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• Installation, Operating and.
• Maintenance Manual
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• HamworthyKSE
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•• CMA CGM FORT ST. GEORG~
HamworthyKSE
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•
•e Hamworthy
V-Line Air cooled
• Compressor
• Electra-mechanical Model

• PCH 1547
•
• This manual covers model

• VA40 :JG P.3G III

• FINISHED PLAN

• '*' m
JUN30,¥B

• ~ ~ 1} 'i'ij
CHINA SHlPBlJU.01NG CORP.

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• I I
• ISSUE 2 0699

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• HAMWORTHY KSE LIMITED

• Fleets Corner, Poole, Dorset, BH17 OJT, England

Telephone: +44 (0)1202 662600

• Facsimile: Spares +44 (0)1202 665444 Sales +44 (0)1202 666363 Service +44 (0)1202662622

• Offices, Associate Companies and Agents throughout the world

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• -160
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•
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• WARNING

• 1. The following manual must be read before proceeding with installation, operation and maintenance of

•
this equipment.

•
2. Health & Safety Act Compliance. Before working on this equipment personnel should be made aware
of, and ensure compliance with, the Health and Safety Regulations appropriate to this class of work.

• 3. The handling points are indicated on the unit and must be used. The hooks of slings must be fitted to
lifting eyebolts using shackles.

• 4. Before proceeding with maintenance on the unit, or making adjustments to its connections and fittings,

• it must be stopped and isolated electrically and mechanically and the outlet valves closed. Some units
on automatic standby duty, or isolators are remote from the unit and extra care is then necessary to

• ensure that isolation is complete.

• Hamworthy reserves the right to make changes to the design of the machine without prior notice.

• NOTE: Where the compressor has been supplied with an electronic controller, the operating and
maintenance information detailed in supplement 1540A should be read in addition to this instruction

• manual.

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• Page 3

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CONTENTS

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SECTION 1 - INSTALLATION 1-1
1.1 LOCATION 1-1
1.2 MOUNTING 1-1

• 1.3
1.3.1
COMMiSSiONING
Commissioning Procedure
1-1
1-1

• SECTION 2 - OPERATING PROCEDURE.

2.1 DESCRIPTION
2-1
2-1

• 2.2
2.3
CONTROL AND OPERATING PHILOSOPHy
MANUAL MODE RUNNING
2-1
2-1

• 2.4
2.5
AUTOMATIC RUNNING (ONLY POSSIBLE WITH SOLENOID DRAIN VALVES FITTED)
GENERAL
2-2
2-2

• SECTION 3 - MAINTENANCE
3.1 GENERAL.
3-1
3-1

• 3.1.1
3.2
Maintenance Schedule
MAINTENANCE INSTRUCTIONS
3-2
3-2

• 3.2.1
3.2.2
Lubrication Oil Checking
Lubrication Oil: Changing
3-2
3-3

• 3.2.3
3.2.4
Air Suction Filter/Silencer Removal and Replacement
Concentric Valve Removal/Replacement - Both Cylinders
3-3
3-3

• 3.2.5
3.2.6
First Stage Cylinder and Piston RemovaL
First Stage Cylinder and Piston Re-assembly
3-7
3-8

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3.2.7 Final Stage Cylinder and Piston Removal. 3-9
3.2.8 Final Stage Cylinder and Piston Re-assembly 3-10

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3.2.9 Air Cooler Tubes Removal 3-11
3.2.10 Connecting Rod Big End Bearing Removal 3-11

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3.2.11 Bearing Removal and Re-assembly to Connecting Rods 3-11
3.2.12 Connecting Rod Assembly Fitment to Compressor 3-12
3.2.13 Drive Motor and Coupling Removal from Compressor 3-13

• 3.2.14 Drive Motor and Coupling Assembly to Compressor

3.2.15 Flywheel and Drive End Oil Seals Removal from Compressor.
3-13
3-14

• 3.2.16 Flywheel and Drive End Oil Seal Re-assembly to Compressor.

3.2.17 Crankshaft and Main Bearing Removal from Compressor
3-15
3-16

• 3.2.18 Crankshaft and Main Bearings Re-assembly to Compressor

3.2.19 Oil Level Switch Remove/Clean/Replace
3-16
3-17

• 3.2.20 Air Safety Valves

3.3 ELECTRICAL MAINTENANCE
3-17
3-17

• 3.4
3.5
FAULT FINDING CHART
TOOLS REQUIRED FOR VA40 COMPRESSOR MAINTENANCE.
3-18
3-19

• SECTION 4 - TECHNICAL DATA

4.1 GENERAL
4-1
4-1

• 4.2
4.3
PERFORMANCE
OTHER DATA
4-1
4-1

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4.4 RECOMMENDED MAXIMUM WEAR CLEARANCES 4-2
4.5 CRANKCASE LUBRiCANTS 4-3

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4.5.1 Approved Oils 4-3
4.5.2 Oil Company Equivalent Oils 4-3
4.5.3 Additional Maintenance for Machines Lubricated with Synthetic Oils 4-3

• SECTION 5 - DRAWINGS 5-1

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• Page 5

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FIGURES

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Figure 3.1 VA40 First Stage Valve 3-5
Figure 3.2 VA40 Final Stage Valve 3-6
Figure 3.3 Connecting Rod 3-12
Figure
Figure
3.4
5.1
Gap between Coupling and Flywheel
Typical Arrangement of V Line Air Cooled Compressor
3-14
5-1 •
Figure
Figure
5.2
5.3
Crankcase & Cooler Tubes
Compressor Drive
5-3
5-4 •
Figure
Figure
5.4
5.5
First Stage Cylinder & Piston
Final Stage Cylinder & Piston
5-5
5-6 •
Figure 5.6 Compressor Separator & Pipe Work 5-7
•
TABLES •
Table 3.1 Fastener Torque Settings 3-1 •
Table
Table
3.2
3.3
Maintenance Schedule
Concentric Valves - Items List.
3-2
3-7
•
Table
Table
3.4
3.5
Switch Settings
Fault Finding Chart
3-17
3-18
•
Table
Table
3.6
4.1
Tools required for Compressor Maintenance
Capacity and Power at 30 Bar
3-19
4-1
•
Table
Table
4.2
4.3
Operating Parameters
Recommended Maximum Wear Clearances
4-1
4-2
•
Table
Table
4.4
5.1
Oil Company Equivalent Oils
List of Parts for Figure 5.1
4-3
5-2
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Table 5.2 List of Parts - VA40 Compressor 5-8

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Page 6
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• Spare Parts and Service

• Spare Parts can be ordered direct from the following address:

Hamworthy KSE Ltd. Telephone: +44 (0)1202 662600

• Fleets Corner
Poole, Dorset
Facsimile:
Email:
+44 (0)1202665444
poolespares@hamworthykse.com

• BH17 OJT, England

• or via any Hamworthy KSE office or agency throughout the world.

When ordering spare parts, the following information is required to ensure that correct parts are supplied:

• Type and serial number of machine:

"em Number and ful/ desaipnon of part required:
Obtained from machine nameplate
Obtained from details in this publication

• Technical Service and Advice:

• Technical service and advice can be obtained during normal working hours from the above address, on the
follOwing contact numbers

• Telephone:
Facsimile:
+44 (0)1202 662663
+44 (0)1202 662622

• Email: pooleservice@hamworthykse.com

• or via any Hamworthy KSE office or agency throughout the world.

•
Outside normal working hours a 24 hour emergency faciltty is available. Inttial telephone contact number is
England +44 ( 0 ) 1 2 0 2 6 6 2 6 6 3 . .

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• Continued ...

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Overseas Hamworlhy KSE Offices

•
Holland Hamworlhy KSE BV
Aploniastraat 33
South
Africa
Hamworlhy Engineering Africa (Ply) Lld
Po Box 50435
•
•
NL-3804CC, Randburg, 2125
Rotterdam, Netherlands Gauteng, Johannesburg,
TeI: + 31 1046204777 South Africa
Fax: +31104159046 TeI:
Fax:
00 27 11 7923886
00 2711 7923889
EMAIL: hamworth@global.eo.za •
China Hamworlhy KSE Shanghai Sweden Hamworthy KSE AB
•
•
Room 7-0 Vi Dian Plaza, Kampegalan 3
No. 746 Zhao Jia Bang Road, S<>411 04 Gothenburg,
Shanghai 200030 Sweden
Tel:
Fax:
+ 86 21 64455665
+ 86 21 84459875
EMAIL: w97oo1@guomai.sh.cn
Tel:
Fax:
+ 46 31 7257900
+ 46 31 725 7800
EMAIL: goteborginfo@hamworthykse.eom •
Germany Hamworlhy KSE GmbH UK Hamworlhy KSE Lld
•
•
Wachslrasse 17/24 Fleets Corner
0-28195 Bremen, Postfaeh 103840 Poole, Dorset
Ge-28038 Bremen, Germany England. BHI70JT
Tel:
Fax:
+ 49 421 335840
+ 49 421 3358498
TeI:
Fax:
+ 01202662600
+ 01202658793
•
•
EMAll: bremeninfo@hamworthykse.com EMAIL: Info@hamworthykse.eom

Korea Hamworthy KSE Korea Lld UAE Duba; Hamworlhy KSE Dubai
14~ Floor Hyundai Building #1193-5
Choryang 3 dong, Don9-gu,
Pusan, Korea (601-013)
CID Daikai Middle East
Dy 16011 AI Jadaf, Po Box 62073
Dubai UAE •
Tel:
Fax:
+ 82 51 4658461-5
+ 82 51 4637498
TeI:
Fax:
00 971 43240335
00 971 43240336
•
•
EMAIL: korea@hamworthyl<se.eom EMAIL: ahussaln@hamworthykse.eom

India Hamworlhy KSE Pvt Lld U.S.A. Hamworlhy KSE Ine

C-l55 Mittal Court, Nariman Point,
Mumbai 400 021 India
Houston 1011 Highway 6 South
Suite 208, Houston
•
•
TeI: + 91 22 2872394 TX 77077, USA
Fax. + 91 22 2872394 TeI: + 1 281 7593280
EMAIL: hamworthykseindia@vsnl.com Fax: + 1 281 7598308

Norway Hamworthy KSE AJS

Joseph Kellers vel 20
New Jersey Hamworlhy KSE Ine
571 Central Avenue •
Tranby
PO Box 83, N-3401 Ller, Norway
Ste 112, New Providence
NewJersey07974,USA
•
•
Tel. + 47 32 85 92 00 TeI: + 1 908 8980544
Fax. + 47 32 85 21 93 Fax: + 1 908 8980377
EMAIL: tranby@hamworthykse.com

Singapore Hamworlhy KSE PTE Lld, NewOrieans Hamworthy KSE Ine

•
•
15 Benoi Crescent 1418 Edwarcfs Avenue
Singapore 629978 Suite B
Tel. + 65 261 6066 New Orleans

•
Fax. + 65 261 6011 Louisiana 70123
EMAIL: singapore@hamworthykse.eom Tel: + 1 504 734 5525
Fax: + 1504 7345718

California Hamworthy KSE Ine

•
•
6 Neal Court
San Pablo;·Califomia 94806
USA
Tel:
Fax:
+ 1 5107244625
+ 1 5107248839
•
•
•
Continued ...

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•
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•
•
• Overseas Hamwonhy KSE Agencies

• ARGENTINA AUSTRALIA BANGLADESH

•
Neptune S.A. Caba (Aust) Ply Lld Marintec Lld
Calle Mendoza 3185-5°-B 41 Barry Avenue 30 Agrabad Commercial Area
1340 Beunos Aires, Argentina MOOdale, Nsw 2223 PO Box No 201B, Bandar

• Tel
fax
00 541 143226041
00 541 14 3225790
Australia
TeI 00 61 295342100
Chlttagong, Bangladesh
Tel 00 880 31502834

•
Fax 00 61 2 95335332 Fax
Email caba@caba.bu.aust.com

• BRAZIL
Tridente Brazil
BULGARIA
Martimex-Marine Trading SRO
CANADA
HKSECanada

• Rua Vlsconde Inhauma

134- Gr 1513, Rio De Janeiro
Cervenej Armady 1
03601 Martin,
3853543 Canada Inc,
113, Cushman Road, Untt 60,

•
Rj - Brazil 20091-000, Brazil Slovakia St Catharlnes, Ontario,
Tel 00 55 21 2331489 Tel 00 421 8424248801 Canada
fax 00 55 21 5167543 fox 00 4218424133753 L2M 6S9

• Emall japgomeS@tridente.com.br Emall marine@martlmex.sk Tel

fax
00 1 905 6884922
00 1 905 6!l89028

• CHILE COLUMBIA CZECH REP.

• Lanz Y Cia Lldo

Calle Or M Barros Borgono 233
Consulnaval Uda
Edificio Colseguros Oficlna 501
Martimex-Marine Trading SRO
cervene] Armady 1

•
Casilla 16389, Santiago Calle Cohera Del Gobemador, Cartegena 03601 Martin,
Chile Columbia Slovakla
Tel 00 56 2 2352707 Tel 005756848413 Tel 00 421 8424248801

• Fax
Email
00 56 2 2357329
efadlC@lanzco.cl
fax 00 57 5 6841640 Fax
Emall
00 421 8424133753
marlne@martimex.sk

• CROATIA CYPRUS ECUADOR

• Eureka International D.O.O

Marmontova 14
Sheerline Marine Services
Gladstone & Androu Str
5ertemar Lld
El Oro 1303 Y Guaranda

•
Hr-21000 SpliI, Oasis Complex, Limassol, Po Box 5699, GuayaqulI
Croatia Cyprus 3311 Ecuador
Tel 00 385 21 343381 TeI 00 357 5 345319 TeI 00 593 4 4459581330027

• fax 00 385 21 344825J34B360 fax

Email
00 357 5 345639
seraphid@nautilus.spidemet.net
Fax
Email
00 593 4 4401541445335
sertroch@gye.satnet.net

• EGYPT FRANCE GERMANY

• International Marine Center

6 Mahmoud Azmy street (21131)
Etablissements Tiano S.A
2 Bis, Rue De la Baume
Wilhelm Rump KG
Buchhelslerstrabe 6

•
Po Box 95 (21321), Ibrahlmleh Fr-75008 Pans, France Ge-20457, Hamburg
Alexandria, Egypt Tel 00 33 1 45619932 Germany
Tel 00 20 3 4876959 fax 00 33 1 42256962 Tel 00 49 40 3178420

• fox 00 20 3 4877969 Email alfred-tiano@ets-tiano.fr fax

Email
00 49 40 3194841
113304.2717@compuserve.com

• GREECE ICELAND INDONESIA

• Marine & Industrial Systems ltd

4-6 Efplias street
S Stefaanson & Co ltd
Po Box 1006
P.T Slnofa Intermarine
JI Re Martadlnata No 19

•
Piraeus, 185 37 Reykjavik, Iceland Tg Priok Jakarta Utara, Indonesia
Greece Tel 00 35419141244 Tel 00 62 21 6902196
Tel 00 30 1 4282828 fax 00 354 1678936 fax 00 62 2143910156

• Fax
Email
00 30 1 4183827
mlsltd@aias.gr

• ISRAEL ITALY ITALY

• B. Soler & Co Lld

Po Box 221
Avichail 42910, Israel
Sirn Sri
Via Del lazzaretto Vecchlo 9
It-34123 Trieste, Italy
Sirn Sri
Via Casaregis 22/1

•
11-16129 Genova, Italy
Tel 00 972 9 8822319 Tel 00 39 0 40 304247 TeI 00 39 010588771
foX 00 972 9 8825211 fax 00 39 0 40 308196 fax 00 39 0 10 542678

•
Email simts@tin.lt Emall sim.ge@pn.iInet.tt

•
•
•
 •
•
•
•
JAPAN KUWAIT MALAYSIA
Fesco Japan UtI Panah Jaya Services SON BHO

•
The Trading & Ind. Equipment CO
3f Shinei Building 13 30-1, Jalan 8I62a
(T.I.E.C.OI
2-Chome, 4-Ban Sakemachi-Oouri, Chuo-Ku Bandar Menjalara, 52200 Kuala LUrJ1lur
Po Box 2159, 13022 Safa!

•
Kobe 652-0B31, Japan Malaysia
KuwaitC.R.13104
Tel 00 81 78 3323399 Tel 00 60 3 6333984
TeI 00 965 4819188
Fax 00 81 78 3323363 Fax 00 60 3 6334055
Fax 00 965 4810387
Email tony-carvalho@bin-nisf.com

•
MALTA NEW ZEALAND

caba [New Zealand) Lld

OMAN
Trans-Oceanlc Trading Est •
•
Thomas C Smith & Co Lld
12 St Chr1stopher street 37 Clyde Slreet Po Box 1892
Valetla, VII 06 Malta Whangarei, New Zealand Postal Code 112, Ruwi

•
TeI 00 356 245071 Tel 00 64 9 4383881 Sultanate Of Oman,
Fax 00 356 242056 Fax 00 64 9 4300854 Tel 00 968 7965031787912
Fax 00 968 702981

•
Email info@lcsmith.com
Email totest@gto.net.om

PHILLIPINES

•
PAKISTAN POLAND
Marsson
Uniled Traders Romac Lld
Haroon Chambers
Aftaf Hussain Road, Karachi 74000
17th Floor Goldloop Towers
One Goldloop Plaza, Amber Avenue
Ortigas Centre, Pasig City, Phillipines
UI Ciolkowskiego 7a125
PI 80-483, Gdansk
•
•
Pakistan Poland
Tel 00 63 2 6338547
TeI 0092212414916 Te) 00 48 58 3487203
Fax 00 63 2 6338567
Fax 00 92 21 2416862 Fax 00 48 58 3463694

•
Email marsson@mnl.sequel.net
Email barbararomac@poczta.onet.pl

•
PORTUGAL QATAR ROMANIA
Gel\Weller Soc: De Equip. MartIomos E AJ-Ahed Trading & Contracting Co Total Trading Sri
industrials
Travessa Do Alecrirn 3-2
Po Box 3266
Doha,Oatar
118 Oomneasca Street
6200 Galatz, Romania
•
•
Box2005,1101 Lisbon Tel 00 974 44140221314 Tel 00 40 36 418542
Portugal Fax 00 974 4414021 Fax 00 40 36 480740
TeI 00 351 21 3420021 Email alahed@qatar.nel.qa Email ttr@elia.eu.com
Fax

RUSSIA
00 351 21 3420026

SERBIA SLOVAKIA •
Transas Marine Martimex-Marine Trading SRO Martbnex-Marine Trading SRO
•
•
2112 Obukhovsky Oborony Cervenej Armady 1 Cervenej Armady 1
St Pelersburg, 193019 03801 Martin, 03601 Martin,
Russia S10vakia

•
Slovakia
TeI 00 7 812 3253131 TeI 00 421 8424248601 Tel 00 421 8424248601
Fax 00 7 812 5671901 Fax 00 421 8424133753 Fax 00 421 8424133753

•
Email dmitriy .Iagoutin@transas.com Email marlne@martlmex.sk Email rnarine@martimex.sk

SPAIN TAIWAN THAILAND

Equipos Nomaval sa Ming Tzong Hamg Trading Co Lld Thai KoIon Co Lld
•
Nunez De Balboa 15-3 0

•
31-3 No 90 Chung Shan Heng Road 1093178 15th Floor Centralcity Tower
E;"'28001, Madrid Kaoshiung 80015, Taiwan Bangna-Trad Road (Km3) Bangna,
Spain R.O.C Prakanong
TeI
Fax
00 34 91 5752960
00 34 91 5783898
TeI
Fax
00 886 7 2316188
00 686 7 2816738
Bankok 10260, Thailand
Tel 00 66 2 7456488-n (10 Unes)
•
•
Email noma@arrakis.es Fax 00 66 2 7456152

UKRAINE
Transas Marine Uk Ud
•
•
Commodore House
Mountbatten Business Centre, 16-18
Millbrook Road East
Southampton S015 1HY,
UK
TeI 02380 633900
V13
•
Fax
Email
02380233700
sales@transas.co.uk
•
•
•
•
•
• SECTION 1-INSTALLATION

• SECTION 1· INSTALLATION
•
•
1.1 LOCATION

•
The suction inlet should be installed in a well ventilated position so that air drawn into the compressor is as
cool and dry as possible and there is good circulation to the compressor cooling fan and drive motor integral
cooling fans and all the compressor external surfaces.

• The compressor must be positioned with the axis of the crankshaft and motor fore and aft in the vessel to

• ensure adequate lubrication during the vessels normal roll, pitch, list and trim modes.

• 1.2 MOUNTING

• The compressor should be mounted on support plates or pads and supported by a ribbed structure suitable
for the type and weight of the compressor. The pads/plates must be clean and flat to within 1 mm. Shims

• should be used if necessary. Refer to general arrangement drawing supplied with the compressor
documentation package for mounting feet or anti-vibration mounts dimensions and positions and weight of

• the compressor.

• 1.3 COMMISSIONING

• WARNING

• 1. DO NOT MAKE ANY ADJUSTMENTS TO THE COMPRESSOR, ITS CONNECTIONS OR

FITTINGS WHILST THE COMPRESSOR IS RUNNING OR ON STANDBY DUTY.

• 2. DO NOT RUN THE COMPRESSOR UNLESS ALL PROTECTIVE GUARDS FITTED TO IT AND

• ITS PRIME MOVER ARE IN PLACE.

• 1.3.1 Commissioning Procedure

• 1. Ensure compressor is isolated from its electrical supply.

• 2. Check lubricating oil level in crankcase sump.

•
3. Before initial start up or when the compressor has not been run for 5 weeks or more carry out the
following procedures.

• Remove the plugs from the side wall of the first stage cylinder and final stage cylinder head.

• Pour 20 millilitres of lubricating oil through the exposed holes.

• Replace plugs.

• NOTE: After adding oil, the compressor must be barred over at least 3 complete revolutions to ensure
lubrication of the cylinder bores during initial start up and minimise the risk of the piston causing a

• hydraulic lock when the compressor is started.

• 4. Remove upper guard section (167) from fan housing adaptor (170).

• 5. Using a bar (not supplied) through the air intake, in one of the holes in the flywheel turn over the
compressor through at least three complete revolutions.

• WARNING: TAKE PRECAUTIONS TO PREVENT INJURY TO PERSONNEL WHILST OBSERVING THE

• DIRECTION OF ROTATION OF THE FLYWHEEL THROUGH THE UNGUARDED BARRING OVER

ACCESS APERTURE.

• 6. Connect the electrical supply and carry out a momentary start and stop.

•
• Page 1-1

•
 •
SECTION 1 • INSTALLATION
•
•
•
7. Check that rotation of compressor is clockwise looking on the drive end of the compressor (indicated
by cast arrow). If direction of rotation is incorrect, take appropriate steps to correct.

8. Isolate starter, refit fan housing adaptor (170).

•
9. Press start button. The compressor is brought on line to charge the air system. Check the following
details within the first minute of the run. •
Check that cooling air is blown from the bell housing outlet, over the integral finned cooler tubes. •
Check that final stage air pressure is increasing over ambient pressure values. •
10. Allow compressor to continue to run under the control of the system pressure switch.
•
The compressor must run continuously for approximately 30 minutes to reach normal operating
•
temperature. It may be necessary to bleed off air from the system to prevent the compressor stopping
prematurely.
•
11. Check the operation of the system pressure switch.
•
12. After satisfactory operation of the pressure control system, the compressor is now commissioned for
•
use. The compressor may be either left running (on line) to charge the air system or stopped.

•
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Page 1-2
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•
• SECTION 2 - OPERATING PROCEDURE

• SECTION 2 - OPERATING PROCEDURE

• 2.1 DESCRIPTION

•
•
The standard V-Line compressor is supplied with an air delivery gauge, fusible plug, low lubricating oil switch
and two manual drain valves.

• The fusible plug is fitted to protect the compressor by shutting it down if the temperature rises above the normal
maximum operating temperature. As an option, a high air temperature switch can be fitted in place of the fusible plug.

• The second pole of the switch may be connected to give a panel indicated waming of approaching shutdown
temperature.

• The low lubricating oil switch (double pole) will also shut down the compressor if it detects the oil level is

• below the minimum requirement. An adjustable time delay is included to overcome false tripping due to the
roll and pitch of the vessel. A second pole may be connected to give a panel warning of approaching

• shutdown oil level.

• The compressor can be started by either star/delta or direct-on-line methods.

• 2.2 CONTROL AND OPERATING PHILOSOPHY

• The compressor is fitted with protection devices which immediately stop and unload the compressor, when it
is connected to a suitable starter, (supplied by Hamworthy or the customer) if any of the follOWing events

• occur:

• - minimum oil level

- high compressor motor current
shutdown and optional pre-alarm
shutdown only

• - emergency stop button operation shutdown only

•
As an option, a high final air delivery temperature switch can also be filted, with shutdown and optional pre-
alarm settings.

• The control panel is capable of the following functions:

• - selection of automatic mode - local or remote start/stop sequence

•
• selection of manual mode - local start/stop only

If more than one compressor is charging the system a selector switch should be filted enabling the sequence

• in which the compressors should work Le. lead and follow.

• 2.3 MANUAL MODE RUNNING

• Energise the starter panel by operating the main isolator.

Set mode switch S 1 to MAN.

• Set local/remote switch S2 to LOCAL

Ensure manual drains are open or set drain switch S3 to AUTO if solenoid drain valves are fitted.

• Press RESET push button.

• The compressor will start and run in this mode overriding the low oil level shutdown device and high air
temperature shutdown device when filted. When manual drain valves are filted, they must be closed before

• the compressor will come "on load". The emergency stop bulton and motor thermal overloads will still stop
the machine. Note: the manual drain valves must be opened to unload the machine before the compressor is

• re-started. If the machine is filted with solenoid drain valves it will automatically unload.

• Compressor and air system protection during manual mode running are given by first and final stage air
safety valves and any other safety device filted to the installed system.

•
•
• Page 2-1

•
 •
SECTION 2 • OPERATING PROCEDURE
•
Starting, running and run down cycles when solenoid valves are fitted are as for normal (automatic) running •
as described with the exception of the following:
•
- oil level switch overridden
- high air temperature switch overridden (when fitted) •
- Remote start/stop function disabled.
•
2.4 AUTOMATIC RUNNING (ONLY POSSIBLE WITH SOLENOID DRAIN VALVES FITTED)
•
1. Energise the starter panel by operating the main isolator.
Set mode switch Sl to AUTO. •
Set lccal/remote switch S2 as required.
Set drain switch S3 to AUTO •
Press RESET push button.
•
2. On pressing the START button, the compressor runs off-load for a short time (approximately 15 - 20
seconds) after which the drain/unloading solenoid valves are energised to close to charge the system. •
(Note that the compressor will only go on load if the system is not fully charged.)
•
3. The compressor is now controlled by the air system pressure switch. At 5 minute intervals (adjustable)
the drain solenoid valves are de-energised for 2 seconds (adjustable) to drain the separator bowls.
•
4. On air system charged signal, the solenoid valves are de-energised to open to drain and unload the
•
compressor until a signal is received:-
•
on recharge signal the solenoid valves are energised to close causing the compressor to charge the
system
•
if the recharge signal is not received within 5 minutes (adjustable) of the charged signal, the
•
•
compressor stops leaving the solenoid valves open. On recharge signal the compressor starts as for
pressing the START button (and lamp goes out).

5. On pressing the STOP button (or switching Sl to OFF or MAN) the solenoid valves are de-energised
to open to drain the separator bowls, the compressor continues to run-on unloaded for 5 minutes •
(adjustable) before stopping. Pressing the START button during this cycle brings the compressor back
on line to recharge the system. •
6. If the START button is pressed while the air system is fully charged, the compressor starts as •
described in 2. The compressor is then controlled by the air system pressure switch as in 3 and 4
above. •
2.5 GENERAL •
Individual volt-free change-over contacts and control panel mounted .indicator lamps are provided as listed •
below: .
•
- compressor running
- low oil level shutdown
•
• Iow oil level warning (if fitted)
- high air temperature shutdown (if fitted)
•
- high air temperature warning (if fitted)
- compressor motor overload
•
Terminals are provided for a remote emergency stop push-button (if required)
•
Warning (pre-alarm) oil level and high air temperature indicator lamps and volt free contacts, are an optional
extra and are not fitted as standard.
•
•
•
Page 2-2
•
•
•
• SECTION 3 - MAINTENANCE

•
• WARNING
SECTION 3 - MAINTENANCE

•
•
1. BEFORE PROCEEDING WITH MAINTENANCE OR OVERHAUL, THE COMPRESSOR MUST BE
STOPPED AND ISOLATED MECHANICALLY AND ELECTRICALLY, AND VISIBLE WARNING
NOTICES DISPLAYED.

• 2. WHEN WORKING ON AIR PASSAGES THE COMPRESSOR MUST BE VENTED OF ALL

• PRESSURISED AIR.

• 3. VITON O-RINGS AND SEALS. WHEN VITON IS SUBJECTED TO EXCESSIVE

TEMPERATURES (ABOVE 400·C) IT DECOMPOSES AND CAN CAUSE SERIOUS INJURY.

• WHEN REMOVING O-RINGS AND SEALS, PROTECTIVE GLOVES SHOULD BE WORN.

• 3.1 GENERAL

• Routine maintenance of the compressor should be carried out at the intervals listed in the Maintenance

• Schedule under normal conditions. However, the optimum period between servicing will depend upon the
operating conditions.

• Before re-assembly, clean all parts with a suitable cleaning fluid and examine for wear, corrosion, cracks,

• distortion, or any other damage. Renew as necessary. Refer to the wear tolerances given in Section 4 -
Technical Data.

• Renewalljoints, gaskets. and Q-ring seals.

• When re-assembling compressor components ensure that all flat faced joints and O-rings are refitted. Great

• care must be taken to ensure that they are not damaged. If they are damaged in any way during assembly
they must be renewed.

• Item numbers in the text refer to items on the sectional Arrangement Drawings which are at the end of this

•
manual.

•
When using Loctite products for nut and screw retention note the following. The shelf life of Loctite is one
year at a storage temperature of 6' - 22·C. All components to be fixed with Loctite should be thoroughly
degreased using a Loctite activator. If cured Loctite is present in a tapped hole or extemal thread, discard

• the bolt or nut, or clean with a die and tap internal threads. All fasteners must be torqued to their specified
level (see table).

• Table 3.1 Fastener Torque Settings

•
• M5 M6 M8
Fastener Torque Settings
M10 M12 M16

• 4Nm 6Nm 16 Nm 32 Nm 53 Nm 132 Nm

•
•
•
•
•
•
• Page 3-1

•
 •
SECTION 3 - MAINTENANCE
•
3.1.1 Maintenance Schedule •
Table 3.2 Maintenance Schedule •
•
•
Commissioning Normal Operating Services
Period

~ ~ -.
en
.c
. ~ ~ ~ r! " . •
m
>
~I!!
e::J m
>
~ I!!
c:
o ::J
Eo
l!! .. ::J
m 0
>o.c
.. ::J
m 0
>o.c
m
~
"5;:;
crI!
c:
0

•
•
0 ... .c 0
o ::J .c o ::J NO It)
l!!
m
~g ~g ~g
>0 0

- >0 0
e
0 m Cl.
::.c It) =.c m mN m

•
It) It)
"0 "0 > ~ > ~ > ~
E
.- 0
C~ et C~ wo WO WO 1- ...
1. Check oil level on dipstick. v' v'

2. Drain and refill lubricating oil. v' v'

•
3. Inspect air inlet filter, clean if
necessary.
v'
•
4. Clean any external debris from
the wire wovenfirming.
v'
•
5. Replace air intake filter. v'
•
6. Clean and inspect
delivery line non-return valve.
v' 30 mins
•
7. Clean first stage valve and
replace seals. Renew final
v' 4 hours
•
stage valve and O-rings.
•
•
.8. Renew first stage valve and v' 2 hours
O-rings.
9. Check settings of all
pressure safety valves,
v' 1 hour
•
replace as necessary.
10. Remove inter/after coolers and v' 4 hours •
clean.
v' •
•
11. Dismantle and measure moving 6 hours
parts for wear.

A complete overhaul is recommended every 5 years or 5,000 running hours. After a major service, follow the
•
•
commissioning procedure detailed in section 1.

•
3.2 MAINTENANCE INSTRUCTIONS

3.2.1 Lubrication Oil Checking

Refer to Technical Data section for oil capacities and recommended lubricants. •
1. Remove filler/dipstick and check oil level. •
2. Fill/top up crankcase oil level if necessary with lubricating oil to full level on dipstick. •
Periodically examine oil in crankcase and ensure that it is not contaminated with condensate. If the oil is •
emulsified (creamy in colour) it must be changed and the crankcase cleaned.
•
If moisture forms without emulsification, as two separate liquids, condensate may be drained from below the
oil. The oil level should then be restored with fresh oil. •
•
Page 3-2
•
•
•
• SECTION 3 - MAINTENANCE

•
•
Crankcase oil contamination is often accompanied by an increase in sump oil level, due to oil being
supported by condensate fluid.

• 3.2.2 Lubrication Oil: Changing

• 1. Remove the drain plug after the compressor has been running, whilst the oil is still warm and drain oil
from the compressor. Dispose of usedoil in accordance with local regulations.

• 2. Clean the magnetic portion of plug before replacing into crankcase.

• 3. Remove and clean oil level switch, see section 3.2.19.

• 4. Refill with fresh oil.

• 3.2.3 Air Suction Filter/Silencer Removal and Replacement

• 1. Before removing the air filter silencer assembly, clean the outside of the filter body.

• 2. Remove wing nut on top of filter.

• 3. Remove top cover.

• 4. Remove filter body, '0' ring, and element.

• 5. Unless filter/silencer assembly is to be re-assembled immediately, cover valve cage aperture.

• 6. Renew element if necessary.

• 7. Reassemble filter.

• 3.2.4 Concentric Valve Removal/Replacement - Both Cylinders

• 1. Remove the bolts securing the first stage separator to the final stage cylinder head. Support the

• separator.

•
2. Remove the four nuts and washers from the top of each cylinder head.

3. Release crankcase breather hose from the hose connector on the first stage cylinder.

• 4. Undo the cooler tube connector on the first stage cylinder and remove the tube.

• 5. Remove cylinder head. Remove concentric valve.

• 6. Cover open cylinder bores and breather hose.

• Dismantling

• NOTE: A valve assembly must not be held directly between vice jaws. Never hammer a spanner when
loosening or tightening the valve nuts.

• 1. Unscrew and remove valve securing nut.

• NOTE: When dismantling valve, note the method and order of renewal of each valve component. Refer to

• the illustration of the valve assembly. to ensure that the components are rebuilt in their correct order.

• 2. Clean all components thoroughly. Remove grease and carbon deposits with a soft brush using a hot
water and soda solution. Care must be taken during the cleaning operation as any surface scratch

• may cause leakage and ultimately a breakage.

• 3. Inspect each component. If any items appear defective, worn or damaged these items must be
renewed.

• Page 3-3

•
 •
SECTION 3 - MAINTENANCE
•
Re-assembly •
1. Assemble the valve components on the lower delivery valve seat and stud. •
CAUTION: Ensure that the components are correctly positioned on their locating pins. •
2. Apply silicone grease into the a-ring groove in the upper valve body and locate a new a-ring in the •
groove.
•
3. Fit the upper suction valve seat in position and fit valve securing nut.
•
4. Check that the valve functions correctly and that plate movement exists. Extreme care must be taken
to ensure that the valve is not scored or damaged in this operation. •
Valve Replacement •
1. Renew '0' rings fitted to concentric valve. •
2. Locate concentric valve to the top of the cylinder. •
3. Locate valve cover to valve. Re-connect crankcase breather hose (31) to the hose connector on the •
first stage.
•
4. Fit washers and nuts to valve cover retaining studs and tighten nuts.
•
5. Renew joint to separator connection on the final stage.
•
6. Refit bolts securing first stage separator to final stage valve cover.
•
7. Reconnect cooler tube connector on first stage.
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Page 3-4
•
•
•
• SECTION 3 MAINTENANCE

• Valve Servicing

• ~~
-==-=-----------
• ______ 1.0

•
• 53

•
• 51

•
•
•
•
•
• 51

• 7

•
•
7
- -----------_.-- .

•
• -,

• -------'-----------------
'-
-....--..................

• ._-----
'--~~
<..,
---,
-"<,_~ 3
~-~

• 8

--. ---
6

• '-", ______ 6

• 2
----------
.....•
--.

• __1.§.

•
• 16

• 52

•
• Figure 3.1 VA40 First Stage Valve

•
• Page 3-5

•
 •
SECTION 3 - MAINTENANCE
•
•
•
Q--------------------- 10 •
•
------'-=

75
•
73
•
•
•
•
•
•
73 •
•
•
•
•
•
•
3
•
6
•
•
9
, \ -. 6

•
2 •
•
•
14 •
-------_lL
74 •
~---

•
•
Figure 3.2 VA40 Final Stage Valve
•
Page 3-6
•
•
•
• SECTION 3 - MAINTENANCE

• Table 3.3 Concentric Valves - Items List

•
•
Quantity
Item Description 1st stage 2nd stage

• / 1 Suction valve seat 1 1

•
/ 2 Delivery valve seat 1 1
/ 3 Suction valve seat 1 1

• ( 4 Delivery valve seat 1 1

• / 6 Suction valve seat 2 2

/ 7 Delivery valve seat 2 2

• ( 8 Centre stud 1 nla

•
9 Centre stud nla 1
I 10 Self locking nut 1 1

• 12 locating pin nla 1

•
14 locating pin 1 1
I 16 Back peg 2 1

•
•
I 51 O-ring 2
I 52 O-ring 1

• I 53 O-ring 1

• 72 O-ring 1

• 73 O-ring 2

•
74 O-ring 1

•
3.2.5 First Stage Cylinder and Piston Removal

•
CAUTION: When removing 1st stage cylinders, it can be difficult to prevent the piston from dropping out of
the bore and falling onto the edge of the cylinder aperture.

• To ensure that this does not occur, strategically place an appropriate cushioning material
immediately the cylinder becomes clear of the crankcase so that if the piston does fall no

• damage can result.

• 1. Remove first stage concentric valve and cover assembly from cylinder as detailed in 3.2.4.

• 2. Remove upper guard section (167) from fan housing motor adaptor.

• 3. Turn over the compressor using a bar until the first stage piston (35) is at the top of its stroke in the
cylinder.

• NOTE: If final stage cylinder has been removed take precautions to protect exposed components in the

• crankcase.

• 4. Lift and guide the cylinder off the piston assembly taking adequate precautions to prevent damage to
the piston assembly as it becomes free from the cylinder.

• WARNING: WITH CYLINDER REMOVED PROTECT PERSONNEL FROM INJURY FROM THE EXPOSED

• STUDS (45) AT ALL TIMES UNTil THE CYLINDER IS RE-ASSEMBLED.

• 5. Identify with non-destructive marker, orientation of piston side and gudgeon pin end towards front of
compressor.

• Page 3-7

•
 •
SECTION 3 - MAINTENANCE
•
•
•
6. Slacken the locknuts (44) which secure the cap head screws, from the underside of the piston.
Remove the 2 cap head screws (43) from the underside of the piston (35) which lock the gudgeon pin

•
(42) in position.

•
7. Supporting the piston push gudgeon pin out of piston and connecting rod (15) taking care when the
pin frees to prevent damage of rod striking piston intemals and crankcase. Remove piston and pin.

8. Cover the crankcase aperture.

•
9. Examine removed components replacing worn/damaged parts as necessary. For wear allowances see
Section 4 - Technical Data. •
NOTE: If required connecting rod small end needle roller bearing (17) may be removed and refitted without •
dismantling compressor any further. Section 3.2.11 refers.
•
3.2.6 First Stage Cylinder and Piston Re-assembly
•
1. Before commencing re-assembly ensure that sufficient Loctite sealant and retainer is available to seal
the cylinder to the crankcase and retain the hexagon socket set screws in the piston. •
The minimum amount of Loctite flange sealant number 573 required is 10 millilitres •
The minimum amount of Loctite nutlock 243 required is 10 millilitres
•
2. Using Loctite Chisel remove all traces of sealant on joint faces of cylinder to crankcase and ensure
surfaces are grease free. (Ensure sealant does not enter crankcase - remove if necessary.)
•
3. If new piston rings are being fitted gap rings to cylinder to a closed gap of 0.125/0.255mm.
•
4. Clean threads in piston and cap head screw. With locknut fitted, coat cap head screw with Loctite
•
Nutlock 243. Screw cap head screw into piston.
•
5. Lightly oil the gudgeon pin and fit through the piston into the connecting rod small end bearing,
aligning piston and pin markings to front of compressor. Position gudgeon pin ends equally distant in
•
from the piston side faces and align the machined mark on the gudgeon pin end face in line with the
piston axis pointing away from the cylinder.
•
Lightly fasten cap head screws ensuring location in gUdgeon pin locating dimples.
•
6. Torque cap screw and lock nut as appropriate. Refer to Table 3.1 Fastener Torque Settings.
•
7. Fit rings as follows to the piston.
•
a. Barrel faced ring top groove.(face marked "top" facing the piston crown)
•
Taper faced ring second groove (identified by the internal chamfer - face marked "top" facing the
piston crown) •
s.a.c. ring bottom groove. •
8. Align adjacent ring gaps on piston at 180· to each other. While compressing the piston rings, slide
•
cylinder over the piston and ring assembly. . .

•
9. Coat crankcase (joint face to cylinder) with Loctite flange sealant 573.

•
10. Lower cylinder into contact with crankcase

•
•
11. Fit concentric valve and cover assembly to cylinder as detailed in section 3.2.4.

12. Refit fan housing motor adaptor guard (167).

•
Page 3-8
•
•
•
• SECTION 3 - MAINTENANCE

• 3.2.7 Final Stage Cylinder and Piston Removal

• 1. Remove concentric valve (72) from cylinder (66) as detailed in section 3.2.4.

• 2. Remove guard from the fan housing motor adaptor.

• 3. Using a bar turn over the compressor until the second stage piston (60) is at the top of its stroke in the

• cylinder.

• NOTE: If the first stage cylinder has been removed, take precautions to protect exposed first stage
components in the crankcase.

• 4. Remove the 2 screws (83) and washers (82) securing the separator assembly to the cylinder.

• 5. By striking the cylinder gently with a soft headed mallet, break the seals between the cylinder and

• crankcase.

• 6. Lift and guide the cylinder off the piston assembly taking adequate precautions to prevent damage to
the piston assembly as it becomes free from the cylinder.

• WARNING: WITH CYLINDER REMOVED PROTECT PERSONNEL FROM INJURY FROM EXPOSED

• STUDS AT ALL TIMES UNTIL CYLINDER IS REASSEMBLED TO CRANKCASE.

• 7. Identify with non-destructive marker, orientation of piston side and gudgeon pin end towards front of
compressor.

• 8. Remove the hexagon socket set screw (65) from the underside of the piston (60) which lock the

•
gudgeon pin (64) in position.

•
9. Support piston and push gudgeon pin out of piston and connecting rod (19) Ensure that the
connecting rod does not strike and damage the piston internals and crankcase when the pin releases.
Remove piston and gudgeon pin.

• 10. Cover the crankcase aperture, connecting rod small end bearing, and passage ways on separator.

• 11. Examine removed components replacing worn/damaged parts as appropriate. For wear allowances

• see Section 4 - Technical Data.

• NOTE: Connecting rod small end needle roller bearing (21) may be removed and refitted without dismantling
compressor any further. Section 3.2.11 refers to the procedure.

•
•
•
•
•
•
•
•
•
•
• Page 3-9

•
 •
SECTION 3 - MAINTENANCE
•
3.2.8 Final Stage Cylinder and Piston Re-assembly •
NOTE: Loctite nutlock 243 may not cure on components under oily conditions - see general notes - •
section 3.
•
1. Before commencing reassembly ensure that sufficient Loctite sealant and retainer is available to seal
the cylinder to the crankcase and retain the hexagon socket set screws in the piston. •
Minimum amount Loctite flange sealant 573 required is 10 millilitres. •
Minimum amount Loctile nutlock 243 required is 10 millilitres.
•
2. Using Loctite Chisel, remove all traces of sealant on joint faces of cylinder to crankcase and ensure
surfaces are grease free. •
3. If new piston rings are being fitted gap rings to cylinder to a closed gap of 0.052/0.182mm.
•
4. Clean piston and socket set screw threads . Coat screws with Loctite Nutlock 243 and screw into
•
piston.
•
5. Lightly oil the gudgeon pin and fit through the piston into the connecting rod small end bearing,
aligning piston and pin markings to the front of the compressor. Position gudgeon pin ends equally
distant in from the piston side faces and align the machined mark on the gudgeon pin face in line with
the piston axis pointing away from the cylinder.
••
6. Ensure the screw locates correctly in the gudgeon pin dent. Torque screw as appropriate.
•
7. Fit rings as follows to the piston.
•
a. Barrel faced ring top groove (face marked "top" facing piston crown).
•
Taper faced ring second groove (identified by the intemal chamfer - face marked "top" facing piston
crown)) •
S.O.C. ring bottom groove. •
8. Align adjacent piston ring gaps on piston at 180· to each other. While compressing the piston rings,
•
slide cylinder over the piston and ring assembly.
•
9. Coat crankcase (joint face to cylinder) with Loctite flange sealant 573.
•
10. Lower cylinder into contact with crankcase.

•
•
11. Fit new gasket (81) between cylinder and separator header (80). Do not grease gasket or joint faces.

•
Fit concentric valve and valve cover to cylinder as detailed in section 3.2.4.

•
12. Torque bolts (83) to the appropriate level.

•
13. Refit fan housing motor adaptor guard.

•
•
•
•
•
Page 3-10
•
•
•
• SECTION 3 - MAINTENANCE

• 3.2.9 Air Cooler Tubes Removal

• 1. Remove the cooler tubes in sequence, starting from the non-drive end of the compressor. Remove the

• first stage (outer) tubes first.

• 2. Clean inside the tubes by flushing through with Ardrox or a similar chemical.

• 3. Clean the outside of the tubes using compressed air or, if there is oil residue on the tubes, use low
pressure steam. Avoid damaging the fins on the tubes. If the tubes become bent they may be gently

• straightened using thin nose pliers.

• 4. Assemble the tubes in the reverse order to their removal. Take care not to damage the fins as the
lower tubes are manoeuvred under the compressor.

• 3.2.10 Connecting Rod Big End Bearing Removal

• 1. Drain oil and dispose of in accordance with local regulations.

• 2. Remove the first and final stage cylinders and pistons as detailed in Section 3.2.5. and 3.2.7

• 3. Remove the screws (157) and washers (158) securing the crankcase inspection cover (155).

• 4. Remove the screw securing the low oil level switch DIN connector, if fitted, and unplug the connector.

• 5. Using a soft headed mallet gently tap the side faces of the crankcase inspection cover to break its seal

• with the crankcase. Remove the cover.

• 6. Remove screw (23), tab washer (24) and retaining washer (22).

•
7. Using a puller over the first stage connecting rod (15) big end withdraw rod off crankshaft complete
with cylindrical roller (big end) bearing (16).

• 8. Remove spacer (18) from crankshaft.

• 9. Using a puller as in 7 withdraw final stage connecting rod (19) complete with cylindrical roller (big end)
bearing (20).

• 3.2.11 Bearing Removal and Re-assembly to Connecting Rods

• NOTE: When the connecting rods have been removed both the big and small end bearings should be

• renewed.
Gudgeon pins must always be replaced at the same time as the small end bearings.

• 1. Press out the big and small end bearings from the connecting rod.

• 2. Clean big and small end bores of connecting rod, ensure all trace of old retaining compound and any

• oil or moisture is removed from the big end bore, degrease if necessary.

• 3. Remove big end bearing from its protective wrapping, c1ean/degrease outer diameter to remove all
trace of oil or grease.

• 4. The big end bearing is a transition fit to the connecting rod. Determine if the resultantfit is interference

• or clearance and fit accordingly as follows:

•
•
•
• Page 3-11

•
 •
SECTION 3 • MAINTENANCE
•
5. Interference fit. •
a. Coat outer diameter of big end bearing with Loctite 603 high strength retainer ensuring no . •
retainer enters the bearing internals during this operation.
•
Cold press the big end bearing into the connecting rod. Bearing must be fitted to the connecting rod in
accordance with the following sketch ensuring that the NON CIRCLlP SIDE of the bearing is •
flush with the face shown.
•
. - - - - - - - - - - + F i t bearing flush with this side
•
•
•
•
........._ - - Machined dimple reference •
•
•
Figure 3.3 Connecting Rod

•
Clearance fit.

•
Fit as for an interference fit but support the bearing in position to ensure that the NON CIRCLlP SIDE
of the bearing is flush with the face shown in (b) above until the Loctite 603 has cured sufficiently to
retain the bearing in position.

6. Lubricate small end bore of connecting rod and cold press small end bearing into the connecting rod •
ensuring that lubricating holes in bearing and con rod eye are aligned.
•
3.2.12 Connecting Rod Assembly Fitment to Compressor
•
1. Remove pin (3). Screw a length of M16 x 2 x 185 mm long studding (not supplied) into the tapped hole
in the crankshaft pintle. •
2. Arrange the final stage connecting rod (19) with the cast dipper rod pointing downwards and the small
end through the crankcase aperture for the first stage cylinder. Align the big end bearing onto the
crankshaft pintle. Using the retaining washer (22) and an M16 nut (not supplied) wind the nut onto the
••
studding to push the big end bearing onto the pintle until the washer is flush with pintle end. Remove
washer and nut.
•
3. Align spacer (18) with big end bearing on pintle and push bearing and spacer onto pintle with washer
•
and nut as described above.
•
4. Repeat the procedure for the first stage connecting rod (15) (the cast dipper must be pointing
downwards) until the assembly is pushed solidly against the shoulder on the crankshaft. Remove
•
studding, nut and retaining washer.

•
5. Assemble retaining washer (22), new tab washer (24) and screw (23) to pintle. Torque screw to
appropriate level and fold tabs on tabwasher against hexagon head.
•
6. Assemble first stage cylinder components to compressor as detailed in 3.2.6.
•
7. Assemble second stage cylinder components to compressor as detailed in 3.2.8.
•
8. Fit drain plug (160) to crankcase.
•
•
~~ge
",,'-
3-12
•
•
•
• SECTION 3 - MAINTENANCE

•
• 9. Clean joint faces of crankcase inspection cover (155) and crankcase. Apply Loctite flange sealant 574
to cover joint face. Fit cover to crankcase and secure with the 5 screws (157) and washers (158)

• refitting the 2 cable clips (if fitted) between washer and cover.

•
10. Reconnect low oil level switch DIN connector if fitted and tighten retaining screw.

• 11. Recommission compressor as detailed in section 1.

•
3.2.13 Drive Motor and Coupling Removal from Compressor

•
1. Place a suitable support under the crankcase close to its connection to the drive motor.

2. Remove the fasteners securing the mount under the drive motor to the ship's seating.

•
•
3. Remove the bolts (191) and spring washers (192) securing the drive motor to the crankcase/fan
housing adaptor.

• 4. Using suitable lifting tackle, lift and slide the drive motor complete with drive coupling element (190),
coupling hub, and hexagon socket head cap screws, out of the crankcase.

• 5. If required, remove drive coupling element (190) from its coupling hub by removing the four radial

• hexagon socket head cap screws.

• 6. If required, remove the four coupling element drive pins from the flywheel fan drive clamp.

• 3.2.14 Drive Motor and Coupling Assembly to Compressor

• Important note for fitting coupling

• In addition to the operational sequence 1 to 9 listed below the coupling must be assembled in accordance
with the following notes:

• a. The radial and axial screws connecting the rubber element to the hubs must all be tightened to

• the torque given in the operational sequence. Tightening torques which are too low will
inevitably lead to slackening of the screws in service and consequently to the destruction of the

• coupling.

•
Ensure that on tightening the screws the aluminium bushes in the rubber part are not twisted at
the same time, but sit straight. In order to reduce friction between the screw head and the

•
aluminium part, a small amount of grease should be applied under the head of the screw before
fitting. If necessary use a suitable tool for applying counter pressure on the element to prevent
twisting of the rubber part during tightening of the screws. This is particularly important with the

• radial screws, otherwise the cylindrical faces between the aluminium insert and the hub will not
engage on the full area, but only on two corners. If the coupling is supplied in a pre-assembled

• state, do not dismantle it, but fit it in this condition.

• b. Fit the hubs onto the shafts or the adaptor plate onto the flywheel. Position the element with the
side having the rubber face free of the axial aluminium inserts towards the flange hub and,

• using the radial screws, mount it on the cylindrical hub. During this process, the rubber element
is pulled together radially and receives its pre-Ioad. Then push the coupled elements together

• and in so doing, carefully slide the coupling with light axial pressure onto the socket bolts. The
rubber element is subjected to a little more radial compression by the socket bolts, and the pre-

• load is thus increased. The axial bores in the rubber element should be smeared lightly with
grease beforehand to allow the socket bolts to slide easily in the inserts.

• 1. If removed reassemble drive coupling pins to flywheel.

• Tighten coupling pins to a torque of 220 Nm.

•
• Page'3-13

•
 •
SECTION 3 • MAINTENANCE
•
•
2. If removed, assemble drive coupling hub to drive motor shaft. To determine the coupling position on
the motor shaft, measure the distance from the motor fixing flange to the flywheel. Position the
•
coupling on the motor shaft to give al· 2 mm gap between the coupling extremes (not the hub) and
the flywheel (A).
•
•
•
•
•
••
•
Figure 3.4 Gap between Coupling and Flywheel
•
3. If removed assemble drive element onto hub with hexagon socket head cap screws. Tighten screws to
a torque of 220 Nm (M16) or 500 Nm (M20).
•
4. Clean out the bell housing to remove any debris caused by cooling air fan inlet and exhaust.
•
5. Using suitable lifting tackle, lift and slide the drive motor whilst aligning the drive element with the
•
coupling pins, slide the drive element onto the coupling pins and the motor flange location diameter on
the crankcase.
•
6. Fit bolts (191) and spring washers (192) through drive motors flange onto crankcase.
•
7. Remove support placed under crankcase.
•
8. Fit holding down bolts to drive motor or anti vibration mount.
•
9. Recommission compressor as detailed in section 1.
•
3.2.15 Flywheel and Drive End Oil Seals Removal from Compressor
•
1. Remove drive motor and coupling as detailed in section 3.2.13. Note drive pins (190B) need not be
removed from the flywheel. •
2. Slacken the socket set screws (9) on drive bush (11). •
3. Remove 2 of the clamp screws and use in the tapped holes provided in the drive bush to jack the bush •
out of the flywheel. Remove drive bush.
•
4. Using suitable lifting tackle remove flywheel from crankcase.
•
(Note tapped hole in periphery of flywheel is M12).
•
5. Drain oil and dispose of in accordance with local regulations.
•
6. Remove the 5 screws (157) and washers (158) securing the crankcase inspection cover (155).
•
7. Using a soft headed mallet gently tap the side faces of the crankcase inspection cover to break its seal
with the crankcase. Remove cover.
•
•
_,iPage 3-14
•
•
I
•
• SECTION 3 - MAINTENANCE

• 8. Wedge a piece of clean bar (not supplied), through the front of the compressor between the crankshaft

• balance weight and the rectangular oil reservoir to prevent the crankshaft from rotating.

• 9. Remove socket setscrew (9). Using a c-spanner or similar tool (not supplied) unscrew the bearing
adjustment sleeve.

• 10. Lever lip seal (6) out of crankcase with an appropriate tool (not supplied) taking care not to damage

• the housing bore in the crankcase.

• 11. Remove '0' ring (7) from crankshaft.

• 3.2.16 Flywheel and Drive End Oil Seal Re-assembly to Compressor.

• 1. Fit new radial shaft seal (5) to crankcase.

• 2. Fit '0' ring (7) onto crankshaft adjacent to bearing taking care in passing over the thread on the
crankshaft.

• 3. Wedge a piece of clean bar (not supplied) through the front of the compressor between the balance

• weight and the rectangular oil reservoir to prevent the crankshaft from turning carry out the following
operation.

• 4. Screw the bearing adjustment sleeve onto the crankshaft and engage with the drive end bearing. Use

•
a C-spanner or similar implement (not supplied).
~.

5. Rotate assembly of crankshaft through two complete turns and check, by trying to rock the assembly,

• that the taper roller main bearings are seated correctly (i.e. little or no up and down movement of any
part of the assembly).

• 6. Attach a Dial Test Indicator (DTI) to the end face of the crankcase resting on the end of the crankshaft.

• 7. Push or pull the crankshaft assembly, while turning from side to side, and note the end float.

• 8. An end float of between 0.05/0.10mm is required in the main bearings which is to be obtained as follows:

• a. If the end float is greater than 0.10mm, using a c-spanner as in operation 4, screw the bearing

• adjustment sleeve further onto the crankshaft until the required end float is achieved. Rotate the
assembly before each reading through two complete revolutions to centralise the bearings.

• b. If the end float is less than 0.05mm or the bearings are preloaded (no end float):

• Using a c-spanner as in operation 4 unscrew the bearing adjustment sleeve 90°. Lightly tap the
drive end of the crankshaft to loosen the drive end main bearing inner race. If this technique does

• not loosen the bearing, the M16 tapped hole in crankshaft big end bearing pintle may be used to
apply tension to crankshaft to loosen the bearing in conjunction with tapping the drive end.

• Carry out adjustment technique as in (a) until required end float is achieved.

• 9. Replace socket setscrew (9).

• 10. Using suitable lifting tackle ease the flywheel onto the crankshaft.

• 11. Fit drive bush (13) to flywheel and crankshaft and torque the clamping screws on the bush to a torque
of 35 Nm. Check alignment of the flywheel face using a DTI.

• 12. Reassemble drive motor and coupling to compressor as detailed in section 3.2.14.

• 13. Clean joint faces of crankcase inspection cover (155) and mating face on crankcase. Apply Loctite

• multi gasket 574 to cover joint face. Fit cover to crankcase and secure with the 4 screws (157) and
washers (158) refitting the 2 cable clips (156) between washer and cover (if fitted).

• 14. Recommission compressor as detailed in section 1.

• Page 3-15

•
 •
SECTION 3 - MAINTENANCE
•
3.2.17 Crankshaft and Main Bearing Removal from Compressor •
NOTE: If the main bearings are removed it is recommended that they are renewed. •
1. Remove first and second stage cylinders, connecting rods, drive motor and coupling, flywheel and oil •
seals as detailed in sections (3.2.5.) (3.2.7), (3.2.10), (3.2.13), (3.2.15) respectively.
•
2. Screw a length of M16 x 2 studding (not supplied) into the tapped hole in the crankshaft. Place a bar
or similar (not supplied) across open front of compressor and using an M16 nut (not supplied) exert a •
force onto the end of the crankshaft.
•
3. Gently tap the drive end of the crankshaft with a soft headed mallet and tighten the M16 nut as in
operation 2, draw the crankshaft out of the inner race of the drive end taper roller main bearing. •
4. Taking care to prevent the drive end inner cage dropping off the crankshaft withdraw the crankshaft
•
complete with non-drive end taper roller bearing inner race.
•
5. Using a suitable puller (not supplied) or by levering on the inner race lip (not on the rollers or cage)
extract the non drive end taper roller bearing inner race from the crankshaft.
•
6. Using a mild steel drift (not supplied) drift out the drive end and non drive end taper roller bearing
•
outer races from the crankcase taking care not to damage the housing bore for the lip seal in the
crankcase drive end.
•
3.2.18 Crankshaft and Main Bearings Re-assembly to Compressor
•
1. Before reassembly ensure crankcase intemals and crankshaft are clean.
•
2. Lightly oil the drive end main bearing location bore in the crankcase.
•
3. Using a mild steel drift (not supplied), drift the outer bearing cup of the drive end main bearing (5) into
•
•
position in the crankcase.

4. Lightly oil the non drive end main bearing location bore in the crankcase.

5. Fit non drive end main bearing (4) outer race in position as described in operation 3. •
•
.:
6. Preheat non drive end main bearing inner race assembly to 140'C.

7. Lightly oil crankshaft non drive end bearing journal location. •

8. Fit the heated inner race assembly on to the crankshaft journal and allow to cool before gently tapping
home against shoulder with a mild steel sleeve drift (not supplied).
•
9. Insert crankshaft into crankcase, wedge crankshaft into position ensuring that the non drive end main
bearing inner race assembly is mated correctly to the outer race. •
10. Lightly oil the crankshaft drive end main bearing journal. •
11. Preheat drive end main bearing inner race assembly to 140'C. •
12. Fit the heated inner race assembly onto the crankshaft and into the bearing outer race. •
13. Refit oil seal and flywheel as described in section 3.2.16.
•
•
•
•
Page 3-16
•
•
•
• SECTION 3 -MAINTENANCE

• 3.2.19 Oil Level Switch Remove/Clean/Replace.

• 1. Drain compressor of lubricating oil as detailed in section 3.2.2.

• 2. Loosen screw securing the DIN connector and unplug connector.

• 3. Remove screw (142) and washer (143) securing dual oil level switch (140) to crankcase.

• 4. Lever switch out of crankcase taking care not to damage the '0' rings (141).

• 5. Remove screws and slide sleeve off body.

• 6. Clean switch by removing all metallic particles.

• 7. Reassemble switch, replace DIN connector and re-fill compressor with oil, refer to section 3.2.2.

• 3.2.20 Air Safety Valves

• These valves are all pre-set maximum working pressure duly of the compressor. The air safely valves are

• statically set at a pressure which equates to the 10% statutory over pressure requirement, making allowance
for the dynamic pressure pluses found with the compressor. The safely valve settings are shown on the test

• certificate.

• The safely valves must NOT be tampered with and it is recommended that a replacement valve should
always be fitted if there is any doubt as to the valve's condition.

• Each valve is screwed into position.

• First Stage Air Pressure Safely Valve (147)

•
Located on the first stage separator. Associated joint washer (148).

•
Final Stage Air Pressure Safety Valve (149)
Located on the final air block. Associated joint washer (150).

• 3.3 ELECTRICAL MAINTENANCE

• It is recommended that switch settings are periodically checked. Refer to the separate data sheet for
settings:

• Table 3.4 Switch Settings

• SETTING

•
SWITCH
Oil level switch Should activate when oil level falls below fill mark.

• High air temperature switch Alarm 80'C

• Shutdown 90'C

•
•
•
•
•
•
• Page 3-17

•

SECTION 3 - MAINTENANCE
3.4 FAULT FINDING CHART
FAULT
Final stage air safety valve
blowing.
Whilst in automatic (default)
mode
Whilst running in manual
mode
First stage air safety valve
blowing.
High first stage pressure
(First stage air safety valve
blowing)
Internal knocking noise from
compressor.
Compressor will not achieve
operating pressure or is
operating at a reduced
capacity.
Concentric valves require
frequent cleaning.
Excessive moisture in final
air delivery pipe work. and/or
final stage cylinder/
intercooler.
Oil seeping out from Drive end lip or O-ring seal adjustment
underside of crankcase near sleeve to crankshaft leaking.
drive motor.
Excessive oil consumption.
Page 3-18
•
•
•
Table 3.5 Fault Finding Chart •
•
•
POSSIBLE CAUSE REMEDIAL ACTION
Air system charged signal and final Reset signal pressure settings lower than safety valve set
•
•
stage air pressure shutdown settings pressure (Note: maximum working pressure of compressor
greater than safety valve set pressure is 33 barg)
•
Stop valve closed in final air delivery Open all stop valves in pipework
pipework
Non-return valve installed incorrectly. Corred installation.
Air system pressure safety devices set
higher than safety valve setting.
Correct safety device pressure settings as appropriate.
•
The first stage air safety valve is unlikefy to operate when the compressor is running automatically as
the compressor will be sh ut down by the high first stage air pressure transducer first. See below. •
Intercooler blocked Remove cooler tubes. Clean cooler tubes and interconnecting
pipewor1< •
Suction side of final stage valve leaking Remove valve, cJeanlinspectlrenew.
•
Delivery side of final stage valve
leaking
Remove valve, deanlinspectlrenew.
•
Delivery side of final stage valve
leaking to suction side
Remove valve cage, renew O-rings and check joint washers
under dome nuts.
•
Worn big or small end bearings Strip down compressor for inspection, renew worn parts.
•
Worn main bearings. Strip down compressor, check crankshaft end float. Renew
worn parts.
•
Damaged concentric valve.
Piston slap.
Remove valves, dean inspect and renew if necessary.
Remove cylinders, check clearances, renew worn parts
•
Worn drive element.
(cylinder, piston rings.)
Renew drive coupling element.
•
Concentric valves damaged or dirty. Remove valves, clean inspect and renew jf necessary. (note
reduced capacity normally indicates first stage fault)
•
•
•
Solenoid drain/unload valve tautly. Check solenoid valve function, renew parts as necessary.
Worn or damaged piston rings/ piston. Remove cylinders, check rings are free in piston groove,
•
renew worn, distorted or damaged rings, piston as
appropriate.
Excessive cylinder component wear Remove cylinders, renew cylinder, piston, rings as necessary
Suction filter/silencer blocked. Renew element.
•
•
Non-recommended grade of lubricating Drain lubricating oil, replace with recommended grade.
oil used.
Ensure concentric valves, cylinder components (cylinder,
•
Concentric valves overheating.
piston, rings) and cooling water system is maintained in good
working order.
Solenoid drain/unload valve fautly. Check solenoid valves function, renew components as
necessary.
•
•
Unload drain cycle incorrect tor
•
Reprogram solenoid drain/unload valves "dwell" and "spit"
operating conditions. times to suit operating conditions.
•
Remove flywheel adjustment sleeve and drive lip seal and 0-
ring. Renew seal and O-ring. Refer to Section 3.2.15.
Worn cylinder components. Remove cylinders, check cylinder, piston, rings. Renew
components as appropriate.
•
•
•
•
•
• SECTION 3 - MAINTENANCE

•
•
3.5 TOOLS REQUIRED FOR VA40 COMPRESSOR MAINTENANCE

Table 3.6 Tools required for Compressor Maintenance

•
• C spanner 2" - 6"
Press

• Dial test indicator and magnetic base

•
8" screwdriver
Water pump pliers .

• Steel lump hammer

• 12" adjustable spanner

Feeler gauges (O.02 -1.0mm)

• 19 mm aft combi spanner

•
17 mm aft combi spanner
13 mm aft combi spanner

• 22 mm x 24 mm open ended spanner

• 19 mm aft Yz" square drive socket

13 mm aft y." drive socket

• 2.5 mm aft hexagon key

•
5 mm aft hexagon key
6mm aft hexagon key

• 2.5 mm aft hexagon key x y." square drive

•
5 mm aft hexagon key x y." square drive
6 mm aft hexagon key x Yz" square drive

• y." square drive torque wrench (4 - 20 Nm)

•
Yz" square drive torque wrench (30 - 150 Nm)
19 mm aft crowstoot spanner

• 22 mm aft crowstoot spanner

•
24 mm aft crowstoot spanner

•
•
•
•
•
•
•
•
•
•
• Page 3-19

•
•
• SECTION 4· TECHNICAL DATA

•
• SECTION 4 - TECHNICAL DATA

• 4.1 GENERAL

• Compressor Type VA40

•
4.2 PERFORMANCE

Maximum working pressure

•
33 bar.

•
4.3 OTHER DATA

Table 4.1 Capacity and Power at 30 Bar

•
• Nominal Speed
VA40

• R.P.M.
1000 1200 1500 1800

• Output
M3/hour
22 28 34 40

• Absorbed Power
kW
4.6 5.5 6.7 8.0

• Outputs quoted are bottle charging rates.

• Noise - 89 dB (A) at 1 Metre

• Table 4.2 Operating Parameters

• Maximum air inlet temperature

VA40
45°C

• Maximum air outlet temperature Will not substantially exceed 93°C

• Lubrication system Splash

• Sump capacity min. 3 litres

max. 4 litres

•
• Fusible plug setting 121°C

•
•
•
•
•
•
•
•
•
• Page 4-1

•
 •
SECTION 4 - TECHNICAL DATA
•
4.4 RECOMMENDED MAXIMUM WEAR CLEARANCES •
Table 4.3 Recommended Maximum Wear Clearances •
Feature Feature Measured Renew When •
Note: All dimensions are in millimetres.
First staqe cylinder (Nominal bore 125 mm) •
Piston
Cvlinder bore
A Skirt (2) measured 15mm UD from base
B Maximum diameter at anv point
< 124.7
< 125.164 •
Piston to cylinder bore C Clearance between measured values A & B >0.40
•
Top and second D Piston rina width < 2.900
•
•
piston rings, piston ring E Piston rinQ qroove width > 3.15
grooves. F Clearance between measured values D and E > 0.200

•
G Piston ring gap when fitted to bore > 0.89

Conformable slotted oil <4.9

•
H Piston rinQ width
control ring, piston ring I Piston rina aroove width > 5.15

•
groove J Clearance between measured values H and I > 0.20
K Piston ring gap when fitted to bore > 0.89

Gudgeon pin and small L GUdgeon pin (2)

end bearina
< 19.941
•
Final staoe cvlinder (Nominal bore 52 mm)
Piston
Cylinder bore
M Skirt (2) measured 15mm UP from base
N Maximum (2) at anv oomt
< 51.85
> 52.125
•e
0 Clearance between measured values M & N > 0.2

•
Piston to cylinder bore

•
Top and second P Piston rina width < 1.92
piston rings. piston ring Q Piston rinQ qroove width > 2.14

•
grooves R Clearance between measured values P & Q > 0.180
S Piston ring gap fitted to bore > 0.71

Conformable slotted oil T Piston rinQ width < 4.455

•
•
control ring, piston ring U Piston rina aroovewidth > 4.65
groove V Clearance between measured values T & U > 0.20
W Piston ring gap fitted to bore > 0.51

•
•
Gudgeon pin and small X Gudgeon pin (2) <19.941
end bearino

•
•
•
•
•
•
•
•
•
Page 4-2
•
•
•
• SECTION 4 - TECHNICAL DATA

• 4.5 CRANKCASE LUBRICANTS

• 4.5.1 Approved Oils

• Shell Corena P100 Castrol Aircol SN100

• Extensive tests have been carried out on the V-Line compressor using Shell Corena P100 (mineral)

• and Castrol Aircol SN100 (synthetic) lubricants. These oils have been found to give good results over
extended service and Hamworthy recommend their use to ensure satisfactory operation of the compressor.

• 4.5.2 Oil Company Equivalent Oils

• The following lubricants have not been tested by Hamworthy with the V-Line compressor, but are offered as

• equivalents by the oil companies.

• Table 4.4 Oil Company Equivalent Oils

• Mineral Oils
,

•
Supplier Oil Type
BP Energol RC 100

• Castrol Aircol PO 100

•
Esso Zerice S100
Mobil Rarus 427

• Texaco Regal 100

•
Synthetic Oils
Esso Synesstic 100 (Synthetic Oil)

• Mobil Rarus 827

•
Texaco Synstar, DE100 (Synthetic Oil)

• The V-Line compressor is designed to achieve the best possible results using mineral oils. A recommended
lubricating oil should be used at all times to ensure safe and efficient operation with minimum wear. The

•
suggested maintenance intervals are based on the results of extensive tests using Shell P100 mineral oil.
Specific measures have been taken to ensure extended service before components need cleaning to remove
carbon.

• Hamworthy recommend the use of mineral oil as the most economic lubricant. If synthetic oils are to be used

• the following maintenance revisions are necessary.

• 4.5.3 Additional Maintenance for Machines Lubricated with Synthetic Oils

• Initial run and oil change periods to be as detailed in Maintenance section.

• After initial 500 running hours using mineral oil lubricant:

• 1. Drain the old mineral lubricant completely whilst the oil is warm.

• 2. Thoroughly clean the crankcase sump.

• 3. Inspect and thoroughly clean compressor valves (as detailed in Maintenance section).

• 4. Replace all items removed, renew any damaged seals or gaskets.

• 5. Refill with synthetic oils, and run as normal.

•
• Page 4-3

•
 SECTION 5 - DRAWINGS

SECTION 5 - DRAWINGS

Oll -\
'"
~

~
~

.".

eo I '-----\\ Ill,
"Il~

"'I VfrA

'"

Figure 5.1 Typical Arrangement of V Line Air Cooled Compressor

Page 5-1
SECTION 5 - DRAWINGS
•
•

Table 5.1 List of Parts for Figure 5.1 •

•
1
2
Final stage air pressure gauge
Suction filter silencer
•
3 First stage safety valve
•
4
5
Final stage safety valve
Fusible plug •
6 Oil drain plug
•
7
8
Oil filler/dipstick
Final air delivery
•
9 Motor terminal box
•
10
11
Lifting lugs
First stage separator •
12 First stage hand drain valve
•
13 Final stage hand drain valve

For more detailed information including dimensions and connection sizes, regarding the actual compressor
supplied, refer to the general arrangement drawing supplied with the compressor documentation package.
•
•

•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
~e~
•
•

•
• • • • • • • • •• • • • • • • •• •• • • • • • • • • ••• •• •
125123124 281~
" rj-

:~~ ~ -._
~. .149

~~!,~ fi @-~ ~!~

120
129:::- :~'-17 f..l. ~A_'_
./~~~~
-----------------1
...
327
130
392 --"-_. >:"--.J V &-..::...~
391 ~~ \!) o--... ._..~
i5it ~
253
.., 252

~
cC" ' 51
c
~
CD
250
en
N ~
0
~
~~ -,
,..
01
::>
n
01
III
CD
I!O 155
0
0
0
co
~

-I
c
C"
CD
III

III
m
0
-I
6
141 Z
140
en
,
C
;U

~
"tJ
Ql
cc
(1)
Z
C)
'"• III
'"
"1J CIl
DJ m
<C o
ID
::!
en
J,.. oz
'",
o

~z
oCIl

"Tl

.
cS'
c
CD

...'"
0
0

.
3
"0
CD
III

.
III
0
0
::I.
<
CD
173
172
•
• SECTION 5 - DRAWINGS

•
•
•
•
•e
•
•
• ';-- 46
47

•
31
49

•
48
112

•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
• Figure 5.4 First Stage Cylinder & Piston

• Page 5-5

• (\
 •
SECTION 5 • ORAWINGS
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Figure 5.5 Final Stage Cylinder & PiIS t on

•
Page 5-6
•
•
•
• SECTION 5-0 RAWINGS
--
•
•
•
•
•
•
•
• \
• \
426
427

• }
• /

• l.
•
• ".
"'"

•
•
• 4()()

•
401
'402
403

• 411

• 403.. . . . . .,
< ; ............

• 400
--------- ~~~€iD
~~~
• 428
429
401
~...........
406
. -c.,.____
.................. _~_ -~~
.

•
•
• 412
413
0

• 414
415

•
•
•
• Figure 5.6 Compressor Separator & Pipe Work

• Page 5-7

•
 •
SECTION 5 - DRAWINGS
•
Table 5.2 List of Parts· VA40 Compressor •
Item DescriDtion Quantitv •
1
2
Crankcase
Crankshaft
1
1 •
4
3 Pin
Drive end main bearino
1
1 •
5
6
Non-drive end main bearina
Radial shaft seal
1
1 •
7
8
O-rino
Main bearina adiustment sleeve
1
1 •
9
10
Socket setscrew
Flvwheel
1
1 •
11
12
Bush cone clam--;;jiiO element
Fan blade
1
8 •
13
14
Drive clamo, f1vwheel - fan
Caoscrew
1
4 •
15
16
Connectinn rod 1st stane
Bearina - cvlindrical roller
1
1 •
17
18
Bearino - needle roller
Soacer - connectinarods
1
1 •
19
20
Connectinn rod 2nd stace
Bearina - cvlindrical roller
1
1 •
21
22
Bearino - needle roller
Relaininawasher
1
1 •
23
24
Setscrew
Tab washer
1
1 •
30
31
Adaotor
Hose
1
18cm •
35
36
Piston -1 staoe
Piston rina - s.O.C.
1
1 •
37 Piston ring -
taoer face comoression
1
•
38
39
Piston rino - barrel face comoression
CVlinder - 1" stane
1
1 •
40
41
Plua
Joint washer
1
1 •
42
43
Gudoeon nln - 1" staoe
Socket screw
1
2 •
44
45
Nut
Stud
2
4 •
46
47
Valve cover - 1SI slaae
Adaotor
1
1 •
48
49
Stud counlinn
Joint washer
1
1 •
50
51
Concentric valve
O-rino
1
1 •
52
53
O-rinn
O-rina
1
1 •
54
55
Washer
Nut
4
4 •
60
61
Piston - 2"" stane
Piston rina - S.o.e.
1
1 •
62 Piston ring -
taoer face comoression
1
•
63 Piston ring -
barrel face comoression
1
•
•
Page 5-8
•
•
•
• SECTION 5 - DRAWINGS

• Table 5.2 List of Parts - VA40 Compressor (Cont'd)

• Item Description Quantity

• 64
65
Gudgeon pin
Socket setscrew
1

•
2
66 Cvlinder - 2~ staae 1
67 Stud 4

• 70
71
Valve cover
Blankina oluo
1
1

• 72
73
Concentric valve
O-ring
1

•
1
74 O-rino 1
75 O-rina 1

• 76
77
Washer
Nut 1
1

• 78
80
Evebolt
Separator
1
1

• 81
82
Gasket
Setscrew
1
2

• 83
64
Washer
Screw
2
1

• 85
90
Washer
Stud couolino
1
1

• 91
94
Joint washer
Stud couonno
1

•
1
95 Joint washer 1
96 Bulkhead fittino 5

• 97
105
Bulkhead fittino
na
Cooler tube - 2 staae
5
4

• 108
110
Transfer pipe
Cooler tube - 1 stage
1
4

• 112 Transfer pipe

1st stage - cooler pack
1

• 113
120
Transfer pipe - 1st staqe separator
Air deliverv block
1
1

• 121
122
Setscrew
Washer
2
2

• 123
124
Stud coupling
Joint washer
1
1

• 125 Transfer pipe

final air - deliverv block
1

• 129
130
PluQ - hex socket with ceotive seal
Fusible otua
1
1

• 131
140
Joint washer
Dual level switch
1
1

• 141
142
O-rina
Screw
2
1

• 143 Washer 1

• 147
148
Safety valve
Joint washer
1
1

• 149
150
Final stage safety valve
Joint
1
1

• 155
156
Crankcase cover
Cable clips
1
2

• 157
158
Setscrew
Washer
5
5

•
• Page 5-9

•
 •
SECTION 5 • DRAWINGS
•
Table 5.2 List of Parts - VA40 Compressor (Cont'd) •
Item DescriDtion Quantitv •
160
161
maanetic drain oluo
Diostick with seal
1
1 •
166
167
Suction filter silencer
Guard - fan housinq adaotor 2
1
•
168
169
Screw
Sorina washer
8
8 •
170
171
Fan housino adaotor
Hollow dowel oin
1
•
•
4
172 Bolt 4
173 senno washer 4
190
191
Couelino
Bolt - motor to fan housmo adaotor
1
•
•
4
192 Washers - 191 4
195 Motor mountino foot

•
1
196 Bolt 2
Taoer washer

•
197 2
198 Serine washer 2
199 Nut 2
213
214
Anti-vibration mount
Bolt
2
2 •
215
216
SorinQ washer
Anti-vibration mount
2
1 •
217
218
Setscrew
SerinQ washer
1
1 •
219
245
Taoer washer
Setscrew
1
4 •
246
247
Serino washer
Terminal box
4
1 •
248
249
Stud
Brass washer
1
1 •
250
251
Brass nut
Brass washer
1
1 •
252
253
SorinQ washer
Washer
1
1 •
254
255
Nut
Nut
1
1 •
281
325
Pressure QaUQe
Non-return valve
1
1 •
326
327
Nioole
Joint washer
1
2 •
390
391
Blankina otua
Temoerature switch
1
1 •
392 Joint washer 1
•
400
401
Joint washer
Adaotor
1
1 •
402
403
Joint washer
Ball valve
1
1 •
404
405
Elbow ..
Adaotor valve
1
1 •
406
407
Hex. Adaotor
Joint washer
1
1 •
408
409
1st staae drain/un/oader block
Joint washer
1
1 •
•
Page 5-10
•
•
•
• SECTION 5 - DRAWINGS

•• Table 5.2 List of Parts - VA40 Compressor (Cont'd)

Item Description Quantity

• 410
411
Hex. Adaptor
Elbow
1
1

• 412
413
Joint washer
Adaptor
1
1

• 414
415
Joint washer
Solenoid valve
1
1

• 416 Solenoid valve coil 1

• 420
421
Joint washer
Stud coupling
1
1

• 422
423
Transfer pipe
Stud couelina
1
1

• 424
425
Joint washer
2nd staoe drainlunloader block
1
1

• 426
427
Screw
Serina washer
1
1

• 428
429
Joint washer
Adaptor
1
1

• 430
431
Serina washer
Ball valve
1
1

• 432
433
Elbow
Joint washer
1
1

• 434
435
Adaptor
Joint washer
1
1

• 436
437
Solenoid valve (boav oniv)
Solenoid valve coil
1
1

•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
• Page 5-11