. Check condition of 3rd & 4th stage cylinder bores & clean air passages.

54362m.doc

CompAir UK Ltd


Page 3


Replace all valves, piston rings, gudgeon pins, bearings etc. Check condition of 1st, 2nd & 3rd stage cylinder bores. Clean all water jackets, hydraulic test all coolers. re-calibrate all pressure gauges replace if faulty. Replace drive belts/coupling rubbers. Function test all ancillaries. Check condition of suction filter internals, clean or replace as necessary. O Nfof Change oil (sump capacity 45 litres)Mineraloil25litres. Change oil filter. Changesuctionfilterelement.

2 1 1


98384/1022 98262/1009 98262/1063

Joint kit valve 98504/1002 1st stage 1 1 98650/1519 2nd stage valve 1 98650/1039 3rd stage valve 1 98650/1049 4th stage valve 1 98650/1794 Servicekitdiaphragmdrainvalves 4 98650/1535 Servicekitburstingdisc 2 C201556/100 Sacrificialanode(corrosionrod) 2 98163/1002 Check cylinder bores for wear Inspect all piston ring grooves and piston lands for wear Deglaze all liners/bores when fitting new piston rings 1ststagepistonringset 1 98477/1085 2ndstagepistonringset 1 98477/1086 3rdstagepistonringset 1 98477/1087 4th stage piston rings 2 98477/1143 4th stage piston 1 C203035 4th stage liner 1 C203034 1st stage gudgeon pin 1 C85727/1 2nd,3rd&4thstagegudgeonpin 3 C85727/2 2nd,3rd&4thstagegudgeonpincirclips 6 95650/25 1ststagegudgeonpincirclips 2 95650/30 1st stage S/E bush 1 C200016 2nd,3rd&4thstageS/Ebearings 3 96072/74 Check crankshaft journals & oil seal diameter for wear 1st,2nd,3rd&4thstageB/Ebearings 4 C201109 Crankshaft D/E oil seal 1 95605/135 Main bearing bush 2 C85736/2 Thrust washer 2 98074/1004 1ststagesafetyvalve 1 98650/1020-3.8 2ndstagesafety valve 1 98650/1021-24 3rdstagesafetyvalve 1 98650/1022-100 4thstagesafetyvalve 1 98650/1190-385 Surgevesselsafetyvalve 1 98650/1011 Re-calibrate/renew or check high temperature switch settings Re-calibrate/renew or check pressure gauges Cleanse 4th stage cooler coil internally/externally Cleanse all separators, cooler covers & cooler assemblies Hydraulically test all cooler assemblies Check oil pump & drive Check tightness of all fasteners after initial run Check condition of all other ancillaries.

54362m.doc

CompAir UK Ltd


Page 1

SYNTHETIC OIL IMPORTANT - DAILY & BEFORE STARTING Check oil level top up if necessary INIT IAL SERVICE 100 HOURS OR ELA PSED TIME . 6 MONTHS

Change from Mineral oil. Change oil filter element. Cleanse crankcase. Repeat after MAJOR OVERHAUL (9000) hours or anyintermediateoverhaul. NoOff Change oil (total capacity 45 litres) - REAVELLITE ‘S’ 20 litres. +REAVELLITE‘S’5Litres Change oil filter Check belt tension & condition of all ancillaries Check for oil & air leaks Check tightness of all fasteners

2 1 1


Change suction filter element. Clean 3rd & 4th stage valves. Routinecheckofdrive&ancillaries. NoOff

AT 3000 HOURS OR

Change oil & oil filter. Change suction filter element. Clean

ELA TIM E 24 PSED MONTHS

Part Ref RSP5436/s.1

98384/1002 98384.1001 98262/1009


Changesuctionfilterelement 1 98262/1063 ‘O’ Ring 3rd stage valve cover upper 1 98504/1108 ‘O’ Ring 3rd stage valve cover lower 1 98504/1107 Back-up ring 3rd stage valve cover lower 1 98504/1113 ‘O’ Ring 3rd stage valve 1 95604/24 ‘O’ Ring 4th stage valve cover upper 1 98504/1110 ‘O’ Ring 4th stage valve cover lower 1 98504/1109 Back-up ring 4th stage valve cover lower 1 98504/1091 ‘O’ Ring 4th stage valve 1 95604/20 Check belt tension/drive couplings & condition of all ancillaries Check for oil & air leaks Check tightness of all fasteners Check condition of 3rd & 4th stage cylinder bores & clean air passages..

1st &hrag 2ndmstage 4th ditio stage valve. Service RSP5436/s.3 Ref diap drainvalves. valves.Service Check con n of sacrific ial anode. No Off Part Change oil (total capacity 45 litres) - REAVELLITE ‘S’ 20 Litres. 2 98384/1002 +REAVELLITE‘S’5LIitres 1 98384.1001 Change oil filter 1 98262/1009 Changesuctionfilterelement. 1 98262/1063 ‘O’ringkitvalvemaintenance 1 98504/1001 Servicekit4thstagevalve 1 98650/1832 Servicekitdiaphragmdrainvalves 4 98650/1535 Check belt tension/drive couplings & condition of all ancillaries Check for oil & air leaks Check tightness of all fasteners Check condition of 1st, 2nd & 4th stage cylinder bores & clean air passages.


Service 3rd stage valve. Change suction filter element. Replacesacrificiaal node Changesuctionfilterelement. ‘O’ Ring 3rd stage valve cover upper ‘O’ Ring 3rd stage valve cover lower

Part Ref NoOff 1

RSP5436/m.4

98262/1063 1 98504/1108 1 98504/1107

Back-up ring 3rd stage valve cover lower 1 98504/1113 Servicekit3rdstagevalve 1 98650/1059 Sacrificialanode(corrosionrod). 2 98163/1002 Check belt tension/drive & condition of all ancillaries Check for oil & air leaks Check tightness of all fasteners Check condition of 3rd stage cylinder bore & clean air passages. Check and clean final cooler coil assembly and pipework if fitted

54362s.doc

CompAir UK Ltd


Page 2


Change oil & oil filter. Cleanse crankcase. Service 1st & 2nd stage valves. Replace 4th stage valve. Replace 4th stage piston rings. Replace bursting discs. Service diaphragm dravianlves. N Ooff Change oil (total capacity 45 litres) - REAVELLITE ‘S’ 20 litres. +REAVELLITE‘S’5Litres Change oil filter Changesuctionfilterelement. ‘O’ringkitvalvemaintenance 1ststagevalveservicekit


2

98384/1002 1 98384.1001 1 98262/1009 1 98262/1063 1 98504/1001 1 98650/1518

2nd stage valveservicekit 11 98650/1533 4th stage valve 98650/1794 4th stage piston rings 2 98477/1143 Servicekitdiaphragmdrainvalves 4 98650/1535 Servicekitburstingdisc 2 C201556/100 Check tightness of all fasteners Check belt tension/drive couplings & condition of all ancillaries. Check condition of sacrificial anode (corrosion rod) Check condition of 1st & 2nd stage cylinder bores & clean air passages. AT 7500 HOURS OR ELA PSED TI ME 60 MONTHS

Change suction filter element. Replace 3rd stage valve. Service 4th stage valve. Replace sacrificial anode. Routine checkdrive&ancillaries NoOff Changesuctionfilterelement. ‘O’ ring 3rd stage valve cover upper ‘O’ ring 3rd stage valve cover lower Back-up ring 3rd stage valve cover lower 3rd stage valve ‘O’ ring 4th stage valve cover upper

1

1


98262/1063 1 98504/1108 1 98650/1107 1 98504/1113 98650/1049 1 98504/1109

‘O’ ring 4th stage valve cover lower 1 98504/1110 Back-up ring 4th stage valve cover lower 1 98504/1091 Servicekit4thstagevalve 1 98650/1832 Sacrificial anode 2 98163/1002 Check tightness of all fasteners Check belt tension/drive couplings & condition of all ancillaries. Check condition of 3rd & 4th stage cylinder bores & clean air passages.

54362s.doc

CompAir UK Ltd


Page 3


Replace all valves, piston rings, gudgeon pins, bearings etc. Check condition of 1st, 2nd & 3rd stage cylinder bores. Clean all water jackets, hydraulic test all coolers. re-calibrate all pressure gauges replace if faulty. Replace drive belts/coupling rubbers. Function test all ancillaries. Check condition of suction filter internals, clean or replace as necessary. O Nfof Change oil (sump capacity 45 litres) REAVELLITE ‘S’ 20 litres. +REAVELLITE‘S’5Litres Change oil filter. Change suctionfilterelement. Joint kit 1st stage valve 2nd stage valve 3rd stage valve 4th stage valve Servicekitdiaphragmdrainvalves Servicekitburstingdisc Sacrificialanode(corrosionrod) Check cylinder bores for wear Inspect all piston ring grooves and piston lands for wear Deglaze all liners/bores when fitting new piston rings. 1ststagepistonringset 2ndstagepistonringset 3rdstagepistonringset 4th stage piston rings 4th stage piston 4th stage liner

2


1 1

98384/1002 98384.1001 98262/1009

1 1 1 1 1 1 4 2 2

98262/1063 98504/1002 98650/1519 98650/1039 98650/1049 98650/1794 98650/1535 C201556/100 98163/1002

1 1 1 2 1 1

98477/1085 98477/1086 98477/1087 98477/1143 C203035 C203034

1st stage gudgeon pin 1 C85727/1 2nd,3rd&4thstagegudgeonpin 3 C85727/2 2nd,3rd&4thstagegudgeonpincirclips 6 95650/25 1ststagegudgeonpincirclips 1 95650/30 1st stage S/E bush 1 C200016 2nd,3rd&4thstageS/Ebearings 3 96072/74 Check crankshaft journals & oil seal diameter for wear 1st,2nd,3rd&4thstageB/Ebearings 4 C201109 Crankshaft D/E oil seal 1 95605/135 Main bearing bush 2 C85736/2 Thrust washer 2 98074/1004 1ststagesafetyvalve 1 98650/1020-3.8 2ndstagesafetyvalve 1 98650/1021-24 3rdstagesafetyvalve 1 98650/1022-100 4thstagesafetyvalve 1 98650/1190-385 Surgevesselsafetyvalve 1 98650/1011 Re-calibrate/renew or check high temperature switch settings Re-calibrate/renew or check pressure gauges Cleanse 4th stage cooler coil internally/externally Cleanse all separators, cooler covers & cooler assemblies Hydraulically test all cooler assemblies Check oil pump & drive Check tightness of all fasteners after initial run Check condition of all other ancillaries.

54362s.doc


SECTION 9

ILLUSTRATED PARTS LIST 98407/1176PL HOW TO ORDER SPARES IN ORDER TO AVOID UNNECESSARY DELAY, PLEASE QUOTE THE FOLLOWING:1.

THE RE QUIRED S HIPPING, AND INVOICING ADDRESS.

2.

MACHINE MODEL TYPE, REFERENCE NUMBER, EXAMPLE - H5436.2

3.

MACHINE NUMBER STAMPED ON NAMEPLATE, EX AMPLE - H5 436.2.101

4.

PUBLICATION NUMBER, EXAMPLE 98407/1176PL/01/09/96

5.

DESCRIPTION, EXAMPLE - CRANKSHAFT

6.

ITEM REFERENCE, EXAMPLE - BF

7.

PART NUMBER, - EXAMPLE - D66397

8.

QUANTITY R EQUIRED.

1176.doc

Page 35


Page 361176.doc

CompAir UK Ltd PUBLICATION 98407.1176PL Page 1

ILLUSTRATED PARTS LIST FOR

H5336.2, & H5436.2

CONTENTS PAGE CRANKCASE ------------------------------------------------------------------------ A --------3 RUNNING GEAR-------------------------------------------------------------------- B --------5 1ST & 2ND STAGE CYLINDER ASSEMBLIES---------------------------- C --------7 3RD & 4TH STAGE CYL INDER ASSEMBLIES ---------------------------D --------9 COOLER BODY ASSEMBLY ---------------------------------------------------E ------- 11 4TH STAGE COOLER & SEPARATOR ASSEMBLIES ----------------- F -------13 1ST, 2ND & 3RD STA GE COOLER A SSEMBLIES ----------------------G -------15 LUBRICATION ---------------------------------------------------------------------- H -------17 DRAIN VALVE & SURGE VESSEL ASSE MBLY-------------------------- J -------19 EXTERNAL COMPONENTS ---------------------------------------------------- K -------21 DRIVE ARRANGEMENTS -------------------------------------------------------L ------- 23 1ST STAGE CONCENTRIC VALVE ASSEMBLY-------------------------M-------25 2ND STAGE CON CENTRIC VALVE ASSEM BLY ------------------------ N -------27 3RD STAGE CONCENTRIC VALVE ASSEMBLY ------------------------ P -------29 4TH STAGE CONCENTRIC VALVE ASSEMBLY-------------------------Q-------31 1ST & 2ND STAGE DIA PHRAGM DRA IN VALVE ASSE MBLY ------R -------33 3RD & 4TH STA GE DIAPHRAGM DRAIN VALV E ASSEMBLY------ S -------35 SERVICE TOOLS------------------------------------------------------------------- V ------- 36

1176pl.doc

28/10/02

Page 1


AC A19 A20 A16 A17 A18

* Thrust Washers fitted to older machines are now obsolete. If a replacement part is required a new type main bearing bush may be su lied. New compressors have new type main bearing bush fitted with integral thrust washer.

A21

AB A12 A13 A14 A11

A30

A32 A33

AA A15

A34 A35

A31

A10 A22 A23

A9

A24 A25 A30 A31 A29

A Page 2

1176pl.doc

28/10/02

A28 A27 A26 A7 A8 A6 A5 A4 A3 A2 A1 AA

CRANKCASE ASSEMBLY


LIST A ASSEMBLIES CRANKCASE ASSEMBLIES Assyno AA AB AC

Description Crankcase Assy Housing Assy O/E Housing Assy D/E

ComprisingOf A1,2,3,4,5,6,7,8,7&15 A11,12,13&14 A17,18,19,20&21

Used on – No off H5336.2 H5436.2

PartNo. E42798.100 E60010.100 D66384.100

1 1 1

1 1 1

* IF FITTED - LATER COMPRESSORS HAVE A MODIFIED MAIN BEARING BUSH, AS THE THRUST WASHERS ARE NOW OBSOLETE.

PARTS

CRANKCASE ASSEMBLE ItemNo A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 A28 A29 A30 A31 A32 A33 A34 A35

Description

PartNo.

Crankcase E42798 Gasket,blankingflange C200998 Flange, blanking C200999 Screw 95018.200 Glass, oil level 98281.1002 Indicator,oillevel 98381.1013 Plug, oil drain PS1068.5 Seal, oil drain 98660.1156 Screw 95018.274 Screw 95000.314 Washer, thrust If fitted* see note 98074.1004 Housing,O/Ebearing E60010 Gasket,O/Ehousing D100354 Bush, O/E housing C85736.2 Stud D66720.12.238 Washer,thrustIffitted*seenote 98074.1004 Bush, D/E housing C85736.2 Gasket,D/Ehousing D100353 Housing,D/Ebearing D66384 Seal, D/E oil 95605.135 Screw 95000.314 Switch,lowoilpressure 98524.1042 Seal,lowoilpressswitch 98660.1155 Filler/breather,oil 98262.1023 Screw 95018.134 Door, crankcase C85742 Screw 95000.283 Gasket, door C200868 Plug PS1454.4 Plug PS1068.3 Seal 98660.1154 Serial Number Plate RP513 Rivet PS2189.1 Rotation Plate RP507.1 Rivet PS2189.1

USED On No Off AssyRef.H 5336.2 H5436.2 AA AA,AK AA AA AA AA AA AA

1

1

1 1

1 1 2

1 1 1 1

2 1 1 1 1

2 7 1

AB AB AB AB

1 1 1

AC AC AC AC AC

1 1 1 1 1

2 7 1 1 1 1

2

2 1 1 1 1 1

8 1 1

8 1 1

1

1 6

6

4

4 24

24

4

4 2 2 2

1

2 2 2 1

2 1

2 1

2

2

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Page 3


BC B12 B11

BB

BD B13 B14

B12 B11 B8 B9 B10

B13

BE

B14 B15 B4 B3

B8.1 B2

B7

B1 B5 B A

B1 BA

B6

B6 B5

BF B16 B17 B18 B19

BK B24 BH

B20 BG

B20 B21 B22

B23 BJ B4 B3

B24 B25 B26 BL B27

B2

B2

B28 B1 B6 BA B5

B Page 4

1176pl.doc

RUNNING GEAR ASSEMBLIES

28/10/02

B29 B3 BN B4 B1 B5 BA B6


LIST B ASSEMBLIES

Conn Rod Assy Piston Assy, 1st stage Piston ring set, 1st stage Piston ring set, 2nd stage

Used ON – No Off ComprisingOf PartNo H5336.2 H5436.2 B1, 5 & 6 U270.A 4 4 B8,9,10,11 & 12 D66376.50 1 1 B11 & 12 98477.1085 1 1 B13 & 14 98477.1086 1 1

Piston Assy, 2nd stage Crankshaft assy Piston ring set, 3rd stage Piston Assy, 3rd stage Crosshead assy, 3rd stage Piston ring set, 4th stage Plunger assy, 4th stage Keeplate assy, 4th stage Crosshead assy, 4th stage

B3,4,13,14 & 15 B16,17, 18 & 19 B20 B20,21 & 22 B3, 4 & 23 B24 B25, 26 & 29 B27 & 28 B3, 4 & 29

RUNNING GEAR ASSEMBLIES AsseyNo BA BB BC BD BE BF BG BH BJ BK BL BM BN

Description

D67052.50 D66397.100 98477.1087 C86543.50 D67086.50 98477.1178 C203035.50 C86314.50 D67053.50

1 1 1 1 2 0 0 0 0

1 1 1 1 1 1 1 1 1

PARTS RUNNING GEAR ItemNo Description B1 Connecting Rod B2 BearingS/E,2nd,3rd,4th B3 Circlip,2nd,3rd,4th

PartNo. D66395 96072.74 95650.25

B4 B5 B6 B7 B8 B9 B10 B11 B12 B13 B14 B15 B16 B17 B18 B19 B20 B21

Pingudgeon,2nd,3rd,4th Bolt, conn rod Bearing B/E Bush S/E, 1st stage Piston, 1st stage Pingudgeon,1ststage Circlip, 1st stage Ring,oilcontrol,1ststage Ring,piston,1ststage Ring,piston,2ndstage Ring,oilcontrol,2ndstage Piston, 2nd stage Crankshaft Platekeep,crankshaft Washertab,crankshaft Bolt, crankshaft Ringpiston,3rdstage Screw

B22 B23 B24 B25 B26 B27 B28 B29

Piston, 3rdstage C86543 Crosshead,3rd/4thstage D67086 Ringpiston,4thstage 98477.1143 Plunger, 4th stage C203035 Screw 95028.134 Platekeep,4thstage C86314 Shoeplunger,4thstage(iffitted) C86315 Crosshead,4thstage D67053

C85727.2 95006.237 C201109 C200016 D66376 C85727.1 95650.30 98477.1049 98477.1059 98477.1060 98477.1061 D67052 D66397 C11359-44 C11359-45 C75163.3 PS1159.108 95018.201

AssyRef. BA BE,BJ,BN BE,BJ,BN BA BA BB BB BB BB/BC BB/BC BD/BE BD/BE BE BF BF BF BF BG/BH/BJ BH/BJ BH/BJ BJ BK/BL BK BM BM BL/BN BN

USED On No Off H5336.2 H5436.2 4

4

3 6

3 6

3 8 4

3 8 4

1

1 1 1 2 1 2 2 1 1

1 1 2 1 2 2 1 1 1

1

1 1 1 4

1 1 1 4 1

1

1 2 0 0

1 1 2 1 0

0

4 1

0 0

1 1

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Page 5


C32 CE C31 C16 C30

C15 CB

C14

C29

C13

C28 CD

C12

C27

C14.1 C11

C26 C25

C11.1 C8

C24 C22 C23 C22

C10 C9 C6

C21 CC

C7 C6 CA

C17

C1 C5

C18

C2 C20 C19

C3 C4

C Page 6

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28/10/02

1st & 2nd STAGE CYLINDER ASSEMBLIES


LIST C ASSEMBLIES Used On - No Off ComprisingOf PartNo. H5336.2 H5436.2 Cylinder assy 1st stage C1,2,3,4,5,6,7,9&10 E43030.50 1 1 C12,13,14,15 & 16 Cover assy 1st valve E67081.100 1 1 Cylinder assy 2nd stage C17,18,19,20,21,22,23,25 E60011.100 1 1

1ST & 2ND ST AGE CYLINDER ASSEMBLIES AssyNo CA CB CC

Description

CD

Liner assy 2nd stage

& 26 C27,28 & 29

D100005.100

1

1

CE

Cover assy 2nd valve

C31 & 32

D100004.100

1

1

PARTS USED On No Off AssyRef.H 5336.2 H5436.2

1ST & 2ND ST AGE CYLINDER ASSEMBLIES ItemNo C1 C2 C3 C4 C5 C6 C7 C8 C9 C10 C11

Description Cylinder, 1st stage 'O' ring Seal Dowty Plug Screw 'O' ring 'O' ring Screw Stud Nut Valveconc.1ststage

PartNo. E43030 95602.113 PS1322.4 PS1068.4 95018.273 95602.74 95602.132 95000.314 D66720.12.53 95111.7 98650.1519

CA CA,KA CA CA CA CA CA CA CA -

C12 C13 C14 C15 C16 C17 C18 C19 C20 C21 C22 C23 C24 C25 C26 C27 C28 C29

'O' ring 95602.149 'O' ring 95602.150 Cover,1ststagevalve D67081 Seal 98660.1157 Plug PS1068.6 Cylinder, 2nd stage E60011 'O' ring 95602.113 Plug PS1068.4 Seal Dowty PS1322.4 Screw 95018.273 'O' ring 95602.74 'O' ring 95602.116 Screw 95000.314 Stud D66720.12.53 Nut 95111.7 'O' ring 95602.98 Liner,2ndstagecylinder D100005 'O' ring 95602.100

CB/KA CB/KA CB CB CB CC CC/KA CC CC CC CC/KA CC/KA CC CC CD/KA CD CD/KA

C30 C31 C32

Valve 'O' ring conc.2ndstage Cover,2ndstagevalve

CE/KA CE

98650.1039 95602.101 D100004

1 1 0

1 1 1 1 4

1 4

2 1

2 1 3 6 6

1

3 6 6 1

1 1

1 1

1

1 1 0

1 1

1 1 1 1

1

1

0

1 4

4

2 1

2 1 3 6 6

1 1 3

3 6 6 1 1 3

11

11

1

1

1176pl.doc

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Page 7


D12

DD

D35

D21 D20 D19 D18

DC D16 D14 D15 DH D42 D34 D41

D35

D38 D39 D37 D36 DF

D34

DB

D11 D10 D9 D6 D8 D7 D5

D13

D33

D32 D29 D31 D30 DG D28 D27 D26

D25

5336

D24 D2 D1 DA

D Page 8

1176pl.doc

28/10/02

D22 D23 DE

3rd & 4th STAGE CYLINDER ASSEMBLIES

D29 D31 D30 DG D28 D27 D26


LIST D ASSEMBLIES 3RD & 4TH STAGE CYLINDER ASSEMBLIES

AssyNo DA DB DC DD DE DF DG DG DH

Used On - No Off ComprisingOf PartNo. H5336.2 H5436.2 D2&1 Guide crosshead, 3rd D67049.100 1 1 Cylinder assy. 3rd stage D5,6,7,8,9,10 & 11 E60170.50 1 1 D14,15,& 16 Liner assy. 3rd stage C86301.100 1 1 D18,19,20 & 21 Cover assy. 3rd stage C86318.100 1 1 D22 & 23 Guide crosshead, 4th D67049.100 1 1 D36,37,38 & 39 Cover assy. 4th stage C86319.100 1 1 Cylinder assy. 4th stage D26,27,28,29,30 & 31 E61234.50 0 1

Description

Cylinder assy. Liner assy. 4th dummy stage

& 32 D100051.50 D26,27,28,29,30,31 34, 41 & 42 C203034.100

1 0

0 1

PARTS 3RD & 4TH STAGE CYLINDER ASSEMBLIES ItemNo Description D1 D2 D3 D4 D5 D6 D7 D8 D9 D10 D11 D12 D13

Guidecrosshead,3rdstage 'O' ring Nut Screw 'O' ring Cylinder, 3rd stage Plug Seal Dowty Seal Dowty Plug Stud Pipeassy.watertransfer Nut

D14 D15 D16 D17 D18 D19 D20 D21 D22 D23 D24 D25 D26 D27 D27 D28 D29 D29.1 D30 D31 D32 D33 D34 D35 D36 D37 D38 D39 D40 D41 D42

'O' ring Liner, 3rd stage 'O' ring Valve conc. 3rd stage 'O' ring Ring,back-up 'O' ring Cover valve, 3rd stage Guidecrosshead,4thstage 'O' ring Screw Nut 'O' ring Plug Plug Seal Dowty Cylinder, 4th stage Cylinder, dummy Seal Dowty Plug Stud Nut Liner, 4th stage Valve conc. 4th stage 'O' ring Ring, back-up 'O' ring Cover,valve,4thstage 'O' ring 'O' ring

PartNo. D67049 95602.102 95111.7 95018.273 95602.91 E60170 PS1068.3 PS1322.3 PS1322.6 PS1068.5 D66720.20.85 D100710.1 95111.11

USED On No Off AssyRef. H5336.2 H5436.2 DA DA,KA DB/KA DB DB DB DB DB DB -

95602.81 DC/KA C86301 DC 98504.1108 DC/KA 98650.1049 98504.1108 DD/KA 98504.1113 DD/KA 98504.1107 DD/KA C86318 DD D67049 DE 95602.102 DE/KA 95018.273 95111.7 95602.91 DG/KA PS1068.3 DG PS1068.6 DG PS1322.3 DG E61234 DG D100051 DG PS1322.8 DG PS1068.3 DG D66720.20.85 DG 95111.11 C203034 DH/KA 98650.1794 98504.1110 DF/KA 98504.1091 DF/KA 98504.1109 DF/KA C86319 DF/KA 95602.72 DH/KA 95604.79 DH/KA

1

1 1

1 1 6

1 6

1

1

1

1 1

1

1 1

1 1 1 4

1

1 4 1

4 1

1

4 1

1

1

1

1

1 1 1

1 1 1

1

1 1

1 1 1

1 6 1

6 1

1

1 1 0

0 1

1

1

0

1 1 0

0 1 0 0 0

0 0

1 4 4 1 1

0 0 0

1 1 1

0

1 0 0 0

0 2 1

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Page 9


E5

E4

E6

E2

E7 E8 E9 EB

E3 E11 E26 E10 E25 EB G21 E1

E12 E13 E29 E28

E14 E24 E24.1 E27 G5 EB E30

E31 E37

E36

E16

E15

E32 E23 E18 & E22

E17

E19E, 20&E21

E33 E34 E35 EA E33

E Page 10 1176pl.doc

INTERSTAGE COOLER BODY ASSEMBLY 28/10/02


LIST E ASSEMBLIES Used On - No Off ComprisingOf PartNo. H5336.2 H5436.2 E33, 34, 35 C201556.100 1 1 E1,9,25,27,30,G5,21 E60109.1.100 1 1

COOLER BODY ASSEMBLY AssyNo Description EA Disk bursting & gaskets EB Body cooler assy.

PARTS ItemNo E1 E2 E3 E4 E5 E6 E7 E8 E9 E10 E10.1 E11 E12 E13 E14 E15 E16 E17 E18 E19 E20 E21 E22 E23 E24 E24.1 E25 E26 E27 E28 E29 E30 E31 E32 E33 E34 E35 E36 E37 E38

Description

COOLER BODY

PartNo.

Body, cooler Plug Seal Door, cooler Screw Cover,coolerinspection Gasket Nut Stud Panel, pressure gauge Panel,pressuregauge Screw Gauge,pressure4thstage Gauge,pressure3rdstage Gauge,pressure2ndstage

E60109.1 PS1068.5 98660.1156 D100168 95033.556 C200527 D100026 95111.9 D66720.16.99 C86481 C200121 95093.368 98288.1005 98288.1004 98288.1003

Gauge, pressure 1ststage Gauge,pressure oil Seal Pipeassy.gauge,1ststage Pipeassy.gauge,2ndstage Pipeassy.gauge,3rdstage Pipeassy.gauge,4thstage Pipeassy.gauge,oil Seal Eyebolt, lifting Eyebolt, lifting label Stud Nut Stud Nut Nut Stud Seal, dowty

98288.1002 98288.1001 98660.1153 D100027.4 D100027.5 D100027.6 D100027.7 D100027.8 98660.1102 98086.1002 PS1723 D66720.10.125 95111.6 D66720.16.89 95111.9 95111.6 D66720.10.75 PS1322.3

Plug burstingdisk Gasket, Disk,bursting-plastic Disk,bursting-metal Cover, bursting disk Screw Stud

PS1068.3 C81788 C200053 C201658.2 C200584 95000.282 D67975.12.40

AssyRef.

USED On No Off H5336.2 H5436.2

EB

1 -

1 2 2

-

2 2

1 -

1 26

-

26

1 KA EB

-

1 1 5 5

0 1

1 0

-

8 1 1

--

8 1 1 1

11

11

-

1 5 5

5 1 1 1 1 1

5 1 1 1 1 1

-

4

-

5

3

-

3

1 EB EB EB -

EA/KAEA/KA EA/KA -

1 17 17 5 5 2 2

1 2 1 1 1 1 4 8

17 17 5 5 2 2 1 2 1 1 1 1 4 8

1176pl.doc

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Page 11


F43 F42 F41 F43

FB

F42

F19 F17 F18 F17 F16 F15 F13 F14 F12 F38 F39 F11 F10 F40 F9 F8 F7

F28 F27 F26 F30 F29 FC F25 F24 F23 F22 FB

F6

FA F2 F3

F5 FAF4 F1

F32 F31 F33 F37 F35 F36 F35 FD

F Page 12 1176pl.doc

F34

F44

4th STAGE COOLER & SEPARATOR 28/10/02


LIST F ASSEMBLIES 4TH STAGE COOLER & SEPARATOR ASSEMBLY AssyNo Description ComprisingOf PartNo. FA Bottom assy. separator F 5&1 C201853.50 F7,8,9,12,13,14,15,16,17, C202957.50 FB Cover assy. cooler

Used On - No Off H5336.2 H5436.2 0

1 0

1

0

1

19,20,21,22,23,24,25,38, 39,40,41,42

FC

Coil assy. cooler

TH

ItemNo F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 F15 F16 F16.1 F16.2 F17 F18 F19 F20 F21 F22 F23 F24 F25 F26 F27 F28 F29 F30 F31 F32 F33 F34 F35 F36 F37 F38 F39 F40 F41 F42 F43 F44

F26,27,28,29,30

E60565.50

PARTS

USED On No Off Descrip4tionSTAGE COOLER & SEPARATOR PartNo. AssyRef. H5336.2 H5436.2 Fitting,bottom Seal Plug Ring,back-up 'O' ring Body,separator 'O' ring Ring,back-up Nut, back Shroud Pipe, inlet Fittingtop,separator Stud Nut Seal Plug(optional)

C201853 98660.1153 PS1814.4 98504.1093 95602.116 C201856 95602.116 98504.1093 95411.269 C202955 C202963 D100629 D66720.10.130 95111.6 98660.1156 PS1454.6

Switch, Pocket,H.A. H .A.temperature temperature Seal Adaptor Valve,non-return 'O' ring Cover,O/Ecooler Plug Seal Valve,safety Seal Coil,cooler 'O' ring 'O' ring Stud Nut Screw Bracket,support

C202960.1 C201708 98660.1155 C82148 98650.1655 95602.62 D100630 PS1814.1 98660.1156 98650.1190-385 98660.1155 E60565 95602.87 95602.39 D66720.8.42 95111.5 95000.315 C201899

Washer Screw Seal Adaptor, drain valve Valve,drain Adaptor Pipe,outlet Deflector Rod, tie Plate,blanking Nut Spring Washer

95148.14 95000.282 98660.1153 98261.1451 98261.1071 C202957 C202954 C202956 C200218 C201920 95111.6 95179.7

FA FA FA FA/KA FA/KA FB/KA FB/KA FB FB FB FB FB FB FB FB FB FB FB FB FB/KA FB FB FB FB FB FC FC/KA FC/KA FC FC FB FB FB -

-

0 0 0 0 0 0 0 0 0 0 0 0 0

1 1 1 1 1 1 1 2 1 1 1 1 4 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 4 4 1 1 2 2 2 1 1 1 1 1 0 0 0

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 2 0 0 4 0 0 0 0 0 0 0 0 0 0 1 2 2

2

2 1176pl.doc

28/10/02

Page 13


G26 G32

G27

G33

G18 G19

G20

G28

G21

G29

G17

G25

G31

G15

G31

G14 G16

G23 G24

G41

5336 ONLY G43 G44

G22

G39

G42

G34

G35

G4

G36

G3

G9 G8 G37 G38 G5

G1

G Page 14 1176pl.doc

28/10/02

G6

G7

G2

1st, 2nd & 3rd STAGE COOLERS

G10

G11


LIST G ASSEMBLIES 1ST, 2ND & 3RD STAGE COOLER PARTS AssyNo Description GA Separator Assembly

ComprisingOf G7,34,35,36,37,38,39,40

PartNo.

Used On - No Off H5336.2 H5436.2

E61182

1

1

PARTS 1ST, 2ND & 3RD STAGE COOLER PARTS ItemNo Description G1 Cover, cooler Gasket, 3rd stage G2 G3 Seal G4 Valve,safety3rdstage G5 Tube,cooler3rdstage G6 Gasket, 3rd stage G7 Separator, 3rd stage G8 Plug, reducing G9 Seal G10 Seal G15 Valve,safety2ndstage G16 Cover, cooler G17 Plug G18 Plug G19 Seal G20 Gasket G21 Tubes,cooler G22 Plug G23 Plug G24 Seal G25 Cover, cooler G26 Plug G27 Seal G28 Seal G29 Plug G30 Plug G31 Gasket G32 Seal G33 Valve,safety G33 Valve,safety G34 Cap, separator G35 'O'ring,separator G36 Pipe,outlet,separator G37 Shroud,separator G38 Mushroom,separator G39 Nut, separator G40 Plug, separator G41 Valve,non-return G42 Union G43 Washer ¾" BSP G44 Washer ½" BSP

PartNo. C200173 C200060 98660.1155 98650.1022-100 C200796.2 C200060 E61142 C73732.14 99660.1157 98660.1153 98650.1021-24 D101616 PS1454.7 PS1068.3 98660.1154 C200061 C200098.1 PS1454.7 PS1068.2 98660.1153 D101615 PS1068.3 98660.1154 98660.1155 PS1068.4 PS1454.7 D100025 98660.1155 98650.1020-3.8 98650.1020-4.8 C202884 95602.83 C202883 C202869 C202881 95111.7 PS1454.6 98650.1566 98156.1415 98660.1156 98660.1155

USED On No Off AssyRef.H 5336.2 H5436.2 KA

1 1 -

EB KA -

1 1 1

1 10 1 1 0 -

KA EB KA GA GA GA GA GA GA GA -

1 1 10 1 1 1

1 0 1 1 1 1 1 1 30 3 2 2 1 1 1 1 1 2 1 1 1 0 0 1 1 1 1 1 1 1 1 1 1

1 1 1 1 1 1 1 1 30 3 2 2 1 1 1 1 1 2 1 1 1 0 1 1 1 1 1 1 1 0 0 0 0

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Page 15


HA H10 H9 H7

H24 H22 H13

H21

H2

H1

H14 H15 H66

H67 H65 H11

H43

H61 H62 H63

H23

H41

H69 H68 H70

H64

H42 H40 H39 H38 H37 H36

H32 H33 H34 H35

H Page 16 1176pl.doc

28/10/02

LUBRICATION ASSEMBLIES


LIST H ASSEMBLIES LUBRICATION PARTS ASSEMBLIES

AssyNo HA HB HC

Used On - No Off ComprisingOf PartNo. H53362 H5436.2 H7, Pump, Oil Drive Assy 10 & 9 C85737.3 1 1 H7, 9, 10, 12 & 13 Pump, Oil Assy C85737.2.50 1 1 Oil Pipe Assy 4th Stage H61,62,63,64,65 & 66 D100579.7 0 1

Description

PARTS LUBRICATION PARTS ItemNo H1 H2 H7 H9 H10 H11 H12 H13 H14 H15 H22 H23 H24 H24.1 H32 H33 H34 H35 H36 H37 H38 H39 H40 H41 H42 H43 H61 H62 H63 H64 H65 H66 H67 H68 H69 H70

Description

PartNo.

Gasket C200869 Pin, dowel 95502.366 Pin, dowel 95504.424 Fitting, drive C85737.1 Pin, tension 95540.165 Filter, oil 98262.1009 Gasket C200900 Pump, oil 98446.1001 Screw 95000.255 Screw 95000.257 Screw 95000.256 Outer End Cover D100234 Screw 95000.285 Nut 95111.6 Pipe, oilgaugefeed D100579.3 Pipe,oilpressureswitchfeed D100579.4 Pipe,oilfeedbearings D100579.2 Pipe,oilsuctionfeed D100579.1 Pipe, breather C73514.420.90 Socket, breather 95405.1027 Pipe, stand breather C200748 Filter, breather 98262.1044 'O'ring,breather 98504.1079 Coupling,stud,breather C200886 Pipe, breather 98617.1003 Elbow,stud,breather 95440.234 Nipple 95414.161 Valve,non-return 98650.1877 Elbow-was95405.51 98156.1664 Coupling-onlyusedwith95405.51 98156.1045 Pipe M3130.1046 Coupling 98156.1046 Bracket C203037 Clamp, pipe 98150.1042 Screw 95018.170 Nut 95111.4

USED On No Off AssyRef.H 5336.2 H5436.2 KA HA/HB HA/HB HA/HB HB HB/KA HB KA HC HC HC HC HC HC -

1

2 2 1 1 1

1

2 2 1 1 1

1

1

1

1 1 2 10

1

1 2 10 1

4 4 1 1 1 1

4 4 1 1 1 1

1 1

1 1

1

1 1

1 1 1 1 1

1 1 1 1 0

1

0

1

0 0

1 1 0 0 0

0

1 1 1 1

1 0

1 1

1176pl.doc

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Page 17


1st Stage Pressure from Separator J29

J23 J24

J20

J26

J25 J21

J21 J27

J22

2nd Stage

J18

1st Stage Separator Drain.

J17 J13

J38 J37 J11

4th Stage Separator Drain.

J22 J22

J19

J28

J26

J24

J39

3rd Stage

J24 J30

J11

J31

J12 J34

J30

J36

J24 J9 J6

J12

J15 J13

J16

J24

J24 J33 J35

J32 J8

J7

J15 J13 J14

J29

J10 J9 J8

J22

J7

3rd Stage Separator Drain.

J30 J6

J1

J24

J2 J3 J5

J4

J32 J34 J33 J24

J2

J Page 18 1176pl.doc

DRAIN VALVES & SURGE VESSEL 28/10/02

J3


LIST J ASSEMBLIES PARTS DRAIN VALVE & SURGE VESSEL PARTS ItemNo Description J1 Valve, safety J2 Seal J3 Vessel, surge J3.1 Vessel, surge J4 Plug, blanking

PartNo. 98650.1011 98660.1157 E60337 E60339 PS1068.1

J5 J6 J7 J8 J9 J10 J11 J12 J13 J14 J15 J16 J17 J18 J19 J20 J21 J22

Screw Seal, nylon Seal, nylon ring 'O' Nipple Valveassy,diaphragmdrain Bolt Seal Seal Elbow Coupling, stud Pipe, nylon Elbow Seal Nipple Pipe, nylon Coupling, stud Seal

95000.281 C201488.2 C201488.1 95602.67 95414.165 U334.L 95006.157 RT6495.56 98660.1156 95405.97 95440.46 98617.1014 95411.24 98660.1155 95414.164 98617.5106 95440.30 98660.1152

J23 J24 J25 J25.1 J25.2 J25.3 J26 J27 J28 J29 J30 J31 J32 J32.1 J33 J33 J34 J35

Coupling, banjo Seal Valve,solenoid220V50hz Valve,solenoid110V50hz Valve,solenoid220V60hz Valve,solenoid110V60hz Nipple Tee Pipe Elbow Coupling, stud Pipe Valveassy,diaphragmdrain Valveassy,diaphragmdrain Coupling, banjo Coupling, banjo Pipe Coupling, banjo

95440.579 98660.1153 PS2197.1 PS2197.2 PS2197.3 PS2197.4 95414.161 95405.349 98617.5106 95440.178 98156.2116 M3130.0603 U334.J U334.K 98156.2097 98156.2259 M3130.0603 98156.2094

J36 J37 J38 J38 J39

Pipe Coupling, stud Seal Seal, dowty Elbow, coupling

AssyRef.

M3089.1008 98156.1050 98660.1154 PS1322.3 98156.1239


-

1 -

-

1 1

0 1 1 -

-

1 2 2

-

4

2 1 1 1 1

-

1 1 1

1 2 -

1 2 5

1

-

-

5 1

6

1 opt opt opt

2 1 1 1

1 -

-

3 1

0 1 -

0 1 1

1 -

1 1 0

1 1

-

6

1 opt opt opt 2 1 1 0

-

1

-

2 2 3 1

2 1 -

-

4

1 2 3 1

-

4

1

-

-

2 4 4

2 1

-

1 1 0 1

1 1

1

1

1 0 1

1 0

1 1

1176pl.doc

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Page 19


K2

K1 K2 K10.1, K31 & K32 K4

K3

K5 FINAL DELIVER

K5.1 K7

2 STAGE 5336 3RD STAGE 5436

K6

K7 K6

K18

K17 K16 K15 K14 K13 K11

K20 K19 K21 K22 K23.1 K23

K K24

K Page 20 1176pl.doc

28/10/02

EXTERNAL COMPONENTS


LIST K ASSEMBLIES PARTS EXTERNAL COMPONENTS

Used On - No Off ComprisingOf PartNo. H5336.2 H5436.2 Gasket Overhaul kit A2,11,19,29.: C2,6,7,12,13,18,22 98504.1002 1 1 ,23,27,29,31.:D2,5,14,16,18,19,

AssyNo Description KA

KB

'O' ring Valve kit

20,23,26,36,37,38,40, 41.:E7,33,34,35.:F4,5,7,8, 19.1,20,27,28.:G2,6,19,30.:H1,1 2,16,18,40,53.J8.:K19,21.:M10,: N7,:P7,:Q7 C12,13,31.:D18,19,20,36,37,38, 98504.1001 40.:F19.1 M10,:N7,P7,Q7

1

1

Note: The overhaul and valve maintenance kits above may have more items than needed for current or a particular compressor model of a 5336, 5436 or 5436H, this is to allow for all models and past versions.

PARTS EXTERNAL COMPONENTS PARTS ItemNo K1 K2 K3 K4 K5 K5 K5.1 K6

Description

PartNo.

Pipeassy.3rdstagesuction Seal Pipeassy.3rdstagedelivery Seal Thermometer,3rdstage Thermometer,3rdstage Thermometer,finalstage Pocket, thermometer

D100576.2 98660.1156 D100576.3 98660.1156 C202556.8 C202556.3 C202960.1 C201708

K6.1 K7 K10.1 K11 K11.1 K13 K13.1 K13.2 K14 K15 K16 K17 K18 K19 K20 K21 K22 K23

Pocket, thermometer Seal Bracket thermometer , Rod, corrosion Anode, corrosion rod Pipeassy.finaldelivery Seal Diamond Union Seal, ring Pipeassy.4thstagesuction Pipeassy.watertransfer Seal PipeAssy.2ndstagesuction Gasket Screw Gasket Screw Filter/silencer,inlet

C201710 98660.1156 C203063 C202833 98163.1002 E60741 C86896.1 C201579 C86896.1 D100576.5 D100710.2 PS1322.8 D100576.1 C200118 95000.284 C11359-62 95000.312 98262.1010

K23.1 K24 K31 K31.1 K32

Flange inlet Element,filter/silencer Plate Legend Plate Legend Screw Button Head

C202814 98262.1063 C203057 C203062 95033.386

USED On No Off AssyRef. H5336.2 H5436.2 -

1

1

-

2 1

-

2

-

1

-

-

1 0 1 2

1 0 0

2

-

0

2

0

-

2

0 1

1 1

-

2 1

-

2 1

KA KA -

-

1 1

-

2

1 1

-

-

0

1

1 1

-

-

2

0 1 1 0

-

2 1

1 4 1 4

1 4 1 4

1 0 0 1 2

1

1 0

1

1 0 2

1176pl.doc

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Page 21


DRIVE ARRANGEMENTS L1

L2

L3 L4

L5 L6

DIRECT DRIVE

L7 L9 L6

L9

L8

L6 L8

L7

L7

2.8 2.18

2.6

On Motor

2.172 .162 .7

VEE DRIVE

2.12 2.15 2.1 2.11 2.2 2.3

L Page 22 1176pl.doc

2.9 2.4 2.14 2.13 2.12 2.5

28/10/02

2.10


LIST L DIRECT DRIVE ARRANGEMENTS – TYPICAL PARTS REFNUMBER. L1 L2 L3 L4

DESCRIPTION HOUSING BELL SCREW FLYWHEEL KEY

PARTNUMBER PS1813.12 95000.315 E60248.2 PS1130.21

L5 L6 L7 L8 L9

SCREW WASHER SPRING MOUNTANTIVIBRATION SPACER SCREW

95000.312 95179.8 98418.1015 C200854 95000.312

NO.OFF 1 10 1 1 3 3

1 3 1

LIST L VEE DRIVE ARRANGEMENTS – TYPICAL PARTS REFNUMBER. 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.14 2.15 2.16 2.17 2.18

DESCRIPTION MOTOR PLATE MOTORADJUSTINGBLOCK MOTORADJUSTINGSCREW STUD M16 MOTOR BRACKET FLYWHEEL VEE BELT GUARD KEY SETSCREW M8 SETSCREW M10 SETSCREW M12 SETSCREW M16 NUT M16 WASHER M12 SETSCREW M20 TAPERLOCK BUSH PULLEYMOTORØ160 VEE BELTS

PARTNUMBER C200716 C86469 C86470.1 D66720.16.60 E60017 E60249 E60253 PS1130.21 95000.260 95000.281 95000.315 95000.344 95111.9 95148.20 95000.373 98074.1120 98080.1217 98080.1451

NO.OFF 2 2 2 2 1

1

1 1 4 1 4 7 2 4 4 1 1 5

1176pl.doc

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Page 23


Note: Valve is shown inverted. M1

M2

M3

M4

M5 M6 M7 M8 M9 M12

M10 M11

M Page 24 1176pl.doc

28/10/02

1ST STAGE CONCENTRIC VALVE


LIST M ASSEMBLIES PARTS 1ST STAGE VALVE ASSEMBLIES AssyNo Description MA Kit,maintenance

ComprisingOf M2,3,4,5,6,7,10,11

PartNo.


98650.1518

1

1

PARTS 1ST STAGE VALVE PARTS ItemNo M1 M2 M3 M4 M5 M6 M7 M8 M9 M10 M11 M12

Description Valve complete Body, lower Plate, valve Plate, spring Plate, spring Washer, lift Plate, valve Washer, lift Peg Peg 'O' ring Nut Body, upper Withdrawer, Valve

PartNo.

AssyRef.

98650.1519

MA MA MA MA MA MA

95602.93

C200066.1

USED On No Off H5336.2 H5436.2 1

1

1 1 2 2 1 1 1

MA/KB MA -

1 1 2 2 1 1 1 2 2

2 2

1

1 1

1

1 1

1

1

1176pl.doc

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Page 25


Note: Valve is shown inverted. N1

N2

N3

N2

N4

N5 N6 N9 N7 N8

N Page 26 1176pl.doc

28/10/02

2ND STAGE CONCENTRIC VALVE


LIST N ASSEMBLIES PARTS 2ND STAGE VALVE ASSEMBLIES AssyNoD escription NA Kit,maintenance

ComprisingOf

PartNo.

N2,3,4,5,7,8

98650.1533

Used On - No Off H5336.2 H5436.2 1

1

PARTS 2ND STAGE VALVE PARTS ItemNo Description N1 N2 N3 N4 N5 N6 N7 N8 N9

Valve complete Body, lower Plate, valve/backing Plate, spring Plate, spring Plate, valve Peg 'O' ring Nut Body, upper Withdrawer, Valve

PartNo.

AssyRef.

98650.1039

NA NA NA NA

95602.55

C84096.1


NA/KB NA -

1

1

1

1 2

2

4 3 1

4 3 1 2

2

1

1 1

1

1 1

1

1

1176pl.doc

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Page 27


Note: Valve is shown inverted.

P1

P2

P3

P2

P4

P5

P6

P7 P8 P9

P Page 28 1176pl.doc

3RD STAGE CONCENTRIC VALVE 28/10/02


LIST P ASSEMBLIES PARTS Used On - No Off H5336.2 H5436.2

3RD STAGE VALVE ASSEMBLIES AssyNo Description PA Kit,maintenance

ComprisingOf

PartNo.

P2,3,4,5,7,8,9

98650.1059

1

1

PARTS 3RD STAGE VALVE PARTS ItemNo P1 P2 P3 P4 P5 P6 P7 P8 P9

Description Valve complete Body, lower Plate, valve/backing Plate, spring Plate, spring (pack) Plate, valve Body, upper 'O' ring Washer Nut Withdrawer, Valve

PartNo.

USED On No Off AssyRef. H5336.2 H5436.2

98650.1049

-

95604.24

C200142

PA PA PA PA PA/KB PA PA -

1

1

1

1 2

2

4 1 1 1

4 1 1 1 1

1 1 1

1

1 1 1

1176pl.doc

28/10/02

Page 29


Note: Valve is shown inverted.

Q1

Q2

Q3

Q4

Q5

Q6

Q7 Q8

Q Page 30 1176pl.doc

28/10/02

4TH STAGE CONCENTRIC VALVE


LIST Q ASSEMBLIES PARTS 4TH STAGE VALVE ASSEMBLIES AssyNo QA

Description Kit,maintenance

PartNo.

Q2,3,4,5,7,8

98650.1832

PARTS 4TH STAGE VALVE PARTS ItemNo Q1 Q2 Q3 Q4 Q5 Q6 Q7 Q8

Description Valve complete Body, lower Plate, valve Plate, spring Spring Plate, valve Body, upper 'O' ring Nut Withdrawer, Valve


ComprisingOf

PartNo.

QA QA

C200142

1

USED On No Off AssyRef. H5336.2 H5436.2

98650.1794

95604.20

0

QA QA QA/KB QA -

0

1

0 0 0

1 1 4 0

0 0

1 1 1

0

1 0

0

1 1

1176pl.doc

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Page 31


R10 R2

R1

R4

R12 R6 R7

R11

R8 R4 R9 R4

R10

R8 R7 R6 R5 R4 R3 R2 R1

R Page 32 1176pl.doc

28/10/02

1ST & 2ND STAGE DIAPHRAGH DRAIN VALVE


LIST R ASSEMBLIES PARTS 1ST & 2ND STAGE DIAPHRAGM DRAIN VALVE ASSEMBLIES AssyNo RA RA

Description

ComprisingOf PartNo.

Kit, valvemaintenance R3,5,6,7,11,12 Kit,diaphragmmaintenance R4,8


98650.1531 98650.1535

1 2

1 2

PARTS USED On No Off AssyRef. H5336.2 H5436.2

1ST & 2ND ST AGE DIAPHRAGM DRAIN VALVE PARTS ItemNo Description R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11

Valve complete Nut, back Body Seat Gasket Valve Assembly Plate, mushroom Screw Diaphragm Cover, centre Bolt Valve Assembly

R12

Seat

PartNo. U334.L PS1290.4 C200841 C200842 C200722 C201980 98210.1002 C200841 95006.133 C201981 C201417

-

1 2

RA RB RA RA RA RB RA RA

1 2 2 1 4

1 2

2 1 4 1 2

2 2 1

2 2 1

6 1

6 1

1

1

1176pl.doc

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Page 33


S10 5436 MK2 S2 S1 S4 S3

S5

S6 S7 S8 S4 S9 S4 S7 S5

S8

5336 MK2

S6

S12

S4 S3 S11

S2 S1

S9 S4

S10 S6

S7

S8

S5 S4 S3 S2 S1

S Page 34 1176pl.doc

3rd & 4th STAGE DIAPHRAGH DRAIN VALVE 28/10/02


LIST S ASSEMBLIES PARTS 3RD & 4TH STAGE DIAPHRAGM DR AIN VALVE ASSEMBLIES AssyNoD escription SA Kit,valvemaintenance SA Kit,diaphragmmaintenance

ComprisingOf PartNo. S3,5,6,7, S4,8

98650.1532 98650.1535

Used On - No Off H5336.2 H5436.2 0 1

1 2

PARTS 3RD & 4TH STAGE DIAPHRAGM DRAIN V ALVE PARTS USED On No Off ItemNo Description S1 S2 S3 S4 S5 S6 S7 S8 S9 S9 S10 S11 S12

Valve complete Valve complete Nut, back Body Seat Gasket Valve Assembly Plate, mushroom Screw Diaphragm Cover, centre Cover, end Bolt Screw Nut

PartNo. U334.J U334.K PS1290.4 C200840 C201159 C200722 C201981 98210.1002 C200841 C200719 95006.133 95000.229 95111.4

AssyRef. SA SB SA SA SA SB -

H5336.2 H5436.2 0 1 1

1 0 2 1 1 2

1 2

2 2 4 2 2

1 1 0 1

2 2 1 0

3 3 3

6 0 0

1176pl.doc

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Page 35


LIST V SERVICE TOOLS Description

ParNt umber

ValveWithdrawer ValveWithdrawer Valve Withdrawer PistonWithdrawer Liner Withdrawer Stud for do Nut for do PistonRingCompressor CylinderLiftingPlate

Page 36 1176pl.doc

28/10/02

C200142 C200066.1 C84096.1 C200066.2 C200420 C200421 95111.7 C200445 C200069.3

WhaFtor

NO o ff

3rd&4thStageValves 1stStageValve 2ndStageValve 1st&2ndStagePistons

1

2nd Stage Liner 2nd Stage Liner 2nd Stage Liner 1stStagePistonRings 3rd&4thStageCylinders

2 1 1 2 2

1 1 1

CompAir UK Ltd PUBLICATION 98407/1176 Page 37

SECTION 10

ANCILLARY EQUIPMENT PARTDESCRIPTION PRESSURE MAINTAINING VALVE FINALPRESSURESWITCHVEEDRIVERADIATOR, WATER PUMP DRIVE SOLENOIDVALVEANTI VIBRATION MOUNTS WATERCONTROLVALVE RADIATORCOOLINGSYSTEMGENERAL-

PARTREFERENCE 4362000W0000000 43620000B000000 436200000P00000 436200000004000 436200000000300 436200000000005 U231.H

PUBLICATION APP059 APP081 APP012G APP073 APP138 APP003 APP071 APP077

NOTE: Standard parts are available where indicated by either a number or letters. The letters indicate than an item is available as a component of an assembly. Non-listed or individual items of assemblies where reference number are not indicated, are not standard replacement parts and can only be obtained at the discretion of CompAir UK Ltd. 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.

25/07/02

1176.doc

Page 37

CompAir UK Ltd PUBLICATION 98407/1176 Page 38

Page 3825 /07/02

1176.doc

CompAir UK Ltd APP012c - 5417 & 5436 Mk2 BELT ALIGNMENT & TENSIONING Page 1

RECOMMENDED VEE BELT ALIGNMENT & TENSIONING. BELT DRIVE ALIGNMENT

DISTANCE PIECES

STRAIGHT EDGE

STRAIGHT EDGE

50 mm

COMPRESSOR

ELECTRIC MOTOR

COMPRESSOR

SLIDE BASE 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 2.

RECOMMENDED TENSIONING FORCES

CENTRE DISTANCE

BELT TENSION INDICATOR APPLIED TO MID-SPAN 8.2 mm 5.1 - 6.6 kgf STRAIGHT EDGE

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 slide base 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 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 slide base holding down screws to their correct torque setting.

app012c.doc

CompAir UK Ltd APP012c - 5417 & 5436 Mk2 BELT ALIGNMENT & TENSIONING Page 2

CONTRACT SPECIFIC PARTS FITTED:MOTORPULLEY TAPER-LOCK BUSH BELT2000SPB

Y407750.013A 1off 98074.1119 1off Y507750.013A 3off

Using the table below select the correct belt tension force as follows:1. Belt Section - i.e example SPC 2. Small Pulley size - i.e. example 224 to 355 3. Belt deflection per mm of span = 6.1 to 9.2 kgf

Belt Section Belt Section SPB

TABLE Force required to deflect belt 16 mm per metre of span Small Pulley Ø mm 160to224 236to315

Newton (N) 35to50 50to65

Kilogram force (kgf) 3.5to5.1 5.1to6.6

Method of Belt Tensioning. Using a 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 datum. belt, on single belt drives place a straight edge across the two pulleys to act as a

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 tensio n indicator is not available, a suitably scaled spring balance and rule will suffice.

BELT TENSION INDICATOR

DEFLECTION IN mm

app012c.doc

DEFLECTION FORCE IN kgf

CompAir UK Ltd APP073 WATER PUMP DRIVE Page 1

WATER PUMP DRIVE 5236, 5336, 5436 MK2, 5436.3 & 5437.1 15

19

16 4

22

2

9

20

1 21 18

5 3

14 10 11

12

17 7 6

8

13

SEE LUBRICATION SECTION IN HANDBOOK FOR DETAILS OF OIL PUMP ETC.

ItemNo ParN to 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

C201503 C201504 C201537 C201538 C201809 C85739/1 C85740/1 D100526 D100527 PS1180/9 PS1923/3 PS2062 95000/227 95000/254 95000/256 95111/5 98146/1001 98315/1102 98446/1009 95071/27 98156/3113 95405/869

Description Gasket water pump Gasket water pump Sprocketwaterpumpdrive Gasketwaterpumpbracket Flange water pump Sprocketwaterpumpdrive Pillarchaintensioner(iffitted) Cover outer end Bracketwaterpumphousing Clip hose Capscrew Chainwaterpumpdrive Setscrew Setscrew Setscrew Nut Tensionerchain(iffitted) Hose plastic Pump water Screw cone point Hose adaptor Bush hexagon male & female (5236) only

NoOff 2 2 1 1 2 1 2 1 1 6 4 1 2 6 3 3 1 2 1 1 2 1

App073.doc

CompAir UK Ltd APP073 WATER PUMP DRIVE Page 2

App073.doc

CompAir UK Ltd APP076A EXPANSION TANK COOLING SYSTEM INSTRUCTIONS Page 1

EXPANSION TANK WATER COOLING SYSTEM SPECIAL INSTRUCTIONS FOR FILLING COMPRESSOR 5336 & 5436 MK2 5436 MK2 ILLUSTRATED EXPANSION TANK

WATER COOLING SYSTEM FILLER CAP

VENT PIPE

WATER PUMP CONNECTING PIPES

OUTLET CONNECTION TO WATER SUPPLY

WATER PUMP

INLET CONNECTION TO WATER SUPPLY

app076a.doc

CompAir UK Ltd APP076A EXPANSION TANK COOLING SYSTEM INSTRUCTIONS Page 2

EXPANSION TANK WATER COOLING SYSTEM SPECIAL INSTRUCTIONS FOR FILLING COMPRESSOR BEFORE INITIAL STARTING 1.

FILLING AND BLEEDING THE WATER SYSTEM. CAPACITY APPROXIMATELY 5336 & 5436 MK2 - 100 LITRES. See before starting procedure in HANDBOOK in conjunction with the following. 1. 2. 3.

Ensure the inlet & outlet connections are connected to a suitable closed circuit water system. Ensure all water drain plugs/cocks etc. are closed. Remove expansion tank filler cap.

4. 5. 6. 7. 8. 9.

Allow system to fill by turning on the water supply. Fill system with clean fresh water. Replace filler cap. Start compressor, run for 2 minutes and stop. Gently release filler cap, remove and top-up. With filler cap removed, start compressor and slowly fill with water until all air bubbles in water pipes are evacuated. Note: any small air bubbles will evacuate during running through the vent pipe. 10. Replace filler cap.

TOPPING UP. 2.

TOPPINGUP. If hot, it is best to leave until cool before attempting to top-up cooling water. 1. 2. 3. 4.

app076a.doc

Gently release filler cap, Remove and top-up to required level. Replace filler cap. Start compressor, check for air bubbles in water pipes as above.

CompAir UK Ltd APP077 RADIATOR COOLING SYSTEM GENERAL Page 1

TYPICAL RADIATOR WATER COOLING SYSTEM SPECIAL INSTRUCTIONS FOR STARTING COMPRESSOR COOLANT (ANTI-FREEZE) FILLER CAP

COOLING WATER PIPE OUTLET

RADIATOR

DRAIN WATER PUMP COOLING WATER PIPE INLET

COOLING WATER PIPE RETURN

BEFORE INITIAL STARTING 1.

FILLING AND BLEEDING THE WATER SYSTEM. C 53O1M 5,P 53R1E7S,5S4O 15R&S5E4T17 5236 5336, 5436, 5436.3.HA & 5437

APPR4O0XLIIM TRAETSE CAPACITY 1L1I2TRES 100 LITRES

See before starting procedure in HANDBOOK in conjunction with the following. 1. 2. 3. 4. 5. 6. 7. 8. 9.

2.

Ensure all water drain plugs/cocks etc. are closed. Remove radiator filler cap. Fill system with clean coolant. (Antifreeze mixture should be used in low temperature environments) Replace filler cap. Start compressor, run for 2 minutes and stop. Gently release filler cap, remove and top-up. Replace filler cap. Re-start compressor, if any large air bubbles are evident in the pipework stop compressor. Repeat (6), (7) & (8) unt il air bubbles are evacuated. Note: any small air bubbles will evacuate during normal running through the vent pipe.

TOPPINGUP. If hot, it is best to leave until cool before attempting to top-up cooling water. 1. 2. 3. 4.

Gently release filler cap, Remove and top-up to required level. Replace filler cap. Start compressor, check for air bubbles in water pipes as above.

app077.doc

CompAir UK Ltd APP077 RADIATOR COOLING SYSTEM GENERAL Page 2

app077.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'.

B A

Red Pointer

3

1

4

2

Green Pointer

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. APP 089 HIGH AIR PRESSURE SWITCH Page 1

HIGH AIR PRESSURE SWITCHES PART NUMBERS SEE BELOW OPERATION Located as close as possible to the stage delivery line, the pressure switch stops the compressor when the upper pressure limit is attained. 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 Pressure switches may be mounted in any convenient position close 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 to the compressor electrical control circuit terminals marked "Pressure Switch" terminals 11 and 12 as below. See wiring diagram for particular pressure switches and contract for correct details. 13

11

14

12

Setting Example of pressure setting. Set pressures

98524/1057 Y507851/002 Y507851/003

3rd Stage 2nd Stage 1st Stage

97 bar g rising 23 bar g rising 4 bar g rising

Alternative tools Turn screw anti-clockwise or clockwise to raise or lower the RED pointer to the setting required.

app089.doc

CompAir UK Ltd. APP 089 HIGH AIR PRESSURE SWITCH Page 2

app089.doc

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 TechnicalDetails PartNo PS2197.1 PS2197.2 PS2197.3 PS2197.4 PS2197.5 PS2197.6 PS2197.7 PS2197.8 PS2197.9 PS2197.10 PS2197.11 PS2197.12

Voltage 230 110 220 110 24 110 230 24 12 24 125 48

Electrical connection Connector Protection Cablethreadsize Coil Coilduty Voltage tolerance from normal Port Size Orifice Size Maximum working pressure Working fluid Ambient temperature range

Hz 50 AC 50 AC 60 AC 60 AC DC DC DC 50 AC DC 60 AC DC 50AC

Currentconsumption CurrentInrush Hold 26 VA 16 VA 26 VA 16 VA 26 VA 16 VA 26 VA 16 VA 10 watts 10 watts 10 watts 26 VA 16 VA 10 watts 26 VA 16 VA 10 watts 26VA 16VA

Amps pin to DIN 46242 ToDIN43650 IP65 PG9 Class'H'180°Cinsulation Continuous -10% to +10% G 1/8" Ø1.6mm 12 bar g. Air, water, gas, fuel oil & non corrosive liquids. -15°C to +50°C

1

0

2

app138.doc

CompAir UK Ltd PUBLICATION APP 138 - 3 WAY SOLENOID VALVES PS2197 Page 2

app138.doc

CompAir UK Ltd APP 071 WATER VALVE U231 Page 1

WATER VALVE NORMALLY CLOSED U231.F & U231.H OPERATION Located on the water inlet to the compressor the valve stops water flowing through the compressor on shut down. This is achieved by means of a diaphragm-operated valve piped to the compressor LP pressure, on shut down the air pressure is released from the diaphragm thus closing the valve. A by pass screw is provided, this can be removed to give an adequate cooling flow of water when running the compressor continuously on/off load even when the valve is closed. LP Pressure Port G1/4

Diaphragm kit

Packing gland nut

Stuffing box kit

Stem & disc kit M3 x 0.5 By-Pass Screw

INLET

Fitted internally

Ø BSP Ports

TEMPERATURE Fluids : water, gas, air, oil and steam. Ambient

PART NUMBERS 98560.1291 U231.F 98650.1292 U231.H 98650.1293 -

ØPortSizeBSP 1/2" 3/4" 1"

+ 5° to + 180°C + 5° to + 60°C

Øorificemm 15 20 25

*M.S.Pbar 16 16 16

* Maximum Service Pressure (LP pressure)

App071.DOC


MAINTENANCE AND SPARES KITS Part Number Description Stem & Disc Kit 98405.1004 Stuffing Box & Nut Kit Diaphragm Kit Stem & Disc Kit 98504.1005 Stuffing Box & Nut Kit Diaphragm Kit Stem & Disc Kit 98405.1006 Stuffing Box & Nut Kit Diaphragm Kit 98650.2208 Stem&DiscKit

Makers Part Number 97701319 97701320 97700017 97701321 97701320 97700017 97701322 97701320 97700018 97701319

98650.2209

Stuffing Box & Nut Kit

97701320

98650.2210

DiaphragmK it

97700017

98650.2211 98650.2212 98650.2213

Stem &DiscKit Stem &DiscKit DiaphragmKit

97701321 97701322 97700018

Used on 98650.1291 98650.1292 U231.F 98650.1293 U231.H 98650.1291 98650.1291 98650.1292 - U231.F 98650.1293 - U231.H 98650.1291 98650.1292 - U231.F 98650.1292-U231.F 98650.1293-U231.H 98650.1293-U231.H

DISMANTLING AND RE ASSEMBLING Tightening Sequence for all water valves The procedure outlined below is to be used when dripping or pooled water is noticed around the water control valve. The procedure described below is intended for the technician to stop the water from dripping around the water control valve packing. All adjustments are to be achieved while the compressor is running. Step 1: Obtain a pair of adjustable pliers. “Multigrip pliers” work best. Step 2: Grasp the packing gland nut on the water control with the " Multigrip pliers ". The packing gland nut is located between the water control valve crossmembers and is of the cylindrical design. The packing nut is knurled. Step 3: Rotate the packing gland nut clockwise, looking from the top, 1/16 of a turn. Step 4: Observe the water control valve shaft while the compressor is running. When the compressor system unloads and reloads, the shaft running through the packing gland nut should move freely. Observe the packing gland while the shaft is moving. Check for additional water leaks. If water continues to leak repeat step 3 and 4 until no leaks are detected.

App071.DOC


WATER VALVE NORMALLY OPEN 98650.1298 IF FITTED OPERATION Located on the water inlet to the compressor this valve is often used as a by pass valve when compressors are operating in tandem and using the same water supply i.e. a normally closed and normally open valve fitted. Water flowing through the compressor is shut down by means of the normally closed valve whilst the water is by passed by to other compressors means of the normally open valve. This is achieved by means of diaphragm operated valves piped to the compressors LP pressure, on shut down the air pressure is released from the diaphragm thus closing the normally closed valve, at the same time opening the normally open valve. A by pass screw is provided in the normally closed valve, this can be removed to give an adequate cooling flow of water when running the compressor continuously on/off load even when the valve is closed.

App071.DOC


App071.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 by to CompAir UK Ltd may unsafe and hazardous conditions or recommended result in damage the equipment over create 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 Advantages: • • • • • •

compressor lubricant.

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 +44(0)1473602222 +44 (0) 1473 556027 +44(01) 473601704 +44(0)1473601282

Telephone: Customer Service: Fax: PartsFax: www.CompAir.com e-mail: [email protected]

Compair 5336 5436 Mk2 Operator Manual

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