Operator Manual: For A

CompAir UK Ltd
OPERATOR MANUAL
for a
H5404, H5405 Mk4, H5405E.1800 &
H5405E.1300 MK1
Aircooled Air Compressors
In any correspondence please quote; COMPAIR JOB NUMBER:-

CUSTOMER:-
CUSTOMER ORDER NUMBER:-
MACHINE NUMBER:- 5404.4, 5405.4 & 5405E
PUBLICATION NUMBER:- 98407.1228
ISSUE DATE:- JANUARY 2008
CompAir UK Ltd. Reavell House
53-56 White House Road IPSWICH ENGLAND IP1 5PB
Telephone: +44 (0) 1473 242000 Fax: +44 (0) 1473 745451 Parts Fax: +44 (0) 1473 743468 Service +44 (0) 1473 242097
www.compair.com e-mail:- sales.ipswich@compair.com
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 242097 - PARTS +44 (0) 1473 743468
logsheetm.doc
DATE REMARKS DATE REMARKS
logsheetm.doc
5000 SERIES COMPRESSORS
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
1 ~ OWNERSHIP DATA
TECHNICAL DATA
It is recommended that details taken from the compressor and motor nameplates are recorded below.
CompAir UK Ltd Ipswich CONTACT DETAILS
Contact Name: Sales Telephone: +44 (0) 1473 242000
Address: Notes:
CompAir UK Ltd
Reavell House
53-56 White House Road
Ipswich IP1 5PB
ENGLAND
Telephone: +44 (0) 1473 242000 Fax: +44 (0) 1473 745451
Contact Names: Parts Telephone: +44 (0) 1473 242000

Parts Fax: +44 (0) 1473 743468
Contact Names: Service: +44 (0) 1473 242097
For any comments or queries about the contents of this manual, please write to CompAir UK Ltd.
at the above address, marked for the attention of Mr. Owen Dale, Technical Author.
2 ~ FOREWORD
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.
CompAir UK Ltd Ipswich H5000 Series compressors are designed and manufactured to give optimum
performance, with long life and reliability.
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 tel+44 (0)1473 242097
and Parts department tel (+44 (0) 1473 242000) Fax (+44 (0) 1473 743468 and Sales (+44 (0) 1473
242000 Fax (+44 (0) 1473 743482 at CompAir UK Ltd., Ipswich (UK)
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.
3 ~ 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.
4 ~ SAFETY PROCEDURES
• 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.
4.1 ~ GENERAL
CompAir UK Ltd Ipswich compressor safety relates to the document BS EN1012-1 Compressors and
Vacuum Pumps - Safety requirements and the UK Pressure Systems Health & Safety Regulations S.I. No.
128.
• Most accidents which occur during the operation and maintenance of machinery result of failure 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 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.
• CompAir UK Ltd cannot anticipate every possible circumstance, which might represent a potential
hazard. The WARNINGS in this manual are therefore not all inclusive. If the user employs an operating
procedure, an item of equipment or a method of working which is not specifically recommended by
CompAir UK Ltd then they must ensure that the unit will not be damaged or made unsafe and that there
is no risk to persons or property.
• Failure to observe these precautions given under "Safety Precautions" may be considered dangerous
practice or misuse of the compressor
• Read and understand all WARNINGS, CAUTION AND MANDATORY LABELS on the unit before
operating or carrying out maintenance or servicing.
4.2 ~ WARNINGS, CAUTIONS & NOTES

The following details for this Safety Section relate to ESSENTIAL SAFETY REQUIREMENTS referred to in
Machinery Directive 89/392/EEC, Amended 91/286/EEC.
∗ Warnings call for attention to operating procedures involving specific hazards which could cause injury
or death and are identified by the following
RISK OF DANGER RISK OF HIGH PRESSURE RISK OF GAS EXHAUST
RISK OF ELECTRIC SHOCK RISK OF HOT SURFACE CONSULT MANUAL

4.3 ~ GENERAL SAFETY PRECAUTIONS
• When using cleaning solvents, local Health and Safety Regulations must be complied with. Provide
good ventilation and use suitable protection such as a breathing filter mask, safety glass, protective
apron and gloves.
• Safety footwear should be compulsory in all workshops. Safety helmets must be worn if there is any risk
of falling objects.
• If using compressed air for cleaning purposes, ensure safety regulations are complied with and
appropriate clothing worn.
• Never direct compressed air onto your skin or at other people. Never use compressed air to clean loose
dirt from clothing.
• Before releasing compressed air through a hose make sure the free end is held securely so that it
cannot whip and cause injury.
• Avoid injury by using a hoist to lift heavy loads. Check that all chains, hooks, shackles and slings are in
good condition and are of the correct capacity. They must be tested and approved according to local
safety regulations.
• Cables, chains or ropes should never be applied to lifting eyes. Always use an appropriate shackle or
hook, properly positioned. Arrange lifting cables so that there are no sharp bends. Use a spreader bar
to avoid side loads on hooks, eyes and shackles and never leave a heavy load unattended.
• When a load is on a hoist stay clear of the danger area beneath and around it. Keep lifting acceleration
and speed within safe limits.
4.4 ~ INSTALLATION PRECAUTIONS
• Competent personnel under a qualified supervisor must only carry out installation work.
• A fused isolator switch must be fitted between the main power supply and the compressor.
• Precautions must be taken to ensure that no injury is caused to passers-by through loose clothing being
sucked into compressor intake.
• Ensure that the discharge pipe from the compressor to the user pipework, receiver or storage is free to
expand and that no flammable material is within the vicinity. If any such material is close-by take steps
to preclude ignition.
• A manual shut-off valve should be fitted in the discharge line to allow the compressor to be isolated.
Non return valves cannot be relied upon for isolating parts from a pressure system. A safety valve must
be installed between any compressor unit and the isolating valve.
• A pressure-reliving device must be fitted to every pressure vessel, or equipment containing air or gas
above atmospheric pressure. Never remove or tamper with safety devices, guards or insulation fitted. In
order to limit the risk of Legionnaires Disease, CompAir UK LTD advise caution with the use of cooling
towers for water cooling the compressor. Closed circuit or direct mains cooling is preferred.
• Pipework or other parts with a surface temperature above 70°C, which may be accidentally touched in
normal operation, must be guarded or insulated. Other high temperature pipework should be clearly
marked and all pipework should be clearly marked.
4.5 ~ OPERATIONAL PRECAUTIONS
• Competent personnel under a qualified supervisor must only operate the compressor.
• Do not operate compressor with any removable inspection cover removed e.g. crankcase doors, valve
covers etc.
• Never remove or tamper with safety devices, guards or insulation materials.
• The compressor must only be operated at the supply voltage and frequency for which it is designed.
Always isolate power before maintenance or servicing.
• When mains power is ON, lethal voltages are present in the electrical circuits and extreme caution is
need when essential work is carried out on the electrical system. ALWAYS CONSULT A QUALIFIED
ELECTRICIAN BEFORE ANY SUCH ESSENTIAL WORK.
• Do not open starter compartment to touch electrical components while voltage is applied unless it is
necessary for measurement, test or adjustment. Such work should always be carried out by a qualified.
Electrician with appropriates tools and protection against an electrical hazard.
• If the unit is equipped with a Remote Control device, attach warning notices stating "THIS UNIT CAN
BE STARTED REMOTELY" in prominent locations, one on the outside of the unit, the other inside the
control compartment.
• As a further safeguard, take adequate precautions that no one is working or checking the unit before
attempting to switch on remotely controlled equipment. Attach a "CHECK THAT ALL PERSONNEL
ARE CLEAR OF UNIT BEFORE STARTING" or similar notice.
• Compressed air and gas piping, together with cooling water piping and other parts, with surface
temperature greater than 70°C and may be accidentally touched, should be guarded or insulated.
• If there is any indication that the compressor is overheating it must be shutdown. (A high air or gas
temperature switch is fitted as standard to guard against operating with excessive temperature).
Beware of burns from hot oil and water when working on a unit recently shutdown.
• Do not operate the unit when guards provided for protection for all rotating and reciprocating parts have
been removed for essential maintenance. Secure guards following any servicing or repair.
• Local noise regulations must be observed. Ear defenders are suggested by Noise at Work Regulations
1989 when the level is greater than 85 dB A at one meter. Be aware high noise levels can interfere with
communication.
4.6 ~ MAINTENANCE & REPAIR PRECAUTIONS
• Competent persons under qualified supervisor must carry out maintenance repair and modifications.
• The compressor will have a preserving oil applied to interior surfaces (Oil lubricated models). Oil free
models will have desiccant bags in valve covers and distance pieces.
• Handling components such as seals, gaskets and diaphragms should not present a personnel hazard.
Preservation oils again should not present a personnel hazard if handled under normal handling
practices.
• Whilst compressors are asbestos free, treat all damaged gaskets as asbestos - when the Asbestos at
work regulations apply.
• Viton 'O' seals under normal operating conditions are safe.
• However, should there be a fire within the compressor or these seals are likely to exceed a temperature
of 300°C the material will decompose.
• Degraded Viton gives off Hydrogen Fluoride fumes and if in contact with the skin an acid formed
causes severe burns.
• If Viton seals appear charred or gummy do not touch with unprotected hands: use neoprene or PVC
gloves.
• Wash the area with limewater and avoid breathing any fumes. If contamination of the skin occurs
washes with limewater and seeks medical advice.
Pre-Maintenance Operation
• Isolate the compressor from the main electrical supply. Lock the isolator in the OFF position and
remove fuses.
• Attach a label " WORK IN PROGRESS - DO NOT APPLY VOLTAGE".
• Close the isolating valve between the compression unit and user's pipework. Close the isolating valve
in the cooling water inlet pipe. Attach a label "WORK IN PROGRESS - DO NOT OPEN".
• Check that all pressurised gas trapped in the system is released to atmosphere or safely to gas
storage. Check that all pressure gauges register zero.
• Ensure that the cooling water system has been drained.
• Check that the drain valve on the delivery manifold is clear and gas pressure has been released.
• Check that all interstage drains are open to ensure any gas trapped between stages has been
released.
• Stand clear of all valve covers when removing the securing screws.
• When removing valve covers for valve replacement, ensure a minimum of two threads is left engaged
on the valve cover securing screws. Lever the valve cover until the 'O' seal is disengaged from the port
in the cylinder head. Remove the securing screws and take out valve cover.
• Use only lubricating oils and greases approved by CompAir UK LTD to avoid potential hazards
especially the risk of explosion or fire and the possibility of decomposition or generation of
hazardous gases.
• Always clean oil spills from the surrounding floor before and after maintenance work.
• Make sure all instructions concerning operation and maintenance are strictly followed and that the
complete unit, with all accessories and safety devices, is kept in good order.
• The accuracy of pressure gauges and temperature switches should be regularly checked at least 13
month intervals and thoroughly examined at least every 48 months. They must be renewed or service
exchanged when acceptable tolerances are exceeded.
• Protection devices should be tested at each regular service interval and replaced or service exchanged
if not functioning correctly. The maximum pressure for safety valves under fault conditions is 1.10 times
the set pressure, the set pressure being a minimum of 1.05 times the maximum operating pressure to
ensure seat tightness.
• Never use a light source with an open flame for inspection.
• Before dismantling any part of the compressor be sure that all heavy movable parts are secure.
• After completion of any maintenance or repair ensure that no tools, loose items or rags are left on or
inside the compressor.
• Do not use any flammable liquid to clean valves, filter elements, cooler passages, pipe bores or any
component carrying a flow of air or gas during normal operation. If chlorinated hydrocarbon substances
are used for cleaning, safety precautions must be taken against toxic vapours, which may be released.
DO NOT USE 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.
• Keep the compressor clean at all times.
• Protect components and exposed openings by covering with a clean cloth or tape during repair or
maintenance work.
• Protect the motor, intake, electrical and regulation components against the entry of moisture e.g. steam
cleaning.
• Precautions must be taken when carrying out welding or any repair operation which generates flames
or sparks. The adjacent components must be screened with non-flammable material and if oil present,
the system must first be cleansed thoroughly by steam cleaning.
• Condensate (oil and water mixture from compression process) must be regarded as trade effluent and
is therefore not suitable for discharge into a surface water sewer, soakaway or watercourse.
PROTECT THE ENVIRONMENT USE APPROVED METHODS OF DISPOSAL.
4.7 ~ PRECAUTIONS IN THE EVENT OF FIRE
• Use extreme caution when handling components that have been subjected to fire or very high
temperature. Some components may contain fluoroelastomer materials, which decompose under these
conditions to form highly corrosive residues. Skin contact can cause painful and penetrating burns
resulting in permanent skin and tissue damage.
CompAir UK Ltd PUBLICATION 98407.1228
Page 1
AMENDMENTS
5404 MK4, 5405 MK4, 5405E.1800 & 1300

ISSUE No MOD Note No CHANGE - M/C SERIAL DATE PAGE No
2 - Add inhibition procedures 20/11/2001 12
3 NPR81 Add details of 5405E.1800 & 1300 18/12/02 9,11,12,
21,23
4 BOM Breather pipe now part of assembly NOV 2003 24, 25, 31
CHANGES C204099, coupling part number changed & 33
95540.84
5 5752 Suction filter part number changes JAN 2008 30, 31 &
33
1228 issue 5
Page 2
1228 issue 5
Page 3
H5404 MK4, H5405 MK4, H5405E.1800 & 1300
BARE SHAFT COMPRESSOR SECTION
CONTENTS
PAGE
COMPRESSOR LOG SHEET--------------------------------------------------ex
SAFETY SECTION ---------------------------------------------------------------ex
AMENDMENTS ---------------------------------------------------------------------1
INDEX ---------------------------------------------------------------------------------3
SECTION 1- GENERAL INFORMATION ------------------------------------5
SECTION 2 - TECHNICAL DATA----------------------------------------------9
SECTION 3 - LUBRICATION --------------------------------------------------10
SECTION 4 - MAINTENANCE -------------------------------------------------11
SECTION 5 - VALVE MAINTENANCE -------------------------------------15
SECTION 6 - FAULT GUIDE ---------------------------------------------------17
HOW TO ORDER SPARES ----------------------------------------------------19
SECTION 7 - BUILD LISTS ----------------------------------------------------21
SECTION 8 - ADDITIONAL INFORMATION-------------------------------49
1228 issue 5
Page 4
1228 issue 5
Page 5
SECTION 1 - GENERAL INFORMATION

5405 MK4 ILLUSTRATED
CYLINDER
OIL FILLER
1STSTAGE
OIL LEVEL GAUGE
SUCTION FILTER
SAFETY VALVE
1ST STAGE
CYLINDER
3RD STAGE
CYLINDER
2ND STAGE
SAFETY VALVE
2ND STAGE CRANKCASE
BREATHER
SEPARATOR
2ND STAGE
SERIAL NUMBER OIL DRAIN PLUG
SEPARATOR DRAIN
CONNECTION FINAL DELIVERY
1/4" BSPP CONNECTION
Ø8 MM
These machines are three cylinder, single acting, W configuration, air-cooled compressors. The 5404
& 5 MK4 are fitted with a grooved and vaned driving flywheel to force air over the cylinders and
coolers whilst the 5405E is fitted with a grooved driving flywheel and separate multi-bladed cooling fan
mounted between the compressor and the flywheel.
Air entering through the suction filter is increased in pressure as it passes through each stage of the
compressor until it reaches the final specified delivery pressure. Heat exchangers, positioned in the
air stream from a cooling fan, are provided after each stage together with a separator after the second
stage heat exchanger.
1.1 - LUBRICATION
All models are splash lubricated.
The specified lubricant must be used at all times to ensure safe and efficient operation with minimum
wear and maximum protection against moist air corrosion.
Recommendations are the result of extensive research at CompAir UK Ltd works and all responsibility
for the use of a lubricant other than that recommended is placed on the purchaser and his oil
company.
Only synthetic oils are recommended for these compressors.
THE NORMAL GUARANTEE MAY BE INVALIDATED SHOULD A FAILURE BE ATTRIBUTED, BY COMPAIR UK

LTD, TO THE USE OF A LUBRICANT NOT RECOMMENDED.
1228 issue 5
Page 6
1.2 - 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.
The manufacturing process allows the oils to be produced to close tolerances giving performance
which is consistent from batch to batch.
1.3 - COOLING
Cooling is provided by a vaned flywheel on each of the 5404 & 5 MK4 models and on the 5405E by a
high performance fan mounted on the crankshaft. The cooling air passes over the coiled coolers and
the finned cylinders and covers.
1.4 - DRIVE
Drive is normally by vee belts from a suitable power source such as an electric motor or diesel/petrol
engine. SEE APP012 for vee belt drive details.
1.5 - RUNNING GEAR

Main, big end and small end bearings are all replaceable. However, it is often simpler to replace the
last two complete with a new connecting rod to avoid the risk of distorting the existing rod when
removing the old outer bearing.
1.6 - VALVES
On all models 1st stage valves are of the reed type whilst the second and third stages each have a
single valve combining suction and delivery functions. Both valves fitted to these stages are of the flat
plate, low lift, multi-ported type. The valves also function as stage cylinder heads, incorporating inlet
and outlet air connections.
1.7 - SITING REQUIREMENTS
RECOMMENDED INSTALLATION INCORRECT INSTALLATION

COOLING AIR ENTERS, PASSES OVER COOLING AIR ENTERS, PASSES OVER
MACHINE AND AS HEATED AIR, IT IS MACHINE AND THEN AS HEATED AIR,
EXHAUSTED FROM THE MACHINE RE-CIRCULATES IN THE MACHINE
ENVIRONMENT. ENVIRONMENT.
NOTE: In small buildings and enclosures the outlet vents should have a minimum cross sectional area of 0.3
M² and for enclosures the fan inlet should be sealed by means of a duct between fan guard and the wall to
prevent re-circulation of cooling air.
When the compressor has to be situated next to a wall or bulkhead in a large building in which there is no
opening, the fan cowl inlet must always be more than 300 mm from the wall or bulkhead to avoid restriction of
cooling air flow to the compressor.
1228 issue 5
Page 7
1.8 - ELECTRICAL
The electrical connections to the set must always comply with local regulations which are applicable,
and to be suitable for the overloads involved. A qualified electrician must always install wiring. As the
maintenance periods for the compressor are determined on an hours run basis. To indicate when
routine maintenance becomes due, fitting an hours run meter is recommended.
TYPICAL WIRING DIAGRAM - MANUAL START/AUTO STOP.
CONNECTIONS
HR HOURS COUNTER
SV 1 SOLENOID VALVE (DEMISTER TANK)
SV 2 SOLENOID VALVE (DRAINAGE SYSTEM)
1RT1 TIMED DRAINAGE TIMER
1228 issue 5
Page 8
1228 issue 5
Page 9
SECTION 2 - TECHNICAL DATA

WIDTH LENGTH
Three stage, three cylinder, single acting, air cooled Model

compressors. 5404 MK4 5405 MK4 5405E.1800 5405E.1300
Minimum working pressure bar 85 85 85 85
Maximum working pressure bar 350 350 350 350
Maximum speed rpm 1300 1300 1800 1300
Minimum speed rpm 1000 1000 1000 1000
1st stage piston displacement at max speed m3/h 12 19 26.3 19
Stage working pressures at max. pressure 1st stage bar 4.6 6.6 6.2 6.6
2nd stage bar 48.2 54.4 55.1 54.4
Starting unloading diaphragm drain valves on second and third stages
Normal operating parameters - see lubricant duties
Maximum inlet pressure bar 0.07 0.03 0.03 0.03
Cooling air flow rate m3/h 2500 2500 3400 3400
1st stage cylinder bore Ø mm 70 88 88 88
2nd stage cylinder bore Ø mm 36 36 36 36
3rd stage cylinder bore Ø mm 14 14 14 14
Stroke mm 40 40 40 40
Mean piston speed at maximum speed m/s 1.73 1.73 1.4 1.73
Safety valve set pressure 1st stage bar 6 8.3 9.0 8.3
2nd stage bar 54 68.9 68.9 68.9
Final stage supply bar + 10% + 10% + 10% + 10%
1st stage suction connection Rp 1 1 1 1
Final delivery connection Rc 8mm 8mm 8mm 8mm
Maximum vibration level (in any direction) mm/s 40 40 40 40
Nett weight of bare compressor and pulley kg 36 39 40 40
Overall dimensions - Length mm 361 361 370 370
Width mm 530 530 530 530
Height mm 505 505 510 510
Rotational inertia of flywheel pulley and compressor kgm2 0.144 0.144 0.144 0.144
*Note: The 5405E 1800 operating limitation for Breathing Air Applications at maximum speed & duty is
250 hours per year.
1228 issue 5
Page 10
SECTION 3 - LUBRICATION
Development in the field lubrication is continually changing and at the date of compilation of this publication the
following information applies. At all times the responsibility for use of an oil other than the recommended grade is
placed on the customer and his oil supplier, as our normal guarantee will be invalidated should be attributed, by us,
to the lubricant used.
1. THE RECOMMENDED LUBRICANTS FOR MACHINES MANUFACTURED BY COMPAIR UK LTD., ARE

THOSE GRADES LISTED
2. THE ALTERNATIVES (NOT NECESSARILY EQUIVALENTS) TO THESE GRADES ARE THOSE SPECIFIED
BY THE OIL COMPANIES SUPPLYING THE OIL AND NOT COMPAIR UK LTD .(UNLESS OTHERWISE
STATED).
3. COMPAIR UK LTD, CANNOT BE HELD RESPONSIBLE FOR INCORRECT INFORMATION CONCERNING

ALTERNATIVE LUBRICANTS.
4. AT ALL TIMES THE RESPONSIBILITY FOR USE OF AN OIL OTHER THAN THE RECOMMENDED GRADE
IS PLACED ON THE CUSTOMER AND HIS OIL SUPPLIER, AS OUR NORMAL GUARANTEE WILL BE
INVALIDATED SHOULD FAILURE BE ATTRIBUTED BY US TO THE LUBRICANT USED.
OIL TYPES 5000 SERIES AIR-COOLED
Approved lubricants for use in the 5000 series air cooled reciprocating compressors have been evaluated for
performance and compatibility with materials used in their construction. The type of oil recommended for all air
cooled compressors is SYNTHETIC.
MINERAL OIL
Mineral oil can be used on restricted duties. For restricted duty details contact CompAir UK Ltd.
SYNTHETIC OILS
Reavellite, Anderol 555, Shell Madrela AP100, Mobil Rarus 827 and Castrol SN 100
RUNNING IN
It is recommended all 5000 series air cooled compressors both new and overhauled be run in on synthetic oil.
ALTERNATIVE LUBRICANT - RUNNING IN ONLY
Mineral oil can be used for running in I.E. MOBIL RARUS 427 or SHELL CORENA P100 for a period of 100 hours,
after which the machine should be drained, flushed through and filled with the recommended synthetic oil.
BREATHING AIR APPLICATIONS
ONLY REAVELLITE S or W, Anderol 555, Anderol 495 (ambient temperature -10 to +15) and Mobil Rarus 827 are
suitable for this application.
RECOMMENDED OILS 5000 SERIES AIR-COOLED COMPRESSORS

COMPRESSING AIR.
COMPRESSOR AMBIENT OIL RECOMMENDED SUMP CAPACITY

TYPE TEMPERATURE °C SEE SPECIAL NOTES (Litres)
5404 & 5405 0 to +45 Reavellite S (1)(2)(3) 1.6
5404 & 5405 -10 to +15 Reavellite W 1.6
5405E 0 to +45 Reavellite S (1)(2)(3)(4) 1.6
5405E -10 to +15 Reavellite W (4) 1.6
SPECIAL NOTES
(1) MOBIL RARUS 427 can be used for some restricted duties contact CompAir UK Ltd for details.
(2) If the Compressor is fitted with a sump heater the oil can be used down to -10°C.
(3) The temperature range of compressors supplied prior to June 1991 is 15 to 45°C.
(4) Subject to an operating limitation of 250 hours per year when on MAXIMUM speed and duty.
1228 issue 5
Page 11
SECTION 4 - MAINTENANCE
W A R N I N G :-
1. BEFORE PROCEEDING WITH MAINTENANCE ON THE COMPRESSOR IT MUST BE STOPPED AND
ISOLATED ELECTRICALLY AND MECHANICALLY AND VISIBLE WARNING NOTICES DISPLAYED.
2. IN ADDITION ALL INTERNAL PRESSURE MUST BE RELEASED WITH THE UNIT ISOLATED FROM
THE SUPPLY AND STORAGE RESERVOIR.
Note:-
An O&M manual must cater for a wide variety of operating duties, ambient conditions and methods of
control. Periods given in this manual allow for the worst combination and are also based on
preventative maintenance rather than operation until failure occurs.
4.1 - GENERAL
It is useful to record pressure, temperatures, oil used etc., in a log against hours run, as this builds up a detailed
record of machine condition. It can also give an indication of impending problems.
4.2 - TORQUE WRENCH SETTINGS FOR NON-LUBRICATED FASTENERS

SEE BUILD LIST PAGE 29
4.3 - DAILY
Check oil level in crankcase and top up if necessary.
Check stage pressures and temperatures.
Ensure finned cooler is clean and free from any build-up of dirt.
4.4 - WEEKLY
Check for oil or air leaks, rectify if necessary.
Check correct operation of all controls.
Check all nuts, screws and fittings for tightness.
4.5 - RECOMMENDED MAINTENANCE 5404 & 5405. SEE RSP5404 & 5405 FOR MORE DETAILS.
SYNTHETIIC OIL RUNNING HOURS (x 1000)

ACTION REQUIRED 0.05 0.5 1.0 1.5 2.0 2.5 3.0
Change OIL X X X X X X X
Change plates & springs all valves X X
Change valves X
Fit new piston rings 3rd Stage X X
Fit new plunger/liner assembly X
Check belt tension X X X X X X X
Clean unloader valves, re-lap seats & replace diaphragms as necessary X X
Complete check & overhaul, hydraulic test coolers X X X X X X X
Note:- * Change after first 50 hours, after major overhaul and annually if less than 500 hours use.
4.6 - RECOMMENDED MAINTENANCE 5405E.1800 SEE RSP5405E.1800 FOR MORE DETAILS.

ACTION REQUIRED 0.05 0.5 1.0 1.5
Change OIL X X X X
Change plates & springs all valves X
Change valves X
Fit new piston rings 2nd Stage X X
Check belt tension X X X X
Clean unloader valves, re-lap seats & replace diaphragms as necessary X
Complete check & overhaul, hydraulic test coolers X
1228 issue 5
Page 12
4.7 - RECOMMENDED MAINTENANCE 5405E.1300 SEE RSP5405E.1300 FOR MORE DETAILS.

ACTION REQUIRED 0.05 0.5 1.0 1.5 2.0 2.5 3.0
Change OIL X X X X X X X
Change plates & springs all valves X X
Change valves X
Fit new piston rings 3rd Stage X X
Check belt tension X X X X X X X
Clean unloader valves, re-lap seats & replace diaphragms as necessary X X
Complete check & overhaul, hydraulic test coolers X X X X X X X
ROUTINE MAINTENANCE
1. After First 15 hours running time
Ensure that alignment and belt tensioning is correct.
2. After First 50 hours running time

Change oil in crankcase. When changing oil drain whilst warm, (*) then slowly pour fresh oil into filler
neck. Wait five minutes, then start compressor and run for five minutes. Stop machine and top-up
crankcase. Examine valves. For tightening torque’s, see SECTION TWO.
3. The next oil change will be after 500 hours running time or annually.
4. Periodically
Remove and renew disposable suction filter.
SEE RSP54044S, RSP54044SW, RSP54054S, RSP54054SW, RSP5405E.1800S & RSP5405E.1800SW

RSP5405e.1300S & RSP5405E.1300SW FOR MORE DETAILS ON ROUTINE MAINTENANCE.
1228 issue 5
Page 13
4.7 SHELF LIFE - INHIBITION PROCEDURE
If the compressor has nether been commissioned, i.e. in stock, every 6 months (or shorter period if
ambient storage conditions are unfavourable i.e. high humidity) it is necessary to carry out the
following inhibition procedure.
4.7.1 Fit a special preserving adapter to the breather connection on the 1st stage cylinder head
(adapter available from CompAir UK Ltd Ipswich for this procedure).
4.7.2 With adapter valve closed, fill with PQ11 (PX4), approximately 15cc.
4.7.3 Remove 3rd stage suction pipe, fit preserving adapter (adapter available from CompAir
UK Ltd Ipswich), fill with PQ11 (PX4), approximately 5cc.
4.7.4 Open valve on 1st stage adapter.
4.7.5 Rotate compressor by hand at least 5 complete revolutions.
4.7.6 Remove both adapters from cylinders, refit respective pipes.
4.7.7 Reseal all openings with threaded plastic plugs.
4.8 STANDING IDLE AFTER RUNNING - INHIBITION PROCEDURE
If the compressor is to stand idle for more than five weeks (or shorter period if ambient storage
conditions are unfavourable i.e. high humidity), it is advisable to carry out the following
recommended inhibition procedure.
4.8.1 Fill to the required level with Shell Ensis 20/30.

4.8.2 Run the compressor.
4.8.3 Switch off the compressor.
4.8.4 Release separator drain screws.
4.8.5 Fit a special preserving adapter to the breather connection on the 1st stage cylinder head
(adapter available from CompAir UK Ltd Ipswich). With valve closed fill to the top with
PQ11 (PX4), approximately 15cc.
4.8.6 Open receiver valve and close separator drain valve.
4.8.7 Run the compressor up to full speed, open valve on 1st stage preserving adapter, stop
compressor after 10 seconds.
4.8.7 Remove 3rd stage suction pipe, fit preserving adapter (adapter available from CompAir
UK Ltd Ipswich), fill with PQ11 (PX4), approximately 5cc.
4.8.8 Rotate compressor by hand for 5 complete revolutions.
4.8.9 Remove adapters from cylinders. Refit respective pipes.
4.8.10 Drain oil from sump.
4.8.11 Reseal all openings with threaded plastic plugs.
1228 issue 5
Page 14
1228 issue 5
Page 15
SECTION 5 - VALVE MAINTENANCE

5.1 - DISMANTLING AND REASSEMBLY OF VALVES
5.2 - GENERAL
Keep a spare oiled and maintained set of valves in store for quick compressor servicing.
Valves may 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.
5.3 - CLEANING AND INSPECTION - ALL STAGES
The valve components should be degreased using a suitable solvent and stiff brush. Carbon deposits
may be removed by gently scraping.
WARNING:- Great care should be taken when removing carbon deposits to ensure that the
seating faces of the valve 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 valve
operation.
5.4 - VALVE REMOVAL 2nd & 3rd STAGE
Disconnect suction and delivery piping.
Remove securing bolts and valve from cylinder.
5.5 - VALVE REMOVAL 1st STAGE
Disconnect nylon tube and delivery pipe.
Remove securing bolts and valve from cylinder.
5.6 - VALVE DISMANTLING AND ASSEMBLY
5.7 - SECOND STAGE VALVE
Second Stage Valve see BUILD LIST ref 85 - 89 for drawing.

To dismantle – invert valve and unscrew and remove the two screws (a) and lift off the lower half of
valve. All internal components, i.e. 'O' ring (c), suction valve/backing plates (f), suction spring plates (g),
delivery valve/backing plates (d) and delivery spring plates (e) can then be removed.
To assemble – Place upper half and lower half of valve body on clean, flat surface with their mating
faces uppermost. Into the upper half fit the 'O' ring (c) into groove and first valve/backing plate (d) into
recess. Place valve springs (e) onto backing plate having first positioned them as follows:–
Hold the springs together with the concave faces facing each other and then rotate one of them until their
outer edges touch all round the circumference and there is a constant gap around the inner edge.
1228 issue 5
Page 16
Place second valve/backing plate (g) on valve springs.
Into the lower half fit first valve/backing plate (f). Fit valve springs (g) having first positioned them as
follows:–
Hold the springs together with the concave faces together and then rotate one of them until their outside
edges touch all round the circumference and there is a constant gap around the inner edge.
Place second valve/backing plate (f) on valve springs.
With a steel rule or similar item placed over suction valve components to prevent them falling out, invert
lower half of valve and fit to upper half ensuring that dowels fit into their location holes and clamping
screw holes align. Withdraw rule and check that the valve halves are touching. Fit screws (a) and tighten
to correct torque. Check freedom of operation of suction and delivery valve plates.
5.8 - THIRD STAGE VALVE
Third Stage Valve see BUILD LIST ref 90 - 94 for drawing.

To dismantle – invert valve and remove screws (a). Lift valve base from valve seat to gain access to the
suction components, i.e. valve/backing plates (d), valve springs (e) and centre plate (f). Remove 'O' ring
(c) from groove in valve base.
Lift valve seat to gain access to the delivery valve components, i.e. valve/backing plates (d), valve
springs (e) and centre plate (f). Remove 'O' ring (b) from groove in valve top.
To assemble – Invert top section of valve and place on clean, flat surface. Fit 'O' ring (b) to groove and
the following delivery valve components into the recess; first valve/backing plate (d), valve spring (e) with
concave face downwards; centre plate (f); valve spring (e) with concave face upwards; and second
valve/backing plate (d).
Fit valve seat on top section of valve ensuring that dowels in top section of valve (not shown) locate in
holes in seat and that clamping screw holes align.
Place valve base on clean, flat surface. Fit 'O' ring (c) to groove and the following suction valve
components into the recess; first valve/backing plate (d); spring plate (e) with concave face downwards;
centre plate (f); spring plate (e) with concave face upwards; and second valve/backing plate (d).
Holding valve seat and top section of valve firmly together to prevent displacement of delivery valve
parts, fit assembly onto valve base ensuring dowels in base locate in holes in valve seat and that the
clamping screw holes align. Fit clamping screw (a) and tighten to correct torque.
5.9 - VALVE REASSEMBLY IN COMPRESSOR

Ensure all mating faces are clean and undamaged. Inspect 'O' ring on top of cylinder liner and replace if
necessary.
Place valve on cylinder and ensure correct orientation
Fit suction and delivery unions and hand tighten only.
Fit the securing bolts and tighten to correct torque.
Tighten suction and delivery unions.
1228 issue 5
Page 17
SECTION 6 - FAULT GUIDE

W A R N I N G :-
1. BEFORE PROCEEDING WITH MAINTENANCE ON THE COMPRESSOR IT MUST BE STOPPED

AND ISOLATED ELECTRICALLY AND MECHANICALLY AND VISIBLE WARNING NOTICES
DISPLAYED.
2. IN ADDITION ALL INTERNAL PRESSURE MUST BE RELEASED WITH THE UNIT ISOLATED FROM
THE STORAGE RESERVOIR.
NOTE:– A 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.
If fault appears immediately or shortly after a service, first examine those parts disturbed during the
service.
The following is a list covering the probable causes of operational faults, together with their suggested
remedies.
Fault Probable Cause Recommendation(s)

6.1 FINAL STAGE Restriction in non-return valve, Existing Installation:
SAFETY VALVE pressure switch fault, pipeline Check functioning and setting of all control valves,
BLOWING blockage clean pipeline filters and service elements.
Check operation of pressure switch.
New Installations:
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.
Check operation of pressure switch
6.2 OTHER STAGE Leaking suction valve in Remove & check condition of suspect valve, clean
SAFETY VALVE following stage and/or replace plates & springs.
BLOWING
6.3 MACHINE Piston ring wear. Check components, renew rings and liners as
RUNS LONGER TO necessary. Check blowby on crankcase breather
ACHIEVE SYSTEM pipe.
PRESSURE
6.4 OVERHEATING Incorrect grade of lubricant. Drain, clean and refill with correct lubricant. Check
condition of valves and air/gas passageways
Dirty stage coolers, especially Clean.

the finned ones.
Fan blades damaged loose. Check, replace or tighten.

(5405E only)
Bad location. see SITING REQUIREMENTS page 4

6.5 CUTS OUT ON Overload set too low. Consult competent electrician.
START UP Insufficient electrical
supply causing low voltage. Consult competent electrician.
Star/Delta timer. Full speed should be obtained by star before

switching to delta. Extend timer period to suit.
1228 issue 5
Page 18
Fault Probable Cause Recommendation(s)

6.6 UNUSUAL Loose components. Trace and rectify.
NOISE(On Load) Air leaks (usually hissing or
whistling) Trace, stop compressor, de-pressurise, renew seal.
Worn bearings, cylinders and

rings (usually heavy knocking, Check clearances and renew as necessary.
(Unloaded) rumbling or slapping).
Piston knocking. Check top dead centre clearance.
Compressor set-up or Check compressor pipework system is firmly

pipework system vibration. secured, check clearances and alignment of
couplings and tension of vee belts.
6.7 HIGH OIL Incorrect grade of lubricant. Change to recommended lubricant.

CONSUMPTION Piston rings/cylinder worn or Check for wear and renew as necessary. When
damaged. renewing, break glaze on cylinder walls.
6.8 PREMATURE Faulty suction filter. Check to ensure filter is not damaged.
WEAR
Incorrect lubricant. Change to recommended lubricant.
1228 issue 5
Page 19
HOW TO ORDER SPARES

TO AVOID UNNECESSARY DELAY OR AN INCORRECT PART BEING
SUPPLIED WHEN ORDERING SPARES PLEASE HAVE READY THE
FOLLOWING INFORMATION:-
1. COMPLETE INVOICING & SHIPPING ADDRESS
2. PARTS MANUAL REFERENCE NUMBER I.E. 98407/1228/18/12/02
3. MACHINE MODEL NUMBER. I.E. 5404
4. MACHINE NUMBER I.E. 5404.4.100
5. ITEM REFERENCE I.E. ITEM REF 05.13
6. PART NUMBER I.E. 98076.1018
7. PART DESCRIPTION I.E BEARING
8. QUANTITY REQUIRED.
1228 issue 5
Page 20
1228 issue 5
Page 21
SECTION 7 - BUILD LISTS
5404 MK4
5405 MK4
5405E.1800 & 1300 MK1
1228 issue 5
Page 22
1228 issue 5
Page 23
AMENDMENT RECORD
ISSUE No. MOD NOTE No. CHANGE/SERIAL NUMBER DATE PAGE No’s
1 NEW - DEC 2002 ALL
2 BOM CHANGES Breather pipe now part of assembly C204099, NOV 2003 2, 3, 9 & 11
coupling part number changed 95540.84
H5404 MK4, H5405 MK4 & H5405E
STANDARD COMPRESSORS
CONTENTS LIST
PAGE
CRANKCASE -------------------------------------------------------------------------------------------------- 001 - 009 3
RUNNING GEAR---------------------------------------------------------------------------------------------- 010 - 030 5
1st, STAGE CYLINDERS ----------------------------------------------------------------------------------- 031 - 050 9
2nd & 3rd STAGE CYLINDERS --------------------------------------------------------------------------- 031 - 050 11
1st & 2nd STAGE COOLER-------------------------------------------------------------------------------- 051 - 070 13
3rd STAGE COOLER & FLYWHEEL -------------------------------------------------------------------- 071 - 080 17
2nd STAGE CONCENTRIC VALVE---------------------------------------------------------------------- 085 21
3rd STAGE CONCENTRIC VALVE ---------------------------------------------------------------------- 090 23
MAINTENANCE KITS---------------------------------------------------------------------------------------- Append 24
DESIGN CLEARANCES ----------------------------------------------------------------------------------- Append 26
TORQUE WRENCH SETTINGS -------------------------------------------------------------------------- Append 26
Due to our policy of continuous improvement we reserve

the right to alter, modify and update without prior notice.
1228 issue 5
Page 24
CRANKCASE
5404MK4, 5405MK4 & 5405E STANDARD MACHINES
01/03
.4 .2 .1 .3
6.1
6.13
6.4
6.2
46.11
6.5
6.14
6.16
6.15 6.8
.9
.9 .3 05
.10 .5
.4 .13
05 .15
.1
.8
6.10
6.12
6.10
6.6
6.7 6.9
.7
.6
0.5 .14 2.1

4.1
.2
.10
.8
6.11
.16 .11 .12

05
01 - 09
1228 issue 5
Page 25
CRANKCASE PARTS
ITEM DESCRIPTION PART N° OFF STG
REF N° 540 540 5405E
4 5
01 BEARING HOUSING D/E Parts:- D100154.100* 1 1 0
.1 Bearing Housing D100154# 1 1 0 001
.2 'O' Ring 95602.98 1 1 0 001
.3 Oil Seal 95605.57 1 1 0 001
.4 Bearing 98076.1019 1 1 0 001
02.1 BRACKET C200836 2 2 0 002
03 BEARING HOUSING D/E Parts:- D101250.100* 0 0 1
.1 Bearing Housing D101250# 0 0 1 003
.2 'O' Ring 95602.98 0 0 1 003
.3 Oil Seal 98505.1005 0 0 1 003
.4 Bearing 98076.1026 0 0 1 003
4.1 BRACKET C202325 0 0 2
05 CRANKCASE Parts:- E60169.50* 1 1 1
.1 End Cover C200563 1 1 1 005
.2 Cover Plate C201336 1 1 1 005
.3 Stud M8 x 25 D100171.8.41 8 8 8 005
.4 Stud M8 x 70 D100171.8.86 4 4 4 005
.5 Crankcase E60169# 1 1 1 005
.6 Plug PS1068.3 1 1 1 005
.7 'O' Ring PS1206.1 1 1 1 005
.8 Setscrew M8 x 16 95000.254 7 7 7 005
.9 Nut M8 95111.5 12 12 12 005
.10 Washer Plain M8 95148.14 7 7 7 005
.11 Socket 3/8" BSP 95405.1003 1 1 1 005
.12 Nipple 95405.798 1 1 1 005
.13 Bearing 98076.1018 1 1 1 005
.14 Joint 98502.1016 1 1 1 005
.15 Joint 98502.1017 1 1 1 005
.16 Ball Valve 98650.1967 1 1 1 005
06.1 PLUG OIL FILLER C200562.1 1 1 1 006
06.2 SOCKET OIL FILLER C200562.3 1 1 1 006
06.3 SEE SECTION 46.11 FOR MORE DETAILS C204099 1 1 1 006
06.4 DIPSTICK C202562 1 1 1 006
06.5 PIPE OIL FILLER C73666.4.176 1 1 1 006
06.6 RIVET ROKUT PS2189.1 2 2 2 006
06.7 NAMEPLATE SERIAL RP513 1 1 1 006
06.8 SETSCREW M8 X 20 95000.255 6 6 6 006
06.9 SETSCREW M8 X 25 95000.256 3 3 3 006
06.10 SETSCREW M8 X 30 95000.257 5 5 5 006
06.11 NUT M8 95111.5 4 4 4 006
06.12 WASHER SPRING M8 95179.6 4 4 4 006
06.13 'O' RING 95602.40 1 1 1 006
06.14 'O' RING 95602.58 1 1 1 006
06.15 WASHER FIBRE 95640.9 1 1 1 006
06.16 BREATHER C204099 1 1 1 006
1228 issue 5
Page 26
RUNNING GEAR
5404 ONLY
23.2 . .1
11 .2 .5
.1
.3 .3 .2 .4
.1
.1 .6 .1
.5 23.1
5405 & 5405E
.2
.4 3
.2
29 .3
.1 .4
13 .2 23.3.1
.3
.4
12 .1
24 .3
.1 28 .2
.3
.1 14
.2
.2
16 .1 18.1
.3
17
18.1 .8 .6 .2 5
.8 .6 .8
17/27
17
.7
.4
.3
.1 5404 & 5405
27
.8 .6 .2 .9 .8
27 5405E
.7
.4
.3
.1
1228 issue 5
10 - 30
Page 27
RUNNING GEAR PARTS

REF N° 5404 5405 5405E
11 PISTON ASSY 1st STAGE Parts:- C200565* 1 0 0
Circlip with Piston 95650.20 2 0 0
.1 Piston with gudgeon pin 98438.1004# 1 0 0 011
.2. Piston Ring 98477.1016# 2 0 0 011
.3 Oil Control Ring 98477.1038# 1 0 0 011
a Piston Ring Set 98477.1099* 1 0 0
12 CONN ROD ASSY 1st STAGE Parts:- C202041.50* 1 0 0
.1 Conn Rod C202041# 1 0 0 012
.2 Bearing B/E 98076.1021 1 0 0 012
.3 Bearing S/E 98076.1022 1 0 0 012
13 PISTON ASSY 2nd STAGE Parts:- C200566* 1 1 1
Circlips with Piston 95650.12 2 2 2
.2. Piston Ring 98477.1002# 1 1 1 013
.3 Piston Ring 98477.1013# 2 2 2 013
.4 Oil Control Ring 98477.1122# 1 1 1 013
.a Piston Ring Set 98477.1101* 1 1 1
14 CONN ROD ASSY 2nd STAGE Parts:- C201061* 1 1 1
.1 Conn Rod C200533# 1 1 1 014
.2 Bearing B/E 98076.1021 1 1 1 014
.3 Bearing S/E ( was 98076.1114 on 5405E) 98076.1023 1 1 1 014
16 CONN ROD ASSY 3rd STAGE Parts:- C201062* 1 1 1
.1 Conn Rod C200535# 1 1 1 016
.2 Bearing S/E 96072.29 1 1 1 016
.3 Bearing B/E 98076.1021 1 1 1 016
17 CRANKSHAFT ASSY Parts:- D100427* 1 1 0
.1 Balance Weight C200554# 1 1 0 017
.2 Crankshaft D100153# 1 1 0 017
.3 Capscrew M8 x 55 95018.207 1 1 0 017
.4 Washer Plain M8 95148.14 1 1 0 017
.5 Key Parallel 8 x 7 x 40 95301.8 1 1 0 017
.6 Inner Ring 98076.1063 3 3 0 017
.7 Locknut M8 98422.1009 1 1 0 017
.8 Spacer 98660.1061 3 3 0 017
18.1 Spacer Conn Rod 98660.1060 4 4 4 018
23.1 PLUNGER/LINER/CROSS/H ASSY 3rd STAGE C203102 1 1 1 023
.1 Liner C203047# 1 1 1
.1.1 Plunger C203048# 1 1 1
.2 Washer Retaining C203049.1 1 1 1
.3 Crosshead 3rd Stage C203049.2 1 1 1
.4 Setscrew M5 x 20lg 95000.203 1 1 1
.5 'O' Ring 95602.18 1 1 1
.6 Piston Rings 98477.1144 2 2 2
1228 issue 5
Page 28
RUNNING GEAR
5404 ONLY
23.2 . .1
11 .2 .5
.1.1
.3 .3 .2 .4
.1
.1.1 .6 .1
.5 23.1
5405 & 5405E
.2
.4 3
.2
29 .3
.1 .4
13 .2 23.3.1
.3
.4
12 .1
24 .3
.1 28 .2
.3
.1 14
.2
.2
16 .1 18.1
.3
17
18.1 .8 .6 .2 5
.8 .6 .8
17/27
17
.7
.4
.3
.1 5404 & 5405
27
.8 .6 .2 .9 .8
27 5405E
.7
.4
.3
.1
1228 issue 5
10 - 30
Page 29
RUNNING GEAR PARTS cont.

REF N° 5404 5405 5405E
23.2 PLUNGER/LINER ASSY 3rd STAGE C203170 1 1 1
.1 Liner C203047# 1 1 1
.1.1 Plunger C203048# 1 1 1
.2 Washer Retaining C203049.1 1 1 1
.3 Setscrew M5 x 20lg 95000.203 1 1 1
.4 'O' Ring 95602.18 1 1 1
.5 Piston Rings 98477.1144 2 2 2
24 CONN ROD ASSY 1st STAGE Parts:- C203080.50* 0 0 1
.1 Conn Rod C203080# 0 0 1 024
.2 Bearing B/E 98076.1021 0 0 1 024
.3 Bearing S/E 98076.1022 0 0 1 024
27 CRANKSHAFT ASSY Parts:- D101249.100* 0 0 1
.1 Balance Weight C203079# 0 0 1 027
.2 Crankshaft D101249# 0 0 1 027
.3 Capscrew M8 x 55 95018.207 0 0 1 027
.4 Washer Plain M8 95148.14 0 0 1 027
.5
.6 Inner Ring 98076.1115 0 0 3 027
.7 Locknut M8 98422.1009 0 0 1 027
.8 Screw M10 x 50 Left hand thread 98500.1003 0 0 1 027
.9 Washer 98660.1092 0 0 1 027
28 CONN ROD ASSY 1st STAGE Parts:- C201063* 0 1 0
.1 Conn Rod C202040# 0 1 0 028
.2 Bearing B/E 98076.1021 0 1 0 028
.3 Bearing S/E 98076.1022 0 1 0 028
29 PISTON ASSY 1st STAGE Parts:- C200564* 0 1 1
Circlip with Piston 95650.20 0 2 2
.2. Piston Ring 98477.1017# 0 2 2 029
.3 Oil Control Ring 98477.1026# 0 1 1 029
.4 Oil Control Ring 98477.1039# 0 1 1 029
a Piston Ring Set 98477.1100* 0 1 1
1228 issue 5
Page 30
1ST STAGE CYLINDERS

46.8
46.9
46.4
46.6
42.1
42.2
42.4
46.10 46.11
.3
.1 41
.2
38.3a 38.3
46.8
46.9
46.4
46.6
34.1/47.1
40.1
34.4/47.2
46.10 46.11
.3
.1 39
.2
1228 issue 5
31 - 50
Page 31
1st, 2nd & 3rd STAGE CYLINDER PARTS

ITEM DESCRIPTION PART N° N° OFF STG
REF 5404 5405 5405E
31 CYLINDER 3rd STAGE Assy Parts:- C203046.100* 1 1 1
.1 Cylinder C203046# 1 1 1 031
.1.1 Stud with cylinder D66720.8.102 6 6 6
.2 Nut M8 98422.1028 6 6 6 031
.3 'O' Ring 98504.1029 1 1 1 031
32 CYLINDER 2nd STAGE Assy D101240.100* 1 1 1
Parts:-
.1 Cylinder D101240# 1 1 1 032
.2 Seal Dowty 1/8" BSP PS1322.1 1 1 1 032
.3 Plug PS1814.2 1 1 1 032
.4 Tension Pin 95540.160 1 1 1 032
.5 'O' Ring 95602.50 1 1 1 032
.6 Joint 98502.1014 1 1 1 032
33 CROSSHEAD GUIDE Assy Parts:- D101244.100* 1 1 1
.1 Crosshead Guide D101244# 1 1 1 033
.2 Joint 98502.1015 1 1 1 033
34.1 COVER 1st STAGE D101094 0 0 1 034
34.2 not used - - - - -
34.3 not used - - - - -
34.3a not used - - - - -
34.4 VALVE REED 1st STAGE 98650.1804 0 0 1 034
34.5 VALVE 2nd STAGE 98650.1883 1 1 1 034
38.1 not used - - - - -
38.2 not used - - - - -
38.3 SUCTION FILTER 98262.1339 1 1 - 038
38.3a ELEMENT – suction filter 98262.1340 1 1 -
39 CYLINDER 1st STAGE Assy Parts:- D100409.100* 0 1 1
.1 Cylinder D100409# 0 1 1 039
.2 Joint 98502.1013 0 1 1 039
.3 'O' Ring 98504.1028 0 1 1 039
40.1 JOINT 1st STAGE COVER 98502.1022 0 1 1 040
40.2 SAFETY VALVE 1st STAGE 98650.1163-8.3 0 1 1 040
.1 Cylinder D100424# 1 0 0 041
.2 Joint 98502.1013 1 0 0 041
.3 'O' Ring 98504.1030 1 0 0 041
42.1 COVER 1st STAGE D100425 1 0 0 042
46.1 VALVE 3rd STAGE C201654 1 1 1 046
46.2 SEAL DOWTY PS1322.1 1 1 1 046
46.3 SEAL DOWTY PS1322.2 1 1 1 046
46.4 NAMEPLATE MADE IN ENGLAND PS1673 1 1 1 046
46.5 PLUG PS1814.2 1 1 1 046
46.6 RIVET ROKUT PS2189.1 2 2 2 046
46.7 CAPSCREW 95018.206 6 6 6 046
46.8 CAPSCREW 95018.208 3 4 4 046
46.9 WASHER M8 95148.14 3 4 4 046
46.10 COUPLING 95540.84 1 1 1 046
46.11 BREATHER ASSEMBLY & PIPE C204099 1 1 1 046
47.1 COVER 1st STAGE D100408 0 1 0 047
1228 issue 5
Page 32
2ND & 3RD STAGE CYLINDERS

46.7
40.2/42.3
34.5/38.2
46.5
46.2
46.3
.4
.5
32
.1
46.1 .2
.3
.6
.2
.1.1
31
.1
.3
.1
33
.2
1228 issue 5
31 - 50
Page 33
1st, 2nd & 3rd STAGE CYLINDER PARTS

REF 5404 5405 5405E
31 CYLINDER 3rd STAGE Assy Parts:- C203046.100* 1 1 1
.1 Cylinder C203046# 1 1 1 031
.1.1 Stud with cylinder D66720.8.102 6 6 6
.2 Nut M8 98422.1028 6 6 6 031
.3 'O' Ring 98504.1029 1 1 1 031
32 CYLINDER 2nd STAGE Assy Parts:- D101240.100* 1 1 1
.1 Cylinder D101240# 1 1 1 032
.2 Seal Dowty 1/8" BSP PS1322.1 1 1 1 032
.3 Plug PS1814.2 1 1 1 032
.4 Tension Pin 95540.160 1 1 1 032
.5 'O' Ring 95602.50 1 1 1 032
.6 Joint 98502.1014 1 1 1 032
33 CROSSHEAD GUIDE Assy Parts:- D101244.100* 1 1 1
.1 Crosshead Guide D101244# 1 1 1 033
.2 Joint 98502.1015 1 1 1 033
34.1 COVER 1st STAGE D101094 0 0 1 034
34.2 not used - - - - -
34.3 not used - - - - -
34.3a not used - - - - -
34.5 VALVE 2nd STAGE 98650.1883 1 1 1 034
38.1 not used - - - - -
38.2 not used - - - - -
38.3 SUCTION FILTER 98262.1339 - - 1 038
38.3a ELEMENT – suction filter 98262.1340 - - 1
.1 Cylinder D100409# 0 1 1 039
.2 Joint 98502.1013 0 1 1 039
.3 'O' Ring 98504.1028 0 1 1 039
.1 Cylinder D100424# 1 0 0 041
.2 Joint 98502.1013 1 0 0 041
.3 'O' Ring 98504.1030 1 0 0 041
42.1 COVER 1st STAGE D100425 1 0 0 042
46.1 VALVE 3rd STAGE C201654 1 1 1 046
46.2 SEAL DOWTY PS1322.1 1 1 1 046
46.3 SEAL DOWTY PS1322.2 1 1 1 046
46.4 NAMEPLATE MADE IN ENGLAND PS1673 1 1 1 046
46.5 PLUG PS1814.2 1 1 1 046
46.6 RIVET ROKUT PS2189.1 2 2 2 046
46.7 CAPSCREW 95018.206 6 6 6 046
46.8 CAPSCREW 95018.208 3 4 4 046
46.9 WASHER M8 95148.14 3 4 4 046
46.10 COUPLING 95540.84 1 1 1 046
46.11 BREATHER ASSEMBLY & PIPE C204099 1 1 1 046
47.1 COVER 1st STAGE D100408 0 1 0 047
1228 issue 5
Page 34
1ST & 2ND STAGE COOLERS

56.2 .1 53.3
52.3 .1
55.2 .2
.1
53.2
55.4 53.1 .4
57.1 .2 56.2
.3 .1 .3
52.10
5405
52.5 56.3
52.4 55.5
52.6
53.4/59.2
.2
.1
.3 .3
.5 55.1
5405E
.6
.4 51
.1
55.4 .2
57.1
.3 .2
.2
.3
.4
55.3
56.1
5404
.1
.4
59.1
.1
.2
54.2
52.11
52.7
52.2
56.3
55.5
52.8
52.9 56.3
52.10 55.5
.4 .3 .2 .1 5
54.1
52.8
52.9
1228 issue 5
51 - 70 52.10
Page 35
1st & 2nd STAGE COOLER PARTS

REF 5404 5405 5405E
51 SEPARATOR ASSY Parts:- D100538* 1 1 1
.1 Collar Nut C200650 1 1 1 023
.2 Body C201602 1 1 1 023
.3 Cover Separator C203441 1 1 1 023
.4 Swirl adaptor C203442 1 1 1 023
.5 'O' Ring 95602.51 1 1 1 023
.6 Swirl fitting 98508.1002 1 1 1 023
52.1 CLAMPS C200576 6 6 6 039
52.2 BRACKET D100183 2 2 2 039
52.3 PIPE ASSY 3rd STAGE SUCTION Parts:- D101317 1 1 1 031
.1 Coupling 1/2" tube x 1/4" BSPT 98156.1801 1 1 1
.2 Pipe 1/2" Aluminium 98617.1018 1 1 1
.3 Coupling 1/2" tube x 1/4" BSPT 98156.2515 1 1 1
.4 Ferrule 98156.2446 1 1 1
52.4 SEAL DOWTY PS1322.1 1 1 1 039
52.5 SEAL DOWTY PS1322.2 1 1 1 039
52.6 PLUG PS1814.2 1 1 1 039
52.7 SETSCREW M6 X 60 95006.130 8 8 0 039
52.8 SCREW CSK 95028.134 1 1 1 029
52.9 NUT 95111.4 8 8 8 039
52.10 WASHER 95149.13 8 8 8 039
52.11 CLIP 98150.1006 1 1 1 029
53.1 CLIP COOLER C200586 0 6 2 053
53.2 SPACER TUBE C200878 0 2 1 053
53.3 SETSCREW M6 X 35 95000.232 0 1 1 053
53.4 SAFETY VALVE 98650.1164- 0 1 1 053
69
54.1 DRAIN VALVE ASSY Parts:- C200659 1 1 1 054
.1 Drain Valve Screw C200656.2 1 1 1
.2 Valve C200656.3 1 1 1
.3 Drain Body C200657.2 1 1 1
.4 Branch Pipe C200657.3 1 1 1
.5 Tension Pin 95540.172 1 1 1
54.2 SEAL DOWTY 98504.1051 1 1 1 054
55.1 PIPE ASSY 1st STAGE C203082 0 0 1 055
.1 St/Steel tube Ø 20 x 250 mm M3090.2017 0 0 1
.2 Elbow Ø 20 x 1/2" BSPT 98156.2593 0 0 1
.3 Union Ø 20 x 1/2" tube 98156.3315 0 0 1
55.3 COOLER COIL ASSY 1st STAGE Parts:- E61252 0 0 1 055
.1 Elbow 1/2" Tube x 3/8" BSPT 98156.2611 0 0 1
.2 Sleeve 98156.2860 0 0 1
.3 Nut 98156.2862 0 0 1
.4 Pipe 1/2" Aluminium 98617.1018 0 0 1
55.4 COOLER COIL ASSY 2nd STAGE Parts:- E61253 0 0 1 055
.1 Elbow 1/2" Tube x 1/4" BSPT 98156.2610 0 0 1
.2 Elbow 1/2" Tube x 3/8" BSPT 98156.2611 0 0 1
.3 Pipe 1/2" Aluminium 98617.1018 0 0 1
.1 Sleeve 98156.2860 0 1 0
.2 Elbow 1/2" Tube x 3/8" BSPT 98156.2611 0 1 0
.3 Coupling 1/2" Tube X 3/8" BSPT 98156.2861 0 1 0
.4 Pipe 1/2" Aluminium 98617.1018 0 1 0
1228 issue 5
Page 36
1ST & 2ND STAGE COOLERS

52.3 .1
55.2 .2
.1
53.2
55.4 53.1 .4
57.1 .2 56.2
.3 .1 .3
52.10
5405
52.5 56.3
52.4 55.5
52.6
53.4/59.2
.2
.1
.3 .3
.5 55.1
5405E
.6
.4 51
.1
55.4 .2
57.1
.3 .2
.2
.3
.4
55.3
56.1
5404
.1
.4
59.1
.1
.2
54.2
52.11
52.7
52.2
56.3
55.5
52.8
52.9 56.3
52.10 55.5
.4 .3 .2 .1 5
54.1
52.8
52.9
1228 issue 5
51 - 70 52.10
Page 37
1st & 2nd STAGE COOLER PARTS cont.
ITEM REF DESCRIPTION PART N° N° OFF STG

5404 5405 5405E
.1 Sleeve 98156.2860 0 1 0
.2 Elbow 1/2" Tube x 3/8" BSPT 98156.2611 0 1 0
.3 Pipe 1/2" Aluminium 98617.1018 0 1 0
.4 Nut 98156.2862 0 1 0
56.3 SETSCREW M6 X 80 95006.134 0 2 0 056
57.1 COOLER COIL ASSY 2nd STAGE Parts:- E60448 1 1 0 031
.1 Elbow 1/2" Tube x 1/4" BSPT 98156.2610 1 1 0
.2 Elbow 1/2" Tube x 3/8" BSPT 98156.2611 1 1 0
.3 Pipe 1/2" Aluminium 98617.1018 1 1 0
.1 Elbow 1/2" Tube x 3/8" BSPT 98156.2611 2 0 0
.2 Pipe 1/2" Aluminium 98617.1018 1 0 0
59.2 SAFETY VALVE 98650.1164- 1 0 0 039
54
1228 issue 5
Page 38
3RD STAGE COOLER & FLYWHEEL

5404MK4 & 5405MK4 STANDARD MACHINES
71.7 71.1 71.5 71.4
73.1
.1 .3
71.6
.1
72.1 .5
.4
71.7 71.2 71.1
71.5 71.4
.2 .5 .3
71.3
72.1
.3
73.1
.2
71.1
71.5
71.4
71.7
1228 issue 5
71 - 73
Page 39
3rd STAGE COOLER & FLYWHEEL PARTS

5404 5405 5405E
71.1 COOLER CLIP C200587 6 6 0 071
71.2 SPACER TUBE C200879 1 1 0 071
71.3 BRACKET F/D PIPE C202563 1 1 0 071
71.4 SETSCREW M6 X 40 95000.233 3 3 0 071
71.5 SPRING WASHER M6 95179.5 3 3 0 071
71.6 CONNECTOR 98156.280 1 1 0 071
9
71.7 SUPPORT WASHERS 98660.110 20 20 0 071
9
72.1 FLYWHEEL ASSY Parts:- E60341 1 1 0 072
.1 Hub C200577 1 1 0
.2 Flywheel/Fan E60179 1 1 0
.3 Setscrew M8 x 20 95000.255 4 4 0
.4 Setscrew M8 x 40 95000.259 1 1 0
.5 Washer Spring M8 95179.6 5 5 0
73.1 COOLER ASSY 3rd STAGE E61269 1 1 0 073
Parts:-
.1 Swivel Nut Elbow 98156.160 1 1 0
4
.2 Union Elbow 98156.218 1 1 0
0
.3 Tube 8 mm x 2000 mm 98617.100 1 1 0
6
1228 issue 5
Page 40
3RD STAGE COOLER & FLYWHEEL

5405E STANDARD MACHINES
75.2 74.7 74.1 74.4 75.7 75.1

.1 .3
74.6
74.5
75.5
74.2
75.3
74.7
74.1
75.5
74.5
74.3
75.5 75.6 71.1 74.7 75.3

.2
75.2
1228 issue 5
74 - 80
Page 41
3rd STAGE COOLER & FLYWHEEL PARTS cont.

5404 5405 5405E
74.1 COOLER CLIP C200587 0 0 6 074
74.2 SPACER TUBE C200879 0 0 1 074
74.3 BRACKET F/D PIPE C202563 0 0 1 074
74.4 SETSCREW M6 X 60 95000.233 0 0 3 074
74.5 SPRING WASHER M6 95179.5 0 0 3 074
74.6 CONNECTOR 98156.2809 0 0 1 074
74.7 SUPPORT WASHERS 98660.1109 0 0 20 074
75.1 FLYWHEEL E61247 0 0 1 075
75.2 COOLER ASSY 3rd STAGE Parts:- E61254 0 0 1 075
.1 Swivel Nut Elbow 98156.1604 0 0 1
.2 Union Elbow 98156.2180 0 0 1
.3 Tube 8 mm x 2000 mm 98617.1008 0 0 1
75.3 SETSCREW M6 X 90 95006.135 0 0 2 075
75.4 CAPSCREW M6 X 20 95018.168 0 0 6 075
75.5 NUT M6 95111.4 0 0 6 075
75.6 SPRING WASHER M6 95179.5 0 0 6 075
75.7 AXIAL FAN 98084.1001 0 0 1 075
1228 issue 5
Page 42
2ND STAGE CONCENTRIC VALVE

85.1.1
c
85.1.2
1228 issue 5
85 - 89
Page 43
2nd STAGE CONCENTRIC VALVE PARTS
ITEM REF DESCRIPTION PART N° N° OFF

540 540 5405E
4 5
85.1 VALVE 2nd STAGE 98650.1883 1 1 1
1.1 'O' Ring 95602.54 1 1 1
1.2 'O' Ring 95602.50 1 1 1
2nd Stage Valve Maintenance 98650.1215 1 1 1
Kit:- *
a Capscrew 95018.134 2 2 2
b 'O' Ring 95602.50 1 1 1
c 'O' Ring 95602.54 1 1 1
d Valve/Backing Plate Delivery 98650.1211 2 2 2
e Spring Plate Delivery 98650.1212 2 2 2
f Valve/Backing Plate Suction 98650.1213 2 2 2
g Spring Plate Suction 98650.1214 2 2 2
1228 issue 5
Page 44
3RD STAGE CONCENTRIC VALVE

d 90.1.1
90.1.2
1228 issue 5
90 - 94
Page 45
3rd STAGE CONCENTRIC VALVE PARTS
ITEM REF DESCRIPTION PART N° N° OFF

5404 5405 5405E
90.1 VALVE COMPLETE C201654 1 1 1
1.1 'O' Ring 95602.16 1 1 1
1.2 'O' Ring 95602.18 2 2 2
3rd Stage Valve Maintenance Kit:- 98650.1199* 1 1 1
a Capscrew 95018.106 2 2 2
b 'O' Ring 95602.16 1 1 1
c 'O' Ring 95602.18 2 2 2
d Valve/Backing Plate 98650.1196 4 4 4
e Spring Plate 98650.1197 4 4 4
f Centre Plate 98650.1198 2 2 2
1228 issue 5
Page 46
MAINTENANCE KITS
DESCRIPTION PART N° N° OFF

5404 5405 5405E
JOINT KIT Consists of:- 98504.1118* 1 1 1
'O' Ring 3rd stage liner 95602.18 2 2 2
'O' Ring 3rd stage cylinder cover to cylinder 95602.18 1 1 1
'O' Ring oil dip stick 95602.40 1 1 1
'O' Ring suction filter adapter 95602.45 1 1 1
'O' Ring 1st stage valve to cylinder cover (inner) 95602.50 1 0 0
'O' Ring 2nd stage valve to cylinder 95602.50 1 0 0
'O' Ring 2nd stage separator cap 95602.51 1 1 1
'O' Ring crankcase breather cap 95602.58 1 1 1
'O' Ring oil regulator block to cylinder 95602.7 1 1 1
'O' Ring oil sight glass 95602.8 2 2 2
'O' Ring 1st stage valve to cylinder cover (outer) 95602.85 1 1 1
'O' Ring D/E bearing housing 95602.98 1 1 1
'O' Ring 1st stage valve to cylinder 98504.1028 0 1 1
'O' Ring 3rd stage crosshead to cylinder 98504.1029 1 1 1
Joint 1st stage cylinder to crankcase 98502.1013 1 1 1
Joint 2nd stage cylinder to crankcase 98502.1014 1 1 1
Joint 3rd stage crosshead 98502.1015 1 1 1
Joint outer end cover 98502.1016 1 1 1
Joint oil pump to crankcase 98502.1017 1 1 1
Joint 1st stage cylinder cover 98502.1021 1 0 0
Joint copper oil sight glass body 98660.1152 1 1 1
Seal dowty separator drain 98504.1051 1 1 1
'O' Ring oil drain crankcase PS1206.1 1 1 1
Seal dowty separator cap plug PS1322.1 1 1 1
Seal dowty 2nd stage valve cover plug PS1322.1 1 1 1
Seal dowty oil regulator block fitting PS1322.1 2 2 2
Seal dowty plug 2nd stage cylinder PS1322.1 1 1 1
Seal dowty 2nd stage safety valve PS1322.2 1 1 1
Seal dowty 1st stage safety valve PS1322.2 1 1 1
Washer fibre oil drain crankcase 95640.7 1 1 1
Washer fibre crankcase breather 95640.9 1 1 1
1228 issue 5
Page 47
1228 issue 5
Page 48
MAINTENANCE KITS cont.

5404 5405 5405E
JOINT KIT Non Asbestos Consists of:- 98504.1304 1 1 1
Joint 1st stage cylinder to crankcase 98502.1013 1 1 1
Joint 2nd stage cylinder to crankcase 98502.1014 1 1 1
Joint 3rd stage crosshead 98502.1015 1 1 1
Joint outer end cover 98502.1016 1 1 1
Joint oil pump to crankcase 98502.1017 1 1 1
The following is to used when NON ASBESTOS JOINTS are used

5404 5405 5405E
Supplementary JOINT KIT Consists of:- 98504.1314 1 1 1
'O' Ring 3rd stage liner 95602.18 2 2 2
'O' Ring 3rd stage cylinder cover to cylinder 95602.18 1 1 1
'O' Ring oil dip stick 95602.40 1 1 1
'O' Ring suction filter adapter 95602.45 1 1 1
'O' Ring 2nd stage valve to cylinder 95602.50 1 0 0
'O' Ring 2nd stage separator cap 95602.51 1 1 1
'O' Ring crankcase breather cap 95602.58 1 1 1
'O' Ring oil regulator block to cylinder 95602.7 1 1 1
'O' Ring oil sight glass 95602.8 2 2 2
'O' Ring D/E bearing housing 95602.98 1 1 1
'O' Ring 3rd stage crosshead to cylinder 98504.1029 1 1 1
Joint copper oil sight glass body 98660.1152 1 1 1
Seal dowty separator drain 98504.1051 1 1 1
'O' Ring oil drain crankcase PS1206.1 1 1 1
Seal dowty separator cap plug PS1322.1 1 1 1
Seal dowty 2nd stage valve cover plug PS1322.1 1 1 1
Seal dowty oil regulator block fitting PS1322.1 2 2 2
Seal dowty plug 2nd stage cylinder PS1322.1 1 1 1
Seal dowty 2nd stage safety valve PS1322.2 1 1 1
Seal dowty 1st stage safety valve PS1322.2 1 1 1
Washer fibre oil drain crankcase 95640.7 1 1 1
Washer fibre crankcase breather 95640.9 1 1 1
1228 issue 5
Page 49
DESIGN CLEARANCES & TORQUE WRENCH SETTINGS
Design Clearances
DESCRIPTION 5404 MK4 5404H 5405 MK4 5405E

mm mm mm mm
Crankshaft End Float 0.35 - 0.84 0.35 - 0.84 0.35 - 0.84 0.05 - 0.50
TDC Clearance 1st Stage 0.30 - 0.84 0.30 - 0.84 0.30 - 0.84 0.30 - 0.84
TDC Clearance 2nd Stage 0.50 - 1.04 0.95 - 1.73 0.50 - 1.04 0.50 - 1.04
TDC Clearance 3rd Stage 0.43 - 1.11 0.43 - 1.11 0.43 - 1.11 0.43 - 1.11
Class 'A' Critical Torque Wrench Settings All Figures ± 5%

For Non Lubricated Fasteners
SIZE DESCRIPTION 5404 MK4 5404H 5405 MK4 5405E

Nm Lbf Nm Lbf Nm Lbf Nm Lbf
Ft Ft Ft Ft
M8 1st Stage Valve Cover 13 10 13 10 13 10 27 20
3/8 1st Stage Valve 21 16 21 16 21 16 21 16
UNF
M8 2nd Stage Valve to Cylinder 16 12 16 12 16 12 16 12
M5 2nd Stage Valve 6 5 6 5 6 5 6 5
M4 3rd Stage Valve 4 3 4 3 4 3 4 3
M8 3rd Stage Valve to Cylinder 16 12 16 12 16 12 16 12
M8 Flywheel 27 20 27 20 27 20 - -
M10 Flywheel to Crankshaft - - - - - - 55 40
M6 Oil Pump Cam - - 11 8 - - - -
M8 Crankshaft Balance Weight 27 20 27 20 27 20 27 20
M5 3rd Stage Plunger - - - - - - 6 5
Class 'B' Torque Wrench Settings All Figures + 5% - 15%

For Non Lubricated Fasteners
SIZE DESCRIPTION 5404 MK4 5404H 5405 MK4 5405E
Nm Lbf Nm Lbf Nm Lbf Nm Lbf
Ft Ft Ft Ft
M6 All Other Fasteners 11 8 11 8 11 8 11 8
Note: Under no circumstances are any deviations from the above figures allowed unless authorised in
writing by the Chief Designer or Development Engineer.
1228 issue 5
Page 50
SECTION 8 - ADDITIONAL INFORMATION

1. BELT DRIVE GENERAL ---------------------------------------------------------- APP012
2. HIGH AIR PRESSURE SWITCH - DIFFERENTIAL------------------------- APP081
3. HIGH AIR PRESSURE SWITCH - FIXED ------------------------------------- APP083
4. HIGH AIR TEMPERATURE SWITCH - OPTIONAL------------------------- APP101
5. CONDENSATE DRAIN SYSTEM------------------------------------------------ APP204
6. CONDENSATE DRAIN SYSTEM------------------------------------------------ APP209
7. SERVICE PLAN 5404 --------------------------------- RSP54044S & RSP54044SW
8. SERVICE PLAN 5405 --------------------------------- RSP54054S & RSP54054SW
9. SERVICE PLAN 5405E.1800 ----------- RSP5405.1800S & RSP5405E.1800SW
10. SERVICE PLAN 5405E.1300 ----------- RSP5405.1300S & RSP5405E.1300SW
1228 issue 5
Page 51
1228 issue 5
CompAir UK Ltd APP012 - GENERAL BELT ALIGNMENT & TENSIONING
Page 1
RECOMMENDED VEE BELT ALIGNMENT

& TENSIONING
BELT DRIVE ALIGNMENT
NO OFF BELTS WILL VARY ON DIFFERENT SETS
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.
RECOMMENDED TENSIONING FORCES
CENTRE DISTANCE
BELT TEMSION
INDCATOR APPLIED TO
MID-SPAN
16 mm deflection per 1 metre of
span
TYPICAL 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 later. 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 (M12 - 95 Newton Metres).(M10 - 55 Newton Metres)
APP012.DOC
CompAir UK Ltd APP012 - GENERAL BELT ALIGNMENT & TENSIONING
Page 2
TABLE
Belt
Section Force required to deflect belt 16 mm per metre of span
Belt Small Pulley Newton Kilogram force
Section Ø mm (N) (kgf)
SPA 100 to 132 20 to 27 1.5 to 2.7
SPA 140 to 200 27 to 35 2.7 to 3.5
SPB 160 to 224 35 to 50 3.5 to 5.1
SPB 236 to 315 50 to 65 5.1 to 6.6
SPC 224 to 355 60 to 90 6.1 to 9.2
SPC 375 to 560 90 to 120 9.2 to 12.2
SPZ 67 to 95 10 to 15 1.0 to 1.5
SPZ 100 to 140 15 to 20 1.5 to 2.0
8V 335 & above 150 to 200 15.3 to 20.4
Z 56 to 100 5 to 7.5 0.5 to 0.8
A 80 to 140 10 to 15 1.0 to 1.5
B 125 to 200 20 to 30 2.0 to 3.1
C 200 to 400 40 to 60 4.1 to 6.1
D 355 to 600 70 to 105 7.1 to 10.7
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).
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 ajacent 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.
BELT TENSION INDICATOR
DEFLECTION DEFLECTION FORCE

IN mm IN kgf
APP012.DOC
CompAir UK Ltd APP 081 PRESSURE SWITCH 98524.1004
Page 1
PRESSURE SWITCH
98524.1004 & 1139
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
A
Green Pointer
3 1
4 2
SETTING
Example of pressure setting to 200 bar minimum and 225 bar maximum.
Turn screw (A) to raise the GREEN pointer to its highest point.
Turn screw (B) so that the higher setting (225 bar) coincides with the RED pointer.
Turn screw (A) again to set the lower pressure 200 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 083 HIGH AIR/GAS PRESSURE SWITCHES
Page 1
HIGH AIR/GAS PRESSURE SWITCH

PART NO: 98524.1054 OPERATING RANGE 50 TO 500 BAR
PART NO: 98524.1133 OPERATING RANGE 0.4 TO 3.5 BAR
PART NO: 98524.1134 OPERATING RANGE 9.5 TO 70 BAR
PART NO: 98524.1191 OPERATING RANGE 1.5 TO 35 BAR
OPERATION - MANUAL START/AUTO STOP
Located as close as possible to the H.P. or stage delivery line, the pressure switch stops the compressor
when the upper pre-set pressure setting is attained.
The snap action contacts switch transforms a rise in pressure into an electrical "Off" signal.
INSTALLATION
Pressure switches may be mounted in any convenient position close the H.P. or stage delivery 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"
see APP092 COMPUTAIR CARD II wiring diagram page 9 for details of connections.
1 2
See APP092 for connection details

Setting
Example of pressure setting.
Turn screw anti-clockwise or clockwise to raise or lower the RED pointer to the HIGH setting required.
Note:- The lower setting is pre-determined as the switch has a fixed deferential.
app083.doc
CompAir UK Ltd APP 083 HIGH AIR/GAS PRESSURE SWITCHES
Page 2
app083.doc
CompAir UK Ltd APP 101 TEMPERATURE SWITCH FUNCTION TEST
Page 1
HIGH AIR/GAS TEMPERATURE SWITCH FUNCTION TEST

FOR 5405E, 5406, 5406E, 5307, 5407, 5407H, 5408, 5309 & 5409
98524/1050 CONTACTS NORMALLY CLOSED
98524/1055 CONTACTS NORMALLY OPEN
The switch should be wired back to the starter which should be arranged with suitable terminals.
Check high air/gas temperature switch for correct functioning every 1800 hours running, annually or discard
and fit new.
98524/1050
a) Shut down compressor and electrically inhibit.

b) Remove high air/gas temperature switch complete with wires in its entirety.
c) Using a suitable electrically heated oil bath fitted with a high temperature cut-out switch,
ie. capable of being heated to high temperatures (180°C) with no danger to life.
d) Using an `A` grade calibrated suitable thermometer immersed into the oil.
e) Immerse the high air/gas temperature switch threaded end only in the oil and secure in
position, do not immerse the electrical connections or coverings.
f) Fit a multimeter or similar to electrical connections/terminals.
g) Heat up oil to set temperature high 175°C ± 8°C terminals should open.
h) Allow oil temperature to fall to 145°C ± 11°C upon which terminals should close.
i) If the switch operates outside these parameters the switch is to be scrapped and replaced.
98524/1055
a) Shut down compressor and electrically inhibit.

b) Remove high air/gas temperature switch complete with wires in its entirety.
c) Using a suitable electrically heated oil bath fitted with a high temperature cut-out switch,
ie. capable of being heated to high temperatures (180°C) with no danger to life.
d) Using an `A` grade calibrated suitable thermometer immersed into the oil.
e) Immerse the high air/gas temperature switch threaded end only in the oil and secure in
position, do not immerse the electrical connections or coverings.
f) Fit a multimeter or similar to electrical connections/terminals.
g) Heat up oil to set temperature high 175°C ± 11°C terminals should close.
h) Allow oil temperature to fall to 145°C ± 11°C upon which terminals should open.
i) If the switch operates outside these parameters the switch is to be scrapped and replaced.
app101.doc
CompAir UK Ltd APP 101 TEMPERATURE SWITCH FUNCTION TEST
Page 2
app101.doc
CompAir UK Ltd APP 204 UNLOADER DRAIN VALVE SYSTEM
Page 1
UNLOADER DRAIN VALVE SYSTEM

OPERATION
Low pressure air/gas (1st stage) is fed to the solenoid valve which when running is open, this in turn holds
the unloader valves closed by means of a diaphragm pushing against the valve plates.
On shut down the solenoid de-energises, air/gas is shut off, any excess being vented into the casing. The
pressure on the diaphragms is released allowing the valves to open, condensate is discharged into the
casing and then into the drainpipe.
On start up, the solenoid opens as the pressure builds up the valves close and the cycle repeats itself.
For continuous running a timer is fitted in the control panel for the drainage system, a signal is passed to the
solenoid valve every 20/30 minutes (depends on ambient temperature/humidity conditions) this closes the
valve for 5 to 6 seconds duration and allows the drains to eject all condensate collected. Note: In HIGH
AMBIENT/HUMIDITY AREAS it is recommended that the drainage cycle time be more frequent contact
CompAir UK Ltd - Customer Service Fax No. +44 (0) 1473 556027 for more details.
The solenoid re-opens for normal operation.
TYPICAL DRAIN SYSTEM LAYOUT

From 3rd/4th Stage Separator From 2nd/3rd Stage
drain or Filtration Unit depending Separator drain or Filtration
upon APPLICATION Unit depending upon
APPLICATION
From 2nd Stage Separator

Condensate drain. Can be plugged on
Discharge some applications
RP1.1/4”
From 1st Stage

Unloader Drain
Delivery Pressure
Valve Assembly
D101438
Solenoid Valve Optional Plug In
PS2197 Timer 98606/1014
Only used when a
control panel is not
fitted.
app204.doc
CompAir UK Ltd APP 204 UNLOADER DRAIN VALVE SYSTEM
Page 2
UDV D101438
Port ‘A’ Ø5mm Port ‘B’ Ø2.5mm

1/4” BSPT 1/8” BSPT
Port ‘C‘ Ø1.5mm
7 1/8” BSPT
7.5
7.4
7.3
7.2
7.1
7.6
4
3
5
CONNECTION DETAILS
Compressor Port A Port B Port C
5307, 5309 & 5309.2 2nd stage 3rd stage -
5404, 5405 & 5405E - 2nd stage 3rd stage
5406 & 5406E 2nd stage 3rd stage 4th stage
5407 5407H & 5407.2 2nd stage 3rd stage 4th stage
5408, 5409, 5409IND & 5409.2 2nd stage 3rd stage 4th stage
PARTS
Item No Description Part No No Off
1 Manifold C203194 1
2 Capscrew M6 x 60 95018/176 2
3 Bush Reducing 95405/861 1
4 'O' ring 95602/15 3
5 Safety Valve 98650/1171 1
6 Pilot Unloader Valve AS FITTED 1
7 Unloader Valve Assembly C203279 1
7.1 Piston C203195 3
7.2 Plate C203196 1
7.3 Gasket C203197 1
7.4 Diaphragm C203198 1
7.5 Body D101409 1
7.6 Capscrew M6 x 20 95018/168 8
app204.doc
CompAir UK Ltd PUBLICATION APP209
Page 1
UNLOADER DRAIN VALVE ASSEMBLIES
OPERATION.
Low pressure air/gas (usually 1st stage) is fed to a solenoid valve which when compressor is running is
open, the air holds the unloader drain valves closed, by means of a diaphragm (B) pushing against the
pistons (A).
Located near to separator/filter drains the Unloader Drain Valve (UDV) is designed to drain any condensate
collected during normal operation i.e.
1. When compressor shuts down on Manual Start/Stop operation.

2. When compressor shuts down on Manual Start/Auto Stop operation.
3. When a timed drainage system is used on Auto Start/Stop continuous operation.
MANUAL START/STOP. - MANUAL START/AUTO STOP.
On Shut-Down the solenoid is de-energised, air/gas is shut off, any excess air/gas being vented into the
manifold. The pressure on the diaphragm is released taking the pressure off the pistons allowing the valves
to open, air/gas/condensate is discharged into the manifold and drain pipe for safe disposal or into a
condensate collection vessel if fitted, this must be periodically emptied.
On Start-Up, the solenoid opens. the pressure builds up, the valves close and the cycle repeats itself.
AUTO START/STOP.
For continuous running a timed drainage system should be used, a signal is passed to the solenoid, every
30 minutes from the starter control panel or by means of an optional timer plug, part number
98606.1014,1015 or 1016, this closes the solenoid valve for 5 to 6 seconds duration allowing all condensate
collected to be discharged through the unloader drain valve system. (Note in HIGH AMBIENT/HUMIDITY
AREAS it is recommended the drainage cycle time be more frequent contact CompAir UK Ltd - Customer
Service Tel. +44 (0) 1473 242097 for more information.
The solenoid valve re-opens for normal operation.
app209.doc
Page 2
INLINE UDV ASSEMBLY D101580

3
PORT 'A'
1ST
STAGE
1
PORT 'B'
A 2ND STAGE
B
PORT 'C'
3RD
STAGE
7 PORT 'D' 4TH STAGE

*AN ORIFICE
2 ADAPTER C89347
MAY BE FITTED
5
VALVE CONTROL
4 FROM 1ST STAGE
PRESSURE BY A 3
WAY NC SOLENOID
VALVE PS2197 SEE
APP 138 & AN
OPTIONAL TIMER
6
PLUG 98606.1014,
1015 OR 1016
CONDENSATE DISCHARGE 1" BSPT
PARTS LIST
ITEM PART NUMBER DESCRIPTION NO OFF
1 D101582 VALVE ASSEMBLY 1ST & 2ND STAGE 1
2 D101581 VALVE ASSEMBLY 3RD & 4TH STAGE 1
3 95019.176 CAPSCREW M6 X 60 LG 4
4 95405.861 REDUCING SOCKET 1
5 98650.1163-4.1 SAFETY VALVE 1
6 C203676 MANIFOLD INLINE 4 POSITION 1
7 95602.15 'O' RING 4
8 PS1454.1 BLANKING PLUG IF FITTED (NOT ILLUSTRATED) 1
SPARES KIT
A C203195 PISTON 4
B C203549 DIAPHRAGM 2
CONNECTION DETAILS
COMPRESSOR TYPE PORT 'A' PORT 'B' PORT 'C' PORT 'D'
5407.2 1ST STAGE 2ND STAGE 3RD STAGE 4TH STAGE
5307.2 1ST STAGE 2ND STAGE 3RD STAGE PLUGGED
* AN ADAPTER MAY BE FITTED ON SOME APPLICATIONS TO THE 4TH STAGE DRAIN PORT TO
SLOW DOWN THE DRAIN PROCESS TO PREVENT OVERPRESSURE OF THE CONDENSATE
COLLECTION SYSTEM.
app209.doc
Page 3
2 X 2 UDV ASSEMBLY D101608

PARTS AS D100580 UNLESS AS STATED BELOW
1 PORT 'B'
2ND STAGE
PORT 'A' 1ST

STAGE
2
PORT 'C'
3RD STAGE
PORT 'D' 4TH

STAGE *AN
7 ORIFICE ADAPTER
C89347 MAY BE
FITTED
6 VALVE CONTROL FROM 1ST
STAGE PRESSURE BY A 3
WAY NC SOLENOID VALVE
PS2197 SEE APP 138 & AN
3
OPTIONAL TIMER PLUG
98606.1014, 1015 OR 1016
PARTS LIST
1 D101582 VALVE ASSEMBLY 1ST & 2ND STAGE 1
2 D101581 VALVE ASSEMBLY 3RD & 4TH STAGE 1
3 95019.176 CAPSCREW M6 X 60 LG 4
5 98650.1163-4.1 SAFETY VALVE 1
6 C203677 MANIFOLD 2 x 2 POSITION 1
7 95602.15 'O' RING 4
8 PS1454.1 BLANKING PLUG IF FITTED (NOT ILLUSTRATED) 1
SPARES KIT
A C203195 PISTON 4
CONNECTION DETAILS
COMPRESSOR TYPE PORT 'A' PORT 'B' PORT 'C' PORT 'D'
5407.2 1ST STAGE 2ND STAGE 3RD STAGE 4TH STAGE
5307.2 1ST STAGE 2ND STAGE 3RD STAGE PLUGGED
* AN ADAPTER MAY BE FITTED ON SOME APPLICATIONS TO THE 4TH STAGE DRAIN PORT TO
SLOW DOWN THE DRAIN PROCESS TO PREVENT OVERPRESSURE OF THE CONDENSATE
COLLECTION SYSTEM.
app209.doc
Page 4
2 VALVE UDV ASSEMBLY D101544

SEE D70549 FOR INSTALLATION
PORT 'B'
3RD STAGE
1
PORT 'A' 2ND

STAGE
VALVE CONTROL
FROM 1ST STAGE
5 PRESSURE BY A 3
WAY NC SOLENOID
VALVE PS2197 SEE
APP 138 & AN
OPTIONAL TIMER
4
PLUG 98606.1014,
1015 OR 1016.
6
CONDENSATE DISCHARGE 1" BSPT
PARTS LIST
1 C203552 UNLOADER VALVE ASSEMBLY 1
2 95019.176 CAPSCREW M6 X 60 LG 2
3 95602.15 'O' RING 2
5 98650.1163-4.1 SAFETY VALVE 1
6 C203551 MANIFOLD 1
SPARES KIT
A C203195 PISTON 2
CONNECTION DETAILS
COMPRESSOR TYPE PORT 'A' PORT 'B'
5404 2ND STAGE 3RD STAGE
5405 2ND STAGE 3RD STAGE
5405E 2ND STAGE 3RD STAGE
app209.doc
Page 5
2
PORT 'C'
3RD/4TH
STAGE
1 OR PLUGGED
A B
PORT 'B' 2ND/3RD

STAGE
PORT 'A' 2ND

3
STAGE OR
PLUGGED
5
VALVE CONTROL
FROM 1ST STAGE
PRESSURE BY A 3
4 WAY NC SOLENOID
VALVE PS2197 SEE
APP 138 & AN
6 OPTIONAL TIMER
PLUG 98606.1014,
CONDENSATE DISCHARGE 1" BSPT 1015 OR 1016
PARTS LIST
2 95019.176 CAPSCREW M6 X 60 LG 2
3 95602.15 'O' RING 3
5 98650.1163-4.1 SAFETY VALVE 1
SPARES KIT
A C203195 PISTON 3
C C203197 GASKET 1
CONNECTION DETAILS
COMPRESSOR TYPE PORT 'A' PORT 'B' PORT 'C'
5307 2ND STAGE 3RD STAGE -
5404 - 2ND STAGE 3RD STAGE
5406 2ND STAGE 3RD STAGE 4TH STAGE
app209.doc
Page 6

2 PORT 'C'
3RD/4TH STAGE
OR PLUGGED
1
A B
PORT 'B' 2ND/3RD

STAGE
3 PORT 'A' 2ND

STAGE OR
PLUGGED
VALVE CONTROL
5 FROM 1ST STAGE
PRESSURE BY A 3
4 WAY NC SOLENOID
VALVE PS2197 SEE
APP 138 & AN
6 OPTIONAL TIMER
PLUG 98606.1014,
CONDENSATE DISCHARGE 1" BSPT 1015 OR 1016
PARTS LIST
2 95019.176 CAPSCREW M6 X 60 LG 2
3 95602.15 'O' RING 3
5 98650.1287-4.6 SAFETY VALVE 1
SPARES KIT
A C203195 PISTON 3
C C203197 GASKET 1
CONNECTION DETAILS
COMPRESSOR TYPE PORT 'A' PORT 'B' PORT 'C'
app209.doc
RECOMMENDED SERVICE PLAN - 5404 Mk4 CompAir UK Ltd
Page 1
SYNTHETIC OIL - STANDARD GRADE
IMPORTANT - DAILY & BEFORE STARTING
Check oil level top up if necessary
INITIAL SERVICE Change oil. Cleanse crankcase, Repeat after MAJOR OVERHAUL Part Ref.
50 HOURS OR (3000 hours) or any intermediate overhaul. No Off RSP5404/4s.1
ELASPED TIME Change oil (sump capacity 1.6 litres) REAVELLITE 'S' 1 Litre 2 98384/1020
6 MONTHS
Check belt tension & condition of all ancillaries
Check for oil & air leaks.
Check tightness of all fasteners.
AT 500 HOURS Change oil. Cleanse crankcase. Renew suction filter. Part Ref.
OR ELAPSED TIME No Off RSP5404/4s.2
12 MONTHS Change oil (sump capacity 1.6 litres) REAVELLITE 'S' 1 Litre 2 98384/1020
Suction filter 1 98262/1036
'O' ring suction filter adaptor 1 95602/45
AT 1000 HOURS Change oil. Cleanse crankcase. Renew suction filter. Change 3rd Part Ref.
OR ELAPSED TIME stage piston rings No Off RSP5404/4s.3
'O' ring 3rd stage liner 3 95602/18
3rd stage piston rings 2 98477/1144
AT 1500 HOURS Change oil. Cleanse crankcase, Service 2nd & 3rd stage valves. Part Ref.
OR ELAPSED TIME Clean 1st stage valve. Renew suction filter. No Off RSP5404/4s.4
Service kit 3rd stage valve 1 98650/1199
Service kit 2nd stage valve 1 98650/1215
'O' ring 1st stage valve (valve to cylinder) 1 98504/1030
Joint 1st stage valve (valve to cylinder cover) 1 98502/1021
Check unloader valves & seats relap if necessary
Check conditiono unloader diaphragms & replace if necessary.
Check condition of all cylinder bores.
Check and clean final cooler assembly finned area.
Ensure fan blades are clean
OR ELASPED TIME stage piston rings No Off RSP5404/4s.5
54044s.doc
RECOMMENDED SERVICE PLAN - 5404 Mk4 CompAir UK Ltd
Page 2
OR ELAPSED TIME No Off RSP5404/4s.6
AT 3000 HOURS Dismantle for inspection renew parts as necessary. Change oil.
OR ELAPSED TIME Cleanse crankcase, Renew 1st, 2nd & 3rd stage valves. Renew Part Ref.
72 MONTHS 3rd stage plunger/liner assembly. Renew suction filter. No Off RSP5404/4s.7
Change oil (sump capacity 1.6 litres) REAVELLITE 'S' 1 Litre 2 98384/1020
3rd stage valve 1 C201654
2nd stage valve 1 C201653
1st stage valve 1 98650/1310
3rd stage plunger/liner assembly 1 C203170
Joint Kit 1 98504/1118
Check condition of unloader diaphragms & replace if necessary.
Dismantle check condition of all running gear etc.
Clean out all cooler assemblies including finned area.
Ensure fan blades are clean
Hydraulically test all cooler assemblies
Check settings of all safety valves & calibrate pressure gauges
54044s.doc
RECOMMENDED SERVICE PLAN - 5404 Mk4-W CompAir UK Ltd
Page 1
SYNTHETIC OIL - WINTER GRADE
50 HOURS OR (3000 hours) or any intermediate overhaul. No Off RSP5404/4sw.1
ELAPSED TIME Change oil (sump capacity 1.6 litres) REAVELLITE 'W' 1 Litre 2 98384/1021
6 MONTHS
OR ELAPSED TIME No Off RSP5404/4sw.2
12 MONTHS Change oil (sump capacity 1.6 litres) REAVELLITE 'W' 1 Litre 2 98384/1021
OR ELAPSED TIME stage piston rings No Off RSP5404/4sw.3
OR ELAPSED TIME Clean 1st stage valve. Renew suction filter. No Off RSP5404/4sw.4
Check and clean final cooler assembly finned area.
Ensure fan blades are clean.
54044sw.doc
Page 2
OR ELAPSED TIME Cleanse crankcase, Renew 1st, 2nd & 3rd stage valves. Renew No Off Part Ref.
72 MONTHS 3rd stage plunger/liner assembly. Renew suction filter. RSP5404/4sw.7
Change oil (sump capacity 1.6 litres) REAVELLITE 'W' 1 Litre 2 98384/1021
Joint Kit 1 98504/1118
54044sw.doc
RECOMMENDED SERVICE PLAN - 5405 Mk4-S CompAir UK Ltd
Page 1
50 HOURS OR (3000) or any intermediate overhaul. No Off RSP5405/4/s.1
ELAPSED TIME Change oil (sump capacity 1.6 litres) REAVELLITE 'S' 1 Litre 2 98384/1020
6 MONTHS
Check for oil and air leaks
Check tightness of all fasteners
OR ELAPSED TIME No Off RSP5405/4/s.2
OR ELAPSED TIME stage piston rings No Off RSP5405/4/s.3
OR ELAPSED TIME Clean 1st stage valve. Renew suction filter. No Off RSP5405/4/s.4
Check and clean final cooler finned area.
54054s.doc
RECOMMENDED SERVICE PLAN - 5405 Mk4-S CompAir UK Ltd
Page 2
OR ELAPSED TIME stage piston rings No Off RSP5405/4/s.5
OR ELAPSED TIME No Off RSP5405/4/s.6
72 MONTHS 3rd stage plunger/liner assembly. Renew suction filter. No Off RSP5405/4/s.7
Joint Kit 1 98504/1118
54054s.doc
Page 1
INITIAL SERVICE Change oil. Cleanse crankcase, Repeat after MAJOR Part Ref.
50 HOURS OR OVERHAUL (3000 hours) or any intermediate overhaul. No Off RSP5405/4sw.1
6 MONTHS
AT 1000 HOURS Change oil. Cleanse crankcase. Renew suction filter. Change Part Ref.
OR ELAPSED TIME 3rd stage piston rings No Off RSP5405/4sw.3
OR ELAPSED TIME Clean 1st stage valve. Renew suction filter. No Off RSP5405/4sw.4
54054sw.doc
Page 2
72 MONTHS 3rd stage plunger/liner assembly. Renew suction filter. No Off RSP5405/4sw.7
Joint Kit 1 98504/1118
54054sw.doc
RECOMMENDED SERVICE PLAN - 5405E-BAC.1800-S CompAir UK Ltd
Page 1
5405E BAC.1800- SYNTHETIC OIL - STANDARD

Check oil level top up if necessary.
INITIAL SERVICE Change oil. Cleanse crankcase, Repeat after MAJOR OVERHAUL No Part Ref
50 HOURS OR (1500 hours) or any intermediate overhaul. Off RSP5405E/b/s.1
6 MONTHS
AT 500 HOURS Change oil. Cleanse crankcase. Renew suction filter element. No Part Ref
OR ELAPSED Off RSP5405E/b/s.2
TIME Change oil (sump capacity 1.6 litres) REAVELLITE 'S' 1 Litre 2 98384/1020
12 MONTHS
Suction filter element 1 98262/1037
OR ELAPSED Service valves. Change 2nd stage piston rings. Off RSP5405E/b/s.3
24 MONTHS
Piston ring set 2nd stage 1 98477/1100
AT 1500 HOURS MAJOR OVERHAUL. Dismantle for inspection renew parts as
necessary. Change oil. Cleanse crankcase, Renew 1st, 2nd & 3rd
stage conn rods. Renew crankshaft assembly. Renew suction No Part Ref
filter. Off RSP5405E/b/s.4
2nd stage valve 1 98650/1883
Plunger/liner assy 3rd stage 1 C203102
3rd stage conn rod assembly 1 C201062
2nd stage conn rod assembly 1 C201061
1st stage conn rod assembly 1 C203080/50
Crankshaft assembly 1 D101249/100
Joint Kit 1 98504/1118
Check unloader valves & seats replace if necessary.
Check condition of all cylinder bores, pistons, piston rings, gudgeon pins etc.
Check condition of all stage valves, clean, refurbish or replace as necessary.
Ensure fan blades are clean, secure and undamaged.
NOTE:- CONTACT COMPAIR UK LTD. DIRECT, YOUR LOCAL COMPAIR COMPANY OR DISTRIBUTOR
FOR SERVICING AT THE RECOMMENDED INTERVALS 24/09/2007 5405Ebs.doc Page 1
RECOMMENDED SERVICE PLAN - 5405E-BAC.1800-SW CompAir UK Ltd
Page 1
5405E BAC.1800 - SYNTHETIC OIL - WINTER

Check oil level top up if necessary.
INITIAL SERVICE Change oil. Cleanse crankcase, Repeat after MAJOR No Part Ref
50 HOURS OR OVERHAUL (1500 hours) or any intermediate overhaul. Off RSP5405E/b/w.1
6 MONTHS
OR ELAPSED Off RSP5405E/b/w.2
TIME Change oil (sump capacity 1.6 litres) REAVELLITE 'W' 1 Litre 2 98384/1021
12 MONTHS
OR ELAPSED Service valves. Change 2nd stage piston rings. Off RSP5405E/b/w.3
24 MONTHS
AT 1500 HOURS MAJOR OVERHAUL. Dismantle for inspection renew parts as
necessary. Change oil. Cleanse crankcase, Renew 1st, 2nd &
3rd stage conn rods. Renew crankshaft assembly. Renew No Part Ref
suction filter. Off RSP5405E/b/w.4
2nd stage valve 1 98650/1883
Plunger/liner assy 3rd stage 1 C203102
Joint Kit 1 98504/1118
Check condition of unloader valves & seats replace if necessary.
NOTE:- CONTACT COMPAIR REAVELL LTD. DIRECT, YOUR LOCAL COMPAIR COMPANY OR DISTRIBUTOR FOR
SERVICING AT THE RECOMMENDED INTERVALS. 5405EBSW.doc 24/09/2007 Page 1
Page 1
5405E.BAC.1300- SYNTHETIC OIL - SPECIAL CONTRACT

INITIAL SERVICE Change oil. Cleanse crankcase, Repeat after MAJOR OVERHAUL Part Ref
50 HOURS OR (4000 hours) or any intermediate overhaul. No Off RSP5405E/s.1
6 MONTHS
AT 500 HOURS Change oil. Cleanse crankcase. Renew suction filter. Part Ref
OR ELAPSED TIME No Off RSP5405E/s.2
AT 1000 HOURS Change oil. Cleanse crankcase. Renew suction filter. Change 3rd Part Ref
OR ELAPSED TIME stage piston rings No Off RSP5405E/s.3
AT 1500 HOURS Change oil. Cleanse crankcase, Service 2nd & 3rd stage valves. Part Ref
OR ELAPSED TIME Clean 1st stage valve. Renew suction filter. No Off RSP5405E/s.4
24/09/2007 5405es.doc Page 1

Page 2
AT 2000 HOURS Change oil. Cleanse crankcase. Renew suction filter. Change 3rd Part Ref
OR ELAPSED TIME stage piston rings No Off RSP5405E/s.5
OR ELAPSED TIME No Off RSP5405E/s.6
MAJOR Cleanse crankcase, Renew 1st, 2nd & 3rd stage conn rod Part Ref
OVERHAUL assemblies. Renewcrankshaft assembly. Renew suction filter. No Off RSP5405E/s.7
Joint Kit 1 98504/1118
Check unloader valves & seats replace if necessary
24/09/2007 5405es.doc Page 2

Page 1
5405E – BAC.1300 SYNTHETIC OIL - SPECIAL CONTRACT - WINTER

INITIAL SERVICE Change oil. Cleanse crankcase, Repeat after MAJOR Part Ref
50 HOURS OR OVERHAUL (3000 hours) or any intermediate overhaul. No Off RSP5405E/sw.1
6 MONTHS
OR ELAPSED TIME No Off RSP5405E/sw.2
AT 1000 HOURS Change oil. Cleanse crankcase. Renew suction filter. Change Part Ref
OR ELAPSED TIME 3rd stage piston rings No Off RSP5405E/sw.3.
AT 1500 HOURS Change oil. Cleanse crankcase, Service 2nd & 3rd stage valves. Part Ref
OR ELAPSED TIME Clean 1st stage valve. Renew suction filter. No Off RSP5405E/sw.4
Check conditionof unloader diaphragms & replace if necessary.
24/09/2007 5405esw.doc Page 1

Page 2
AT 2000 HOURS Change oil. Cleanse crankcase. Renew suction filter. Change Part Ref
OR ELAPSED TIME 3rd stage piston rings No Off RSP5405E/sw.5
OR ELAPSED TIME No Off RSP5405E/sw.6
MAJOR Cleanse crankcase, Renew 1st, 2nd & 3rd stage conn rods. Part Ref
OVERHAUL Renew crankshaft assembly. Renew suction filter. No Off RSP5405E/sw.7
Joint Kit 1 98504/1118
Check condition of unloader valves & seats replace if necessary
Check condition of all cylinder bores, pistons, piston rings gudgeon pins etc.
24/09/2007 5405esw.doc Page 2

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
Reavell House
53-56 White House Road
Ipswich
IP1 5PB
England
Telephone: +44 (0) 1473 242000
Customer Service: +44 (0) 1473 242097
Fax: +44 (0) 1473 745451
Parts Fax: +44 (0) 1473 743468
www.CompAir.com
e-mail: sales ipswich@CompAir.com

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CompAir UK Ltd

In any correspondence please quote; COMPAIR JOB NUMBER:-

CompAir UK Ltd Ipswich cannot accept responsibility for damage,

CompAir UK Ltd Ipswich

CompAir UK Ltd Ipswich CONTACT DETAILS

Contact Name: Sales Telephone: +44 (0) 1473 242000

Contact Names: Parts Telephone: +44 (0) 1473 242000

Contact Names: Service: +44 (0) 1473 242097

4.2 ~ WARNINGS, CAUTIONS & NOTES

RISK OF DANGER RISK OF HIGH PRESSURE RISK OF GAS EXHAUST

RISK OF ELECTRIC SHOCK RISK OF HOT SURFACE CONSULT MANUAL

4.4 ~ INSTALLATION PRECAUTIONS

4.5 ~ OPERATIONAL PRECAUTIONS

4.6 ~ MAINTENANCE & REPAIR PRECAUTIONS

DO NOT USE CARBON TETRACHLORIDE.

PROTECT THE ENVIRONMENT USE APPROVED METHODS OF DISPOSAL.

4.7 ~ PRECAUTIONS IN THE EVENT OF FIRE

5404 MK4, 5405 MK4, 5405E.1800 & 1300

H5404 MK4, H5405 MK4, H5405E.1800 & 1300

BARE SHAFT COMPRESSOR SECTION

SAFETY SECTION ---------------------------------------------------------------ex

SECTION 1- GENERAL INFORMATION ------------------------------------5

SECTION 2 - TECHNICAL DATA----------------------------------------------9

SECTION 3 - LUBRICATION --------------------------------------------------10

SECTION 4 - MAINTENANCE -------------------------------------------------11

SECTION 5 - VALVE MAINTENANCE -------------------------------------15

SECTION 6 - FAULT GUIDE ---------------------------------------------------17

HOW TO ORDER SPARES ----------------------------------------------------19

SECTION 7 - BUILD LISTS ----------------------------------------------------21

SECTION 8 - ADDITIONAL INFORMATION-------------------------------49

SECTION 1 - GENERAL INFORMATION

SERIAL NUMBER OIL DRAIN PLUG

THE NORMAL GUARANTEE MAY BE INVALIDATED SHOULD A FAILURE BE ATTRIBUTED, BY COMPAIR UK

1.2 - SYNTHETIC OILS

1.5 - RUNNING GEAR

1.7 - SITING REQUIREMENTS

RECOMMENDED INSTALLATION INCORRECT INSTALLATION

TYPICAL WIRING DIAGRAM - MANUAL START/AUTO STOP.

SECTION 2 - TECHNICAL DATA

Three stage, three cylinder, single acting, air cooled Model

1. THE RECOMMENDED LUBRICANTS FOR MACHINES MANUFACTURED BY COMPAIR UK LTD., ARE

3. COMPAIR UK LTD, CANNOT BE HELD RESPONSIBLE FOR INCORRECT INFORMATION CONCERNING

OIL TYPES 5000 SERIES AIR-COOLED

ALTERNATIVE LUBRICANT - RUNNING IN ONLY

BREATHING AIR APPLICATIONS

RECOMMENDED OILS 5000 SERIES AIR-COOLED COMPRESSORS

COMPRESSOR AMBIENT OIL RECOMMENDED SUMP CAPACITY

4.2 - TORQUE WRENCH SETTINGS FOR NON-LUBRICATED FASTENERS

SYNTHETIIC OIL RUNNING HOURS (x 1000)

4.6 - RECOMMENDED MAINTENANCE 5405E.1800 SEE RSP5405E.1800 FOR MORE DETAILS.

SYNTHETIIC OIL RUNNING HOURS (x 1000)

4.7 - RECOMMENDED MAINTENANCE 5405E.1300 SEE RSP5405E.1300 FOR MORE DETAILS.

SYNTHETIIC OIL RUNNING HOURS (x 1000)

2. After First 50 hours running time

SEE RSP54044S, RSP54044SW, RSP54054S, RSP54054SW, RSP5405E.1800S & RSP5405E.1800SW

4.7 SHELF LIFE - INHIBITION PROCEDURE

4.8 STANDING IDLE AFTER RUNNING - INHIBITION PROCEDURE

4.8.1 Fill to the required level with Shell Ensis 20/30.

SECTION 5 - VALVE MAINTENANCE

5.3 - CLEANING AND INSPECTION - ALL STAGES

5.4 - VALVE REMOVAL 2nd & 3rd STAGE

Disconnect suction and delivery piping.