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This service manual should be used in conjunction with the user handbook. Note: If you need any specialist help or service, please contact your distributor or CompAir UK Hydrovane quoting the MODEL TYPE and SERIAL NUMBER. Product development CompAir UK Hydrovane adopt a policy of continual product Improvement.
Failure to maintain the compressor correctly, or modifying it without advising that work is being carried out. prior approval from CompAir UK Hydrovane, may also create a hazardous condition. This will also invalidate the warranty. Do not undertake any work until the compressor and receiver if fitted, have been relieved of all pressure.
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Introduction GENERAL HEALTH AND SAFETY PRECAUTIONS (continued) Eye Contact - *Mildly irritating. Flush with copious amounts of When Operating the Compressor warm water. Seek medical advice if necessary. When in automatic mode the compressor will re-start without Aspiration - If there is any suspicion of aspiration into the warning.
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CompAir Hydrovane Introduction Servicing requirements Note: The following preventive maintenance charts cover all Hydrovane compressors using Hydrovane Fluid Force oils. The work to be carried out must be done on or before the hours shown for this action. Read health and safety precautions before starting any work.
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Introduction Preventative Maintenance Schedule Fluid Force Clear Every Every Every Every Every Maintenance Actions and Manual Every Every Install 1000 2000 6000 12000 24000 Reference Week Check RSU temperature Check starter contactors Check motor insulation resistance Clean air/oil radiator external Clean external dirt from motor Clean cabinet air filter Clean solenoids...
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CompAir Hydrovane Introduction Service schedule: Fluid Force 2000 (2000 Hour oil change) The bulk oil temperature must not exceed 90°c (Fluid Force 2000) or 100°c (Fluid Force HPO). If the oil is working above this temperature, the oil life will be reduced.
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Introduction Preventative Maintenance Schedule Fluid Force 2000/HPO Every Every Every Every Every Maintenance Actions and Manual Every Every Install 1000 2000 6000 12000 24000 Reference Week Clean external dirt from compressor Clean non-return filter Clean air filter Grease motor bearings (if applicable) Change Fluid Force 2000 oil Change oil filter Change air filter...
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CompAir Hydrovane Introduction Service schedule: Fluid Force HPO (4000 Hour oil change) The bulk oil temperature must not exceed 90°c. If the oil is working above this temperature, the oil life will be reduced. Note: When changing recommended oil types it is advisable to flush the compressor.
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Introduction Preventative Maintenance Schedule Fluid Force HPO Every Every Every Every Every Every Maintenance Actions and Manual Every Every Install 1000 2000 4000 8000 12000 24000 Reference Week Clean external dirt from compressor Clean oil return filter Clean air filter Grease motor bearings (if applicable) Change Fluid Force HPO oil Change oil filter...
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CompAir Hydrovane Introduction Service Kits Only use genuine CompAir UK Hydrovane parts and approved oils. Oils must not be mixed. Service kits contents Item Part Number Quantity Description Chapter Location KM71 - Maintenance Kit 50273 Air filter 9842 ‘O’ Ring 0053/1 P.T.F.E.
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Introduction Item Part Number Quantity Description Chapter Location 9607 Bonded Seal 9609 Bonded Seal 2K, 2L 9616 Bonded Seal 9619 Bonded Seal 9624 Bonded Seal 9751 ‘O’ Ring 9754 ‘O’ Ring 9810 ‘O’ Ring 9900 ‘O’ Ring 2E, 2L 52109 ‘O’...
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CompAir Hydrovane Introduction Key to symbols used Torque Setting Nm. 22mm Spanner Required (mm) A/F Silco Silco Allen key Required (mm) Grease Required (Specification) Loctite Required and Specification Number Service Tools Required and Part Reference 105 S Lubricate With Sump Oil...
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Introduction Service Tools required 1.5 Wide undercut to base 1.5 Wide undercut to base of thread of thread 36.0 Nozzle orifice Model 120° C.F.M Dia ‘A’ 60° 3.52mm 29.0 2.69mm 23.6 4.03mm 38.0 Dia 'A' Ream Dia 'A' Ream 12.0 Tol :- ±...
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CompAir Hydrovane Introduction Material Material Mild Steel Mild Steel Service Tools (S34) Page 14...
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Parts List and Service Manual Contents Chapter Page Routine Servicing ........... . . 1 ..17 Air-end.
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CompAir Hydrovane Limited This page is intentionally left blank Page 16...
CompAir Hydrovane Limited Routine Servicing Check pressure in Compressor air-end A Introduction Check compressor air-end pressure using compressor pressure WARNING ! gauge. If the correct size of compressor has been installed the gauge should read: READ HEALTH AND SAFETY PRECAUTIONS BEFORE YOU START ANY SERVICE WORK.
Routine Servicing Oil Top-up procedure (Fig 1.1) • Wait until the air-end vent down cycle is complete. • Open test valve to vent pressure from the air aftercooler and associated pipework. • Check that the air-end pressure gauge reads zero. •...
CompAir Hydrovane Limited Routine Servicing Oil draining procedure (Fig 1.3) • Wait until air-end vent down cycle is complete. • Open test valve to vent pressure from air aftercooler and associated pipework. • Check that compressor air-end pressure gauge reads xero.
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Air-end Chapter 2 Contents Section Page Air Intake Arrangement ..........A ..22 Changing air filter .
CompAir Hydrovane Minimum Pressure Valve and Oil Separator Quantity Item Part Number Description MCI-30 Circlip internal 33413 Minimum pressure valve assembly 50225 Male stud elbow 1/4 BSPT-6mm 58470 Adjuster plug 57742 M.P.V body 9758 O ring KM71 9717 O ring...
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Minimum Pressure Valve and Oil Separator Figure 2G - Minimum Pressure Valve and Oil Separator Page 41...
CompAir Hydrovane Intake End Cover - Removal Quantity Item Part Number Description 57747 Stator nut M12 9609 Bonded seal 1/4 KT71 Refer to Health and Safety section before carrying out any service work. Intake end cover removal • Stand drive end of compressor oil chamber on a raised platform.
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Intake End Cover - Removal 19mm Figure 2K - Intake End Cover - Removel Page 49...
CompAir Hydrovane Assembling the Rotor Stator Unit Quantity Item Part Number Description 57746 Stator stud M12 9609 Bonded seal 57747 Nut M12 58017-02 Shim 0.04 mm 58017-03 Shim 0.05 mm KT71 58017-04 Shim 0.08 mm KT71 59370-03 Shim 0.05 mm...
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Assembling the Rotor Stator Unit 19mm Figure 2L - Assembling the Rotor Stator Unit Page 51...
CompAir Hydrovane Assembling the Rotor Stator Unit ... Continued Quantity Item Part Number Description 33831-01 Intake end cover assembly 33831-02 Intake end cover assembly 58039 Intake end cover 59425-04 Taper plug brass 1/2 BSP (non-servo) MG1706-6 Grub screw tuflock M6 x 6...
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Assembling the Rotor Stator Unit ... Continued Figure 2L - Assembling the Rotor Stator Unit ... Continued Page 53...
CompAir Hydrovane Minimum Pressure Valve Assembly Quantity Item Part Number Description MCI-30 Circlip internal 33413 Minimum pressure valve assembly 73283 Elbow 58470 Adjuster plug 57742 M.P.V. Body 9758 O Ring KM71 9717 O Ring KM71 9711 O Ring KM71 57842 M.P.V.
CompAir Hydrovane Oil Cooler;Base Quantity Item Part Number Description 1911 Stud elbow c/w nuts 53549 Stud coupling ½ BSP 70832 Door seal 0.7 m 71129 Stud elbow 71130 Tee ½ x 15 mm 71131 Blanking plug 71432 Cooler 73901 Oil feed pipe...
CompAir Hydrovane Ventdown Assemblies Quantity Item Part Number Description D.O.L STANDARD CONTROL 73220 Solenoid valve 110 V N.O. 73215 Elbow, push-in, R 1/8 “ - 6 mm 73283 Elbow, push-in, R 1/4 “ - 6 mm 73282 Tee, push-in, 6 mm...
CompAir Hydrovane Air-end Part Modifications Air-end Part Modifications Serial No. Prefix Compressor(s) New Part(s) Old Part(s) Service Bulletin Page 66...
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Starter Assembly Part Modifications Figure 3D - 400V, 50Hz and 380/440V, 60Hz Standard Control Starter Page 75...
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CompAir Hydrovane 400V 50Hz and 380/440V 60Hz Standard Control Starter Quantity Item Part Number Description Starter Assembly No. 34409 74029 Contactor 110V 60Hz 74024 Terminal, double stack 74025 End section 74026 Transformer 56132 Fuse 1A 59344 OTC board 56122 Timer...
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400V 50Hz and 380/440V 60Hz Standard Control Starter Figure 3E - 400V, 50Hz and 380/440V, 60Hz Standard Control Starter Page 77...
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CompAir Hydrovane 230V 50/60Hz Standard Control Starter Quantity Item Part Number Description Starter Assembly No. 34423 74112 Contactor 74063 Auxilary contact block 74113 Auxilary contact block 56378 Timer (Star/Delta) 74064 Circuit breaker 56122 Timer 53494 Timer base 59344 OTC board...
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230V 50/60Hz Standard Control Starter Figure 3F - 230V, 50/60Hz Standard Control Starter Page 79...
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CompAir Hydrovane 230V 50/60Hz D.O.L. Standard Control Starter Quantity Item Part Number Description Starter Assembly No. 34424 74029 Contactor 74024 Terminal, double stack 74025 End section 74026 Transformer 56132 Fuse 1A 59344 OTC board 56122 Timer 53494 Timer base 74067...
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230V 50/60Hz D.O.L. Standard Control Starter Figure 3G - 230V, 50/60Hz D.O.L. Standard Control Starter Page 81...
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CompAir Hydrovane Starter Assembly Part Modifications Starter Assembly Parts Modifications Serial No. Prefix Compressor(s) Ref. New Part(s) Old Part(s) Service Bulletin Page 82...
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CompAir Hydrovane Labels Quantity Item Part Number Description 74160 Airend kit Refer to Health and Safety section before carrying out any service work. Page 84...
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CompAir Hydrovane Labels Parts Modifications Label Parts Modifications Serial No. Prefix Compressor(s) Ref. New Part(s) Old Part(s) Service Bulletin Page 86...
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Adjustment procedures shown must only be carried out by authorised persons fully trained and competent in the maintenance of CompAir UK Hydrovane compressors. If you are not able to carry out the work safely, contact your CompAir UK Hydrovane distributor. B - Pressure Switch Adjustment (Fig. 5.1) •...
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Adjustments and Testing E - Oil Temperature • Introduce a small amount of oil and a thermometer into the thermometer pocket. • Allow compressor to run for 30 minutes in order to attain its normal working temperature. • ° Average running temperature should be 88 C approx.
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CompAir Hydrovane Adjustments and Testing This page is intentionally left blank Page 90...
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Fault Finding Chapter 6 Contents Page System Pressure Low ..........A ..92 Low or No Air Delivered by Compressor .
READ HEALTH AND SAFETY PRECAUTIONS BEFORE YOU START ANY SERVICE WORK. Servicing of the compressor must only be carried-out by authorised persons fully trained and competent in the maintenance of CompAir UK Hydrovane compressors. They must fully understand and adopt correct and safe working practices. 05/07 Troubleshooting chart...
Fault Finding Cause Cause Cause Ref Symptom Diagnosis Action (Level 1) (Level 2) (Level 3) Read pressure gauge. If 1 Oil return Separator Replace separator and bar, remove separator cap restrictors flooded with oil return restrictors and bottle and examine. blocked Compressor will run very Rotor blades...
CompAir Hydrovane Fault Finding Cause Cause Cause Ref Symptom Diagnosis Action (Level 1) (Level 2) (Level 3) If separator element are Remove separator cap broken, Replace separator and bottle and examine element, oil return separator. restrictors, clean oil filter and change oil...
Fault Finding Cause Cause Cause Ref Symptom Diagnosis Action (Level 1) (Level 2) (Level 3) Leaking bearing cap Replace end cap gasket gasket Leaking Replace unloader valve unloader valve seat Read pressure gauge in Faulty safety test point and check Worn spring Replace safety valve valve...
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