Compair 5336 5436 Mk2 Operator Manual

CompAir UK Ltd
abcdef
OPERATOR MANUAL
for
H5336.2, & H5436.2
Water-cooled High Pressure
Reciprocating Air Compressors.
In any correspondence please quote: JOB NUMBER:

MACHINE NUMBERS: (on nameplate)
PUBLICATION NUMBER: 98407/1176 iss2
ISSUE DATE: OCTOBER 2000
CUSTOMER ORDER NUMBER:
CompAir UK Ltd. Ranelagh Road IPSWICH ENGLAND IP2 0AQ

Telephone: +44 (0) 1473 602222 Fax: +44 (0) 1473 601704 Parts Fax: +44 (0) 1473 601282 Service +44 (0) 1473 556027
www.CompAir.com e-mail: Ipswich@CompAir.com
CompAir UK Ltd
DECLARATION OF CONFORMITY
98/37/EEC (Machinery Directive)
BS EN292: 1991 (Safety of Machinery)
BS EN1012-1: 1997 (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 Reciprocating Compressor
Model No. _________________________ 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 RANELAGH ROAD, IPSWICH, ENGLAND IP2 0AQ
dclarons que sous notre seule responsabilit quant sa fourniture / fabrication, le matrial dcrit ci-
dessous,
Type de machine Compresseur rotif Compresseur alternatif pistons
No de modle _________________________ No de srie __________________________________
est conforme aux exigences essentielles dhygine et scurit tablies aux Directives ci-dessus.
IPSWICH, ENGLAND
Signature et nom de la personne responsable
DATE ____________________ _______________________

Position
Deutsch Espaol Nederlands !

KONFORMIT TSBESCHEINIGUNG - 98/37/EEC, BS EN292:1991, BS EN1012-1:1997
Wir COMPAIR UK LIMITED
mit Sitz in RANELAGH ROAD, IPSWICH, ENGLAND IP2 0AQ
erklren unsere volle Haftung fr Lieferung / Erzeugung der folgenden gelisteten Maschinen,
Maschinenart Kolbenkompressor
Modellnr. __________________________________ Seriennr.__________________________________________
gem den Gesundheits-und Sicherheitsanforderungen der oben genannten Richtlinien.
IPSWICH, ENGLAND
Unterschrift und Name der verantworlichen Person
DATUM
Position
DECLARACIN DE CONFORMIDAD - 98/37/EEC, BS EN292:1991, BS EN1012-1:1997
COMPAIR UK LIMITED
con domicilio en RANELAGH ROAD, IPSWICH, ENGLAND IP2 0AQ
declara, bajo su exclusiva responsabilidad por el suministro o fabricacin, que la maquinaria descrita a continuacin
Tipo de mquina Compresor rotativo Compresor alternativo
N de modelo ______________________________ N 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 RANELAGH ROAD, IPSWICH, ENGLAND IP2 0AQ

verklaren onder onze volle aansprakelijkheid voor de levering / vervaardiging dat de hierna beschreven machinerie,
Soort machine Zuigercompressor
Type nr ___________________________________ Serie nr ___________________________________________
voldoet aan de essentile Vereisten voor Gezondheid en Veilgheid als gedentificeerd 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 (Machinery Directive)
BS EN292: 1991 (Safety of Machinery)
BS EN1012-1: 1997 (Compressors an 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 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
dclarons que sous notre seule responsabilit quant sa fourniture / fabrication, le matriel dcrit ci-dessous,
Type de machine Compresseur rotatif Compresseur pistons
No de modle ______________________ No de srie ______________________________
concern par la prsente dclaration, est conforme aux exigences essentielles dhygine et
scurit identifies dans les Directives susmentionnes.
Cet quipement ne doit tre mis en service que lorsque lquipement dans lequel il doit tre
intgr a t certifi conforme aux dispositions des Directives susmentionnes.
IPSWICH, ANGLETERRE
Signature et nom du responsable
DATE __________________ __________________________________

Poste
Deutsch Espaol !
EINBEZIEHUNGSERKLRUNG - 98/37/EEC, BS EN292:1991, BS EN1012-1:1997
Wir COMPAIR UK LIMITED
aus RANELAGH ROAD, IPSWICH, ENGLAND IP2 0AQ
erklren da unter unserer alleinigen Verantwortung fr Lieferung/Herstellung die unten aufgefhrte Maschine.
Maschinentyp: Kreiskolbenverdichter Hubkolbenverdichter
Modell-Nr. _________________________________ Serien-Nr. _________________________________________
auf die sich diese Erklrung bezieht, den grundlegenden Arbeitsschutzbedingungen in oben genannten Direktiven
entspricht.
ERKLRUNG
Diese Maschine darf nicht in Betrieb genommen werden, solenge die Konformitt der Maschinen, in
die sie einbezogen werden soll, mit den Auflagen der oben genannten Directiven nicht erklrt worden
ist.
IPSWICH, ENGLAND
Unterschrift und Name der Verantworlichen Person
DATUM_______________________
Position
COMPAIR UK LIMITED
con domicilio en RANELAGH ROAD, IPSWICH, ENGLAND IP2 0AQ
declara, bajo su exclusiva responsabilidad por el suministro o fabricacin, que la maquinaria descrita a continuacin
Tipo de mquina Compresor rotativo Compresor alternativo
N de modelo ______________________________ N de serie ________________________________________
a la que se refiere esta declaracin, cumple las principales normas de seguridad e higiene estipuladas en las directivas
mencionadas anteriormente.
DECLARACIN
Esta mquina no podr ponerse en marcha hasta que haya quedado demostrado que la mquina a la que va
incorporada cumple las disposiciones estipuladas en las 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 RANELAGH ROAD, IPSWICH, ENGLAND IP2 0AQ
verklaren dat, onder onze volledige verantwoordelijkheid ten aanzien val levering/fabricage van de hieronder beschreven
machine.
Type machine Roterende compressor Zuigcompressor
Model nr __________________________________ Serie nr ___________________________________________
waarop deze verklaring betrekking heeft in overeenstemming is met de essentile 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 REF. NO.
COMPRESSOR PRIME MOVER INSTALLED AT OIL GRADE USED:
TYPE: TYPE: CHECK OIL LEVEL
SPEED: B.H.P. CHECK WATER IN/OUT TEMPERATURE
SERIAL NO: DRIVE: DATE INSTALLED: CHECK COOLING FAN BLADES
FINAL FINAL AIR SERVICE
DATE TIME *HOURS STAGE STAGE STAGE PRESSURES PRESSURE PLAN REMARKS SEE SIGNED
RUN TEMP.C TEMP.C #(BAR - PSI) #(BAR - PSI) NUMBER OVER FOR MORE
#50/100 1 2 3 4 5
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
5500
6000
6500
7000
7500
8000
8500
9000
9500
10000
10500
11000
11500
12000
12500
*FILL IN HOURS RUN AS DETAILED ON SERVICE PLAN FOR PARTICULAR COMPRESSOR TYPE
# DELETE AS NECESSARY - FILL IN APPROPRIATE STAGE TRIP TEMPERATURE READING
SERVICE ENGINEER TO SIGN & FILL IN ANY OTHER COMMENTS IN REMARKS COLUMN
SERVICE TELEPHONE +44 (0) 1473 556027 - PARTS +44 (0) 1473 601282
logsheetm.doc
DATE REMARKS DATE REMARKS
logsheetm.doc
CompAir UK Ltd SAFETY SECTION
Page 1
OPERATOR MANUAL - 5000 SERIES AIR

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Page 9
Wash the area with limewater and avoid

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

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

before and after maintenance work.

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

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

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

CompAir UK Ltd PUBLICATION 98407.1176
Page 1
HISTORY RECORD
H5336.2, 5436.2 COMPRESSORS
ISSUE MOD Note M/C SERIAL No CHANGE. - REASON DATE PAGE No

No No
1 NEW NEW FEB 1999 ALL
2 NONE NONE - ADD H5436.N2.B2 DETAILS TO MANUAL & PARTS LIST OCT 2000 VARIOUS
3 NONE DELETED H5436.2. N2.B2 NOW 98407.1307 NOV 2001 VARIOUS
4
5
6
7
8
1176.doc Page 1
Page 2
Page 2 1176.doc
Page 3
CONTENTS
PAGE
CERTIFICATE OF CONFORMITY/INCORPORATION. ex
COMPRESSOR LOG SHEET. ex
SAFETY GENERAL ex
AMENDMENTS 1
INDEX 3
SECTION 1 LEADING PARTICULARS

1.1 UNIT DESIGNATION------------------------------------------------------------------------5
1.2 TECHNICAL DATA - GENERAL ---------------------------------------------------------5
1.3 PRESSURE AND TEMPERATURE ACCEPTANCE LEVELS --------------------6
1.4 RUNNING CLEARANCES -----------------------------------------------------------------7
1.5 CRITICAL TORQUE WRENCH SETTINGS-------------------------------------------8
1.6 NON-CRITICAL TORQUE WRENCH SETTINGS -----------------------------------8
SECTION 2 GENERAL DESCRIPTION
2.1 GENERAL DETAILS ------------------------------------------------------------------------9

2.2 SYNTHETIC OILS --------------------------------------------------------------------------10
2.3 COMPATIBILITY OF MATERIALS WITH SYNTHETIC TYPE OILS -----------11
SECTION 3 INSTALLATION
3.1 HANDLING OF UNIT-----------------------------------------------------------------------13
3.2 LOCATION------------------------------------------------------------------------------------13
3.3 MOUNTING-----------------------------------------------------------------------------------14
3.4 CONNECTIONS, PIPEWORK AND FITTINGS--------------------------------------14
3.5 DRIVE RECOMMENDATIONS ----------------------------------------------------------14
3.6 COOLING -------------------------------------------------------------------------------------15
3.7 ELECTRICAL CONNECTIONS----------------------------------------------------------15
3.8 CONTROL FOR AUTO STOP/START-------------------------------------------------16
3.9 RECOMMENDED ANCILLARIES SUMMARY---------------------------------------16
SECTION 4 COMMISSIONING OR RECOMMISSIONING

4.1 BEFORE STARTING-----------------------------------------------------------------------17
4.2 START-UP PROCEDURE ----------------------------------------------------------------18
4.3 AFTER THE FIRST 15 HOURS RUNNING TIME-----------------------------------18
4.4 AFTER THE FIRST 100 HOURS RUNNING TIME ---------------------------------18
4.5 CHANGING OVER FROM MINERAL TO SYNTHETIC LUBRICANT----------19
SECTION 5 OPERATION & ROUTINE MAINTENANCE
5.1 OPERATION AND DAILY MAINTENANCE ------------------------------------------21

5.2 MAINTENANCE PERIODS ---------------------------------------------------------------22
5.3 VALVE MAINTENANCE PERIODS-----------------------------------------------------23
5.4 MAINTENANCE DETAILS ----------------------------------------------------------------23
1176.doc Page 3
Page 4
SECTION 6 VALVE SERVICING

6.1 GENERAL ------------------------------------------------------------------------------------ 27
6.2 CLEANING AND INSPECTION ALL STAGES -------------------------------------- 27
6.3 VALVE REMOVAL AND DISMANTLING --------------------------------------------- 27
SECTION 7 FAULT GUIDE

7.1 EXCESSIVE PRESSURE ---------------------------------------------------------------- 31
7.2 INSUFFICIENT PRESSURE OR VOLUME ------------------------------------------ 31
7.3 OVERHEATING----------------------------------------------------------------------------- 32
7.4 EXCESSIVE NOISE ----------------------------------------------------------------------- 32
7.5 EXCESSIVE WEAR------------------------------------------------------------------------ 32
7.6 EXTENDED RUNNING ------------------------------------------------------------------- 32
7.7 FAILURE TO START ---------------------------------------------------------------------- 32
SECTION 8 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 OLD DESIGNATION

H5336.2 C5336 MK2
H5346.2 C5436 MK2
Page 4 1176.doc
Page 5
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 ---------------------------------------------------------------- Single acting, three stage H5336, 90 vee
Type ---------------------------------------------------------- Single acting, three stage H5436, 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 -------------------------------------------------------------------------------- 0C
Maximum compressor air intake temperature------------------------------------------------------------ 45C
Maximum ambient for radiator sets
(Contact CompAir UK Ltd for lubricant/duty restrictions) ------------------------------------------ 30\40C
Maximum water inlet temperature--------------------------------------------------------------------------- 37C
Temperature rise across machine -------------------------------------------------------------------10C\12C
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 recommendations are based on normal conditions. If difficulty is experienced a change may be
advisable - refer to CompAir UK Ltd.
COOLING:
Water---------------------------------------------------------------------------- Mains or water pump circulation
Cooling water flow @ 15C ------------------------------------------------------------------------------ 75 l/h/kw
1176.doc Page 5
Page 6
INTERNAL DIMENSIONS: H5336.2 H5436.2

Piston stroke -------------------------------------------------------------- --------------------75 mm ----------- 75 mm
First stage cylinder bore ----------------------------------------------- ------------------- 185 mm --------- 185 mm
Second stage cylinder bore (1st stage on SP1)------------------ --------------------95 mm ----------- 95mm
Third stage cylinder bore (2nd stage on SP1) -------------------- -------------------- 45mm------------ 45mm
Fourth stage cylinder bore (3rd stage on SP1) ------------------- ---------------------- N/A ------------- 22mm
CONNECTIONS:
First stage suction ----------------------------------------------------------------------Special flange adaptor Rp3

Final delivery H5436.2---------------------------------------------------------------------------------------------- Rp
Final delivery H5336.2---------------------------------------------------------------------------------------------- Rp
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:
Stages (bar)
M/c Type Oil First Second Third 4th Delivery
H5336.2: 2.0 - 2.7 2.5 - 2.9 12.8 - 13.9 27.5 N/A
2.0 - 2.7 2.6 - 3.0 13.5 - 15.2 41.3 N/A
2.0 - 2.7 2.7 - 3.1 14.2 - 15.9 55 N/A
2.0 - 2.7 2.75 - 3.2 14.8 - 16.5 69 N/A
2.0 - 2.7 2.75 - 3.2 15.7 - 17.4 85 N/A
H5436.2: 2.0 - 2.7 2.7 - 3.1 16.3 - 17.9 66.1 - 74.1 137.8
2.0 - 2.7 2.7 - 3.1 16.5 - 18.2 73.0 - 81.3 206.8
2.0 - 2.7 2.7 - 3.1 16.7 - 18.4 79.9 - 88.9 257.7
2.0 - 2.7 2.7 - 3.1 17.0 - 18.7 86.8 - 96.5 344.7
Temperatures:
Maximum stage -------------------------------------------------------------------------------------------------------------- 215C
Final Delivery (Max) ----------------------------------------------------------------------------------------------------------70C
These temperatures must not be exceeded except under certain reduced operating conditions,
details of which can be obtained from CompAir Distributors or from CompAir UK Ltd Customer
Service Department.
NOTE: THE MAXIMUM OPERATING TEMPERATURES ARE IMPORTANT TO THE LIFE AND SAFETY
OF THE MACHINE.
Page 6 1176.doc
Page 7
1.4 RUNNING CLEARANCES (MILLIMETRES)

Part Description Stage As Fitted Max.
(mm) Permissible
(mm)
Piston (Plunger) Vertical Clearance 1 0./0.9 0.9
2 0.4/0.9 0.9
3 0.45/1.0 1.0
4 0.35/1.46 1.46
Piston Ring Gaps 1 Taper 0.2/0.45 1.63
Scraper 0.2/0.45 1.43
(Measured in unworn portion of cylinder/liner) 2 Taper 0.1/0.23 1.47
Scraper 0.1/0.23 1.27
3 Plain 0.05/0.18 1.32
H5436.2 Peek 450 4 Plain 0.2/0.4 1.32
Piston Ring Axial Width Clearance 1 Taper 0.04/0.09 0.29
(Measured between groove & top face of ring with Scraper 0.05/0.10 0.30
ring in normal running position). 2 Taper 0.02/0.08 0.28
Scraper 0.05/0.10 0.30
3 Plain 0.03/0.09 0.29
H5436.2 Peek 450 4 Plain 0.03/0.07 0.20
Piston Ring Groove Width 1 Taper 4.80/4.83 4.91
Scraper 8.01/7.99 8.09
2 Taper 3.23/3.20 3.31
Scraper 4.83/4.80 4.91
3 Plain 2.05/2.01 2.13
H5436.2 4 Plain 2.05/2.01 2.13
Piston/Plunger Diameter Above Top Ring 1 184.77/184.74 184.69
1 184.54/184.49 184.44
2 94.91/94.88 94.83
3 44.93/44.90 44.85
H5436.2 4 21.955/21.945 21.9
Cylinder/Liner Diameter 1 185.05/185.00 185.11
2 95.04/95.00 95.10
3 45.03/45.00 45.09
4 22.01/22.00 22.07
Crosshead Diametrical Clearance 3 0.06/0.13 0.19
4 0.06/0.13 0.19
Small End Bearing Diametrical Clearance
In Conn Rod 1 0.01/0.05 0.1
2,3,4 Needle Roller
In Piston 1 -0.003/0.013 0.03
2,3,4 0.025/0.044 0.09
Big End Bearing Diametrical Clearance 1,2,3,4 0.066/0.12 0.24
Small End Bearing End Float 1 0.15/0.64 1.0
2,3,4 0.15/0.55 1.0
Main Bearing Diametrical Clearance 0.05/0.14 0.2
Crankshaft End Float 0.66/0.23 0.75
Coupling Face Distance for Direct Coupled Sets 2.0/6.0 6
1176.doc Page 7
Page 8
1.5 CRITICAL TORQUE WRENCH SETTINGS
Part Description Size No Off Newton metre (Nm) Lbs/Ft

Big end bearing bolts M16 8 203 150
1st & 2nd stage cooler covers M10 17 54 40
3rd stage cooler covers M16 10 236 174
1st stage valve cover M12 6 41 30
2nd stage valve cover M12 6 41 30
3rd stage valve cover M20 4 95 70
4th stage valve cover* M20 4 108 80
4th stage valve cover (5436H only)* M20 4 122 90
1st stage cylinder to crankcase M12 4 95 70
2nd stage cylinder to crankcase M12 4 95 70
3rd & 4th stage crosshead to crankcase M12 6 95 70
3rd & 4th stage cylinders to crosshead guide M12 8 95 70
Flywheel bolt "UNF 1 162 120
3rd stage piston to crosshead M8 1 27 20
NOTE: 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
Part Description Size No Off Newton Metre (Nm) Lbs/Ft

D/E main bearing housing to crankcase M12 8 95 70
O/E main bearing housing to crankcase M12 10 95 70
O/E cover M8 10 27 20
Crankcase door M10 24 54 40
Cooler body to cylinders M12 6 95 70
Bursting disc cover M10 4 54 40
Cooler door M10 26 27 20
1st stage valve M10 1 21 16
2nd stage valve M8 1 11 8
3rd stage valve M6 1 6 5
4th stage valve M5 1 3 2
Motor bell housing M12 10 95 70
Motor bracket to crankcase M16 5 162 120
Oil pump M8 3 27 20
Cylinder lubricator 3/8" 4 35 26
NOTE: 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% -15%.
3. Figures are for NON-LUBRICATED fastenings.
Page 8 1176.doc
Page 9
SECTION 2
GENERAL DESCRIPTION
2.1 GENERAL
Pressure gauges
Lifting eyes
rd
3 stage safety valve th
st 4 stage cylinder
1 stage safety valve
Stage temperature gauges rd
3 stage cylinder
Final stage non-return valve
th
4 stage safety valve
Suction/inlet filter silencer

st Coolant drains
1 stage cylinder
Oil filler
Oil pump th
4 stage cylinder lubricator
Final separator drain valve
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
Page 10
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
4TH STAGE
OIL 25 MICRON CYLINDER PRESSURE
PUMP FILTER 5436 ONLY GAUGE
OIL
RELIEF BYPASS O/E MAIN D/E MAIN LOW OIL
VALVE VALVE BEARING BEARING PRESSURE
ONLY OPENS IF
FILTER BLOCKS
CRANK
SHAFT
OIL
STRAINER FILLER
SUMP
BIG END
BEARING
SMALL END
BEARING
Page 101176.doc
Page 11
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 1 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.
1176.doc Page 11
Page 12
2.3 COMPATIBILITY OF MATERIALS WITH SYNTHETIC TYPE OILS

Acceptable Marginal Not Recommended
A. SEAL MATERIALS
Fluorocarbon (Teflon, FEP) Nitrile Rubber (Buna-N- NBR) Polychloroprene (Neoprene)

Fluorosilicone Rubber Polyurethane Natural Rubber
Silicone Rubber Ethylene-Propylene Styrene-Butadiene Rubber
Nitrile Rubber (Buna-N-NBR) Terpolymer (SBR, Buna-S)
Polysulfide (Thiokol) Epichlorohydrin Butyl Rubber
Chlorosulfonated Polyethylene
Polyacrylate Rubber
Nitrile Rubber (Buna-N-NBR)
B. PAINT
Epoxy Alkyds (baked finish preferred) Acrylic

Baked Phenolic Phenolic Latex (household type)
Two Component Urethane Single Component Urethane Vinyl (PVC)
Moisture cured Urethane Industrial Latex Varnish
Lacquer
C. PLASTICS
Nylon Urethane Polystyrene

Fluorocarbon (Teflon) Polyethylene Polyvinyl Chloride
Polyacetal Polypropylene ABS
Polysulfone Polycarbonate (acrylonitrile/butadiene/styrene
Acrylate & Methacrylate
D. METALS
Steel and alloys Cadmium Zinc

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
Page 13
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 INCORRECT INSTALLATION

COOLING AIR ENTERS, PASSES COOLING AIR ENTERS, PASSES
OVER MACHINE AND AS HEATED OVER MACHINE AND THEN AS
AIR, IT IS EXHAUSTED FROM THE HEATED AIR, RE-CIRCULATES
MACHINE ENVIRONMENT. IN MACHINE ENVIRONMENT.
1176.doc Page 13
Page 14
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 must be given to system and pipework layout. Check piping and connections are
suitable for pressures and capacities and as the compressor is flexibly mounted, (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 recommended 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
Page 15
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 10C
to 12C.
Maximum recommended water inlet temperature is 37C.
It is recommended that temperature gauges be fitted to water inlet and outlet pipes to monitor water
temperatures (mains).
Water flow rate at 15C 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.
1176.doc Page 15
Page 16
3.8 CONTROL CIRCUIT FOR AUTO STOP/START
KEY
R. RELAY.
T.. TIMER.
SV. SOLENOID VALVE
HTS. 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 RECOMMENDED ANCILLARIES SUMMARY
1. Flexible pipe fitted on final delivery.

2. Overload trips.
3. Water inlet and outlet thermometers.
4. Water flow control.
5. Separators and drain traps.
6. Non-return valves.
Page 161176.doc
Page 17
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 DANGEROUS AND ALSO INVALIDATES THE GUARANTEE
4.1 BEFORE STARTING
Low oil pressure switch Remove protective blank
Remove priming
plug
Oil filler
Oil pump High air/gas

temperature
Oil level gauge switches
Drain Plug
Before starting up ensure one is familiar with safety devices and type of control.
NOTE: Low oil pressure and high air temperature switches are pre-set and should not be
adjusted.
H5336.2, & H5436.2: 3rd stage (2nd stage on H5336.2)air temperature protection switch is pre-
set and should not be adjusted.
1176.doc Page 17
Page 18
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: It is not necessary to remove any inhibitor oil which may have been applied
before despatch, unless there are specific instructions attached to the machine
stating otherwise.
4.2 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
Page 19
WARNING: Do not try to correct leaks when 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 11C 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:- 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 If it is
desired to use synthetic lubricant, follow directions as in later section.
FOR FURTHER MAINTENANCE PERIODS REFER TO LATER SECTION.
4.5 CHANGING OVER FROM MINERAL TO SYNTHETIC LUBRICANT
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. Renew oil filter.
4. Inspect suction and delivery valves. If they are covered by carbon and/or heavy lacquer
deposits, Remove and thoroughly clean.
5. Replace all items removed, renew any damaged seals or gaskets.
6. Fill crankcase sump with Reavellite synthetic oil until oil level sight glasses are filled to
upper level.
7. Run compressor following starting procedures.
1176.doc Page 19
Page 20
Page 201176.doc
Page 21
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 exterior of the compressor, especially pipe connections and joints, should be kept clean at all times.
If oil film and condensate are wiped away regularly, any leaks that occur will be more easily seen.
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 10C to 12C. 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
Page 22
For ambient temperatures below 0C 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)
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)
3 Drain sump, replace oil filter, clean & refill sump with synthetic oil
4 Clean suction and delivery valves
N.B. This compressor must not be run on mineral oil.

Daily 1 Check oil level in sump
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 complete overhaul is recommended every 3 years if 8000 (Mineral) or 9000 (Synthetic) running
hours are not reached.
After a minor service run compressor briefly to confirm satisfactory operation.
After a major service recommission the compressor as per commissioning procedure.
Page 221176.doc
Page 23
5.3 VALVE MAINTENANCE PERIODS

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 vessels.
THE ATTENTION OF U.K. USERS IS DRAWN TO THE HEALTH & SAFETY 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 Rod:
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.
1176.doc Page 23
Page 24
1
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
ELECTRIC
MOTOR
COMPRESSOR
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
Page 25
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.
Speed (rpm)
725 - 1230 1300 - 1500
Small Pulley 160 - 265 35.0 - 50.0 N 29.5 - 34.0 N
Diameter (mm) 265 and above 52.5 - 64.0 N 52.0 - 57.0 N
SELECTION TABLE
Belt Force required to deflect belt 15 mm per metre of span

Section Small Pulley Newton Kilogram force
mm (N) (kgf)
SPB 160 to 224 35 to 50 3.5 to 5.1
236 to 315 50 to 65 5.1 to 6.6
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
Page 26
5. Read off the force value indicated by the top edge of the upper marker ring.
6. Compare this force to kgf value shown in the table above.
7. Tighten or loosen belt tensioner to achieve the correct value.
8. If the measured force falls within the values given, the drive should be satisfactory.
Note: - If a belt tension indicator is not available, a suitably scaled spring balance and rule
will suffice.
DEFLECTION DEFLECTION FORCE

IN MM IN kgf
Page 261176.doc
Page 27
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 replacement of the springs and plates is intended, the order in which these
components are removed should be carefully noted so that the valves may be
reassembled with 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.
WARNING: - Great care should be taken when removing carbon deposits to ensure that
the seating faces; of the above components 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.
1176.doc Page 27
Page 28
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.
5. Place the second valve backing plate (N2) on spring plates and then after ensuring
concentricity place lower body (N1) onto assembly. If all components are located
correctly upper and lower bodies will contact.
6. Screw on nut (N9) and tighten to recommended torque.
plates.
8. Ensure O ring is secure in slot in upper valve body.
Page 281176.doc
Page 29
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.
plates.
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 complete cleanliness 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.
1176.doc Page 29
Page 30
Page 301176.doc
Page 31
SECTION 7
FAULT GUIDE
These suggestions are a guide to the more common aspects of fault location. It is assumed that:-
1. Cooling water inlet temperature is correct.

2. Temperature rise across machine is within limits.
3. Cooling water flow rate is correct.
4. Driving unit is efficient and power supply adequate.
5. Correct uncontaminated lubricant.
6. Lubrication system is fully operational.
NOTE:- Safety valve opening indicates excessive pressure and under NO CIRCUMSTANCES must a
safety valve be screwed down to accommodate excessive pressure. THIS IS DANGEROUS. If safety
valve opens or appears faulty, shut down compressor immediately and investigate.
Fault Probable Cause Recommendation(s)

7.1 Excessive Pressure Faulty suction or delivery Service valve(s) as necessary.
valve(s) NOTE: A faulty suction valve
gives excess pressure in previous
stage.
Pressure gauge Check gauge against instrument of

inaccurate. known accuracy.
Pipeline restriction Existing Installation:

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.
Final delivery pressure control Automatic Control:

fault, i.e. air governor (relay) or Inspect control equipment for
pressure switch. malfunction, rectify as necessary.
7.2 Insufficient Pressure or
Volume. Blocked suction filter. 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.
1176.doc Page 31
Page 32
Fault Probable Cause Recommendation(s)

7.3 Overheating Above maximum recommended
operation. Reduce operation level.
Reduced cooling efficiency. Examine cooler(s) for partial

blockage.
7.4 Excessive Noise Machine set up or pipework system Examine machine seating,
vibration. ascertain pipework system is firmly
secured, check clearances and
alignment of couplings and tension
of v-belts.
7.5 Excessive Wear Excessive speed and\or pressure. Operation within limits.
Dirty air and\or suction pipeline. Examine filters and renew

elements. Clean out suction
pipeline.
Excessive moisture content in air Check drainage system and

cylinder. crankcase oil for contamination.
7.6 Extended Running Insufficient speed or machine Up-rate machines if possible or
capacity too low. install parallel unit or larger
replacement. Check v-belts.
7.7 Failure to Start Seizure 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.
Electrical or control fault. Trace and rectify.
Page 321176.doc
Page 33
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
1176.doc Page 33
Page 34
Page 341176.doc
RECOMMENDED SERVICE PLAN - 5336 Mk2-M CompAir UK Ltd
Page 1
MINERAL OIL - SUBJECT TO OPERATING RESTRICTIONS

IMPORTANT - DAILY & BEFORE STARTING
Check oil level top up if necessary
INITIAL SERVICE Change oil & oil filter element. Cleanse crankcase. Repeat
100 HOURS OR after MAJOR OVERHAUL (8000) hours or any intermediate Part Ref
ELAPSED TIME overhaul. No Off RSP5336/2/m.1
6 MONTHS Change oil (total capacity 45 litres) - Mineral oil 25 litres. 2 98384/1022
Change oil filter 1 98262/1009
Check belt tension/drive couplings & condition of all ancillaries
Check for oil & air leaks
Check tightness of all fasteners
AT 1000 HOURS OR Change suction filter element. Clean 3rd stage valves. Part Ref
ELAPSED TIME Routine check of drive & ancillaries. No Off RSP5336/2/m.2
12 MONTHS Change suction filter element 1 98262/1063
REPEAT AT O Ring 3rd stage valve cover upper 1 98504/1108
5000 & 7000 O Ring 3rd stage valve cover lower 1 98504/1107
HOURS Back-up ring 3rd stage valve cover lower 1 98504/1113
O Ring 3rd stage valve 1 95604/24
Check belt tension/drive coupling & condition of all ancillaries
Check condition of 3rd stage cylinder bore & clean air passages.
AT 2000 HOURS OR Change oil & oil filter element. Cleanse crankcase. Change
ELAPSED TIME suction filter element. Clean 1st, 2nd & 3rd stage valves.
24 MONTHS Service diaphragm drain valves. Check condition of Part Ref
sacrificial anode. No Off RSP5336/2/m.3
Change oil (total capacity 45 litres) - Mineral oil 25 litres. 2 98384/1022
Change suction filter element. 1 98262/1063
O ring kit valve maintenance 1 98504/1001
Service kit diaphragm drain valves 3 98650/1535
Check condition of 1st, 2nd & 3rd stage cylinder bores & clean air passages.
AT 3000 HOURS OR Service 3rd stage valve. Change suction filter element. Part Ref
ELAPSED TIME Replace sacrificial anode No Off RSP5336/2/m.4
36 MONTHS Change suction filter element. 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
Service kit 3rd stage valve 1 98650/1059
Sacrificial anode (corrosion rod). 2 98163/1002
Check Non-Return Valve
53362m.doc
Page 2
AT 4000 HOURS Change oil & oil filter. Cleanse crankcase. Service 1st & 2nd
OR ELAPSED TIME stage valves. Replace bursting discs. Service diaphragm Part Ref
48 MONTHS drain valves. No Off RSP5336/2/m.5
1st stage valve service kit 1 98650/1518
2nd stage valve service kit 1 98650/1533
Service kit bursting disc 2 C201556/100
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 Change suction filter element. Replace 3rd stage valve. Part Ref
OR ELAPSED TIME Replace sacrificial anode. Routine check drive & ancillaries No Off RSP5336/2/m.6
O ring 3rd stage valve cover upper 1 98504/1108
O ring 3rd stage valve cover lower 1 98650/1107
3rd stage valve 1 98650/1049
Sacrificial anode 2 98163/1002
53362m.doc
Page 3
AT 8000 HOURS Replace all valves, piston rings, gudgeon pins, bearings etc.
MAJOR OVERHAUL 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 Part Ref
necessary. No Off RSP5336/2/m.7
Change oil (sump capacity 45 litres) Mineral oil 25 litres. 2 98384/1022
Change oil filter. 1 98262/1009
Joint kit 1 98504/1002
1st stage valve 1 98650/1519
2nd stage valve 1 98650/1039
Sacrificial anode (corrosion rod) 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.
1st stage piston ring set 1 98477/1085
2nd stage piston ring set 1 98477/1086
3rd stage piston ring set 1 98477/1087
1st stage gudgeon pin 1 C85727/1
2nd, 3rd & dummy stage gudgeon pin 3 C85727/2
2nd, 3rd & dummy stage gudgeon pin circlips 6 95650/25
1st stage gudgeon pin circlips 2 95650/30
1st stage S/E bush 1 C200016
2nd, 3rd & dummy stage S/E bearings 3 96072/74
Check crankshaft journals & oil seal diameter for wear
1st, 2nd, 3rd & dummy stage B/E bearings 4 C201109
Crankshaft D/E oil seal 1 95605/135
Main bearing bush 2 C85736/2
Thrust washer 2 98074/1004
1st stage safety valve 1 98650/1020-3.8
2nd stage safety valve 1 98650/1021-24
3rd stage safety valve 1 98650/1022-100
Surge vessel safety valve 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
RECOMMENDED SERVICE PLAN - 5336 Mk2-S CompAir UK Ltd
Page 1
SYNTHETIC OIL - STANDARD GRADE

ELAPSED TIME overhaul. No Off RSP5336/2/s.1
6 MONTHS Change oil (total capacity 45 litres) - REAVELLITE S 20 litres. 2 98384/1002
+REAVELLITE S 5 Litres 1 98384.1001
AT 1500 HOURS OR Change suction filter element. Clean 3rd stage valves. Part Ref
ELAPSED TIME Routine check of drive & ancillaries. No Off RSP5336/2/s.2
Check belt tension/drive coupling & condition of all ancillaries
AT 3000 HOURS OR Change oil & oil filter element. Cleanse crankcase. Change
ELAPSED TIME suction filter element. Clean 1st, 2nd & 3rd stage valves.
24 MONTHS Service diaphragm drain valves. Check condition of Part Ref
sacrificial anode. No Off RSP5336/2/s.3
Change oil (total capacity 45 litres) - REAVELLITE S 20 litres. 2 98384/1002
Check condition of 1st, 2nd & 3rd stage cylinder bores & clean air passages.
ELAPSED TIME Replace sacrificial anode No Off RSP5336/2/s.4
Check Non-Return Valve
53362SS.doc
Page 2
OR ELAPSED TIME stage valves. Replace bursting discs. Service diaphragm Part Ref
48 MONTHS drain valves. No Off RSP5336/2/s.5
AT 7500 HOURS Change suction filter element. Replace 3rd stage valve. Part Ref
OR ELAPSED TIME Replace sacrificial anode. Routine check drive & ancillaries No Off RSP5336/2/s.6
53362SS.doc
Page 3
MAJOR OVERHAUL 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
necessary. No Off RSP5336/2/s.8
Change oil (sump capacity 45 litres) REAVELLITE S 20 litres. 2 98384/1002
Joint kit 1 98504/1002
2nd, 3rd & dummy stage gudgeon pin 3 C85727/2
2nd, 3rd & dummy stage gudgeon pin circlips 6 95650/25
2nd, 3rd & dummy stage S/E bearings 3 96072/74
1st, 2nd, 3rd & dummy stage B/E bearings 4 C201109
53362SS.doc
Page 1
MINERAL OIL - RESTRICTED DUTIES ONLY

ELAPSED. overhaul. No Off RSP5436/m.1
TIME 6 MONTHS Change oil (total capacity 45 litres) - Mineral oil 25 litres. 2 98384/1022
AT 1000 HOURS OR Change suction filter element. Clean 3rd & 4th stage valves. Part Ref
ELAPSED TIME Routine check of drive & ancillaries. No Off RSP5436/m.2
REPEAT AT O Ring 3rd stage valve cover upper 1 98504/1108
5000 & 7000 O Ring 3rd stage valve cover lower 1 98504/1107
HOURS Back-up ring 3rd stage valve cover lower 1 98504/1113
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 condition of 3rd & 4th stage cylinder bores & clean air passages..
AT 2000 HOURS OR Change oil & oil filter. Cleanse crankcase. Change suction
ELAPSED TIME filter element. Clean 1st & 2nd stage valves. Service 4th stage Part Ref
24 MONTHS valve. Service diaphragm drain valves. Check condition of No Off RSP5436/m.3
sacrificial anode.
Service kit 4th stage valve 1 98650/1832
Check condition of 1st, 2nd & 4th stage cylinder bores & clean air passages.
ELAPSED TIME Replace sacrificial anode No Off RSP5436/m.4
Check and clean final delivery cooler coil assembly and pipework if fitted
54362m.doc
Page 2
OR ELAPSED TIME stage valves. Replace 4th stage valve. Replace 4th stage Part Ref
48 MONTHS piston rings. Replace bursting discs. Service diaphragm No Off RSP5436/m.5
drain valves.
4th stage valve 1 98650/1794
4th stage piston rings 2 98477/1143
Deglaze liner bore when fitting new piston rings.
AT 6000 HOURS Change oil & oil filter. Cleanse crankcase. Change suction
OR ELAPSED TIME filter element. Replace 3rd stage valve. Service 4th stage
60 MONTHS valve. Replace sacrificial anode. Routine check drive & Part Ref
ancillaries No Off RSP5436/m.6
O ring 4th stage valve cover upper 1 98504/1109
O ring 4th stage valve cover lower 1 98650/1110
Check condition of 3rd & 4th stage cylinder bores & clean air passages.
54362m.doc
Page 3
necessary. No Off RSP5436/m.8
Change oil (sump capacity 45 litres) Mineral oil 25 litres. 2 98384/1022
Joint kit 1 98504/1002
Deglaze all liners/bores when fitting new piston rings
4th stage piston 1 C203035
4th stage liner 1 C203034
2nd, 3rd & 4th stage gudgeon pin 3 C85727/2
2nd, 3rd & 4th stage gudgeon pin circlips 6 95650/25
2nd, 3rd & 4th stage S/E bearings 3 96072/74
1st, 2nd, 3rd & 4th stage B/E bearings 4 C201109
4th stage safety valve 1 98650/1190-385
Cleanse 4th stage cooler coil internally/externally
54362m.doc
Page 1
SYNTHETIC OIL
INITIAL SERVICE Change from Mineral oil. Change oil filter element. Cleanse
100 HOURS OR crankcase. Repeat after MAJOR OVERHAUL (9000) hours or Part Ref
ELAPSED TIME. any intermediate overhaul. No Off RSP5436/s.1
6 MONTHS Change oil (total capacity 45 litres) - REAVELLITE S 20 litres. 2 98384/1002
+ REAVELLITE S 5 Litres 1 98384.1001
Check belt tension & condition of all ancillaries
AT 1500 HOURS OR Change suction filter element. Clean 3rd & 4th stage valves. Part Ref
ELAPSED TIME Routine check of drive & ancillaries. No Off RSP5436/s.2
O Ring 4th stage valve cover upper 1 98504/1110
O Ring 4th stage valve cover lower 1 98504/1109
O Ring 4th stage valve 1 95604/20
Check condition of 3rd & 4th stage cylinder bores & clean air passages..
AT 3000 HOURS OR Change oil & oil filter. Change suction filter element. Clean
ELAPSED TIME 1st & 2nd stage valves. Service 4th stage valve. Service Part Ref
24 MONTHS diaphragm drain valves. Check condition of sacrificial anode. No Off RSP5436/s.3
Change oil (total capacity 45 litres) - REAVELLITE S 20 Litres. 2 98384/1002
+REAVELLITE S 5 LIitres 1 98384.1001
Check condition of 1st, 2nd & 4th stage cylinder bores & clean air passages.
ELAPSED TIME Replace sacrificial anode No Off RSP5436/m.4
Check belt tension/drive & condition of all ancillaries
Check and clean final cooler coil assembly and pipework if fitted
54362s.doc
Page 2
OR ELAPSED TIME stage valves. Replace 4th stage valve. Replace 4th stage
48 MONTHS piston rings. Replace bursting discs. Service diaphragm Part Ref
drain valves. No Off RSP5436/s.5
+ REAVELLITE S 5 Litres 1 98384.1001
AT 7500 HOURS Change suction filter element. Replace 3rd stage valve.
OR ELAPSED TIME Service 4th stage valve. Replace sacrificial anode. Routine Part Ref
60 MONTHS check drive & ancillaries No Off RSP5436/s.6
O ring 4th stage valve cover upper 1 98504/1109
O ring 4th stage valve cover lower 1 98504/1110
Check condition of 3rd & 4th stage cylinder bores & clean air passages.
54362s.doc
Page 3
necessary. No Off RSP5436/s.8
Change oil (sump capacity 45 litres) REAVELLITE S 20 litres. 2 98384/1002
Joint kit 1 98504/1002
4th stage piston 1 C203035
4th stage liner 1 C203034
2nd, 3rd & 4th stage gudgeon pin 3 C85727/2
2nd, 3rd & 4th stage gudgeon pin circlips 6 95650/25
2nd, 3rd & 4th stage S/E bearings 3 96072/74
1st, 2nd, 3rd & 4th stage B/E bearings 4 C201109
4th stage safety valve 1 98650/1190-385
Cleanse 4th stage cooler coil internally/externally
54362s.doc
Page 35
SECTION 9
ILLUSTRATED PARTS LIST
98407/1176PL
HOW TO ORDER SPARES
IN ORDER TO AVOID UNNECESSARY DELAY, PLEASE QUOTE THE FOLLOWING:-
1. THE REQUIRED SHIPPING, AND INVOICING ADDRESS.
2. MACHINE MODEL TYPE, REFERENCE NUMBER, EXAMPLE - H5436.2
3. MACHINE NUMBER STAMPED ON NAMEPLATE, EXAMPLE - H5436.2.101
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 REQUIRED.
1176.doc Page 35
Page 36
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 CYLINDER ASSEMBLIES --------------------------- D --------9
COOLER BODY ASSEMBLY --------------------------------------------------- E -------11
4TH STAGE COOLER & SEPARATOR ASSEMBLIES ----------------- F -------13
1ST, 2ND & 3RD STAGE COOLER ASSEMBLIES ---------------------- G -------15
LUBRICATION ---------------------------------------------------------------------- H -------17
DRAIN VALVE & SURGE VESSEL ASSEMBLY-------------------------- J -------19
EXTERNAL COMPONENTS ---------------------------------------------------- K -------21
DRIVE ARRANGEMENTS ------------------------------------------------------- L -------23
1ST STAGE CONCENTRIC VALVE ASSEMBLY------------------------- M-------25
2ND STAGE CONCENTRIC VALVE ASSEMBLY ------------------------ N -------27
3RD STAGE CONCENTRIC VALVE ASSEMBLY ------------------------ P -------29
4TH STAGE CONCENTRIC VALVE ASSEMBLY------------------------- Q -------31
1ST & 2ND STAGE DIAPHRAGM DRAIN VALVE ASSEMBLY ------ R -------33
3RD & 4TH STAGE DIAPHRAGM DRAIN VALVE ASSEMBLY------ S -------35
SERVICE TOOLS------------------------------------------------------------------- V -------36
1176pl.doc 28/10/02 Page 1

Page 2
* Thrust Washers fitted to AC

older machines are now A16 A17 A18 A19 A20
obsolete. If a replacement
part is required a new type
main bearing bush may be
supplied.
New compressors
have new type main
bearing bush fitted
with integral thrust
washer.
A21
AA
A32 A15 A34
A30 A33
AB A31 A35
A12 A13 A14 A11
A10
A22
A9 A23
A24
A25
A30
A31
A29 A28 A27 A26
A7 A8 A6 A5 A4 A3 A2 A1
AA
A CRANKCASE ASSEMBLY
Page 2 1176pl.doc 28/10/02

Page 3
LIST A
ASSEMBLIES
CRANKCASE ASSEMBLIES Used on No off
Assy no Description Comprising Of Part No. H5336.2 H5436.2
AA Crankcase Assy A1,2,3,4,5,6,7,8,7&15 E42798.100 1 1
AB Housing Assy O/E A11,12,13&14 E60010.100 1 1
AC Housing Assy D/E A17,18,19,20&21 D66384.100 1 1
* IF FITTED - LATER COMPRESSORS HAVE A MODIFIED MAIN BEARING BUSH,
AS THE THRUST WASHERS ARE NOW OBSOLETE.
PARTS
CRANKCASE ASSEMBLE USED On No Off
Item No Description Part No. Assy Ref. H5336.2 H5436.2
A1 Crankcase E42798 AA 1 1
A2 Gasket, blanking flange C200998 AA,AK 1 1
A3 Flange, blanking C200999 AA 1 1
A4 Screw 95018.200 AA 2 2
A5 Glass, oil level 98281.1002 AA 1 1
A6 Indicator, oil level 98381.1013 AA 1 1
A7 Plug, oil drain PS1068.5 AA 1 1
A8 Seal, oil drain 98660.1156 AA 1 1
A9 Screw 95018.274 2 2
A10 Screw 95000.314 7 7
A11 Washer, thrust If fitted* see note 98074.1004 AB 1 1
A12 Housing, O/E bearing E60010 AB 1 1
A13 Gasket, O/E housing D100354 AB 1 1
A14 Bush, O/E housing C85736.2 AB 1 1
A15 Stud D66720.12.238 2 2
A16 Washer, thrust If fitted* see note 98074.1004 AC 1 1
A17 Bush, D/E housing C85736.2 AC 1 1
A18 Gasket, D/E housing D100353 AC 1 1
A19 Housing, D/E bearing D66384 AC 1 1
A20 Seal, D/E oil 95605.135 AC 1 1
A21 Screw 95000.314 8 8
A22 Switch, low oil pressure 98524.1042 1 1
A23 Seal, low oil press switch 98660.1155 1 1
A24 Filler/breather, oil 98262.1023 1 1
A25 Screw 95018.134 6 6
A26 Door, crankcase C85742 4 4
A27 Screw 95000.283 24 24
A28 Gasket, door C200868 4 4
A29 Plug PS1454.4 2 2
A30 Plug PS1068.3 2 2
A31 Seal 98660.1154 2 2
A32 Serial Number Plate RP513 1 1
A33 Rivet PS2189.1 2 2
A34 Rotation Plate RP507.1 1 1
A35 Rivet PS2189.1 2 2
1176pl.doc 28/10/02 Page 3

Page 4
BC BD
B12 B11 B13 B14
BB B12
B13 BE
B11
B8
B14
B9
B10
B15 B4 B3
B8.1
B2
B7
B1
B5 BA
B1
B6
BA B6
B5 BF
B16 B17 B18 B19
BK B24
B20 B20 BG
BH B21
B22
B23
BJ B4
B3 B24
B2 B25
B26 BL
B2 B27
B28
B1
B6 BA B29
B5 B3 BN
B
B4
B1
B5 BA
RUNNING GEAR ASSEMBLIES B6
Page 4 1176pl.doc 28/10/02

Page 5
LIST B
ASSEMBLIES
RUNNING GEAR ASSEMBLIES Used ON No Off

Assey No Description Comprising Of Part No H5336.2 H5436.2
BA Conn Rod Assy B1, 5 & 6 U270.A 4 4
BB Piston Assy, 1st stage B8,9,10,11 & 12 D66376.50 1 1
BC Piston ring set, 1st stage B11 & 12 98477.1085 1 1
BD Piston ring set, 2nd stage B13 & 14 98477.1086 1 1
BE Piston Assy, 2nd stage B3,4,13,14 & 15 D67052.50 1 1
BF Crankshaft assy B16,17, 18 & 19 D66397.100 1 1
BG Piston ring set, 3rd stage B20 98477.1087 1 1
BH Piston Assy, 3rd stage B20,21 & 22 C86543.50 1 1
BJ Crosshead assy, 3rd stage B3, 4 & 23 D67086.50 2 1
BK Piston ring set, 4th stage B24 98477.1178 0 1
BL Plunger assy, 4th stage B25, 26 & 29 C203035.50 0 1
BM Keeplate assy, 4th stage B27 & 28 C86314.50 0 1
BN Crosshead assy, 4th stage B3, 4 & 29 D67053.50 0 1
PARTS
RUNNING GEAR USED On No Off

B1 Connecting Rod D66395 BA 4 4
B2 Bearing S/E, 2nd, 3rd, 4th 96072.74 - 3 3
B3 Circlip, 2nd, 3rd , 4th 95650.25 BE,BJ,BN 6 6
B4 Pin gudgeon, 2nd, 3rd, 4th C85727.2 BE,BJ,BN 3 3
B5 Bolt, conn rod 95006.237 BA 8 8
B6 Bearing B/E C201109 BA 4 4
B7 Bush S/E, 1st stage C200016 - 1 1
B8 Piston, 1st stage D66376 BB 1 1
B9 Pin gudgeon, 1st stage C85727.1 BB 1 1
B10 Circlip, 1st stage 95650.30 BB 2 2
B11 Ring, oil control, 1st stage 98477.1049 BB/BC 1 1
B12 Ring, piston, 1st stage 98477.1059 BB/BC 2 2
B13 Ring, piston, 2nd stage 98477.1060 BD/BE 2 2
B14 Ring, oil control, 2nd stage 98477.1061 BD/BE 1 1
B15 Piston, 2nd stage D67052 BE 1 1
B16 Crankshaft D66397 BF 1 1
B17 Plate keep, crankshaft C11359-44 BF 1 1
B18 Washer tab, crankshaft C11359-45 BF 1 1
B19 Bolt, crankshaft C75163.3 BF 1 1
B20 Ring piston, 3rd stage PS1159.108 BG/BH/BJ 4 4
B21 Screw 95018.201 BH/BJ 1 1
B22 Piston, 3rd stage C86543 BH/BJ 1 1
B23 Crosshead, 3rd/4th stage D67086 BJ 2 1
B24 Ring piston, 4th stage 98477.1143 BK/BL 0 2
B25 Plunger, 4th stage C203035 BK 0 1
B26 Screw 95028.134 BM 0 4
B27 Plate keep, 4th stage C86314 BM 0 1
B28 Shoe plunger, 4th stage (if fitted) C86315 BL/BN 0 1
B29 Crosshead, 4th stage D67053 BN 0 1
1176pl.doc 28/10/02 Page 5

Page 6
C32
CE
C31
C16
C15 C30
CB C14 C29
C13 C28 CD
C12 C27
C14.1
C11
C26
C25
C11.1
C8 C24
C10 C22
C9 C23
C22
C6
C7 C21 CC
C6
CA C1 C17
C5
C18
C2
C3 C20
C19
C4
C 1st & 2nd STAGE CYLINDER ASSEMBLIES
Page 6 1176pl.doc 28/10/02

Page 7
LIST C
ASSEMBLIES
1ST & 2ND STAGE CYLINDER ASSEMBLIES Used On - No Off

Assy No Description Comprising Of Part No. H5336.2 H5436.2
CA Cylinder assy 1st stage C1,2,3,4,5,6,7,9&10 E43030.50 1 1
CB Cover assy 1st valve C12,13,14,15 & 16 E67081.100 1 1
CC Cylinder assy 2nd stage C17,18,19,20,21,22,23,25 E60011.100 1 1
& 26
CD Liner assy 2nd stage C27,28 & 29 D100005.100 1 1
CE Cover assy 2nd valve C31 & 32 D100004.100 1 1
PARTS
1ST & 2ND STAGE CYLINDER ASSEMBLIES USED On No Off

C1 Cylinder, 1st stage E43030 CA 1 1
C2 'O' ring 95602.113 CA,KA 1 1
C3 Seal Dowty PS1322.4 CA 0 1
C4 Plug PS1068.4 CA 1 1
C5 Screw 95018.273 CA 4 4
C6 'O' ring 95602.74 CA 2 2
C7 'O' ring 95602.132 CA 1 1
C8 Screw 95000.314 - 3 3
C9 Stud D66720.12.53 CA 6 6
C10 Nut 95111.7 CA 6 6
C11 Valve conc. 1st stage 98650.1519 - 1 1
C12 'O' ring 95602.149 CB/KA 1 1
C13 'O' ring 95602.150 CB/KA 1 1
C14 Cover, 1st stage valve D67081 CB 1 1
C15 Seal 98660.1157 CB 1 1
C16 Plug PS1068.6 CB 0 1
C17 Cylinder, 2nd stage E60011 CC 1 1
C18 'O' ring 95602.113 CC/KA 1 1
C19 Plug PS1068.4 CC 1 1
C20 Seal Dowty PS1322.4 CC 0 1
C21 Screw 95018.273 CC 4 4
C22 'O' ring 95602.74 CC/KA 2 2
C23 'O' ring 95602.116 CC/KA 1 1
C24 Screw 95000.314 - 3 3
C25 Stud D66720.12.53 CC 6 6
C26 Nut 95111.7 CC 6 6
C27 'O' ring 95602.98 CD/KA 1 1
C28 Liner, 2nd stage cylinder D100005 CD 1 1
C29 'O' ring 95602.100 CD/KA 3 3
C30 Valve conc. 2nd stage 98650.1039 - 1 1
C31 'O' ring 95602.101 CE/KA 1 1
C32 Cover, 2nd stage valve D100004 CE 1 1
1176pl.doc 28/10/02 Page 7

Page 8
D12
DD D21
D20
D19
D18
D35
DC D16
D14 D15 D38
DH D39
D42 D37
D34 D36
D35 DF
D41
D34
D11 D13 D33

D10
D9
DB D6
D8 D32
D7 D29
D5 D31
D30 DG
D28
D27
D26
5336
D25
D24
D2 D1 D29
DA D31
D30 DG
D22 D23
D28
DE
D
D27
D26
3rd & 4th STAGE CYLINDER ASSEMBLIES

Page 8 1176pl.doc 28/10/02
Page 9
LIST D
ASSEMBLIES
3RD & 4TH STAGE CYLINDER ASSEMBLIES Used On - No Off
DA Guide crosshead, 3rd D1 & 2 D67049.100 1 1
DB Cylinder assy. 3rd stage D5,6,7,8,9,10 & 11 E60170.50 1 1
DC Liner assy. 3rd stage D14,15,& 16 C86301.100 1 1
DD Cover assy. 3rd stage D18,19,20 & 21 C86318.100 1 1
DE Guide crosshead, 4th D22 & 23 D67049.100 1 1
DF Cover assy. 4th stage D36,37,38 & 39 C86319.100 1 1
DG Cylinder assy. 4th stage D26,27,28,29,30 & 31 E61234.50 0 1
DG Cylinder assy. dummy D26,27,28,29,30,31 & 32 D100051.50 1 0
DH Liner assy. 4th stage D34, 41 & 42 C203034.100 0 1
PARTS
3RD & 4TH STAGE CYLINDER ASSEMBLIES USED On No Off
D1 Guide crosshead, 3rd stage D67049 DA 1 1
D2 'O' ring 95602.102 DA,KA 1 1
D3 Nut 95111.7 - 1 1
D4 Screw 95018.273 - 6 6
D5 'O' ring 95602.91 DB/KA 1 1
D6 Cylinder, 3rd stage E60170 DB 1 1
D7 Plug PS1068.3 DB 1 1
D8 Seal Dowty PS1322.3 DB 1 1
D9 Seal Dowty PS1322.6 DB 1 1
D10 Plug PS1068.5 DB 1 1
D11 Stud D66720.20.85 DB 4 4
D12 Pipe assy. water transfer D100710.1 - 1 1
D13 Nut 95111.11 - 4 4
D14 'O' ring 95602.81 DC/KA 1 1
D15 Liner, 3rd stage C86301 DC 1 1
D16 'O' ring 98504.1108 DC/KA 1 1
D17 Valve conc. 3rd stage 98650.1049 - 1 1
D18 'O' ring 98504.1108 DD/KA 1 1
D19 Ring, back-up 98504.1113 DD/KA 1 1
D20 'O' ring 98504.1107 DD/KA 1 1
D21 Cover valve, 3rd stage C86318 DD 1 1
D22 Guide crosshead, 4th stage D67049 DE 1 1
D23 'O' ring 95602.102 DE/KA 1 1
D24 Screw 95018.273 - 6 6
D25 Nut 95111.7 - 1 1
D26 'O' ring 95602.91 DG/KA 1 1
D27 Plug PS1068.3 DG 1 0
D27 Plug PS1068.6 DG 0 1
D28 Seal Dowty PS1322.3 DG 1 1
D29 Cylinder, 4th stage E61234 DG 0 1
D29.1 Cylinder, dummy D100051 DG 1 0
D30 Seal Dowty PS1322.8 DG 0 1
D31 Plug PS1068.3 DG 0 1
D32 Stud D66720.20.85 DG 0 4
D33 Nut 95111.11 - 0 4
D34 Liner, 4th stage C203034 DH/KA 0 1
D35 Valve conc. 4th stage 98650.1794 - 0 1
D36 'O' ring 98504.1110 DF/KA 0 1
D37 Ring, back-up 98504.1091 DF/KA 0 1
D38 'O' ring 98504.1109 DF/KA 0 1
D39 Cover, valve, 4th stage C86319 DF/KA 0 1
D40 - - - 0 0
D41 'O' ring 95602.72 DH/KA 0 2
D42 'O' ring 95604.79 DH/KA 0 1
1176pl.doc 28/10/02 Page 9

Page 10
E5
E4
E6
E2 E7
E8
E9 EB
E3
E11
E26
E10
E25
EB G21 E12
E1
E13
E29
E28 E14
E15
E16
E24
E24.1
E27
G5 EB
E30
E31
E37 E36 E32

E23
E18 & E22
E17 E19, E20 & E21
E33
E34
E35 EA
E33
E
Page 10 1176pl.doc 28/10/02
INTERSTAGE COOLER BODY ASSEMBLY
Page 11
LIST E
ASSEMBLIES
COOLER BODY ASSEMBLY Used On - No Off

EA Disk bursting & gaskets E33, 34, 35 C201556.100 1 1
EB Body cooler assy. E1,9,25,27,30,G5,21 E60109.1.100 1 1
PARTS
COOLER BODY USED On No Off

E1 Body, cooler E60109.1 EB 1 1
E2 Plug PS1068.5 - 2 2
E3 Seal 98660.1156 - 2 2
E4 Door, cooler D100168 - 1 1
E5 Screw 95033.556 - 26 26
E6 Cover, cooler inspection C200527 - 1 1
E7 Gasket D100026 KA 1 1
E8 Nut 95111.9 - 5 5
E9 Stud D66720.16.99 EB 5 5
E10 Panel, pressure gauge C86481 - 0 1
E10.1 Panel, pressure gauge C200121 - 1 0
E11 Screw 95093.368 - 8 8
E12 Gauge, pressure 4th stage 98288.1005 - - 1
E13 Gauge, pressure 3rd stage 98288.1004 - 1 1
E14 Gauge, pressure 2nd stage 98288.1003 - 1 1
E15 Gauge, pressure 1st stage 98288.1002 - 1 1
E16 Gauge, pressure oil 98288.1001 - 1 1
E17 Seal 98660.1153 - 5 5
E18 Pipe assy. gauge, 1st stage D100027.4 - 1 1
E19 Pipe assy. gauge, 2nd stage D100027.5 - 1 1
E20 Pipe assy. gauge, 3rd stage D100027.6 - 1 1
E21 Pipe assy. gauge, 4th stage D100027.7 - 1 1
E22 Pipe assy. gauge, oil D100027.8 - 1 1
E23 Seal 98660.1102 - 4 5
E24 Eyebolt, lifting 98086.1002 - 3 3
E24.1 Eyebolt, lifting label PS1723 - 1 1
E25 Stud D66720.10.125 EB 17 17
E26 Nut 95111.6 - 17 17
E27 Stud D66720.16.89 EB 5 5
E28 Nut 95111.9 - 5 5
E29 Nut 95111.6 - 2 2
E30 Stud D66720.10.75 EB 2 2
E31 Seal, dowty PS1322.3 - 1 1
E32 Plug PS1068.3 - 1 1
E33 Gasket, bursting disk C81788 EA/KA 2 2
E34 Disk, bursting - plastic C200053 EA/KA 1 1
E35 Disk, bursting - metal C201658.2 EA/KA 1 1
E36 Cover, bursting disk C200584 - 1 1
E37 Screw 95000.282 - 4 4
E38 Stud D67975.12.40 - 8 8
1176pl.doc 28/10/02 Page 11

Page 12
F43
F42
F41
F43 F42
F19
F17
F18
F17
F16
F15
F13 F28 F27 F26
F14 F30
FB F12 F29 FC
F38
F39
F11 F25 F24 F23 F22
F10 FB
F40
F9
F8
F7
F6
FA
F5 F2 F3
FAF4
F1
F32
F31
F33
F34 F44
F37 F35 F36 F35
FD
F
Page 12 1176pl.doc 28/10/02
4th STAGE COOLER & SEPARATOR
Page 13
LIST F
ASSEMBLIES
4TH STAGE COOLER & SEPARATOR ASSEMBLY Used On - No Off
FA Bottom assy. separator F1 & 5 C201853.50 0 1
FB Cover assy. cooler F7,8,9,12,13,14,15,16,17, C202957.50 0 1
19,20,21,22,23,24,25,38,
39,40,41,42
FC Coil assy. cooler F26,27,28,29,30 E60565.50 0 1
PARTS
TH USED On No Off
4 STAGE COOLER & SEPARATOR
F1 Fitting, bottom C201853 FA 0 1
F2 Seal 98660.1153 FA 0 1
F3 Plug PS1814.4 FA 0 1
F4 Ring, back-up 98504.1093 FA/KA 0 1
F5 'O' ring 95602.116 FA/KA 0 1
F6 Body, separator C201856 - 0 1
F7 'O' ring 95602.116 FB/KA 0 1
F8 Ring, back-up 98504.1093 FB/KA 0 2
F9 Nut, back 95411.269 FB 0 1
F10 Shroud C202955 FB 0 1
F11 Pipe, inlet C202963 FB 0 1
F12 Fitting top, separator D100629 FB 0 1
F13 Stud D66720.10.130 FB 0 4
F14 Nut 95111.6 FB 0 4
F15 Seal 98660.1156 FB 0 1
F16 Plug (optional) PS1454.6 - 0 1
F16.1 Switch, H.A. temperature C202960.1 FB 0 1
F16.2 Pocket, H.A. temperature C201708 FB 0 1
F17 Seal 98660.1155 FB 0 1
F18 Adaptor C82148 FB 0 1
F19 Valve, non-return 98650.1655 FB 0 1
F20 'O' ring 95602.62 FB/KA 0 1
F21 Cover, O/E cooler D100630 FB 0 1
F22 Plug PS1814.1 FB 0 1
F23 Seal 98660.1156 FB 0 1
F24 Valve, safety 98650.1190-385 FB 0 1
F25 Seal 98660.1155 FB 0 1
F26 Coil, cooler E60565 FC 0 1
F27 'O' ring 95602.87 FC/KA 2 2
F28 'O' ring 95602.39 FC/KA 0 1
F29 Stud D66720.8.42 FC 0 4
F30 Nut 95111.5 FC 4 4
F31 Screw 95000.315 - 0 1
F32 Bracket, support C201899 - 0 1
F33 Washer 95148.14 - 0 2
F34 Screw 95000.282 - 0 2
F35 Seal 98660.1153 - 0 2
F36 Adaptor, drain valve 98261.1451 - 0 1
F37 Valve, drain 98261.1071 - 0 1
F38 Adaptor C202957 FB 0 1
F39 Pipe, outlet C202954 FB 0 1
F40 Deflector C202956 FB 0 1
F41 Rod, tie C200218 - 1 0
F42 Plate, blanking C201920 - 2 0
F43 Nut 95111.6 - 2 0
F44 Spring Washer 95179.7 - 2 2
1176pl.doc 28/10/02 Page 13

Page 14
G26
G32
G27
G33
G18
G28
G19 G21
G20
G29
G17
G25
G31
G15
G31
G14
G16 G41
G23 5336 ONLY
G24
G43
G22 G44 G42
G34
G39 G35
G4 G36
G3 G9
G8
G37
G38
G6
G5 G7 G10 G11
G2
G1
G 1st, 2nd & 3rd STAGE COOLERS
Page 14 1176pl.doc 28/10/02

Page 15
LIST G
ASSEMBLIES
1ST, 2ND & 3RD STAGE COOLER PARTS Used On - No Off
GA Separator Assembly G7,34,35,36,37,38,39,40 E61182 1 1
PARTS
ST ND RD USED On No Off
1 ,2 &3 STAGE COOLER PARTS
G1 Cover, cooler C200173 - 1 1
G2 Gasket, 3rd stage C200060 KA 1 1
G3 Seal 98660.1155 - 1 1
G4 Valve, safety 3rd stage 98650.1022-100 - 1 1
G5 Tube, cooler 3rd stage C200796.2 EB 10 10
G6 Gasket, 3rd stage C200060 KA 1 1
G7 Separator, 3rd stage E61142 - 1 1
G8 Plug, reducing C73732.14 - 0 1
G9 Seal 99660.1157 - 1 1
G10 Seal 98660.1153 - 0 1
G15 Valve, safety 2nd stage 98650.1021-24 - 1 1
G16 Cover, cooler D101616 - 1 1
G17 Plug PS1454.7 - 1 1
G18 Plug PS1068.3 - 1 1
G19 Seal 98660.1154 - 1 1
G20 Gasket C200061 KA 1 1
G21 Tubes, cooler C200098.1 EB 30 30
G22 Plug PS1454.7 - 3 3
G23 Plug PS1068.2 - 2 2
G24 Seal 98660.1153 - 2 2
G25 Cover, cooler D101615 - 1 1
G26 Plug PS1068.3 - 1 1
G27 Seal 98660.1154 - 1 1
G28 Seal 98660.1155 - 1 1
G29 Plug PS1068.4 - 1 1
G30 Plug PS1454.7 - 2 2
G31 Gasket D100025 KA 1 1
G32 Seal 98660.1155 - 1 1
G33 Valve, safety 98650.1020-3.8 - 1 1
G33 Valve, safety 98650.1020-4.8 - 0 0
G34 Cap, separator C202884 GA 0 1
G35 'O' ring, separator 95602.83 GA 1 1
G36 Pipe, outlet, separator C202883 GA 1 1
G37 Shroud, separator C202869 GA 1 1
G38 Mushroom, separator C202881 GA 1 1
G39 Nut, separator 95111.7 GA 1 1
G40 Plug, separator PS1454.6 GA 1 1
G41 Valve, non-return 98650.1566 - 1 0
G42 Union 98156.1415 - 1 0
G43 Washer " BSP 98660.1156 - 1 0
G44 Washer " BSP 98660.1155 - 1 0
1176pl.doc 28/10/02 Page 15

Page 16
HA
H24 H10 H9 H7
H22
H21
H13 H2 H1
H14
H15
H66 H61
H67
H62
H65
H63
H11 H23
H43
H41
H69 H68
H70 H64
H42
H40
H39
H32
H38
H37
H36 H33
H34
H35
H LUBRICATION ASSEMBLIES
Page 16 1176pl.doc 28/10/02

Page 17
LIST H
ASSEMBLIES
LUBRICATION PARTS ASSEMBLIES Used On - No Off
Assy No Description Comprising Of Part No. H5336 2 H5436.2
HA Pump, Oil Drive Assy H7, 9 & 10 C85737.3 1 1
HB Pump, Oil Assy H7, 9, 10, 12 & 13 C85737.2.50 1 1
HC Oil Pipe Assy 4th Stage H61,62,63,64,65 & 66 D100579.7 0 1
PARTS
LUBRICATION PARTS USED On No Off
H1 Gasket C200869 KA 1 1
H2 Pin, dowel 95502.366 - 2 2
H7 Pin, dowel 95504.424 HA/HB 2 2
H9 Fitting, drive C85737.1 HA/HB 1 1
H10 Pin, tension 95540.165 HA/HB 1 1
H11 Filter, oil 98262.1009 HB 1 1
H12 Gasket C200900 HB/KA 1 1
H13 Pump, oil 98446.1001 HB 1 1
H14 Screw 95000.255 - 1 1
H15 Screw 95000.257 - 2 2
H22 Screw 95000.256 - 10 10
H23 Outer End Cover D100234 - 1 1
H24 Screw 95000.285 - 4 4
H24.1 Nut 95111.6 - 4 4
H32 Pipe, oil gauge feed D100579.3 - 1 1
H33 Pipe, oil pressure switch feed D100579.4 - 1 1
H34 Pipe, oil feed bearings D100579.2 - 1 1
H35 Pipe, oil suction feed D100579.1 - 1 1
H36 Pipe, breather C73514.420.90 - 1 1
H37 Socket, breather 95405.1027 - 1 1
H38 Pipe, stand breather C200748 - 1 1
H39 Filter, breather 98262.1044 - 1 1
H40 'O' ring, breather 98504.1079 KA 1 1
H41 Coupling, stud, breather C200886 - 1 1
H42 Pipe, breather 98617.1003 - 1 1
H43 Elbow, stud, breather 95440.234 - 1 1
H61 Nipple 95414.161 HC 0 1
H62 Valve, non-return 98650.1877 HC 0 1
H63 Elbow - was 95405.51 98156.1664 HC 0 1
H64 Coupling - only used with 95405.51 98156.1045 HC 0 1
H65 Pipe M3130.1046 HC 0 1
H66 Coupling 98156.1046 HC 0 1
H67 Bracket C203037 - 0 1
H68 Clamp, pipe 98150.1042 - 0 1
H69 Screw 95018.170 - 1 1
H70 Nut 95111.4 - 0 1
1176pl.doc 28/10/02 Page 17

Page 18
st
1 Stage Pressure from Separator
J29
J23
J20 J28
J24 J21
J27
J26
J25
J22 J22 4th Stage

J21 Separator
J22 J26 Drain.
3rd J24
J24 Stage
J39 J30
J19 2nd
J18 Stage J11
1st Stage J31
J17 Separator J12
Drain. J38 J30
J34
J37
J13 J36 J24
J11
J9 J32
J12
J15 J6
J24
J13 J33 J8
J16
J35
J24 J7
J15
J13 J29
J10
J14
J9
J22
J8
3rd Stage
J7 J30 Separator
J6 Drain.
J1 J24
J2
J32
J3
J34
J4 J33
J5
J24
J3
J2
J DRAIN VALVES & SURGE VESSEL
Page 18 1176pl.doc 28/10/02

Page 19
LIST J
ASSEMBLIES
PARTS
DRAIN VALVE & SURGE VESSEL PARTS USED On No Off
J1 Valve, safety 98650.1011 - 1 1
J2 Seal 98660.1157 - 1 1
J3 Vessel, surge E60337 - 0 1
J3.1 Vessel, surge E60339 - 1 0
J4 Plug, blanking PS1068.1 - 1 1
J5 Screw 95000.281 - 4 4
J6 Seal, nylon C201488.2 - 1 2
J7 Seal, nylon C201488.1 - 2 4
J8 'O' ring 95602.67 - 2 4
J9 Nipple 95414.165 - 2 4
J10 Valve assy, diaphragm drain U334.L - 1 1
J11 Bolt 95006.157 - 1 2
J12 Seal RT6495.56 - 2 2
J13 Seal 98660.1156 - 3 3
J14 Elbow 95405.97 - 1 1
J15 Coupling, stud 95440.46 - 2 2
J16 Pipe, nylon 98617.1014 - 1 1
J17 Elbow 95411.24 - 1 1
J18 Seal 98660.1155 - 1 1
J19 Nipple 95414.164 - 1 1
J20 Pipe, nylon 98617.5106 - 1 1
J21 Coupling, stud 95440.30 - 2 2
J22 Seal 98660.1152 - 5 5
J23 Coupling, banjo 95440.579 - 1 1
J24 Seal 98660.1153 - 6 6
J25 Valve, solenoid 220V 50hz PS2197.1 - 1 1
J25.1 Valve, solenoid 110V 50hz PS2197.2 - opt opt
J26 Nipple 95414.161 - 2 2
J27 Tee 95405.349 - 1 1
J28 Pipe 98617.5106 - 1 1
J29 Elbow 95440.178 - 0 1
J30 Coupling, stud 98156.2116 - 1 3
J31 Pipe M3130.0603 - 1 1
J32 Valve assy, diaphragm drain U334.J - 0 1
J32.1 Valve assy, diaphragm drain U334.K - 1 0
J33 Coupling, banjo 98156.2097 - 1 0
J33 Coupling, banjo 98156.2259 - 1 1
J34 Pipe M3130.0603 - 1 1
J35 Coupling, banjo 98156.2094 - 1 1
J36 Pipe M3089.1008 - 1 1
J37 Coupling, stud 98156.1050 - 1 1
J38 Seal 98660.1154 - 1 0
J38 Seal, dowty PS1322.3 - 0 1
J39 Elbow, coupling 98156.1239 - 1 1
1176pl.doc 28/10/02 Page 19

Page 20
K1
K2
K2
K10.1, K31 & K32
K4
K3
K5
FINAL DELIVERY
K5.1
ND
2 STAGE 5336
RD
K7 K6 3 STAGE 5436
K7
K6
K18
K17
K16
K20
K15
K19
K14
K13
K21
K11
K22
K23.1
K23
K
K24
K
Page 20 1176pl.doc 28/10/02
EXTERNAL COMPONENTS
Page 21
LIST K
ASSEMBLIES
PARTS
EXTERNAL COMPONENTS Used On - No Off
KA 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,
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
KB 'O' ring Valve kit C12,13,31.:D18,19,20,36,37,38, 98504.1001 1 1
40.:F19.1 M10,:N7,P7,Q7
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 USED On No Off
K1 Pipe assy. 3rd stage suction D100576.2 - 1 1
K2 Seal 98660.1156 - 2 2
K3 Pipe assy. 3rd stage delivery D100576.3 - 1 1
K4 Seal 98660.1156 - 2 2
K5 Thermometer, 3rd stage C202556.8 - 0 1
K5 Thermometer, 3rd stage C202556.3 - 1 0
K5.1 Thermometer, final stage C202960.1 - 1 1
K6 Pocket, thermometer C201708 - 0 2
K6.1 Pocket, thermometer C201710 - 1 0
K7 Seal 98660.1156 - 1 2
K10.1 Bracket , thermometer C203063 - 1 1
K11 Rod, corrosion C202833 - 1 1
K11.1 Anode, corrosion rod 98163.1002 - 1 1
K13 Pipe assy. final delivery E60741 - 0 1
K13.1 Seal Diamond C86896.1 - 0 2
K13.2 Union C201579 - 0 2
K14 Seal, ring C86896.1 - 0 2
K15 Pipe assy. 4th stage suction D100576.5 - 0 1
K16 Pipe assy. water transfer D100710.2 - 1 1
K17 Seal PS1322.8 - 2 2
K18 Pipe Assy. 2nd stage suction D100576.1 - 1 1
K19 Gasket C200118 KA 1 1
K20 Screw 95000.284 - 4 4
K21 Gasket C11359-62 KA 1 1
K22 Screw 95000.312 - 4 4
K23 Filter/silencer, inlet 98262.1010 - 1 1
K23.1 Flange inlet C202814 - 0 0
K24 Element, filter/silencer 98262.1063 - 1 1
K31 Plate Legend C203057 - 0 1
K31.1 Plate Legend C203062 - 1 0
K32 Screw Button Head 95033.386 - 2 2
1176pl.doc 28/10/02 Page 21

Page 22
DRIVE ARRANGEMENTS
L1
L2
L3
L4
L5
L6
DIRECT DRIVE
L7
L9 L9
L6
L6 On Motor
L8 L8
L7 L7
2.8 2.18 2.6 2.17 2.16 2.7
VEE DRIVE
2.12
2.15
2.1
2.11
2.2
2.3
2.9
L 2.4 2.14 2.13 2.12 2.5 2.10
Page 22 1176pl.doc 28/10/02

Page 23
LIST L
DIRECT DRIVE ARRANGEMENTS TYPICAL
PARTS
REF NUMBER. DESCRIPTION PART NUMBER NO. OFF

L1 HOUSING BELL PS1813.12 1
L2 SCREW 95000.315 10
L3 FLYWHEEL E60248.2 1
L4 KEY PS1130.21 1
L5 SCREW 95000.312 1
L6 WASHER SPRING 95179.8 3
L7 MOUNT ANTI VIBRATION 98418.1015 3
L8 SPACER C200854 3
L9 SCREW 95000.312 1
LIST L
VEE DRIVE ARRANGEMENTS TYPICAL
PARTS
REF NUMBER. DESCRIPTION PART NUMBER NO. OFF

2.1 MOTOR PLATE C200716 2
2.2 MOTOR ADJUSTING BLOCK C86469 2
2.3 MOTOR ADJUSTING SCREW C86470.1 2
2.4 STUD M16 D66720.16.60 2
2.5 MOTOR BRACKET E60017 1
2.6 FLYWHEEL E60249 1
2.7 VEE BELT GUARD E60253 1
2.8 KEY PS1130.21 1
2.9 SETSCREW M8 95000.260 4
2.10 SETSCREW M10 95000.281 1
2.11 SETSCREW M12 95000.315 4
2.12 SETSCREW M16 95000.344 7
2.13 NUT M16 95111.9 2
2.14 WASHER M12 95148.20 4
2.15 SETSCREW M20 95000.373 4
2.16 TAPERLOCK BUSH 98074.1120 1
2.17 PULLEY MOTOR 160 98080.1217 1
2.18 VEE BELTS 98080.1451 5
1176pl.doc 28/10/02 Page 23

Page 24
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
Page 25
LIST M
ASSEMBLIES
PARTS
1ST STAGE VALVE ASSEMBLIES Used On - No Off

MA Kit, maintenance M2,3,4,5,6,7,10,11 98650.1518 1 1
PARTS
1ST STAGE VALVE PARTS USED On No Off

Valve complete 98650.1519 - 1 1
M1 Body, lower - 1 1
M2 Plate, valve MA 1 1
M3 Plate, spring MA 2 2
M4 Plate, spring MA 2 2
M5 Washer, lift MA 1 1
M6 Plate, valve MA 1 1
M7 Washer, lift MA 1 1
M8 Peg - 2 2
M9 Peg - 2 2
M10 'O' ring 95602.93 MA/KB 1 1
M11 Nut MA 1 1
M12 Body, upper - 1 1
Withdrawer, Valve C200066.1 - 1 1
1176pl.doc 28/10/02 Page 25

Page 26
N1
N2
N3
N2
N4
N5
N6
N9
N7
N8
N 2ND STAGE CONCENTRIC VALVE
Page 26 1176pl.doc 28/10/02

Page 27
LIST N
ASSEMBLIES
PARTS
2ND STAGE VALVE ASSEMBLIES Used On - No Off

NA Kit, maintenance N2,3,4,5,7,8 98650.1533 1 1
PARTS
2ND STAGE VALVE PARTS USED On No Off

N1 Body, lower - 1 1
N2 Plate, valve/backing NA 2 2
N3 Plate, spring NA 4 4
N4 Plate, spring NA 3 3
N5 Plate, valve NA 1 1
N6 Peg - 2 2
N7 'O' ring 95602.55 NA/KB 1 1
N8 Nut NA 1 1
N9 Body, upper - 1 1
Withdrawer, Valve C84096.1 - 1 1
1176pl.doc 28/10/02 Page 27

Page 28
P1
P2
P3
P2
P4
P5
P6
P7
P8
P9
P
Page 28 1176pl.doc 28/10/02
3RD STAGE CONCENTRIC VALVE
Page 29
LIST P
ASSEMBLIES
PARTS
3RD STAGE VALVE ASSEMBLIES Used On - No Off

PA Kit, maintenance P2,3,4,5,7,8,9 98650.1059 1 1
PARTS
3RD STAGE VALVE PARTS USED On No Off

P1 Body, lower - 1 1
P2 Plate, valve/backing PA 2 2
P3 Plate, spring PA 4 4
P4 Plate, spring (pack) PA 1 1
P5 Plate, valve PA 1 1
P6 Body, upper - 1 1
P7 'O' ring 95604.24 PA/KB 1 1
P8 Washer PA 1 1
P9 Nut PA 1 1
Withdrawer, Valve C200142 - 1 1
1176pl.doc 28/10/02 Page 29

Page 30
Q1
Q2
Q3
Q4
Q5
Q6
Q7
Q8
Q 4TH STAGE CONCENTRIC VALVE
Page 30 1176pl.doc 28/10/02

Page 31
LIST Q
ASSEMBLIES
PARTS
4TH STAGE VALVE ASSEMBLIES Used On - No Off
QA Kit, maintenance Q2,3,4,5,7,8 98650.1832 0 1
PARTS
4TH STAGE VALVE PARTS USED On No Off
Q1 Body, lower - 0 1
Q2 Plate, valve QA 0 1
Q3 Plate, spring QA 0 4
Q4 Spring QA 0 1
Q5 Plate, valve QA 0 1
Q6 Body, upper - 0 1
Q7 'O' ring 95604.20 QA/KB 0 1
Q8 Nut QA 0 1
Withdrawer, Valve C200142 - 0 1
1176pl.doc 28/10/02 Page 31

Page 32
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
Page 33
LIST R
ASSEMBLIES
PARTS
1ST & 2ND STAGE DIAPHRAGM DRAIN VALVE Used On - No Off

ASSEMBLIES
RA Kit, valve maintenance R3,5,6,7,11,12 98650.1531 1 1
RA Kit, diaphragm maintenance R4,8 98650.1535 2 2
PARTS
1ST & 2ND STAGE DIAPHRAGM DRAIN VALVE PARTS USED On No Off
Valve complete U334.L - 1 1
R1 Nut, back PS1290.4 - 2 2
R2 Body C200841 - 2 2
R3 Seat C200842 RA 1 1
R4 Gasket C200722 RB 4 4
R5 Valve Assembly C201980 RA 1 1
R6 Plate, mushroom - RA 2 2
R7 Screw - RA 2 2
R8 Diaphragm 98210.1002 RB 2 2
R9 Cover, centre C200841 - 1 1
R10 Bolt 95006.133 - 6 6
R11 Valve Assembly C201981 RA 1 1
R12 Seat C201417 RA 1 1
1176pl.doc 28/10/02 Page 33

Page 34
S10
5436 MK2
S2
S1
S4
S3
S5 S6
S7
S8
S4
S9
S4
S8 5336 MK2
S7
S6
S5 S12
S4
S3
S11
S2
S1 S9
S4
S10
S8
S7
S6
S5
S4
S3
S2
S1
S
Page 34 1176pl.doc 28/10/02
3rd & 4th STAGE DIAPHRAGH DRAIN VALVE
Page 35
LIST S
ASSEMBLIES
PARTS
3RD & 4TH STAGE DIAPHRAGM DRAIN VALVE Used On - No Off
ASSEMBLIES
SA Kit, valve maintenance S3,5,6,7, 98650.1532 0 1
SA Kit, diaphragm maintenance S4,8 98650.1535 1 2
PARTS
3RD & 4TH STAGE DIAPHRAGM DRAIN VALVE PARTS USED On No Off
Valve complete U334.J - 0 1
Valve complete U334.K - 1 0
S1 Nut, back PS1290.4 - 1 2
S2 Body C200840 - 1 2
S3 Seat C201159 SA 1 2
S4 Gasket C200722 SB 2 4
S5 Valve Assembly C201981 SA 1 2
S6 Plate, mushroom - SA 2 2
S7 Screw - SA 1 2
S8 Diaphragm 98210.1002 SB 1 2
S9 Cover, centre C200841 - 0 1
S9 Cover, end C200719 - 1 0
S10 Bolt 95006.133 - 3 6
S11 Screw 95000.229 - 3 0
S12 Nut 95111.4 - 3 0
1176pl.doc 28/10/02 Page 35

Page 36
LIST V
SERVICE TOOLS
Description Part Number What For No Off

Valve Withdrawer C200142 3rd & 4th Stage Valves 1
Valve Withdrawer C200066.1 1st Stage Valve 2
Valve Withdrawer C84096.1 2nd Stage Valve 1
Piston Withdrawer C200066.2 1st & 2nd Stage Pistons 1
Liner Withdrawer C200420 2nd Stage Liner 1
Stud for do C200421 2nd Stage Liner 2
Nut for do 95111.7 2nd Stage Liner 2
Piston Ring Compressor C200445 1st Stage Piston Rings 1
Cylinder Lifting Plate C200069.3 3rd & 4th Stage Cylinders 1
Page 36 1176pl.doc 28/10/02

CompAir UK Ltd PUBLICATION 98407/1176
Page 37
SECTION 10
ANCILLARY EQUIPMENT
PART DESCRIPTION PART REFERENCE PUBLICATION

PRESSURE MAINTAINING VALVE - 4362000W0000000 APP059
FINAL PRESSURE SWITCH - 43620000B000000 APP081
VEE DRIVE - 436200000P00000 APP012G
RADIATOR, WATER PUMP DRIVE - 436200000004000 APP073
SOLENOID VALVE - 436200000000300 APP138
ANTI VIBRATION MOUNTS - 436200000000005 APP003
WATER CONTROL VALVE U231.H APP071
RADIATOR COOLING SYSTEM GENERAL - 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 38 25/07/02 1176.doc

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

& TENSIONING.
BELT DRIVE ALIGNMENT
STRAIGHT EDGE
DISTANCE PIECES
STRAIGHT EDGE
50 mm
COMPRESSOR
ELECTRIC
COMPRESSOR MOTOR
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
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:-
MOTOR PULLEY Y407750.013A 1off

TAPER-LOCK BUSH 98074.1119 1off
BELT 2000 SPB 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
TABLE
Belt Force required to deflect belt 16 mm per metre of span
Section
Belt Small Pulley Newton Kilogram force
Section mm (N) (kgf)
SPB 160 to 224 35 to 50 3.5 to 5.1
236 to 315 50 to 65 5.1 to 6.6
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 belt, on single belt drives place a straight edge across the two pulleys to act as a
datum.
5. Read off the force value indicated by the top edge of the upper marker ring.
6. Compare this force to kgf value shown in the table above.
7. Tighten or loosen belt tensioner to achieve the correct value.
8. If the measured force falls within the values given, the drive should be satisfactory.
Note:- If a belt tension indicator is not available, a suitably scaled spring balance and rule will
suffice.
DEFLECTION DEFLECTION FORCE

IN mm IN kgf
app012c.doc
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 13
8
SEE LUBRICATION SECTION IN HANDBOOK FOR DETAILS OF OIL PUMP ETC.
Item No Part No Description No Off

1 C201503 Gasket water pump 2
2 C201504 Gasket water pump 2
3 C201537 Sprocket water pump drive 1
4 C201538 Gasket water pump bracket 1
5 C201809 Flange water pump 2
6 C85739/1 Sprocket water pump drive 1
7 C85740/1 Pillar chain tensioner (if fitted) 2
8 D100526 Cover outer end 1
9 D100527 Bracket water pump housing 1
10 PS1180/9 Clip hose 6
11 PS1923/3 Capscrew 4
12 PS2062 Chain water pump drive 1
13 95000/227 Setscrew 2
14 95000/254 Setscrew 6
15 95000/256 Setscrew 3
16 95111/5 Nut 3
17 98146/1001 Tensioner chain (if fitted) 1
18 98315/1102 Hose plastic 2
19 98446/1009 Pump water 1
20 95071/27 Screw cone point 1
21 98156/3113 Hose adaptor 2
22 95405/869 Bush hexagon male & female (5236) only 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
WATER COOLING EXPANSION
SYSTEM FILLER TANK
CAP
VENT PIPE
WATER PUMP OUTLET

CONNECTING CONNECTION TO
PIPES 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. Ensure the inlet & outlet connections are connected to a suitable closed circuit water system.
2. Ensure all water drain plugs/cocks etc. are closed.
3. Remove expansion tank filler cap.
4. Allow system to fill by turning on the water supply.
5. Fill system with clean fresh water.
6. Replace filler cap.
7. Start compressor, run for 2 minutes and stop.
8. Gently release filler cap, remove and top-up.
9. 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.
TOPPING UP.
2. TOPPING UP.
If hot, it is best to leave until cool before attempting to top-up cooling water.
1. Gently release filler cap,
2. Remove and top-up to required level.
4. Start compressor, check for air bubbles in water pipes as above.
app076a.doc
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.
COMPRESSOR SET APPROXIMATE CAPACITY

5315, 5317, 5415 & 5417 40 LITRES
5236 112 LITRES
5336, 5436, 5436.3.HA & 5437 100 LITRES
See before starting procedure in HANDBOOK in conjunction with the following.
1. Ensure all water drain plugs/cocks etc. are closed.

2. Remove radiator filler cap.
3. Fill system with clean coolant. (Antifreeze mixture should be used in low temperature
environments)
5. Start compressor, run for 2 minutes and stop.
6. Gently release filler cap, remove and top-up.
8. Re-start compressor, if any large air bubbles are evident in the pipework stop compressor.
9. Repeat (6), (7) & (8) until air bubbles are evacuated.
Note: any small air bubbles will evacuate during normal running through the vent pipe.
2. TOPPING UP.
If hot, it is best to leave until cool before attempting to top-up cooling water.
1. Gently release filler cap,

2. Remove and top-up to required level.
4. 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'.
Red Pointer
3 1
Green Pointer
4 2
SETTING
Example of pressure setting to 150 bar minimum and 175 bar maximum.
Turn screw (A) to raise the GREEN pointer to its highest point.
Turn screw (B) so that the higher setting (175 bar) coincides with the RED pointer.
Turn screw (A) again to set the lower pressure 150 bar on the GREEN pointer.
NOTE: ALWAYS USE A CALIBRATED PRESSURE GAUGE WHEN SETTING PRESSURE SWITCHES,
AS THE MARKINGS ON SWITCHES ARE FOR INDICATION ONLY.
app081.doc
CompAir UK Ltd APP 081 PRESSURE SWITCH 98524.1004
Page 2
app081.doc
CompAir UK Ltd. 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 3rd Stage 97 bar g rising

Y507851/002 2nd Stage 23 bar g rising
Y507851/003 1st Stage 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
Technical Details Current consumption

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

Connector To DIN 43650
Protection IP65
Cable thread size PG9
Coil Class 'H' 180C insulation
Coil duty Continuous
Voltage tolerance from normal -10% to +10%
Port Size G 1/8"
Orifice Size 1.6mm
Maximum working pressure 12 bar g.
Working fluid Air, water, gas, fuel oil & non corrosive liquids.
Ambient temperature range -15C to +50C
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
Fitted internally
INLET
BSP Ports
TEMPERATURE
Fluids : water, gas, air, oil and steam. + 5 to + 180C
Ambient + 5 to + 60C
PART NUMBERS Port Size BSP orifice mm *M.S.P bar

98560.1291 1/2" 15 16
U231.F - 98650.1292 3/4" 20 16
U231.H - 98650.1293 1" 25 16
* Maximum Service Pressure (LP pressure)
App071.DOC
Page 2
MAINTENANCE AND SPARES KITS
Part Number Description Makers Part Number Used on

Stem & Disc Kit 97701319
98405.1004 Stuffing Box & Nut Kit 97701320 98650.1291
Diaphragm Kit 97700017
98650.1292
98504.1005 Stuffing Box & Nut Kit 97701320
U231.F
98650.1293
98405.1006 Stuffing Box & Nut Kit 97701320
U231.H
98650.2208 Stem & Disc Kit 97701319 98650.1291
98650.1291
98650.2209 Stuffing Box & Nut Kit 97701320 98650.1292 - U231.F
98650.1293 - U231.H
98650.1291
98650.2210 Diaphragm Kit 97700017
98650.1292 - U231.F
98650.2211 Stem & Disc Kit 97701321 98650.1292 - U231.F
98650.2212 Stem & Disc Kit 97701322 98650.1293 - U231.H
98650.2213 Diaphragm Kit 97700018 98650.1293 - U231.H
DISMANTLING AND REASSEMBLING
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
Page 3
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
Page 4
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 recommended by CompAir UK Ltd may create unsafe and
hazardous conditions or result in damage to the equipment over which CompAir UK Ltd
has no control. Such hazardous conditions may lead to accidents that can be life
threatening, cause substantial bodily injury or result in damage to the equipment.
CompAir UK Ltd can bear no responsibility for equipment in which unapproved

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

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

Compair 5336 5436 Mk2 Operator Manual

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Compair 5336 5436 Mk2 Operator Manual

Uploaded by

Copyright:

Available Formats

CompAir UK Ltd

In any correspondence please quote: JOB NUMBER:

CompAir UK Ltd. Ranelagh Road IPSWICH ENGLAND IP2 0AQ

of RANELAGH ROAD, IPSWICH, ENGLAND IP2 0AQ

Machine Type Rotary Compressor Reciprocating Compressor

Model No. _________________________ Serial No.________________________________

DATE __________________ PRODUCT MANAGER

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

Nous, COMPAIR UK LIMITED

de RANELAGH ROAD, IPSWICH, ENGLAND IP2 0AQ

Type de machine Compresseur rotif Compresseur alternatif pistons

No de modle _________________________ No de srie __________________________________

DATE ____________________ _______________________

Deutsch Espaol Nederlands !

Wir COMPAIR UK LIMITED

mit Sitz in RANELAGH ROAD, IPSWICH, ENGLAND IP2 0AQ

Modellnr. __________________________________ Seriennr.__________________________________________

gem den Gesundheits-und Sicherheitsanforderungen der oben genannten Richtlinien.

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

con domicilio en RANELAGH ROAD, IPSWICH, ENGLAND IP2 0AQ

Tipo de mquina Compresor rotativo Compresor alternativo

N de modelo ______________________________ N de serie ________________________________________

FECHA ______________________ _______________________

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

Wij COMPAIR UK LIMITED

Van RANELAGH ROAD, IPSWICH, ENGLAND IP2 0AQ

Soort machine Zuigercompressor

Type nr ___________________________________ Serie nr ___________________________________________

DATUM _____________________ _______________________

of RANELAGH ROAD, IPSWICH, ENGLAND IP2 0AQ

Machine Type Rotary Compressor Reciprocating Compressor

Model No. _________________________ Serial No. _______________________________

DATE __________________ ______________ PRODUCTS MANAGER

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

Nous, COMPAIR UK LIMITED

de RANELAGH ROAD, IPSWICH, ANGLETERRE IP2 0AQ

Type de machine Compresseur rotatif Compresseur pistons

No de modle ______________________ No de srie ______________________________

DATE __________________ __________________________________

Wir COMPAIR UK LIMITED

aus RANELAGH ROAD, IPSWICH, ENGLAND IP2 0AQ

Maschinentyp: Kreiskolbenverdichter Hubkolbenverdichter

Modell-Nr. _________________________________ Serien-Nr. _________________________________________

con domicilio en RANELAGH ROAD, IPSWICH, ENGLAND IP2 0AQ

Tipo de mquina Compresor rotativo Compresor alternativo

N de modelo ______________________________ N de serie ________________________________________

FECHA _______________________ _______________________

Wij COMPAIR UK LIMITED

te RANELAGH ROAD, IPSWICH, ENGLAND IP2 0AQ

Type machine Roterende compressor Zuigcompressor

Model nr __________________________________ Serie nr ___________________________________________

DATUM ______________________ ______________________

OPERATOR MANUAL - 5000 SERIES AIR

CompAir UK Ltd Ipswich cannot accept responsibility for damage,

CompAir UK Ltd Ipswich

09/10/02 safety5.doc Page 1

Model Type: Motor Serial Number:

Serial Number Motor RPM:

Year: Motor kW:

Maximum Pressure: Motor V. Ph. Hz:

Compressor Lubricant: Motor Bearing Grease:

Capacity M/hr - CFM Notes:

CompAir UK Ltd Ipswich CONTACT DETAILS

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

Model No. _ Serial No.________

No de modle _ No de srie __________

DATE ___

Modellnr. Seriennr.________

N de modelo N de serie __________

FECHA _

Type nr _ Serie nr _________

DATUM _ ___

Model No. _ Serial No. _______

DATE ____ PRODUCTS MANAGER

No de modle No de srie ________

DATE ________________

Modell-Nr. _ Serien-Nr. _________

N de modelo N de serie __________

FECHA _ _

Model nr Serie nr _________

DATUM