501/502 Series
Contents
1. a Xe Hoong HHH foo O a Ug S60ZL 3NVAOYGAH LC 240V O o SS S SS OO DADO Figure 3C 502 Single Phase Starter Page 46 CompAir Ltd 3D Starter Assembly Part Modifications Starter Assembly Parts Modifications Serial No Prefix Compressor s Ref New Part s Old Part s Service Bulletin Page 47 Labels Chapter 4 Contents Chapter Page Label Assembly es E PR a Gn eR a ye de po e a 4A 49 Label Assembly parts Modifications x e x e K ee es 4B 51 Page 48 CompAir Ltd 4A Labels Quantity Item Part Number Description Kit All 01 02 1 34303 Label PURS 501 504 1 2a 34299 Label 501 1 2b 34300 Label 502 1 3 34302 Label assembly Classic 501 504 1 Refer to Health and Safety section before carrying out any servic2. Thread Size mm Setting Nm 6 15 8 35 10 60 12 95 16 160 42 400 Page 8 CompAir Ltd Introduction Service Tools required 1 5 Wide undercut to base of thread Nozzle orifice Dia A mm 1 00 1 98 Dia A Ream Tol 0 025 Material EN1A Service Tools Test Nozzle Stator Slave Stud S73 Page 9 Introduction Two Leg Puller S34 Setting Gauge S89 Page 10 CompAir Ltd Introduction This page is intentionally left blank Page 11 Parts List and Service Manual Contents Chapter Page Routine Servicing sik ae bere emere dead ernennen AU on Er 14 alla plo EF FR O tt a A a a At te a papa n De a 20 Starter Assembly Here ae Hae dhs db PERS dou Be 40 Label ss cea rr A ER Ra Do eR Y PF k REE SR p da d e eo SLI ci 48 Adjustments and Testing i isse RR a ger E e aci Duo sad 52 a Lia MGI ed YH EUW pote eee SHED ne I O FYDR FFF Id k l 65 den s 56 Page 12 CompAir Ltd This page is intentionally left blank Page 13 Routine Servicing 1 Chapter 1 Contents Section Page Introduction En Gales We nc Ea i DER led s 15 Checking Operation of Compressor Len en ea ee en FR EF anan none B z 15 Check the Compressor Operating Temperatur
3. 3A 01 02 Three Phase PUTS Starter Quantity ltem Part Number Description Kit Starter Assembly No 33732 01 33732 03 1 72105 Motor cable 1 2 50935 Warning label 1 3 57123 Mains cable 1 4 1 5 1 1 72758 Safety barrier 71895 01 Over temperature circuit board hb k k 6a 72016 Overload 3 0 4 7 Amp 6b 72017 Overload 4 0 6 3 Amp 1 72014 Contactor 1 1 72034 Emergency stop push button 1 1 72135 Start push button green 1 1 Starter assembly 33732 01 501 415Volt 3 Phase 50 Hz Starter assembly 33732 03 502 415Volt 3 Phase 50 Hz Refer to Health and Safety section before carrying out any service work Page 41 01 02 Three Phase PUTS Starter 3A Figure 3A 01 02 Three Phase PUTS Starter Page 42 CompAir Ltd 3B 01 Single Phase PUTS Starter Quantity ltem Part Number Description Kit Starter Assembly No 33734 01 1 72106 Motor cable 1 2 50935 Warning label 1 3 56627 Mains cable 1 4 72758 Safety barrier 1 5 71895 01 Over temperature circuit board 1 6 73791 Overload 7 5 10 5 Amp 1 7 72015 Contactor 1 8 72134 Emergency stop push button 1 9 72135
4. Recti reading normal reading less than normal 2 ii y y Restriction in airline e g Air intake filter blocked Valves closed Ir intake filter blocke Yes No Rectify No Yes L Rectify y y Minimum pressure Pressure control valve valve stuck closed stuck in open position Yes gt Rectify No Yes pRectity v Separator element blocked Yes L Rectify Page 60 CompAir Ltd 6 Excessive Oil Consumption O Page 61 Fanit Medel type Cause Excessive oil consumption Possible high oil temperature Possible high power absorption Wrong type or grade of oil No Replace Compressor over filled or not sited level Excessive air demand Separator element fractured Blocked oil return filters No Yes Clean O Rings damaged in separator assembly No ae Replace Excessive Condensate in oil chamber Fault Finding
5. Ensure that the user Handbook is not permanently removed from the compressor Check that there are no signs of damage and or oil leaks from the air end cooler and associated pipework After completing work tools and foreign matter should be removed from the compressor and its surrounding area In the unlikely event of a compressor fire dry powder or carbon dioxide fire extinguishers should be used Never use water Before Working on Compressor 1 Potentially dangerous voltages are used to power this machine Do not carry out any work until the isolator is locked in the off position Fit a safety notice to the isolator advising that work is being carried out and that the isolator must not be switched on If in doubt then a qualified electrician may remove the fuses and keep them in a secure place until work is complete 2 Ensure the compressor has been safely isolated from the main air system and cannot be re introduced until all work has been completed Fit a safety notice to the isolation valve advising that work is being carried out 3 Do not undertake any work until the compressor and receiver if fitted have been relieved of all pressure 4 Wait until the compressors vent down cycle is complete 5 Open the test valve to release any pressure contained in the aftercooler or associated pipework 6 Check that the air end pressure gauge reads zero Do not proceed until it does 7 Carefully unscrew the compressor fi
6. No Yes Rectify O Fault A Model type ti Symptom Internal high pressure to low pressure leak No Yes Rectify Page 58 CompAir Ltd 6 High Pressure EI Medel type J type Li Symptom Cause Page 59 High pressure Safety valve blows Rapid rise in compressor pressure offload Safety valve setting too high No Yes Renew Pressure control valve stuck No e Rectify MPV not operating correctly e Rectify Blocked pressure control valve or filter Pressure switch faulty Yes Rectify Fault Finding Fault Finding 6 Low Air Output Compressor Stops Unexpectedly Low or no air Compressor stops output cfm unexpectedly P ME W e h Malfunction of air Pressure switch tools equipment set low No Adjust A SELLER Y 1 Rapid pressure loss Over temperature in air system i fault PII 1 No H ARectify AME HU ER y Pressure gauge i reading less than Motor overload tripped A normal ________ 1 No Rectify y y Check compressor air output using air flow Supply voltage low indicator No Rectify y Compressor seizing ER e E Bag a No
7. Adjustment Figure 5 3 Minimum Pressure Valve and Safety Valve Lift Pressure Figure 5 4 Pressure Control Valve Page 54 CompAir Ltd 5 Adjustments and Testing H Oil Temperature Allow compressor to run for 30 minutes in order to attain its normal working temperature Average running temperature should be approximately 60 C above ambient I Air Output Fig 5 5 Screw test nozzle into compressor outlet Close outlet valve and start compressor continuous run e Open outlet valve fully Pressure on gauge should not fall below 9 5 bar 10 bar machine J Leakage Check Examine all external seals gaskets and pipe connections for air or oil leakage No leaks are permissible Figure 5 5 Air Output Page 55 Fault Finding 6 Chapter 6 Contents Page Introduction ip a api ase nme mm NF ee eee re ER E EG E Re Sa n RR RU RP ER eae m RE Gn ai D High Temperature suce ee edic a na cee a EE NT RR R K A RN ke Ge dod 58 High Pressures aoo deseas dye abdo eb edo eda DU dd n Dae AO TEE ao l 4 59 Low Air Output ee caw Y peha ee eee POTE er kn ae De 60 Compressor Stops UnexpectedlY e eee ene ee ke en eee a nen ns 60 Excessive Oil Consumrptior ie kip end d E ML a 61 Page 56 CompAir Ltd 6 Introduction WARNING READ HEALTH AND SAFETY PRECAUTIONS BEFORE YOU START ANY SERVICE WORK SERVICING OF THE COMPRESSOR MUST ONLY BE CARRIED OUT BY AUTH
8. COMPRESSOR COUPLING necessary 501 SETTING ACHIEVED BY TAPPING COUPLING DOWN TO HEADED KEY MOTOR COUPLING gt X lt 501 LOCATION RING TO REAR OF IMPELLOR X 2 MM 502 PURS COUPLING TO SEAL FACE X 13 5 MM 502 LOCATION RING TO REAR OF IMPELLOR X 5 MM 502 PUTS COUPLING TO SEAL FACE X 35 MM Page 31 PURS Motors Couplings Receivers 577 20 19 18 17 Ri No 2C Figure 2C PURS Motors Couplings Receivers Page 32 CompAir Ltd 2D PUTS Motors Couplings Tripod ltem Part Number Description Kit EL nd All 01 02 1 70061 Drive key compressor 1 2a 70068 Drive coupling 1 2b 71909 Drive coupling 1 3a 56565 Coupling spider KT52 1 3b 70952 Coupling spider KT52 1 4 56955 Grub screw 4 5a 57487 Impellor Motor coupling 1 5b 70950 Impellor Motor coupling 1 6 56589 Drive key motor 1 7a 56441 32 Motor 1 1 Kw 18 220 240V or 1 7b 73769 01 Motor 1 1 Kw 3Q 380 415V or 1 7C 57240 Motor 1 5 Kw 18 220 240V or 1 7d 73043 Motor 1 5 Kw 3Q 380 415V or 1 7e 72148 32 Motor 2 2 Kw 18 220 240V or 1 7f 73770 10 Motor 2 2 Kw 30 380 415V or 1 8 MS108 25 Hex head bolt M8 x 25mm 9 MW8 Washer M8 4 10 MWG8 Spring washer M8 4 11 MN108 Nut M8 4 12 50474D Self tapping screw 2 13 56
9. above this temperature the oil life will be reduced Note When changing recommended oil types it is advisable to flush the compressor Preventative Maintenance Schedule Fluid Force 2000 HPO Every Every Every Every Ever NU a Manual install Man 1000 2000 6000 12000 24000 hrs hrs hrs hrs hrs Suitable sited Y Y Y Y P4 v Adequate ventilation Y Y v Y 4 Y Ambient temperature V Y Y Y V 4 V Y Sufficient access Y Clear of airborne contaminants v Y Y Y v Y Y Y Torque electrical connections 4 Y V Y Check oil level at filler plug 1B Y Y Y Y Y Y Check correct drive rotation Y Y Check for air leaks 5l Y Y Y P4 Y Check for oil leaks 5J Y Y Y Y Y Y Check air filter 1C Y Check power on load Y Y Y Y Y Check power off load PUTS Y Y Y Y Y Check oil temperature 1B Y Y Y Y Y Y Check motor cable glands secure Y Y Y 4 Y Check motor for damage Y v Y Y Y Check motor for loose connections 1C Y Y Y Y Y Check motor cables and earth Y Y Y Y Y Check motor for vibration Y Y Y P4 Y Check oil seal P4 Y Y Check drive media Y Y Y Check operation of non return valve Y 4 Y v Y Check starter contactors Y Y Y Check motor insulation resistance Y Clean air oil radiator external 1C Y Y Y Y Y Clean external dirt from motor 1C Y Y Y Y P4 Y Clean external dirt from compressor 1C Y Y Y Y Y Y Clean air filter Y Y Change Fluid F
10. enclosure while the compressor is operating 5 Beware of hot surfaces both the air end and electric motor are designed to run at elevated temperatures 6 Compressed air is potentially dangerous and can be fatal if misused Do not allow compressed air jets discharged from any pipe or nozzle to make contact with your body 7 Wear safety glasses and suitable clothing when using or working in an area where compressed air is being used 8 Hazardous vapours fumes can be produced if compressed air is used to remove chemicals cleaning agents and lubricants from eguipment and components Suitable respiratory and extraction eguipment may be reguired in these circumstances Never use compressed air for cleaning personal clothing 9 Do not use air directly from compressors for breathing purposes If the air is to be used for human consumption then it must be subjected to further treatment to ensure that the levels of contaminants odour and moisture meet the requirements of BS 4275 1974 10 We recommend that the air supply to hand held air guns is regulated to a lower pressure refer to local Health and Safety regulations 11 Do not insert any object or part of body through any opening of the compressor enclosure Serious personal injury and or damage may result 12 Never run the compressor when any covers or guards are missing unless advised to do so in this handbook Potential Oil Health Hazards This section relates to Flui
11. temperature 1B Y Y Y Y Y Y Check motor cable glands secure Y Y Y Y Y Check motor for damage Y v Y Y 4 Y Check motor for loose connections 1C Y Y Y Y Y Y Check motor cables and earth Y v Y Y Y Y Check motor for vibration Y Y Y Y Y Y Check oil seal Y Y Y Check drive media Y Y Y Check operation of non return valve Y V Y Y Y Y Check starter contactors Y Y Y Check motor insulation resistance v Clean air oil radiator external 1C Y Clean external dirt from motor 1C Y Y Y v Y Y Clean external dirt from compressor 1C Y Y Y Y 4 Page 3 Introduction Preventative Maintenance Schedule Fluid Force Clear Every Every Every Every Ever ka Paria Manual aji F Mn 1000 2000 6000 12000 24000 hrs hrs hrs hrs hrs Clean air filter v v Change Fluid Force Clear oil 1C Y Y Y Y Y Y Change air filter 1C Y Y Y Y Y Change intake valve seals 2A Y v v V Change MPV seals 1D Y Y Y Y Change separator element 1C Y Y Y Y Change thermal motor 501 PURS Y Change drive media 2C Y Change oil return filter Y Change oil seal 1F Y Change pressure gauge Y Test minimum pressure valve 5E v Test air delivery 5C Y Y Y Y v Page 4 CompAir Ltd Introduction Service schedule Fluid Force 2000 2000 Hour oil change The bulk oil temperature must not exceed 90 c Fluid Force 2000 or 100 c Fluid Force HPO If the oil is working
12. to remove from separator casing e Removefilter C and clean separator casing and inside of cowl Note Air filter may contain traces of oil and must be disposed of in an approved manner e Fit a new filter C locate on support gauze D e Refit filter cover A and reconnect pipe B Figure 1 1 Outlet and Filler Plug Location Figure 1 2 Air filter location Page 16 CompAir Ltd 1 Routine Servicing Clean cooler and motor Fig 1 3 WARNING Carefully vacuum clean the oil cooler matrix A aftercooler B if fitted and guard rings C on the lantern Vacuum clean or blow dust from motor D and motor grill using low pressure clean dry air Remove safety notices and open air outlet valves Turn mains electrical supply on Test run compressor and check there are no air leaks Replacing the oil separator element Fig 1 4 Remove cap head screws A Gently tap the end cover B until it is clear of the separator casing Unscrew the oil separator element C and discard Note Oil separator element contains oil and must be disposed of in an approved manner e Fita new separator element Ensure that the O ring E is in place Do not over tighten e Refit end cover B Ensure cover is positioned correctly and bolt holes are in line Be careful not to damage O ring D when refitting Refit cap head screws A Tighten to 6 Nm Oil change pr
13. 106 16 Hex head screw M6 x 16mm 1 25 MS2105 10 Pozi panhead screw M5 x 10mm 3 26 MS705 45 Skt head screw M5 x 45mm 2 27 MWG5 Spring washer M5 2 28 MWG6 Spring washer M6 1 Refer to Health and Safety section before carrying out any service work Change the filter elements 19a 8 20a every 12 months Page 37 Aftercooler Dryer Mk 2 Filters 2F m a MM Mae AS P tu EGE SO T X Ma U DY o 435A009 Figure 2F Aftercooler Dryer Mk 2 Filters Page 38 CompAir Ltd 2G Air End Parts Modifications Air End Parts Modifications Serial No Prefix Compressor s Ref New Part s Old Part s Service Bulletin Page 39 Starter Assemblies 3 Chapter 3 Contents Chapter Page 01 02 Three phase PUTS starter erer ene ee ere FR ug SA vs 41 01 Single phase PUTS Start r vei N ae e ia a RR aB ss su 43 02 Single phase PUTS starter VYYY YF RF eee renn A ug SC ale sa 45 Starter assembly part modifications etre e er ee eee area Rug aD NP an 47 Note For compressors with receivers PURS starters are a combined unit with the pressure switch see 2C 12a f Page 40 CompAir Ltd
14. 2105 10 Pozi panhead screw M5 x 10mm 26 MS705 45 Skt head screw M5 x 45mm DR 1 D109 a ll 27 MW6 Plain washer M6 28 MWG5 Spring washer M5 29 MWG6 Spring washer M6 Refer to Health and Safety section before carrying out any service work Change the filter elements 19a amp 20a every 12 months Page 35 Aftercooler Dryer Mk1 Filters 2E Va gt MO N A CS EGS EEE ui K MG EG Figure 2E Aftercooler Dryer Filters Mk 1 Page 36 CompAir Ltd 2F Aftercooler Dryer Mk 2 Filters Item Part Number Description Kit All 01 02 1 73619 Adaptor 2 2 1397 Stud coupling 1 3 1892 Stud coupling 2 4 3534 Assembled drain filter 1 5 54474 Spire fastener 3 6 59067 Support cowl 1 7 59068 Cowl Aftercooler 1 8 59069 Aftercooler 1 9a 70793 Hex nipple 1 9b 73619 Adaptor 1 10 56934 Bend 2 11 57687 Valve 1 12 72376 Pipe Air end to aftercooler 1 13 74380 Support bracket 1 14 73537 Pipe dryer Receiver 1 15a 74373 Dryer 1 15b 74374 Dryer 1 16 74381 Bracket 1 17a 73554 Stud elbow 1 17b 1884 Stud elbow 1 18 57690 Adaptor 1 19 CF0005B Filter GP 9 L S 1 19a CE0005B Element 1 20 CF0005C Filter HE 9 L S 1 20a CE0005C Element 1 21 GP1019 Fixing kit filters 1 22 MN105 Nut M5 2 23 MN106 Hexagon Nut M6 1 24 MS
15. 2A 11 32653 1 Oil return plug assembly 2A 12 56300 1 O Ring 2B 13 56410 1 Flexible pipe 14 56422 1 Valve seat 2A 15 56423 1 Coupling element white 16 56528 1 Insert 2B 17 56565 1 Coupling element black 2D 18 56624 1 Fibre washer 2A 19 58327 2 Copper washer 2A 20 70952 1 Coupling element blue 2C 2D 21 9754 1 O ring 22 9648 1 Copper Washer 23 58117 1 Lens 24 58426 1 Lens clip Note Spare parts to be stored in original packaging and in a dry environment Repaired or replacement units should be protected against corrosion and mechanical damage during storage Page 7 Introduction Key to symbols used E Silco 660 577 Torque Setting Nm Grease Required Specification l 22mm f 6mm Loctite Required and Specification Number Service Tools Required and Part Reference Lubricate With Sump Oil Spanner Required mm A F Allen key Required mm Recommended Oils Fluid Force Clear Fluid Force 2000 Note Do not mix oils Torgue settings Listed below are recommended torgue settings Note Torgue settings must be applied when indicated Recommended Grease Silkolene 660 Motor Grease Esso Unirex N3 Shell Albida R2 Shell Nerita HV SKF LGHQ3 Castrol Optimol PD2 Torgue Settings
16. 758 Lock nut 2 14 59800 Cable gland 2 15 Starter refer to chapter 3 1 15a 33734 01 Starter 240V 1 1 Kw 1 15b 33732 01 Starter 415V 1 1 Kw 1 15c 33736 01 Starter 220 240V 2 2 Kw 1 15d 33732 03 Starter 415V 2 2Kw 1 16 72114 Starter support plate 1 17 56572 Tripod 1 18 72112 Cable gland M16 con 1 Refer to Health and Safety section before carrying out any service work Page 33 PUTS Motors Couplings Tripod 2D Figure 2D PUTS Motors Couplings Tripod Page 34 CompAir Ltd 2E Aftercooler Dryer Mk1 Filters Item Part Number Description Kit All 01 02 1 1396 Equal coupling 2 2 1397 Stud coupling 1 3 1892 Stud coupling 2 4 3534 Assembled drain filter 1 5 54474 Spire fastener 3 6 59067 Support cowl 1 7 59068 Cowl Aftercooler 1 8 59069 Aftercooler 1 9 70793 Hex nipple 1 10 56934 Bend 2 11 57687 Valve 1 12 72376 Pipe Air end to aftercooler 1 13 73535 Support bracket 1 14 73537 Pipe dryer Receiver 1 15a 73538 Dryer 1 15b 73539 Dryer 1 16a 73541 Bracket 1 16b 73542 Bracket 1 17 73554 Stud elbow 18 57690 Adaptor 19 CF0005B Filter GP 9 L S 19a CE0005B Element 20 CF0005C Filter HE 9 L S 20a CE0005C Element 21 GP1019 Kit wedge 22 MN105 Nut M5 23 MN106 Hexagon Nut M6 24 MS106 16 Hex head screw M6 x 16mm 25 MS
17. A Separator Intake End Cover Item Part Number Description Kit n All 01 02 23 9718 O Ring KT52 1 24 MCI 26 Circlip 1 25 73101 Gasket KT52 1 26 56801 Lift plate 1 27 56426 Screw 2 28 57443 Pressure control valve PUTS machines only 1 29 57531 Bush PUTS machines only 1 30 56289 Safety valve PURS machines only 1 31 34078 Discharge tube assembly 1 32 56431 Discharge fitting 1 33 56434 Nut 1 34 56624 Fibre washer KT52 2 35 32410 Oil separator feed assembly 1 36 MG1706 06 Grub screw 1 37 73100 Oil impingement cowl 1 38 58327 Folded copper washer KT52 1 34407 03 Separator casing assembly 1 39 73034 Separator case 1 40 56299 Socket head screw M6 x135mm 6 41 56275 Separator stud 1 42 57029 Oil separator element KM51 1 43 9799 O Ring 1 44 70166 Blowdown valve filter amp O Ring 1 45 58307 Oil return plug 1 46 57244 Filter 1 47 58327 Folded copper washer KT52 1 Refer to Health and Safety section before carrying out any service work Intake assembly Remove screws 27 lift plate 26 and circlip 24 e Fit parts contained in service kit e Refill compressor with approved oil when assembly is complete Page 23 Separator Intake End Cover 2A Figure 2A Separator Intake End Cover Page 24 Com
18. Illustrated Parts and Service Manual 501 502 Series Stationary Air Compressors ST 15926 00 Issue B Mar 00 Introduction This publication contains parts lists and service information please read it carefully before you attempt to service or carryout adjustments on the compressor This service manual should be used in conjunction with the user handbook Note If you need any specialist help or service please contact your distributor or CompAir UK Hydrovane quoting the MODEL TYPE and SERIAL NUMBER Product development CompAir UK Hydrovane adopt a policy of continual product Improvement The information in this handbook whilst fully up to date when issued may be subject to change without notice Guality standards CompAir UK Hydrovane Ouality Management Systems are approved to BS EN ISO 9002 CompAir UK Hydrovane Limited Claybrook Drive Washford Industrial Estate Redditch Worcestershire E mail Sales Hydrovane co uk B98 ODS Telephone Redditch 01527 525522 England Fax Rediditch 01527 521140 AN INVENSYS COMPANY Model range This handbook relates to all 01 02 50 Hz compressors model types 501 009570 9903 onwards 502 010828 9902 onwards Classic 01 Classic 02 PURS10 PURS10 PRDS10 PRDS10 PUTS10 PUTS10 Terminology 01 amp 02 z 1 1 amp 2 2 kW 10 Normal working pressure bar PURS Package Unit Receiver and Starter PUTS Package Unit Tripod and Starter PRDS Pack
19. ORISED PERSONS FULLY TRAINED AND COMPETENT IN THE MAINTENANCE OF COMPAIR UK HYDROVANE COMPRESSORS THEY MUST FULLY UNDERSTAND AND ADOPT CORRECT AND SAFE WORKING PRACTICES Ifyou are unable to carry out the work safely in the required manner then your CompAir UK Hydrovane distributor will be pleased to help The range of minor faults which may occur with your Hydrovane compressor can be grouped under the following four categories HIGH TEMPERATURE Pressure rises until safety valve lifts HIGH PRESSURE Oil temperature higher than 90 C LOW AIR OUTPUT Lack of air at point of usage EXCESSIVE OIL Oil discharged into air CONSUMPTION system The symptoms and actions for these faults are detailed on the following pages Page 57 Fault Finding Fault Finding High Temperature High temperature Compressor cuts out Compressor seizing Reduce oil life Incorrect oil level No Yes Top up Unapproved oil incorrect grade of oil being used No ves Replace Dirty or blocked cooler No jes Clean Re circulation of hot air or lack of ventilation No L Rectify Thermostatic valve stuck in closed position No Yes i Incorrect stator end clearance Rectify nol Yes Rectify Oil relief valves leaking No Yes Internal oil passage Rectify blocked No Yes Rectify Oil return plug blocked
20. Renew washer 7 and reassemble Discharge pipe 10 should be positioned 15 1 2 to machine axis on assembly Setting gauge S89 will simplify this operation Page 27 Remove compressor from motor Remove drive media Remove backplate if applicable 35 36 and lantern 37 38 40 Remove oil cooler 42 Remove cooler couplings 44 Renew self adhesive gaskets 41 and 22 Renew O rings 43 Oil Chamber Rotor Stator Unit Lantern 2B E n N 9 B Cy Nm 3 9 Sy Ne 0 21 1 N N D oo um e n 4 k 5 ai 17 22mm 2 SIE U PA N 31 3029 36 E gt 16 lnm ps 33 32 40 Figure 2B Oil Chamber Rotor Stator Unit Lantern Page 28 CompAir Ltd 2C PURS Motors Couplings Receivers ltem Part Number Description Kit nn All 01 02 1 70061 Drive key compressor 1 2a 70068 Coupling 1 2b 71909 Coupling 1 3 56955 Grub screw 4 da 56565 Coupling spider 1 4b 70952 Coupling spider KT52 1 5a 57487 Impellor Motor coupling 1 5b 70950 Impellor Motor coupling 1 6 56589 Drive key motor 1 7a 56441 32 Motor 1 1Kw 18 220 240v or 1 7b 73769 10 Motor 1 1Kw 38 380 415v or 1 7c 57240 Motor 1 5Kw 18 220 240v or 1 7d 73043 Motor 1 5Kw 38 380 415v or 1 7e 72148 32 Mot
21. Start push button green 1 Starter assembly 33734 01 501 220 240 Volt Single Phase 50 Hz Refer to Health and Safety section before carrying out any service work Page 43 01 Single Phase PUTS Starter 3B Figure 3B 01 Single Phase PUTS Starter Page 44 CompAir Ltd 3C 02 Single Phase PUTS Starter Quantity ltem Part Number Description Kit Starter Assembly No 33736 01 1 72135 Start push button green 1 2 72134 Emergency stop push button 1 3 52014 Warning label 1 4 56677 M20 Cable gland 2 5 56758 M20 Lock nut 2 6 58712 Mains cable 1 7 72112 M16 Cable gland 1 8 72113 M16 Lock nut 1 9 MS2104 25 M4 x 25mm Pozi pan head screw 1 10 73145 Transformer 240V 24V 24VA 1 11 72461 Enclosure 1 12 72151 Contactor 1 13 72152 Overload 18 25 Amp 1 14 72144 Motor cable 1 15 72093 Over temperature control PCB 1 Starter assembly 33736 01 502 220 240 Volt Single Phase 50 Hz Refer to Health and Safety section before carrying out any service work Page 45 02 Single Phase PUTS Starter 3C
22. age Unit Receiver Dryer and Starter 01 02 Classic Parts Service Manual English ST 15926 00 Iss B 03 00 CompAir Ltd Introduction OWNERSHIP RECORDS Model Number R P M Maximum Bar Serial Number KWE aaa Local CompAir UK Distributor Name Address th ine eter a ONA Akan Contact Telephone Fax R a ee Aaa die ERR dias Email GENERAL HEALTH AND SAFETY PRECAUTIONS Please read carefully and proceed in accordance with the following instructions before installation operation maintenance or repair of the compressor unit The Health and Safety at Work Act 1974 In order to comply with your responsibilities under the above act it is essential that the compressor is transported positioned installed operated and maintained by competent persons in accordance with the instructions in this handbook The compressor warranty will be invalidated if unapproved spare parts or lubricants are used Using such items may cause the efficiency and service life of the compressor to be reduced and could create a hazardous condition over which CompAir UK Hydrovane has no control Failure to maintain the compressor correctly or modifying it without prior approval from CompAir UK Hydrovane may also create a hazardous condition This will also invalidate the warranty Consequential damage of any nature is not covered by the warranty Read and fully understand the contents contained in the user handbook
23. at the air end pressure gauge reads zero Pour a small amount of oil into the thermometer pocket of the oil filler plug Screw a temperature gauge or thermometer into the thermometer pocket Assuming the compressor is serviced correctly the machine is capable of operating in ambient temperatures up to a maximum of 40 C At this ambient the bulk oil temperature measured at the filler plug should be 70 90 C Check oil temperature When the compressor is working the temperature should be Initial start up and warm up period lt 70C Optimum working temperature 70 95 C High temperature 95 100 C Stop See fault finding section gt 100 C Check pressure air line systems Check the air line system pressure by using the receiver mounted pressure gauge Condition 10 bar When compressor is stopped 9 6 10 4 bar Normal working pressure 8 0 9 6 10 4 bar Check pressure compressor air end To check the air end pressure use the pressure gauge located in the air end Condition 10 bar After vent down air end pressure should read 0 bar Pressure when stopped Initial start up 8 seconds approx 0 4 0 6 0 bar When charging the air line 4 0 6 0 9 6 10 4 bar Normal working pressure 8 0 9 6 10 4 bar When compressor is stopped 9 6 10 4 O bar Page 15 Routine Servicing Check oil level e Check that the air end pressure gauge reads zero Remove fill
24. d Force oil For other lubricants refer to the Health and Safety Instructions issued with the relevant product 1 There are no significant hazards associated with this product when properly used and in the application for which it was designed Freguent and or prolonged skin contact may give rise to skin irritations and it is recommended that protective gloves are worn The carcinogenic action of mineral oils should be brought to the attention of all users 2 Theoilmay be hot so take care when carrying out oil changes 3 Do not keep oily rags in pockets or wear contaminated clothing Do not inhale fumes or vapours Do not swallow Avoid eye contact 4 Always wash hands after use and before eating drinking smoking and using the toilet 5 Ingestion Do not induce vomiting because of the risk of aspiration Wash mouth out with water Give 1 2 pint milk Seek immediate medical attention 6 Skin Contact Mildly irritating Remove by wiping Wash with soap and water Apply emollient cream 7 Eye Contact Mildly irritating Flush with copious amounts of warm water Seek medical advice if necessary 8 Aspiration If there is any suspicion of aspiration into the lungs for example during vomiting admit to hospital immediately 9 Inhalation Remove from exposure into fresh air If necessary give artificial respiration or oxygen Seek medical advice 10 Pressure injection Obtain immediate medical attention even if i
25. e 00 0 0 0c cece e 15 Check Pressure Air line System YYVYY FF en 15 Check Pressure Compressor Air end FFF en 15 Check Oil Level cosas cea tbe ERR ar Deren 15 Draining Air Receiver iiis ss mem te e ERE PLIT EEP ENEO TEREE ENSE P ne a 5 Basic Service Procedure lele ee el FF an FE an ena nn anana an o EE 15 Oil Top Up Procedure se ceso re coca n war OE ar a Exe a s 16 Check Compressor Oil Filter 4 cada hk ge eee a PAGO RAE EUR RET EOM Kom ed 16 Compressor Air Intake Replacement es 16 Clean Cooler andi Motor 2s ur re ERE 3S A UR RR LR LE RUE Dr 8 17 Replacing the Oil Separator Element lete seen nn 17 Oil Change Procedure ll ele el FF kn FFF EF ena ma en 17 Electrical ChecK8 2 45 sex ure a En a Ka a ob ko m Y BB R dell na g 18 Minimum Pressure Valve i e rime aaa mem p ee us Duos ss 18 Pressure Control ValV amp el ll kl ka FF n E hat s 18 OST S O E kaz E a Na Pie ek aa ann 18 Page 14 CompAir Ltd 1 A Introduction WARNING READ HEALTH AND SAFETY PRECAUTIONS BEFORE YOU START ANY SERVICE WORK Ensure genuine parts are available for fitment Frequency of service work will depend on a Time periods mentioned in introduction b Climatic conditions c Installation B Checking Operation of the Compressor Check the compressor operating temperature Wait until air end vent down cycle is complete Check th
26. e work Page 49 Labels a VAS AWG AA fa At Hydrovane 501 504 PURS 34303 2 S gt Ve KOWO 128 Ve LONG Las Ad A ANE IND La hy A ANG ZAM a L Force L Force X Compair Hydrovane Ltd Redditch B98 Ods England ON CompAir Hydrovane Ltd Redditch B98 Ods England 34300 Hydrovane or failure to observe the maintenance instructions may have serious SAFETY and or WARRANTY implications genuine part or failure to comply with C maintenance instruction A WARNING A The use of REPLACEMENT PARTS AND LUBRICANTS not supplied or approved by Hydrovane accept no responsibility for damage or injury caused by use of non Hydrovane 501 504 lt Classic 34302 Figure 4A Labels Page 50 4A CompAir Ltd 4B Labels Parts Modifications Label Parts Modifications Serial No Prefix Compressor s Ref New Part s Old Part s Service Bulletin Page 51 Adjustments and Testing 5 Chapter 5 Contents Section Page Introduction ci rn t RR TE S na e
27. ect of handling operation servicing or repair even if not expressly stated in this instruction notice Page 2 CompAir Ltd Introduction Servicing requirements Note The following preventive maintenance charts cover all Hydrovane compressors using Hydrovane Fluid Force oils The work to be carried out must be done on or before the hours shown for this action Read health and safety precautions before starting any work Service schedule Fluid Force Clear Oil 1000 Hour oil change The bulk oil temperature must not exceed 90 c If the oil is working above this temperature the oil life will be reduced Note When changing to Fluid Force Clear the compressor must be flushed out with Fluid Force Prime in order to comply with USDA H1 standard Preventative Maintenance Schedule Fluid Force Clear Every Every Every Every Ever mn Manual install CNN iad 1000 2000 6000 12000 24000 hrs hrs hrs hrs hrs Suitable sited Y Y Y Y Y Y Adequate ventilation Y v Y Y 4 Y Ambient temperature Y Y Y V Y 4 V 4 Sufficient access Y Clear of airborne contaminants Y Y Y v Y Torque electrical connections Y Y Check oil level at filler plug 1B Y Y Y Y Check correct drive rotation Y 4 Check for air leaks 5l Y Y Y Y Check for oil leaks 5J Y Y Y Y Check air filter 1C Y Check power on load Y Y Y Y 4 Check power off load Y Y Y 4 Y Y Check oil
28. er plug and check inside oil chamber Oil should be filled to overflow if not top up see oil top up procedure Draining air receiver see fig 1 1 e Wait for air end vent down cycle to finish Position suitable container beneath condensate drain valve E WARNING NN THE AIR RECEIVER IS PRESSURISED TAKE GREAT CARE WHEN CARRYING OUT THE NEXT OPERATION DO NOT ALLOW ANY COMPRESSED AIR JETS TO MAKE CONTACT WITH YOUR BODY Carefully open drain valve E and allow pressure to fall slowly to zero Collect all condensate drained from receiver Note Condensate may contain traces of oil and must be disposed of in an approved manner Close drain valve E and open air outlet valve A C Basic Service Procedures WARNING N STOP THE COMPRESSOR AND ISOLATE FROM MAINS ELECTRICAL SUPPLY LOCK THE ISOLATOR IN THE OFF POSITION FIT A SAFETY NOTICE TO THE ISOLATOR ADVISING THAT WORK IS BEING CARRIED OUT ON THE COMPRESSOR CLOSE THE AIR OUTLET VALVE TO ISOLATE THE COMPRESSOR FROM THE AIR LINE SYSTEM FIT A SAFETY NOTICE TO THE VALVE ADVISING THAT IT IS NOT TO BE OPENED DO NOT PROCEED UNTIL GAUGE READS ZERO WHEN CHANGING RECOMMENDED OIL TYPES IT IS ADVISABLE TO FLUSH THE COMPRESSOR WHEN CHANGING TO FLUID FORCE CLEAR THE COMPRESSOR MUST BE FLUSHED OUT WITH FLUID FORCE PRIME Routine Servicing Oil Top up procedure Fig 1 1 e Wait until the air end vent down cycle is complete Check that the air end press
29. il to bearing Place rotor 1 in casing Refit new oil seal Fit drive coupling If blades 2 are to be re used they must be removed from the slots and marked using a felt tipped pen NOT SCRATCHED so that each blade can be replaced in the same position Page 25 Blades and slots must be perfectly clean and fitted with rounded edge outwards Marks must be correspond with slots if original blades are refitted Examine stator for damage Ensure cutaway is clearly defined by two straight lines along length of bore Ensure stator bore and end faces are free from debris Rotor stator Refitting Stand oil chamber vertically on wooden block Renew O ring 11 Apply smear of oilto 0 0015 0 038mm shim and position pipe Fit rotor complete with blades Fit new oil seal Fit drive coupling Check overall end clearance using straight edge and feeler gauges between rotor and stator Apply smear of oil to end stator and fit shims to give total end clearance of between 0 003 0 076mm and 0 004 0 089mm Fit intake end cover using service tool S73 Renew gasket Oil Chamber Rotor Stator Unit Lantern 2B E n N 9 B Cy Nm 3 9 Sy Ne 0 21 1 N N D oo um e n 4 k 5 ai 17 22mm 2 SIE U PA N 31 3029 36 E gt 16 lnm ps 33 32 40 Figure 2B Oi
30. l Chamber Rotor Stator Unit Lantern Page 26 CompAir Ltd 2B Oil Chamber Rotor Stator Unit Lantern ltem Part Number Description Kit un All 01 02 22 71550 Cooler gasket KT52 1 23 9607 Bonded seal 1 24a 73845 Thermoswitch PU PURS models only 1 1 24b 72079 01 Thermistor probe PUTS models only 1 1 25 PE567 C6 Pozipan screw 26 PE553 Cable clip 27 56528 Insert PURS models only KT52 1 28 32153 Thermostatic valve assembly PURS models only 1 29 MN110 Nut 30 MWG 10 Spring washer 31 MW10 Washer 32 MS708 30 Screw M8 x 30 4 33 MWG 8 Spring washer 34 MS708 25 Screw M8 x 25 35 57630 Backplate 1 36 56383 Guide ring 1 37 32446 Lantern assembly 1 38 57563 Guard ring 1 39 56393 Cooler stud 4 40a 57774 Lantern PUTS models only 1 40b 70485 Lantern PURS models only 1 41 58365 Cooler gasket KT52 1 42a 56294 Oil cooler 1 1 42b 57773 Oil cooler PUTS models only 1 43 9707 O Ring KT52 44 56386 Cooler coupling 45 74261 O Ring 1 Refer to Health and Safety section before carrying out any service work Oil Cooler Oil Relief Valve Stator Discharge Pipe Remove screw 8 and washer 7 Remove support 6 and valve plate 5 Check plate 5 for wear or damage Renew if necessary Ensure valve seating face is perfectly flat Use emery stone to obtain flatness e Remove all traces of emery dust
31. lantern and cooler assembly can be removed if desired Remove the compressor coupling 2 and key 1 examine and replace necessary On re assembly ensure setting dimensions on page 30 are achieved for the coupling Ensure grub screw 3 have the correct torgue and locktite applied PURS Motors Couplings Receivers 577 20 19 18 17 Ri No 2C Figure 2C PURS Motors Couplings Receivers Page 30 CompAir Ltd 2C PURS Motors Couplings Receivers ltem Part Number Description Kit GN All 01 02 14 58958 Male to female elbow 1 15 73938 Receiver 75 litre 1 16 33305 Pipework assembly containing 1 17 56934 Elbow 1 18 57690 Adaptor 1 19 57687 Non return valve 1 20 70666 Stud coupling 2 21 70949 Delivery pipe 1 22 MS108 25 Hex head bolt M8 x 25mm 4 23 MW8 Washer M8 4 24 MWG8 Spring washer M8 4 25 MN108 Nut M8 4 Refer to Health and Safety section before carrying out any service work Motor drive coupling e On reassembly ensure setting dimensions on page 34 are achieved for the coupling Before dismantling the drive the compressor air end must be lt Ensure grub screws 3 have the correct torque and locktite removed applied Remove fan coupling 5 and key 6 examine and replace if
32. ller plug If any air or oil escapes before plug is fully removed stop Do not remove the plug until all pressure is lost 8 Safety devices fitted to the compressor or air line system should be checked at regular intervals and replaced if faulty They should not be tampered with or modified Non return valves should not be used as isolation devices 9 To ensure the compressor operates safely you must carry out the specified maintenance procedures 10 Only approved lubricants should be used for flushing purposes 11 Extreme caution should be taken if the compressor has been subjected to severe operating temperatures or fire Certain components may contain fluoroelastomer materials and under these conditions can leave extremely corrosive residues Severe burns and permanent skin and tissue damage can be a result of skin contact 12 The Health and Safety information contained in this Handbook is only intended to give general guidelines Page 1 Introduction GENERAL HEALTH AND SAFETY PRECAUTIONS continued When Operating the Compressor 1 When in automatic mode the compressor will re start without warning 2 f an automatic re start device is fitted allowing the compressor to start when power is re applied or operation is controlled from a remote location additional warnings will be reguired 3 Do not remove any plugs or release pipework when the compressor is running 4 Do not attempt to open the starter
33. minus to reduce cut out pressure compressor stops at a lower pressure plus to increase cut out pressure compressor stops at a higher pressure Note Cut out higher stop pressure must not be set above 10 4 bar To adjust the lower cut in start pressure turn screw marked P2 towards minus to reduce differential and restart the compressor at a higher pressure plus to increase differential and restart the compressor at a lower pressure Re fit pressure switch cover Switch mains electrical supply on Start compressor and carry out check settings procedure E Minimum Pressure Valve Fig 5 3 Close outlet valve and start compressor Open outlet valve fully to atmosphere Check the gauge pressure reading When set correctly the gauge should show 5 bar The valve will operate satisfactorily between 4 bar and 6 bar F Safety Valve Lift Pressure Fig 5 3 Where fitted Safety valve preset to lift as follows 10 bar compressor 11 bar Should the safety valve be faulty it cannot be adjusted and must be renewed as a complete unit G Pressure Control Valve Fig 5 4 Close outlet valve and start compressor continuous run Gauge should read 10 5 bar max 10 bar PUTS e Should gauge read differently DO NOT attempt to adjust the valve Renew as a complete unit Note the pressure setting written on valve when reordering Figure 5 2 Pressure Switch
34. n na A ee ee 53 Pressure Switch ee EA iE RRR a ae Bo a 53 Check Setting Procedures Ill el ere FFF FF a en ano uu O 53 Pressure Switch Adjustments esu ie Bona ge ae Rock e em r needs D icm 54 Minimum Pressure Valve ee er RR K R e B pob E REFER Es gee ats 54 Safety Valve Lift Pressure eee n Dias woah as ex 54 Pressure Control ValV8 eve a Bae a Wie nee ete ER a Guissona 54 Oil Temperature ue dees se pagent ee at pa ER whee EE RA Ada ad A Hos 55 Air Output 2 ik ema e pU aa PC RI PIE rr sedie dde lum usa 55 Leakage Check sea v cs dede ee esent dawn E dra dr tai ege ap dans Jom n 55 Page 52 CompAir Ltd 5 Adjustments and Testing A Introduction WARNING READ HEALTH AND SAFETY PRECAUTIONS BEFORE MAKING ANY ADJUSTMENTS Adjustment procedures shown must only be carried out by authorised persons fully trained and competent in the maintenance of CompAir UK Hydrovane compressors Ifyou are not able to carry out the work safely contact your CompAir UK Hydrovane distributor B Pressure Switch Fig 5 1 The pressure switch C is locatedin the air receiver and is pre set at the factory The recommended cut out pressure high pressure switch setting is a maximum and must not be exceeded The cut in pressure re start pressure switch setting may be adjusted to suit your application Factory setting 10 bar machines Cut out 9 6 10 4 bar max Cut in 6 0 6 8 bar Note Do not adjust unless p
35. njury appears minor See Cautionary Notice SHW 397 Effects of Mineral Oil on the Skin and MS B 5 Skin Cancer Caused by Oil published by the Health and Safety Executive 11 Spillage Soak up with absorbent clay 12 Waste Disposal Oil condensate filter elements etc should be disposed of in accordance with local regulations Do not allow oil to contaminate water supplies Warnings Cautions and Notes 1 Warning WARNING is used in the text of this handbook to identify specific hazards which can cause injury or death This type of hazard is identified below Risk of electric shock Risk of danger Risk of hot surfaces Pressurised vessel gt P Pressurised ocmponent or system gt Pe D Unit is remotely controlled and may start without warning Eye Protection Must be worn Dust protection must be worn P Read the instruction manual O Do not operate the machine without the guard being fitted 2 Caution CAUTION is used in the text of this handbook to identify incorrect procedures which can cause damage to the compressor 3 Notes NOTE is used in the text of this handbook to draw attention to specific points of importance Hydrovane declines all liability in the event of material damage or bodily injury resulting from negligence in the application of these precautions from non observation or lack of elementary supervision in resp
36. ocedure Fig 1 5 Remove filler plug A discard bonded seal B e Place container at least 1 0 Litre capacity beneath oil drain plug D e Carefully remove drain plug D and discard bonded seal C Collect all the oil that drains from the compressor Note Any waste oil collected must be disposed of in an approved manner e Refit drain plug D using a new bonded seal Tighten to 20 Nm Fill to overflow with an approved oil e g Fluid Force Do not overfill Note Oils must not be mixed e Refitfillerplug A using a new bonded seal Tighten to 25 Nm Turn mains electrical supply on and open air outlet valve e Test run compressor Check pressure and Inspect for oil leaks Figure 1 3 Cooler and motor location Figure 1 4 Separator element location Figure 1 5 Oil change procedure Page 17 Routine Servicing Electrical checks WARNING N AN Remove the starter panel and pressure switch covers e Check for any signs of overheating and ensure that all electrical connections are tightened to correct torque settings Note Pay special attention to power connections and cables connected to contactors and incoming terminals Refit and secure covers Check electric motors WARNING Remove any dust or dirt from motor bodies and motor air intake grills e Reinstate all covers Remove safe
37. or 2 2Kw 18 220 240v or 1 7f 73770 10 Motor 2 2Kw 30 380 415v or 1 8 74016 Safety valve 1 9 56540 1 2 BSP Hex nipple 1 10 56633 Outlet tap 2 11 58664 Pressure gauge 1 12a 74004 Pressure switch and starter 1 12b 74005 Pressure switch and starter single phase M C 1 12c 74121 Pressure switch amp starter 1 1Kw 30 380 415V 1 12d 74423 Pressure switch amp starter 1 1Kw 18 220 240V 1 12e 74124 Pressure switch amp starter 1 5Kw 30 380 415V 1 12f 74122 Pressure switch amp starter 2 2Kw 30 380 415V 1 1 Refer to Health and Safety section before carrying out any service work Compressor removal re fitting Disconnect the thermistor thermoswitch probe cable from either the pressure switch assembly PURS or the starter assembly PUTS Drain the oil from the compressor and cooler into a suitable container Disconnect the pipework from the compressor to aftercooler where applicable Support the compressor before removing 4 off nuts and washers from the motor flange If reguired remove 4 off cap head screw securing the backplate where fitted Remove the compressor from the support and place on a suitable work surface Page 29 Removing bell housing Using an extension socket remove screws and washers Compressor drive coupling Before dismantling the drive the compressor air end must be removed from the motor Remove the drive element 4 examine for wear and replace if necessary For improved access the
38. orce 2000 oil 1C 4 Y 4 Y Change air filter 1C Y Y Page 5 Introduction Preventative Maintenance Schedule Fluid Force 2000 HPO Maintenance Actions and Manual in Every Every Good SGT Grey yan lavan N Bek hrs hrs hrs hrs hrs Change intake valve seals 2A v Change MPV seals 1D Y Y Y Y Change separator element 1C Y Y Change thermal motor 501 PURS Y Change drive media 2C Y Change oil seal IE Y Change pressure gauge Y Test minimum pressure valve 5E Y Y Y v 4 Test air delivery 5C Y Y Page 6 CompAir Ltd Introduction Service Kits Only use genuine CompAir UK Hydrovane parts and approved oils Oils must not be mixed Service kits contents ltem Part Number Guantity Description Chapter Location KM51 Maintenance Kit 1 74015 1 Air filter 2A 2 57029 1 Separator element 2A 3 9609 1 Bonded Seal 4 9611 1 Bonded Seal 2B 5 9613 1 Bonded Seal 6 9615 1 Bonded Seal 2B 7 9703 1 O Ring 2A 8 9709 1 O Ring 2A 9 9711 1 O Ring 2A 10 9821 1 O Ring 2A KT52 Top Up Kit 1 71553 1 Oil seal 2B 2 56391 1 Gauge 2A 3 74014A 2 Shim Red 2B 4 74014B 2 Shim Blue 2B 5 74014C 2 Shim Green 2B 6 73101 1 Gasket Separator End Cover 2A 7 58365 01 1 Gasket cork 2B 8 71550 1 Gasket rubber 2B 9 9707 10 O Ring 2B 10 9718 1 O Ring
39. pAir Ltd 2B Oil Chamber Rotor Stator Unit Lantern Quantity Item Part Number Description Kit All 01 02 la 56281 Rotor 1 1 1b 57775 Rotor PUTS models only 1 2 70233 Blade 8 3a 74014C Shim green KT52 A R 3b 74014D Shim amber A R 3c 74014A Shim red KT52 A R 3d 74014B Shim blue KT52 A R 4 73999 Stator assembly 1 5 56302 Valve plate 2 6 56586 Valve support 2 7 AGS203 B Lockwasher 2 8 FS702 3 Socket head screw 4BA 2 9 57416 Tension pin 2 10 73995 Outlet assembly 1 11 56300 O Ring KT52 1 12 73997 Oil chamber 1 13 56637 Bearing 1 14 GHC2 6 Helicoil 1 15 GHC3 6 Helicoil 1 16 73917 Drain plug 1 17 9611 Bonded seal KM51 1 18 71127 Filler plug 1 19 9615 Bonded seal KM51 1 20 71553 Oil seal KT52 1 21 MS1606 20 Countersunk screw 2 Refer to Health and Safety section before carrying out any service work Rotor stator removal Remove drive coupling refer to 3C Stand oil chamber 12 verticaly on wooden blocks Remove intake end cover and discard gasket refer to 2A Remove stator 4 Note position and thickness of shims 3 Remove rotor having first removed grub screw burrs on shaft to retain blades 2 in position Discard O Ring 11 Rotor stator Examine Inspect both end faces and bearings for wear Renew if necessary Stand main casing on block of wood and apply o
40. ressure switch is under pressure and the compressor has been safely isolated from the mains electrical supply Pressure sensing Since the pressure switch is located into the air receiver we recommend that you do not fit a non return valve in your air line system If a non return valve is essential for your application then the air supply to the switch must be relocated after the non return valve C Check Setting Procedures Cut out stop pressure Close air outlet valve A Start compressor allow pressure to rise until compressor cuts out stops Check and record cut out pressure shown on pressure gauge B Cut in re start pressure Carefully open air outlet valve A allow pressure to fall slowly until compressor cuts in re starts e Check and record cut in pressure shown on pressure gauge B Stop compressor a a y Figure 5 1 Pressure Switch Location Page 53 Adjustments and Testing D Pressure Switch Adjustment Fig 5 2 Close air outlet valve A e Start compressor allow pressure to rise until compressor cuts out stops WARNING ISOLATE THE COMPRESSOR FROM MAINS ELECTRICAL SUPPLY LOCK THE ISOLATOR IN THE OFF POSITION FIT A SAFETY NOTICE TO THE ISOLATOR ADVISING THAT WORK IS BEING CARRIED OUT ON THE COMPRESSOR Remove pressure switch cover To adjust the cut out higher stop pressure turn the screw marked P1 towards
41. rrs on chamber C Refit new seal and remove applicator Fit power coupling in correct position Renew O rings on cooler couplings Fit new seal using service tool S72 and secure with fixing Screws Reassemble compressor and fill with oil Figure 1 7 Pressure Control Valve and Cil Return Valve dfe 7 Figure 1 8 Oil Seal Page 18 CompAir Ltd 1 Routine Servicing This page is intentionally left blank Page 19 Air end 2 Chapter 2 Contents Chapter Page separator Intake End Cover sri ryu khe Re tega aa ae caii ee fa 2A 21 Oil Chamber Rotor Stator Unit Lantern x 9 60 9 N 9 9 9 aK K 9 KR eee ee AB ui aaa 25 PURS Motors Couplings Receivers cn 20 2353 31 PUTS Motors Couplings Tripod se aia ce era ee af 2D 2 5 33 Aftercooler Dryer Mk1 Filters X NR ler lenn FF FR R 0 uu La DE NA 35 Aftercooler Dryer MK2 Filters serten lenn Y eee DR ues 37 Air End Parts Modific tions or 2 00 era Re ann nee 20 sa 39 Note Parts contained in service kits are shown in kit column Apply Loctite sparingly Ensure cross drillings etc do not become blocked Page 20 CompAir Ltd 2A Separator Intake End Cover Item Part Number Description Kit ny All 01 02 1 56633 Outlet tap PUTS models only 1 2 57574 Intake filter cowl 1 32254 Separator co
42. ty notices D Minimum Pressure Valve Fig 1 6 Remove separator end cover A Remove circlip B Parts C and D will be pushed out by spring J Remove piston G This is simplified using long nose pliers Renew O rings E F and H Apply smear silicon grease before fitting Check piston G and non return valve D for wear Renew if necessary Testingofthe minimum pressure valveis itemised in Chapter 5 E Pressure Control Valve PUTS only Cil Return Valve Fig 1 7 e Drain oil Remove separator housing A Remove pressure control valve B and note settings 7 or 10 bar Renew bonded seal C Remove oil return valve D Renew filter and O ring E if unserviceable Renew bonded seal F e Renew flexible tube G When fitting separator housing use two studs S73 to ensure correct alignment of tube G with discharge pipe on stator e Separator feed tube H should be positioned 18 2 to machine axis on assembly Setting gauge S83 will simplify this operation Refill compressor with oil when assembly is complete Testing of the control valve is itemised in Chapter 5 F Oil Seal Fig 1 8 Drain oil Before any work can be carried out on the seal the compressor must be removed from the motor Remove lantern and cooler Remove drive coupling Remove screws Pull oil seal assembly out of oil chamber Clean seal housing and remove bu
43. ure gauge reads zero Note If pressure gauge does not fall to zero then non return valve D may be faulty Drain air receiver following procedure above Do not reopen air outlet valve A e Carefully unscrew oil filler plug B Remove filler plug B retain bonded seal C Fill to overflow with an approved oil e g Fluid Force Do not overfill Note Oils must not be mixed Examine bonded seal if not damaged refit to filler plug Refit seal and filler plug tighten to 25 Nm Remove safety notices Check compressor air filter Fig 1 2 WARNING The air filter C is located beneath the filter cover A Filter cover will slide over adapter and pipe B e Wait until air end vent down cycle is complete e Open test valve to vent pressure from the receiver and associated pipework Check that air end pressure gauge reads zero Firmly pull filter cover A to remove from separator casing Remove air filter C slide over adaptor and pipe B Clean separator casing and inside of filter cover Vacuum clean or blow dust out of filter using low pressure clean dry air Renew filter as below if it cannot be cleaned satisfactorily Refit air filter C locate on support gauze D Refit filter cover A Compressor air intake filter replacement Fig 1 2 The air filter C is located on support gauze D beneath the filter cover A Disconnect pipe B Firmly pull filter cover A
44. ver assembly 1 3 56914 Separator end cover 1 4 9413 Spring 1 5 9703 O Ring KM51 1 6 56838 MPV Piston 1 7 56836 Valve plate 1 8 9709 O Ring KM51 1 9 9711 O Ring KM51 1 10 56837 MPV end plug 1 11 MCI 19 Circlip 1 12 MS705 20 Socket head screw M5 x 20mm 6 13 56391 Pressure gauge KT52 1 14 9821 O Ring KM51 1 15 74015 Intake filter KM51 1 16 70416 Intake filter support 1 34044 Intake end cover assembly 17 73129 Intake end cover 1 18 56637 Bearing 1 19 70392 Sleeve 1 20 56659 Restrictor 1 21 56437 Valve plate 1 22 56422 Intake valve seat KT52 1 Refer to Health and Safety section before carrying out any service work Changing air filter Pressure control valve oil return valve Refer to Basic Service Procedures Refer to Chapter 1 E Fit parts contained in service kits Removing minimum pressure valve Refer to Chapter 1 D Changing oil separator Remove end cover 3 Renew O ring 14 Unscrew oil separator 42 e Renew O ring 43 Oilseparator cannot be cleaned If found to be faulty or blocked it must be renewed Page 21 Separator Intake End Cover 2A Figure 2A Separator Intake End Cover Page 22 CompAir Ltd 2
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