CompAir HV04 Troubleshooting guide

Parts List/Service Manual
HV04 - HV07 Models (ACS)
Stationary Air Compressors
ST 16049-00 Iss A 05/2003
Cover HV04-07 parts list 3/10/03 3:26 pm Page 1

Parts List/Service Manual
HV04 - HV07 Models (ACS)
Stationary Air Compressors
ST 16049-00 Iss A 05/2003
GB

This page is intentionally left blank

ST 16049-00A 3
Contents
Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.1 About this Publication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.2 Product development . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.3 Quality standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.4 Model range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.5 Terminology: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.6 Ownership Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
1.7 Local CompAir UK Ltd Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
1.8 Service Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.9 Key to symbols used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
1.10 Torque Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
2 Adjustments and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
2.1 Minimum Pressure Valve (Fig. 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
2.2 Safety Valve Lift Pressure (Fig. 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
2.3 Servo Valve (Fig. 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
2.4 Oil Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
2.5 Air Output (Fig. 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
2.6 Leakage Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
2.7 Setting the Run-On Timer (located in Starter Box) . . . . . . . . . . . . . . . . . . . . . . . .12
2.8 Testing Vacuum Relief Valve (Fig. 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
2.9 RS Speed Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
3 Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.1 System Pressure Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
3.2 Low or No Air Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
3.3 High Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
3.4 Excessive Oil Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
3.5 Oil Mist From Air Intake When Stopping and/or Rapid Venting . . . . . . . . . . . . . . .16
3.6 Unusual Noise or Vibration During Running . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
3.7 Safety Valve Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
3.8 Slow/No Ventdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
3.9 Motor Overload or High Power Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
4 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.1 Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
4.2 Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
4.3 Air Intake End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
4.4 Changing the Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
4.5 Minimum Pressure Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
4.6 Air End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
4.7 Servicing the Unloader Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
4.8 Servicing the Servo Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
4.9 Air End (Cont’d) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
4.10 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
4.11 Rotor Stator Unit (RSU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
4.12 Dismantling the Rotor Stator Unit (RSU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
4.13 Rotor Stator Unit (cont’d) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
4.14 Drive End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
4.15 Cooler Matrix and Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
4.16 Oil Filter and Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
4.17 Inverter and Oil Level Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
4.18 Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
4.19 Control Group DOL and Star Delta . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
4.20 Parts Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
5 Starter Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.1 Typical Starter Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
5.2 Starter (34687) 5kW 400V 50 Hz DOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
5.3 Starter (34682) 7.5kW 400V 50 Hz Star/Delta . . . . . . . . . . . . . . . . . . . . . . . . . . .50

Contents
4ST 16049-00A
5.4 Starter (34756) 7.5 kW 50/60Hz Variable Speed . . . . . . . . . . . . . . . . . . . . . . . . .52
5.5 Starter (34724) 7.5kW 230/460V 60Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
5.6 Starter (34787) 4kW 230V 60Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
5.7 Starter Units Part Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

ST 16049-00A 5
1 Introduction
1Introduction
1.1 About this Publication
This publication contains parts lists and service information,
please read it carefully before you attempt to service or carry out
adjustments on the compressor.
This publication should be used in conjunction with the User
Handbook.
If you need any specialist help or service, please contact your
distributor or CompAir UK Ltd quoting the MODEL, TYPE and
SERIAL NUMBER.
1.2 Product development
CompAir UK Ltd adopt a policy of continual product development.
The information in this handbook, whilst fully up to date when
issued, may be subject to change without notice.
1.3 Quality standards
Note: These instructions comply with the latest European
Directives regarding content and are valid for machines carrying
the CE mark.
1.4 Model range
This handbook relates to all HV04 - HV07 compressors, model
types:
This publication refers to compressors with serial numbers:
V04-000001
V05-000001
V07-000001
1.5 Terminology:
CompAir UK Ltd
Claybrook Drive
Washford Industrial Estate
Redditch
Worcestershire
B98 0DS
England
Web:
E-mail:
Telephone:
Fax:
www.CompAir.com
[e-mail]
[phone]
[phone]
HV04 - HV07
V04ACS07-4035D000
V04ACS010-4035D000
V05ACS07-4035D000
V05ACS10-4035D000
V07ACS07-4035S000
V07ACS10-4035S000
V07ACS07-4035V000
V04ACS07-2336D005
V05ACS07-2336D005
V05ACS10-233D005
V07ACS07-2336D005
V07ACS10-2336D005
Serial Number
Segment Signifies
V Vane
04, 05, 07 kW motor
AC Air Centre
S Standard Control
07, 10 Delivery pressure in bar
40 400, volt
3 3 phase
5, 6 50Hz, 60Hz
D, S, V Direct On Line, Star/Delta, Variable Speed
000
005 European specification (50Hz) American specification (60Hz)

Introduction 1
6ST 16049-00A
1.6 Ownership Records
1.7 Local CompAir UK Ltd Distributor
Model Number: .................................................. Serial Number: ..................................................
R.P.M: .................................................. kW: ..................................................
Maximum Bar: ..................................................
Name: .................................................. Contact: ..................................................
Address: .................................................. Telephone: ..................................................
.................................................. Fax: ..................................................
.................................................. Email: ..................................................

ST 16049-00A 7
1 Introduction
1.8 Service Kits
Only use genuine CompAir UK Ltd parts and approved oils.
Oils must not be mixed.
Service kits contents
Item Part Number Quantity Description Chapter Location
KO457 Kit Oil Change
75155 2 Air filter element
75279 2 Oil Filter
9824 2 ‘O’ Ring
9617 2 Bonded Seal 5/8”
Item Part Number Quantity Description Chapter Location
KM 457 Main Service Kit, 4000 hours or 2 years
9613 2 ‘O’ Ring
75246 2 Quadralip Seal
75230 2 Unloader Valve Seat
75021 2 Spring
75099 2 ‘O’ Ring
9609 2 Bonded seal
57596 2 Vacuum valve seal
9705 2 ‘O’ Ring
9704 2 ‘O’ Ring
9706 2 ‘O’ Ring
0071 2 MPV seat
9711 2 ‘O’ Ring
9619 2 Bonded seal
98262-214 2 Separator cartridge
9708 2 ‘O’ ring
75205 2 Barrel coupling
75202 2 Sintered filter
75022 2 Thermal by-pass valve and spring
75155 2 Air filter element
75279 2 Oil filter
9617 2 Bonded seal 5/8”
9824 2 ‘O’ Ring
9708 2 ‘O’ Ring
KT457 Top-up Kit
9722 2 ‘O’ Ring
2056 2 Shaft Key
50054 2 Safety Valve 150psi/(175psi Part # 50053)
34774 2 Stator shim pack
75331-01 2 Stator shim L 4K
75331-02 2 Stator shim L 4K
75332-01 2 Stator shim U 4K
75332-02 2 Stator shim U 4K
75333-01 2 Stator shim L 4K
75333-02 2 Stator shim L 4K

Introduction 1
8ST 16049-00A
Note: Spare parts to be stored in original packaging and in a dry
environment. Repaired or replacement units should be protected
against corrosion and mechanical damage during storage.
75334-01 2 Stator shim U 4K
75334-02 2 Stator shim U 4K
34775 2 Stator shim pack
75327-01 2 Stator shim L5
75327-02 2 Stator shim L5
75328-01 2 Stator shim U5
75328-02 2 Stator shim U5
75329-01 2 Stator shim L5
75329-02 2 Stator shim L5
75330-01 2 Stator shim U5
75330-02 2 Stator shim U5
34776 2 Stator shim pack
75323-01 2 Stator shim L7
75323-02 2 Stator shim L7
75324-01 2 Stator shim U7
75324-02 2 Stator shim U7
75325-01 2 Stator shim L7
75325-02 2 Stator shim L7
75326-01 2 Stator shim U7
75326-02 2 Stator shim U7
9810 2 ‘O’ Ring
9708 2 ‘O’ Ring
74610 2 Oil Seal
9810 1 ‘O’ Ring
75099 2 ‘O’ Ring
9831 2 ‘O’ Ring
9606 2 Bonded Seal 1/8”
75034 2 Unloader Valve Spring
58117 2 Sight Level Glass
9754 2 ‘O’ Ring
9750 2 ‘O’ Ring
74381 2 ‘O’ Ring
9712 2 ‘O’ Ring

ST 16049-00A 9
1 Introduction
1.9 Key to symbols used
1.10 Torque Settings
Listed below are recommended torque settings.
Note: Torque settings must be applied when indicated.
Torque Setting Nm. Spanner Require (mm) A/F
Grease Required
(Specification) Allen Key Required (mm)
Loctite Required and
Specification Number Lubricate With Sump Oil
15
Nm
15
Nm
22mm
Silc
o
660
Silco
660
5mm
577
577
Recommended Oils Recommended Grease
Fluid Force 2000 Silkolene
Fluid Force HPO Motor Grease
Fluid Force Clear Esso Unirex N3
Shell Albida R2
Shell Nerita HV
SKF LGHQ3
Note: Do not mix oils. Castrol Optimol PD2
Torque Settings
Thread size (mm) Setting (Nm)
615
835
10 60
12 95
16 160
42 400

Introduction 1
10 ST 16049-00A
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ST 16049-00A 11
2 Adjustments and Testing
2 Adjustments and Testing
2.1 Minimum Pressure Valve (Fig. 1)
Note: 10 bar machine details are in brackets.
(a) Start compressor.
(b) Open outlet valve fully to atmosphere with silencer fitted.
(c) Check the lowest pressure gauge reading obtainable. This
should be 5.5 - 6.6 bar.
(d) Adjust pressure by using the sdjusting screw ( C).
2.2 Safety Valve Lift Pressure (Fig. 1)
(a) Close outlet valve. Start compressor (continuous run).
(b) Screw in servo until safety valve (B) lifts. Gauge pressure
should be 10 bar (7 bar models) or 12 bar (10 bar
models).
(c) If lift pressure is incorrect, replace the valve complete.
2.3 Servo Valve (Fig. 1)
The servo valve controls pressure at a pre-set factory setting
when there is no demand for air. The specified setting is a
maximum and must not be exceeded.
Factory setting 7 or 10 bar models :- 7.5 to 8.0 bar or 10.5
to 11.0 bar.
If the servo needs minor adjustments or a lower pressure is
required then carry out the following procedure:
(a) Turn mains electrical supply on at isolator.
(b) Close air outlet valve to air-line system and open test
valve.
(c) Fit silencer to test valve.
(d) Select continuous run mode and start compressor.
(e) Adjust test valve so that the air-end pressure gauge reads
approx 7 bar (10 bar) and allow compressor to warm up.
(f) After approximately 10 minutes, close the test valve and
stop compressor.
(g) Remove air filter cover.
(h) Release servo lock-nut.
(i) Check test valve and air outlet valve are closed.
(j) Start compressor and allow pressure to stabilise.
(k) Check compressor pressure gauge reading:
If reading too low, turn grub-screw (B) clockwise to
increase pressure.
Note: Must not exceed 8.0 bar (11.0 bar).
If reading too high or a lower operating pressure is
required, turn grub-screw (B) counter-clockwise to
decrease pressure.
(l) Open and close the test valve and check that pressure
stabilises at required setting.
(m) Secure lock-nut (D).
(n) Refit air filter and cover.
Fig. 1 - Minimum Pressure, Vacuum and Servo
Valves
New image under creation by SH

Adjustments and Testing 2
12 ST 16049-00A
2.4 Oil Temperature
(a) Introduce a very small amount of oil and a thermometer
into the horizontal thermometer pocket.
(b) Allow compressor to run for 30 minutes in order to attain
its normal working temperature.
(c) Average running temperature should be 80°C approx.
(d) Refit filler plug and its seal when testing is completed.
(e) Average running temperature should be approximately
50°C above ambient.
2.5 Air Output (Fig. 2)
(a) Screw test nozzle into compressor outlet valve.
(b) Close outlet valve and start compressor.
(c) Open outlet valve fully to atmosphere.
(d) Pressure indicated on the compressor gauge should not
fall below 6.5 bar (9.5 bar).
(e) Test nozzle diameter must be reamed to a tolerance of
± 0.025 mm.
2.6 Leakage Check
(a) Examine all external seals, joint and pipe connections for
air or oil leakage.
(b) No leaks are permissible.
2.7 Setting the Run-On Timer (located in
Starter Box)
(a) The run-on timer sets the required duration of off-load
running after which the compressor will stop.
(b) The timer is factory preset to 3 minutes standard control,
3 minutes electronic control, below 3 minutes constant
run, but may be reset to suit the individual air system.
Note: Do not set the timer to less than 2 minutes.
(c) For guidance, each division between the marks S (short
delay) and L (long delay) on the timer, represents
approximately one minute delay time.
2.8 Testing Vacuum Relief Valve (Fig. 1)
(d) Close the air outlet tap and start the compressor, open
and close the outlet valve while listening for any blade
noise (rattle), close the outlet tap and stop the
compressor.
(e) If noise is detected re-setting is probably necessary,
remove top and front panel covers and remove the air
intake filter complete with support by removal of three
MS706-16 screws.
(f) Slacken the locknut and turn the adjusting screw
clockwise fully in, do not tighten, unscrew anti-clockwise
half a turn, just sufficient to eliminate any minor blade
noise.
(g) Cooling fan has over temperature protection (160°C) in
circuit and will stop the compressor, each phase of the fan
is protected by 2Amp fuses.
Fig. 2 - Test Nozzle 59636-00
2.9 RS Speed Compressors
Target Pressure Setting
The system target pressure may be adjusted by pressing the ‘up’
arrow on the keypad to increase pressure or ‘down’ arrow to
decrease pressure. The pressure is indicated on the keypad LED
display; with the required pressure in view press the FUNC/DATA
key to store.
Speed control unit frequency setting
If the default factory pressure setting is altered the compressor
motor maximum speed must also be adjusted. Operating at too
high a maximum speed may result in an electric motor overload
condition. Refer also to user warning above.
(a) Ensure that power is available at the compressor.
(b) If amber reset lamp 'r' is illuminated press reset button '1'.
(c) Turn the selector switch from position '1' to position '0'.
(d) Unlock keypad (see below).
(e) Press PRG key to obtain the program menu.
(f) Select program 2 (Data check) using Up/Down keys.
(g) Select function F03 using Up/Down keys.
(h) Press the Function/Data key to select the frequency (Hz)
setting.
(i) The current frequency setting will be displayed in the LCD
monitor window. Note that the right hand digit will be
flashing.
(j) Press the Up/Down key to decrease or increase the
frequency setting. Refer to chart below.
(k) Press the Function/Data Select key to store the new
setting.
Nozzle orifice
Dia 'A Model Bar C.F.M.
No Sizes HV04 7 TBA
No Sizes HV04 10 TBA
3.52-01 HV05 7 29
2.69-02 HV05 10 23.6
4.03-03 HV07 7 38
3.11-06 HV07 10 31.5
1.5 Wide undercut to base
of thread
1.5 Wide undercut to base
of thread
120°
60°
9.0
3/8 BSP
3/8 BSP
Dia 'A' Ream
Tol:-±0.025
Dia 'A' Ream
To l :- ± 0.025
12.0
12.0
18.5
36.0
Ø8
Ø13.7
3/8 BSP
3/8 BSP
Material EN1A
Material EN1A

ST 16049-00A 13
2 Adjustments and Testing
(l) Press PRG key to return to the LED monitor.
(m) Press the Function/Data Select key until the required LED
display appears, e.g. motor speed.
(n) Re-lock keypad (see below).
Unlocking keypad
(a) Press PRG key to obtain the program menu.
(b) Select program 2 (Data check) using Up/Down keys.
(c) Select function code F00.
(d) Function/Data key will highlight a value of 1.
(e) Change value 1 to 0 by pressing the Down and Stop keys
together.
(f) Press the Function/Data key to store.
Re-locking keypad
(a) Press PRG key to obtain the program menu.
(b) Select program 2 (Data check) using Up/Down keys.
(c) Select function code F00.
(d) Function/Data key will highlight a value of 0.
(e) Change value 0 to 1 by pressing the Down and Stop keys
together.
(f) Press the Function/Data key to store.
Continuous running option
If the flow demands of the system result in continual and rapid
stopping and starting of the motor the compressor speed control
unit may be set to continuous running as follows:
(a) Ensure that power is available at the compressor.
(b) If amber reset lamp 'r' is illuminated press reset button '1'.
(c) Turn the selector switch from position '1' to position '0'.
(d) Unlock keypad (see above).
(e) Press PRG key to obtain the program menu.
(f) Select program 2 (Data check) using Up/Down keys.
(g) Select function F16 using Up/Down keys.
(h) Press the Function/Data key.
(i) Press the Up/Down key to select value '35'.
(j) Press the Function/Data Select key to store the new
setting.
(k) Press PRG key to return to the LED monitor.
(l) Press the Function/Data Select key until the required LED
display appears, e.g. motor speed.
(m) Re-lock keypad (see above).
Note: If this option is selected the compressor will continue to
operate under speed control achieving energy savings compared
with single speed compressor operating at part load.
Maximum pressure/frequency combination settings
* Factory settings
Compressor
model Target pressure
Max
output
frequency
Synchronous
speed
Nominal
off load
Servo
pressure
HV07RS 7 65 2010 8 bar
HV07RS 8 61 1890 9 bar
HV07RS 9 57 1770 10 bar
HV07RS 10 53 1650 11 bar

Adjustments and Testing 2
14 ST 16049-00A
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ST 16049-00A 15
3 Fault Finding
3 Fault Finding
WARNING !
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 Ltd compressors. They must fully understand and adopt correct and safe working practices.
Text in Light Green (Greyed out) is not applicable to these machine models.
3.1 System Pressure Low
Ref Cause (Level 1) Cause (Level 2) Diagnosis Cause (Level 3) Action
1 Demand
exceeds capacity Air leaks in air- line system Audible check for air leaks or time pressure decay Identify and rectify leaks
Compressor too small
2 Low output from
compressor See B
3.2 Low or No Air Delivery
Ref Cause
(Level 1) Cause (Level 2) Diagnosis Cause (Level 3) Action
1 Compressor not
rotating Motor not running Visual check of cooling fan Electrical supply failure Restore supply
System pressure
switch fault Repair pressure switch
Drive coupling
failure Remove grommet from bell housing and visually check coupling Mechanical breakdown Replace coupling
2 Compressor
rotating in
reverse
Visual check of cooling fan against
direction arrow on compressor Motor wiring reversed Correct motor direction (Note that compressor will
be damaged if run in the
wrong direction.)
3 Motor speed low Check motor speed with optical
tachometer Electrical supply fault Check speed and rectify supply
4 Intake filter
blocked Heavy contamination Dismount intake filter and check for presence of excessive dirt Environmental conditions Replace air filter
Maintenance
failure Replace air filter
5 Safety valve
lifting Check for short loud pressure release from behind air filter and oil on air filter See G
6 Minimum
pressure valve
closed
Adjustment
incorrect Read pressure gauge and follow adjustment procedure Service error or Spring wear Adjust MPV
Valve jammed Read pressure gauge. If no output from
compressor, remove MPV and examine Mechanical failure Replace MPV
7 Servo set too low Adjustment
incorrect Follow adjustment procedure. If rated pressure cannot be achieved inside
compressor, remove and change spring
Service error Adjust servo
Servo spring
worn or broken Check length against new spring Replace spring and adjust
8 Oil separation
system blocked Separator element blocked Read pressure gauge. If 1 bar, replace spin on seperator Contamination Replace seperator and return canister
Separatorflooded
with oil Read pressure gauge. If 1 bar, replace spin on seperator Oil return restrictor blocked Replace separator and return restrictor
9 Rotor blades not
extended Blades stuck in rotor Compressor will run very quietly without producing air and no air will be sucked in
through inlet
Oil too thick Check/replace oil

Fault Finding 3
16 ST 16049-00A
Remove intake end cover to inspect
condition of rotor and blades Blades seized Free blades/slots
10 Internal air leaks
in compressor Shim breakdown Dismantle compressor to examine rotor/ stator unit Check temperature, flow and power
Replace stator shims
3.2 Low or No Air Delivery
3.3 High Temperature
Ref Cause
(Level 1) Cause (Level 2) Diagnosis Cause (Level 3) Action
1 Oil level low Incorrectly filled Drain and replace oil to
sight glass
Oil leaks Visually check for external oil Repair leaks, drain and fill
with new oil
Oil carryover Check downstream equipment for signs of
oil contamination See D
2 Dirty/blocked
cooler matrix Visually examine cooler matrix for excessive dirt Clean cooler, drain and fill with new oil
3 Thermal bypass
failure Damagedthermal motor Remove thermal motor and examine. If wax has leaked or piston rod is loose, it
must be replaced. Check function of piston
in hot water @ 90°C
Replace thermal motor,
drain and fill with new oil
4 Dirty/blocked Oil
filter Oil contamination Remove filter and visually check condition Drain oil, clean filter, fill with fresh oil
5 Incorrect oil Service error Remove sample and compare with correct
oil or check source Drain, flush, drain, fill with fresh oil
6 Internal air
leakage Damaged shims Dismantle compressor to examine rotor/ stator unit Dismantle and replace
7 Blocked internal
oil passageways Hydrocarbon deposits Dismantle compressor to examine oil passageways High temperature oil Dismantle, clean and rebuild
3.4 Excessive Oil Consumption
Ref Cause
(Level 1) Cause (Level 2) Diagnosis Cause (Level 3) Action
1 Oil leaks Visually check for external oil Identify source and rectify
2 Compressor
running at
Minimum
pressure
Fit pressure gauge in test point and check
internal running pressure Excessive air demand Rectify system leaks
3 Incorrect oil Service error Remove sample and compare with correct
oil or check source Drain, flush, drain, fill with fresh oil
4 Oil carryover Flooded or
broken separator Check downstream equipment for signs of oil contamination. Remove oil return
restrictor plug and check if blocked
If restrictor plug is blocked,
remove and replace
separator elements and oil
return restrictors
5 Remove separator and examine. If separator element is
faulty, replace separator
element, oil return restrictor,
and change oil
3.5 Oil Mist From Air Intake When Stopping and/or Rapid Venting
Ref Cause
(Level 1) Cause (Level 2) Diagnosis Cause (Level 3) Action
1 Unloader valve
seats damaged Remove air filter and support and observe where mist exits when machine is stopping Replace damaged seats

ST 16049-00A 17
3 Fault Finding
2 Unloader valve
body worn Remove air filter and observe where mist exits when machine is stopping Replace unloader valve body
3 Vacuum valve
seal leaking Remove air filter and observe where mist exits when machine is stopping Replace vacuum valve seal/ gasket
4 Servo valve
leaking Remove air filter and observe where mist exits when machine is stopping Replace servo valve
3.5 Oil Mist From Air Intake When Stopping and/or Rapid Venting
3.6 Unusual Noise or Vibration During Running
Ref Cause
(Level 1) Cause (Level 2) Diagnosis Cause (Level 3) Action
1 Vacuum valve
incorrectly
adjusted
Compressor makes rattling noise when
running off load only Adjust vacuum valve
2 Fan fouling
cooler ducting Visually check for interference Check/realign ducting
3 Damaged/worn
drive coupling Remove grommet from bell housing and visually check coupling. Remove
compressor from motor to verify
Check/replace motor
coupling.
4 Motor bearing
failure Listen for rumbling or screaming noise from each end of motor. Remove
compressor and rotate motor by hand to
check for rough feeling
Check/replace motor
bearings
5 Seized blade in
slot Listen for uneven popping noise from compressor under load. Remove intake
end cover to check condition of blades
Check/free/replace blades
3.7 Safety Valve Lifting
Ref Cause
(Level 1) Cause (Level 2) Diagnosis Cause (Level 3) Action
1 Overpressure in
compressor Servoset toohigh Read pressure gauge Adjust servo
Servo piston
incorrectly
assembled
Remove servo assembly and check
orientation of piston Reassemble servo and adjust
Excessive Air
intake during
offload running
Read pressure gauge Leaking vacuum
valve Replace vacuum valve
Leaking bearing
cap gasket Replace end cap gasket
Leakingunloader
valve Replace unloader valve seat
2 Faulty safety
valve Worn spring Read pressure gauge in test point and check internal pressure when safety valve
blows
Replace safety valve
Damaged/worn
seating Fit pressure gauge in test point and check internal pressure when safety valve blows Replace safety valve
3.8 Slow/No Ventdown
Ref Cause
(Level 1) Cause (Level 2) Diagnosis Cause (Level 3) Action
1 Automatic
Ventdown orifice
blocked
Listen for air loss into intake area after
stopping. Fit pressure gauge in test point to
monitor vent down of pressure
Clean orifice

Fault Finding 3
18 ST 16049-00A
3.9 Motor Overload or High Power Consumption
Ref Cause
(Level 1) Cause (Level 2) Diagnosis Cause (Level 3) Action
1 High pressure
setting Fit pressure gauge in test point and check internal pressure Check/adjust servo
2 Compressor
overheating Fit thermometer in oil filler pocket and check maximum temperature See C
3 Faulty motor Check impedance of motor windings Check motor windings/
bearings repair or replace
4 Seized blade in
slot Listen for uneven popping noise from compressor under load. Remove intake
end cover to check condition of blades
Check/free/ replace blades
5 Compressor
rotor seizing Rotor pushed against intake
end cover
Remove compressor, dismantle and
examine rotor and end cover. Check
setting of coupling
Replace damaged parts
Bearing seizing Remove compressor, dismantle and
examine rotor and bearings Lubrication failure Replace damaged parts