Installation, Operating and Maintenance Manual: Hamworthykse

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• Installation, Operating and
• Maintenance Manual
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• HamworthyKSE
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• CMA CGM FORT ST GEORGIS
• HamworthyKSE
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• Hamworthy
• V-Line Water Cooled
• Compressor
• Electra-mechanical Model
• V150,V200,V250,V375
• PCH 1540
• jG fflG III
• FINISHED PLAN
JJN30. lUll
• '*' ~ ~ ~ 0 'iij
• ChiNA SHIPBUILDING CORP.
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• I I
• ISSUE 3 0799
• 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)1202 662622
• Offices, Associate Companies and Agents throughout the world
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• M-75 -1
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•• WARNING
• 1. The following manual must be read before proceeding with installation, operation and maintenance of
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this equipment.
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2. Health & Safely 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 duly, or isolators are remote from the unit and extra care is then necessary to
• ensure that isolation is complete.
• Hamworlhy 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
• SECTION 1 -INSTALLATION
1.1 LOCATION
1-1
1-1
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1.2 MOUNTING 1-1
1.3 COMMiSSiONING 1-1
•e 2.1
2.2
1.3.1 Commissioning Procedure
SECTION 2 - OPERATING PROCEDURE
DESCRiPTION
CONTROL AND OPERATING PHILOSOPHy
1-1
2-1
2-1
2-1
2.3 NORMAL RUNNING PROCEDURE (AUTOMATIC CONTROL) 2-1
• 2.4
2.5
MANUAL MODE RUNNING
GENERAL
2-2
2-2
• SECTION 3 - MAINTENANCE
3.1 GENERAL.
3-1
3-1
• 3.2
3.2.1
MAINTENANCE INSTRUCTIONS
Lubrication Oil Checking
3-2
3-2
• 3.2.2
3.2.3
Lubrication Oil: Changing
Air Suction Filter/Silencer Removal and Replacement
3-3
3-3
• 3.2.4
3.2.5
First Stage Concentric Valve RemovaUServicinglReplacement
Final Stage Concentric Valve RemovaUServicing/Replacement
3-3
3-7
• 3.2.6
3.2.7
First Stage Cylinder and Piston Removal..
First Stage Cylinder and Piston Reassembly
3-10
3-11
• 3.2.8
3.2.9
Final Stage Cylinder and Piston Removal
Final Stage Cylinder and Piston Reassembly
3-12
3-13
• 3.2.10 Cooler Tubenest and Header Removal.

3.2.11 Tubenest Clean/Examine/Replace
3-14
3-14
• 3.2.12 Cooler Tubenest and Header Assembly to Compressor

3.2.13 Cooler box end cover
3-15
3-16
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3.2.14 Connecting Rod Big End Bearing Removal 3-16
3.2.15 Bearing Removal and Reassembly to Connecting Rods 3-16
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3.2.16 Connecting Rod Assembly Fitment to Compressor 3-17
3.2.17 V150, V200, and V250 Drive Motor and Coupling Removal from Compressor 3-18
3.2.18 V150, V200, and V250 Drive Motor and Coupling Assembly to Compressor 3-18
• 3.2.19 V375 Drive Motor and Coupling Removal from, and Assembly to, Compressor
3.2.20 Flywheel and Drive End Oil Seals Removal from Compressor
3-20
3-20
• 3.2.21 Flywheel and Drive End Oil Seal Reassembly to Compressor

3.2.22 Crankshaft and Main Bearing Removal from Compressor
3-21
3-22
• 3.2.23 Crankshaft and Main Bearings Reassembly to Compressor

3.2.24 Oil Level Switch Remove/Clean/Replace
3-23
3-23
• 3.2.25 Air and Water Safety Valves

3.2.26 Separator Bowl Removal, Spider Examination and Removal
3-24
3-24
• 3.2.27 Spider Fitting and Separator Bowl Reassembly

3.3 WATER CIRCULATING PUMP (if supplied)
3-24
3-25
• 3.3.1
3.3.2
General Overhaul
Service Information
3-25
3-25
• 3.3.3
3.3.4
Dismantling
Reassembly
, 3-25
3-25
• 3.4
3.5
ELECTRICAL MAINTENANCE
FAULT FINDING CHART
3-26
3-27
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3.6 TOOLS REQUIRED FOR COMPRESSOR MAINTENANCE 3-28
SECTION 4 - TECHNICAL DATA 4-1
4.1 GENERAL 4-1
• 4.2
4.3
PERFORMANCE
OTHER DATA.
4-1
4-1
• 4.4
4.4.1
CRANKCASE LUBRiCANTS
Approved Oils
4-3
4-3
• 4.4.2
4.4.3
Oil Company Equivalents
Additional Maintenance for Machines Lubricated with Synthetic Oils
4-3
4-3·
• SECTION 5 - DRAWINGS 5-1
• Page 5
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FIGURES
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Figure
Figure
3.1 First Stage Concentric Valve V150
3.2 First Stage Concentric Valve V200/250/375
, 3-5
3-6
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Figure
Figure
3.3 Final Stage Concentric Valve V150/200/250/375
3.4 Cooler Header V150
3-8
3-15
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Figure
Figure
3.5 Cooler Header V200/250/375
3.6 Connecting Rod: V150
3-15
3-17
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Figure
Figure
3.7 Connecting Rod : V200/250/375
3.8 Coupling
3-17
3-19
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Figure 3.9 Gap Between Coupling and Flywheel. 3-19
Figure 3.10 Location of Angle Steel on Crankcase Rails 3-21
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Figure 5.1 Typical Arrangement of V-Line Water Cooled Compressor with Gauges 5-1
Figure 5.2 Cooler , 5-3
Figure 5.3 Crankshaft and Flywheel 5-4
Figure
Figure
5.4 First Stage Cylinder and Piston
5.5 Final Stage Cylinder and Piston
5-5
5-6 •
Figure
Figure
5.6 Separator
5.7 Gauges
5-7
5-8 •
Figure
Figure
5.8 Cover Assembly for Electronic Controller Model
5.9 V375 Drive Coupling Element and Coupling Hub (Drawing 641600, Issue 1)
5-9
5-10 •
Figure 5.10 V375 Flywheel (Drawing 3416300401, Issue 1) 5-11
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TABLES
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Table 3.1
Table 3.2
Table 3.3
Table 3.4
Fastener Torque Settings
Maintenance Schedule
First Stage Concentric Valves -Items Lis!..
Final Stage Concentric Valves -Items List
3-1
3-2
3-7
3-9
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Table 3.5
Table 3.6
Fixtures to Assist Flywheel Removal
Switch Settings
3-20
3-26
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Table 3.7
Table 3.8
Fault Finding Chart
Tools Required for Compressor Maintenance
3-27
3-28
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Table 4.1 Capacity and Power at 30 Bar 4-1
Table 4.2 Operating Parameters 4-1
Table 4.3 Recommended Maximum Wear Clearances 4-2
Table 4.4
Table 5.1
Oil Company Equivalents
List of Parts for Figure 5.1
4-3
5-2 •
Table 5.2 List Of Parts - V-Line Compressors 5-12
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Page 6 •
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• Spare Parts and Service
• Spare Parts can be ordered direct from the following address:

Harnworthy KSE Ltd. Telephone: +44 (0)1202662600
•• Fleets Corner
Poole, Dorset
BH17 OJT, England
Facsimile:
Email:
+44 (0)1202665444
poolespareS@harnworthykse.com
or via any Hamworthy KSE office or agency throughout the wortd.

e When ordering spare parts, the following infonnation is required to ensure that correct parts are supplied:
• Type and serial number of machine:

Item Number and full description of partrequired:
Obtained from machine nameplate
Obtained from details in this publication
•• Technical Service and Advice:

Technical service and advice can be obtained during nonnal wor1<.ing hours from the above address, on the
following contact numbers
• Telephone: +44 (0)1202 662663
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Facsimile: +44 (0)1202662622
Eman: pooleservice@harnworthykse.com
or via any Hamworthy KSE office or agency throughout the world.
• Outside nonnal wor1<.ing hours a 24 hour emergency faciltty is available. Inttial telephone contact number is
England +44 (0)1202662663.
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• Continued ••,
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Overseas Hamworthy KSE Offices
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Holland Hamworlhy KSE BY Soutll HIBIlWCII1IIyEngineering AMca (PIyl Lld
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Ap!on-..al33 Africa Po Box 50435
NL-3l104 CC, Randburg,2125
RoIIerdam, Nalher1a_ Gautang, Johannesburg,
Tel: + 31 10.01620ern South AlrIca
Fax: + 31 104159046 Tel: 00 27 11 7923B86
Fax: 0027117923889
EMAIL: hamworthCllglobal.co.za
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Clllna HamwCll1lly KSE Shanghai sweden HIBIlWCII1IIyKSE AB
Room 7-0 Vi Dlan Plaza, Kampegalan 3
No. 746 Zhao JIa Bang Road, 5&41104 Golhenburg,
Shanghai 200030
Tel: + 86 21 64455665
Fax: + 86 21 64459875
Sweden
Tel:
Fax:
+ 46 31 725 7900
+ 46 31 725 7800 •
EMAlL: w97oo1C!19uomal.sh.cn EMAIL: goleborgIn1llC!lhamworthylcse.com
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Germany HamwCll1lly KSE GmbH
_ a 17124
UK _CII1IIy KSE Lld
Fleata Comer
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0-28195 Bremen, Poslfach 103840 Poole, Dorset
Ge-28038 Bremen, Germany England. BHI7 OJT
Tel: + 49 421 335840 Tel: + 01202 662600
Fax: + 49 421 3358486 Fax: + 01202 668793
EMAlL: bremenlnlOC!lhamworlhylcse.com EMAIL: 1nl0000hamworthylcse.com
Korea HamwCll1lly KSE Korea Lld

14" Floor Hyundal BUilding #1193-5
UAE Dubal _ _y KSE Dubai
ClO Dalkai Middle East
Dv 16011 AI J_, Po Box62073 •
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Choryang 3 <long, Dong-gu,
Pusan, Korea (601~3) DubalUAE
Tel: + B2 51 465B461-5 Tel: 00 971 43240335
Fax: +B251463749B
EMAlL: koreaCll_.1cse.com
Fax: 00 971 43240336
EMAlL: ahussalnC!lhamworthylcse.com
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India It.nWOithy KSE Pvt Lld
C-155 MiIlaI Court, Nartman Point,
U.SA
Houston
HamwCll1lly KSE Ine
1011 Highway 6 South
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Mumbal 400 021 India SUIte 206, Houston
Tel: + 91 22 2872394 txrterr, USA
Fax. + 91 22 2872394 Tel: + 1 281 7593260
EMAIL: hamworthylcaelndlaC!lvsnl.com
HamwoIthyKSEAIS New Jersey

Fax: + 1 261 7598306
HamwCll1lly KSE Inc •

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Norway
Joaeph KeDen; vel 20 571 central Avenue
Tranby ste 112, New Providence
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PO Box 83, N-3401 Uer, Norway New Jersey 07974, USA
Tel. + 47 32 85 92 00 Tel: + 1 906 6960544
Fax. + 47 32 85 21 93 Fax: + 1 906 69803n
EMAIL: lranbyC!lhamwor1hylcse.com
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Singapore HamwCll1lly KSE PTE Lld. New Orleans HamwCll1lly KSE Ine
15 Beno! Crescent 1416 Edwards Avenue
SIngapore B2997B SulteB
Tel.
Fax.
+ 65 261 6086
+ 65 281 6011
New Orleans
Louisiana 70123
Tel: + 1 504 734 5525 •
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EMAIL: slngaporeC!lhamworthylcse.com
Fax: + 1 504 734 5716
California Hamworthy KSE !ne

6 Neal Court
san Palllo, Califoinia 94606 •
USA
Tot:
Fax:
+ 1 5107244625
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+ 1 5107246639
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Continued .••
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Overseas Hamworthy KSE Agencies
ARGENTINA AUSTRALIA BANGLADESH
• Neptune SA
Calle Mendoza 3185-5·-8
Caba (Aust) Ply Ud
41 Borry Avenue
Marintec Ud
30 Agrabad Commercial Area
• 1340 Beunos Aires, Argenllna

TeI 00 541 143226041
Mortdale, Nsw 2223
Australia
P 0 Box No 2018, Bandar
Chlltagong, Bangladesh
TeI 00 BBO 31502834
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Fax 00 541 143225790 TeI 00 61 2 95342100
Fax 00 81 2 95335332 Fax
EmaU caba@caba.bu.aust.com
• BRAZIL BULGARIA CANADA
• T_BrazII
RUB VlSCOI'1de Inhauma
_ _ Trading SRO
Carvene) Arrnady 1
HKSEC8nada
3B53543Canada Inc,
• 134 - Gr 1513, Rio De Janeiro

R) - Brazil 20091-000, Brazil
TeI 00 55 21 2331489
03601 Martin,
Slovakla
TeI 00 421 8424248601
113, Cushman Road, UnII60,
SI Catharin.., Ontario,
Canada
• Fax
EmaD
00 55 21 5167543
japgomes@1ridenle.com.br
Fax
Emall
00 421 8424133753
martne@martlmex.sk
L2MBS9
lel 00 1 905 8884922
00 1 905 6B89028
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Fax
CHILE COLUMBIA CZECH REP.
• Lanz Y Cia Uda ConsuJnaval Uda Mann.m~eTradingSRO
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CalIe or M Barros Borgono 233 EdIIicIo Colseguros OfiCina 501 Carvene) Arrnady 1
CasiIIa 16389, Santiago Cane Cohera Del Gobemador, Cartegena 03601 MartIn,
Chile Columbia Slovakla
• TeI
Fax
00 56 2 235Z107
00 56 2 2357329
TeI
Fax
00 57 5 6646413
005756641640
TeI
Fax
00 421 8424248601
00 421 8424133753
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EmaU efadlcC!llanzco.c1 EmaD marineQmartirnex.sk
CROATIA CYPRUS ECUADOR
• Eurella ~ D,O.O SheeI1lne Marine Services sertemarUd
• Marmonlova 14
Hr-21000 Spill,
Croalia
G1adstone & Androu SIr
ClasIs Complex, Umassol,
Cyprus 3311
El Ora 1303 Y Guaranda
Po Box 5899, Guayaqull
Ecuador
• TeI
Fax
00 3B5 21 343381
00 3B5 21 344825I34B36O
TeI
Fax
00 357 5 345319
00 357 5 345639
TeI
Fax
00 593 4 4459581330027
00 593 4 4401541445335
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Emall seraphld@nau1ilus.spIdemet.net EmaU aertroch@gya.satnet.nel
EGYPT FRANCE GERMANY
• InlernIIIIonal Marine Center Etabllssements T1ano SA WDhelm Rump KG
••
8 Mahmoud Azmy Street (21131) 2 BIs, Rue De La Baume Buchhelsleralrabe 8
Po Box 95 (21321), Ibrahlmleh Fr-75008 Paris, France Ge-20457, Hamburg
Alexandria, Egypt TeI 00 33 1 45619932 Germany
TeI 00 20 3 4876959 Fax 00 33 1 42256962 TeI 00 49 40 3178420
Fax 00 20 3 4877989 EmaU allred-tiano@els-llano.fr Fax 00 49 40 3194841
EmaD 113304.2717@compuserve.com
• GREECE ICELAND INDONESIA
• Marine & Industrial Systems Ud S stelaanson & Co Ud P.T Slools Intermarlne
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4-6 Efpllas Street Po Box 1008 JI Re Martadlnata No Ig
PinIeus, 185 37 Reykjavik, Iceland Tg Priok Jakarta utara, Indonesia
Greece TeI 00 35419141244 lel 00 62 21 8902196
• TeI
Fax
EmaU
00 30 1 4282826
00 30 1 41838Z1
mlslldCllalas,gr
Fax 00 354 1678936 Fax 00622143910158
• ISRAEL ITALY ITALY
• 11. sorer & Co Ud

Po Box 221
SImSrt
Via Del Lazzaretio Vecchlo 9
SIm Srt
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Via Cssaregls 22/1
AYichaIl42910, Israel 11-34123 Trioste,lIaly 11-18129 Genova, lIaly
TeI 00 972 9 8822319 TeI 00 39 0 40 304247 TeI 00 390 10588nl
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Fax 00 972 9 8825211 Fax 00 39 0 40 308196 Fax 00 39 0 10542678
Emall sirnls@tin.1I EmaH a1m.ge@pn.llnelll
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JAPAN KUWAIT MALAYSIA
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Fesco Japan Ud
31Shinel Building 13 The TI'-.g & Incl. Equipmenl Co
[r.l.E.C.O)
Panah Jaya 5ervIces SDN BHD
3G-1, Jalan 6I62s
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2-ehome, 4-Ban S8kemachi-Oouri, Chuo-Ku Bsndar Menjalara, 52200 Kuala Lumpur
Kobe 652-0831, Japan Po Box 2159, 13022 satet
KuwaD C.R. 13104 Malaysia
TeI 00 B1 78 3323399 TeI 00 60 3 8333984
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Fa 00 81 78 3323363 TeI 00 965 4619188
Fa 00 965 4610387 Fa 00 60 3 6334055
EmaD tony-earvalho@birH>Isf.com
MALTA NEW ZEALAND OMAN

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Thomas C Smith & Co Ud
12 SI Chr1slopher Street
C8b8 (New zealand) Ud
37 Clyde Street
Trans-()ceanlc Trading Elt
Po Box 1892
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Valetla; VII 06 _
TeI
Fa
Email
00 358 245071
00 358 242056
info@lcsmilh.com
Whangarei, New Zealand
TeI
Fa
00 64 9 4363581
00 64 9 4300654
P~ICode112,RuvO
Suttanate Of Oman,
TeI
Fu
EmaU
00 966 7965031767912
00 966 702981
lotest@glo.net.om
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PAKISTAN PHIWPlNES POLAND
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Un_Traders
Haroon Chambers
Marsson
17th Floor GoIdloop T"""'"
One GoIdIoop Plaza, Amber Avenue
Romac:Ud
UI CioIkowskiego 7a125
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AItaf Hussain Road, Karachi 74000
PakIalan
TeI 00 92 212414916
Ortigas Centre, Pasig City, PhlIDpines
TeI 00 63 2 6338541
PI 80-463, Gdansk
Poland
Tel 00 46 56 3461203 •
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Fu 00 63 2 6338561
Fa 00 46 56 3483694
Fa 00 92 21 2416862
EmaD marssonC!lmnl.sequel.net
EmaD barbararornacC!lpoczta.onel.pl
PORTUGAL QATAR ROMANIA

•
_
IndusIrIaIs
Soc De Equip. MarIIomos E AI-AIl8cI Trading & Contracting Co
Po Box 32BB
ToIaI Trading 5rI
118 Domneasca Street
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TIlMlSSll Do AIecr1m 3-2 Doha,Q_ 6200 Galalz. Romania
Box 2005, 1101 LIsbon TeI 00 974 44140221314 TeI 00 40 36 416542
PClfIugal Fu 00 974 4414021 Fa 00 40 36 460740
TeI
Fa
00 351 21 3420021
00 351 21 3420026
EmaD alahedC!lqalar.net.qa EmaD ttrC!letia.eu.com
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RUSSIA SERBIA SLOVAKIA
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Transas MarIne
2112 Obukhovsky Oborony
SI Pelersburg, 193019
_-Marine Trading SRO
Cervenej Armady 1
MarlIrnex-Marine Trading SRO
Cervenej Armady 1
03601 Martin, •
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03S01 MartIn,
Russia Slovalda Slovalda
TeI 00 7 812 3253131 Tel 00 421 8424246601 Tel 00 421 8424246601
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Fa 00 7 812 5611901 Fu 00 421 8424133753 Fa 00 421 8424133753
EmaU dmilriy.lagoulln@transas.com EmaU martne@martimex.sk Email marine@marllmex.sk
SPAIN TAIWAN THAILAND

•
Equlpos Nonumd sa
Nunez De Bslboa 15-3"
E&-28001, Madrid
MIng Tzong Hung Trading Co Lld
31-3 No 90 Chung Shan Hang Road
Keoshlung80015, Taiwan
ThaI KoIon Co Ud
1093118 15th Floor CentraIcllyTower
Bsngna-Trad Road (Km3) Bangna, •
Spain
TeI 00 34 91 5152960
R.O.C
Tel 00 688 7 2316188
Prakanong
8ankok 10260, ThaIland
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•
Fa 00 34 91 5163898 Fu 0068872616736 Tel 00 66 2 7458488-n (10 Unes)
EmaU nornaC!/erralds.es Fa 00 66 2 7456152
UKRAINE
Transas MarIne Ull Ud
Commodore House
Mountbatlen _nass Centre, 16-16
••
M1Dbrook Road East
Southampton S0151HY,
UK •
TeI
Fa
02380 633900
02380 233700
V13
•
EmaU seles@transas.co.uk
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• 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 adequate circulation to the drive motor integral cooling fan 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/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 0.5 mm (1 mm with
anti-vibration mounts). 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 after any servicing has been carried out, 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 in cylinders.
• CAUTION: After adding oil to the valves, 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.
Open air bleed valve (Item C10 in Figure 5.2, Cooler) to remove air trapped in water box
• cooler passages.
• 4. Remove guard covering barring over access aperture in crankcase.
• 5. Using a bar (not supplied) 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.
• Page 1-1
•
•
SECTION 1 -INSTALLATION
•
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6. Connect the electrical supply and carry out a momentary start and stop.
•
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, takeappropriate steps to correct.
•
8. Isolate starter, refit guard (170) covering barring over access aperture.
•
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.
•
•
a. Check that the cooling water system is operating and the outlet from the compressor is
registering a flow.
b. 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 and closely
monitor the temperature differential between cooling water inlet and outlet temperatures, adjusting •
valves etc as appropriate to adjust the water flow rate to achieve a temperature differential of
approximately i5'C. (Note: This temperature differential equates to the nominal flow rate as specified
•
in Technical Data).
•
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.
•
•
•
•
•
•
•
•
•
•
•
••
•
•
•
Page 1-2
•
•
•
• SECTION 2 • OPERATING PROCEDURE
•
• SECTION 2 - OPERATING PROCEDURE
• 2.1 DESCRIPTION
• The standard V-Line compressor is supplied with gauges, a dual set point high air temperature switch, a dual
set point low lubricating oil switch and two solenoid operated drain valves.
• The high air temperature switch (double pole) is fitted to protect the compressor by shutting it down if the
• temperature rises above the normal maximum operating temperature. As an option, the second pole of the
switch may be connected to give a panel indicated warning 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. The second pole may be connected to give a panel warning of approaching
•
shutdown oil level.
The compressor starting method can be either star/delta or direct-on-Iine.
• The compressor may be supplied with a water circulating pump if required.
• 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 shutdown and optional pre-alarm
• -
-
high final delivery temperature
high compressor motor current
shutdown and optional pre-alarm
shutdown only
• -
-
high water pump motor current
emergency stop button operation
shutdown only (of water circulating pump supplied)
shutdown only
• 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 fitted enabling the sequence
in which the compressors should work i.e. lead and follow.
• 2.3 NORMAL RUNNING PROCEDURE (AUTOMATIC CONTROL)
• 1. Energise the starter panel by operating the main isolator.
•
Set mode switch 51 to AUTO.
Set local/remote switch 52 as required.
Set drain switch 53 to AUTO (53 not fitted if hand drain valves supplied)
• 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
• Page 2-1
•
•
SECTION 2 - OPERATING PROCEDURE
•
•
- 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 S1 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 durinq 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.
•
2.4 MANUAL MODE RUNNING
•
Energise the starter panel by operating the main isolator.
•
Set mode switch S1 to MAN.
•
Set locasremote switch S2 to LOCAL.
•
Set drain switch S3 to AUTO (S3 not fitted if hand drain valves supplied).
•
Press RESET push button.
•
The compressor will start and run in this mode overriding the low oil level and high air temperature shutdown
devices. The emergency stop button and motor thermal overloads will still stop and unload the machine. •
Compressor and air system protection during manual mode running are given by first and final stage air and •
water jacket safety valves and any other safety device fitted to the installed system.
•
Starting, running and run down cycles are as for normal (automatic) running as described with the exception
of the following: •
- oil level switch overridden. •
- high air temperature switch overridden.
- remote start/stop function disabled.
•
2.5 GENERAL
•
Individual volt-free change-over contacts and control panel mounted indicator lamps are provided as listed
•
below:
•
- compressor running
- water pump running (if fitted)
•
- low oil level shutdown
- low oil level warning (if fitted)
•
- high air temperature shutdown
- high air temperature warning (if fitted)
•
•
- compressor motor overload
- water pump motor overload (if fitted)
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 •
•
•
•
• WARNING
• 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 WATER AND/OR AIR PASSAGES THE COMPRESSOR MUST BE VENTED
OF ALL PRESSURISED AIR AND DRAINED OF COOLING WATER.
• 3. VITON O-RINGS AND SEALS ARE FITTED TO THIS COMPRESSOR. WHEN VITON IS
•
SUBJECTED TO EXCESSIVE TEMPERATURES (ABOVE 400·C) IT DECOMPOSES AND CAN
CAUSE SERIOUS INJURY.
• WHEN MAINTAINING THE EQUIPMENT 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.
•• When re-assembling compressor components, renew all joints, gaskets, and O-rings seals. Great care must
be taken to ensure that they are not damaged.
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 Loclite should be thoroughly
• degreased using a Loclite activator. If cured Loclite is present in a tapped hole or external 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).
• After any servicing has been carried out, refer to Section 1.3.1, Commissioning Procedure, before restarting.
• M6
Table 3.1 Fastener Torque Settings
MS M10 M12 M16
• 6Nm 16 Nm 32 Nm 53 Nm 132 Nm
•
•
•
•
•
•
•
• Page 3-1
•
•
SECTION 3 - MAINTENANCE
•
•
•
Table 3 2 Maintenance Schedule
Commissioning Normal Operating Services •
Period
- •
..
~
.
~
co
.c
c: l!!. e l!! l!!r! 'C.
.. c: •
•
l!! .. 0
0:::1 :;;
e> e > '" :::I
.. 0 ..
'" 0
:::I
Eo
~l!!
:::I >..c >..c crI!
0 ... .c e ..
..
NO
•
0:::1 .c 0:::1 "'0
>.0
=.c
c' "...
0
-'"
0 >.0
=.c
C' "...
0 .. '"
~g
> ..
~g
.. N
> ..
~g
> ..
",
. . Q.
E~
~J2
•
<I: wo wo wo
1. Check oil level on dipstick. ,f ,f
2. Drain and refill lubricating oil. ,f ,f

•
•
3. Replace air inlet filter. ,f
4. Clean and inspect delivery line ,f 30 mins
5.
non-return valve.
Clean first stage valve and ,f 4 hours •
replace seals. Renew final
stage valve and O-rings. •
6. Renew first stage valve and ,f 2 hours
•
•
O-rings.
7. Check settings of all ,f 1 hour
pressure safety valves,
replace as necessary.
•
8. Remove inter/after coolers and
clean.
,f 4 hours
•
9. Dismantle and measure moving
parts for wear.
,f 6 hours
•
10. Check condition of spider in 1st ,f 6 hours
•
•
nd
and 2 stage separators
. 11. Replace bearings ,f 1 hour
A complete overhaul, IncludIng beanng replacement, IS recommended every 5 years or 5,000 runmng 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. To minimise the risk of
emulsification use a recommended oil, ensure that the compressor is not overcooled by fitting of a water shut
•
off valve, and maintaining a 15°C cooling water temperature rise across the machine.
•
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.
•
Crankcase oil contamination is often accompanied by an increase in sump oil level, due to oil being
•
supported by condensate fluid.
Page 3-2 •
•
•
•
• 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 used oil 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 3.2.23.
• 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 (F8) on top of filter.
• 3. Remove top cover (F6). On V150 wing nut (F4) on top element (F2).
• 4. Remove filter body (F1) complete with inlet resonator (F10), hose clip (F11), '0' ring (F9), and element
(F2).
• 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 First Stage Concentric Valve Removal/Servicing/Replacement
• 1. Remove air suction filter silencer assembly from valve cage as detailed in Section 3.2.3.
• 2. Remove studding (165) and the four nuts (56) and washers (57) from the top of the valve cage (45).
• 3. Release crankcase breather hose (32) from the hose connector (46). (Not applicable on V375).
• 4. Remove valve cage complete with concentric valve (50) using M12 or M16 screws (not supplied) in
•
the two tapped jacking holes. (On V375 use the eyebolt fitted).
5. Cover open bores on cylinder and breather hose.
• 6. Remove stud connector (54) and washer (55) from concentric valve (A1) central stud.
• 7. Remove dome nuts (A2) and joint washers (53) from concentric valve outer side.
• 8. Separate concentric valve from valve cage.
• 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 nut (10).
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.
• Page 3-3
•
•
•
•
3. Inspect each component. If any items appear defective, worn or damaged the whole valve must be
renewed.
•
Re-assembly
•
1. Assemble the valve components on the lower delivery valve seat (2) and studs.
•
CAUTION: Ensure that the components are correctly positioned on their locating pins.
•
2. Fit the upper suction valve seat (1) in position and fit nut (10).
•
3. Check that the valve functions correctly and that plate movement exists. Extreme care must be taken
to ensure that the valve is not scraped or damaged in this operation. •
Valve Replacement •
1. Renew '0' rings (48) fitted to valve cage (45) and '0' rings (51 and 52) fitted to concentric valve. •
2. Assemble concentric valve to valve cage and loosely fit dome nuts (A2), joint washers (53), stud •
connector (54) and washer (55) to concentric valve studs.
•
3. Fit valve cage and valve to cylinder (39) and re-connect crankcase breather hose (32) to the hose
connector. . •
NOTE: V375 only. Refit the valve with the fitting eye uppermost ensuring that the dowel pin aligns with the •
mating hole in the cylinder.
•
4. Tighten stud connector (54) and dome nuts (SOB).
•
5. Fit washers (56) and nuts (55) to studs (42) and tighten nuts.
•
6. Fit studding (165) to stud connector and tighten.
•
7. Reassemble suction filter silencer assembly to valve cage as described in 3.2.3.
•
•
•
•
•
•
•
•
••
•
•
•
Page 3-4
•
•
•
•
• Valve Servicing
•
• 11-------9
~
• 10
Q
_-------::-;:?" 12
•
•
• ----1
•
• (J---=:::==-7
•
• 1----4
•
• 13 _
• ~~
• 3 -=-1
•
• 6-----+H I-----:::=- 9
• 5 _
•
• 3 --------«~
• --------8
•
• 15 -----:::::::::;~ ~::=------15
• 4 ------I-fI ~~~~ffi\_---15
• ----2
• 6----=~~
•
•
• Figure 3.1 First Stage Concentric Valve Vi SO
• Page 3-5
•
•
•
•
•
11-------9
~ _---------:--;7' •
10
12
•
•
•
----1
•
•
•
•
•
•
----4
•
13 -----~~~;::,.. •
3 •
•
5
1----~~9 •
•
•
•
13 -----------=l~
•
1--------- 8
•
15 ------.::::::~ ~:=------ 15 •
14 ------IWII: AA-\----- 15 •
•
~'----2
•
16 - - - - - - - - - •
•
Figure 3.2 First Stage Concentric Valve V200/250/375
•
•
Page 3-6 •
•
•
•
• Table 3.3 First Stage Concentric Valves - Items List
Quantity
• Item Description V150 V200/250 V375
•
1 Suction valve seat 1 1 1
2 Delivery valve seat 1 1 1
• 3 Suction valve plate 1 1 1
•
4 Delivery valve plate 1 1 1
5 Cushion plate 1 1 N/a
• 6 Suction spring plate 1 3 2
•
7 Delivery spring plate 3 4 4
8 Centre stud 1 1 1
• 9 Stud 4 4 8
• 10
11
Self locking nut
Dome nut
1
1
1
1
1
N/a
• 12 Dome nut 4 4 8
• 13
14
Lift washer
Locating pin
2
1
2
1
2
1
• 15 Locating pin 3 3 3
• 16
17
6ack peg
'0' - ring (between 1 and
1
N/a
1
N/a
1
N/a
•• 3.2.5
7, not shown on Figure
3.2)
Final Stage Concentric Valve Removal/Servicing/Replacement
• Removal
• 1. Remove the four nuts (79) and washers (80) from the top of the valve cage.
• 2. Remove valve cage (70) complete with concentric valve (61) using screws (not supplied) in the two
• tapped jacking holes.
• 3. Cover bores on cylinder.
• . 4. Remove dome nuts (62) and joint washers (78) from concentric valok studs.
• 5. Separate concentric valve from valve cage.
•
•
•
•
•
•
•
• Page 3-7
•
•
•
•
•
13
i
•
11--_~
•
•
~~~~~~~--=::::::::~"'-11
•
1
•
12--------0 •
•
•
•
J------4 •
•
3-------1 •
•
•
•
8 ---------J •
•
•
10~----1
I------__=_ 10
•
•
•
•
•
-b------2
•
o •
•
Figure 3.3 Final Stage Concentric Valve V150/200/250/375
•
•
Page 3-8 •
•
•
•
• Table 3.4 Final Staae Concentric Valves - Items List
Quantity
• Item Description V150N200/250 V375
•
1 Suction valve seat 1 1
2 Delivery valve seat 1 1
• 3 Suction valve plate 1 1
• 4 Delivery valve plate 1 1

6 Suction spring plate 2 2
• 7 Delivery spring plate 2 3
•
9 Centre stud 1 1
(shorter on V200/250)
• 10
11
Stud
Dome nut
3
4
6
7
• 12 Locating pin 1 1
• 13
14
Screw
Back peg
3
1
n/a
1
• 15 Lift washer (below 8, not N/a 1
•
shown on Figure 3.3)
• Dismantling
• 1. Unscrew the three socket head cap screws (13) (Not applicable on V375). Unscrew the centre nut
(V2001250 only). 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
the 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, the whole valve must be
replaced with a new assembly.
• Re-assembly
• 1. Assemble the valve components on the lower delivery valve seat (2) and studs and ensure that the
• components are correctly positioned on their locating pins.
• 2. Fit the upper suction valve seat (1) in position. Fit the three socket head cap screws. (Not V375)
• 3. Check that the valve functions correctly and that plate movement exists. Extreme care must be taken
to ensure that the valve is not scraped or damaged in this operation.
• Valve Replacement
• 1. Renew '0' rings (71 and 72) fitted to valve cage (70) and '0' rings (76 and 77) fitted to concentric
• valve (B1).
• 2. Assemble concentric valve (B1) to valve cage (70) and tighten dome nuts (B2) and joint washers (78)
to the valve studs.
• 3. Fit valve cage and concentric valve assembly to cylinder (66).
• 4. Fit 4 off nuts (79) and bright washers (80) to studs (67) and tighten nuts.
• Page 3-9
•
•
•
•
3.2.6 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. Drain compressor of all cooling water.

•
2. Remove water outlet connection from cylinder.
•
3. Remove first stage concentric valve and cage assembly from cylinder as detailed in 3.2.4.
•
4. Remove guard (170) from crankcase.
•
5. Using a bar tum over the compressor 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.
•
6. Remove the bolts (101) and washers (102) securing the cooler header (93) to the cylinder.
•
7. Fit an eyebolt (not supplied) into the tapping in the top of the cylinder and connect to suitable lifting
tackle. •
8. Using lifting tackle and by striking the cylinder gently with a soft headed mallet break the seals •
between the cylinder and crankcase, cylinder and cooler header.
•
9. lift and guide the cylinder off the piston assembly take care 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 (56) AT ALL TIMES UNTIL THE CYLINDER IS RE-ASSEMBLED.
•
10. Identify with non-destructive marker, orientation of piston side and gudgeon pin end towards front of
compressor.
•
11. Slacken the locknuts (42) which secure the cap head screws, from the underside of the piston.
•
Remove the 2 cap head screws (41) from the underside of the piston (35) which lock the gudgeon pin
(40) in position.
•
12. 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.
•
13. Cover the crankcase aperture.
14. Examine removed coniponents replacing worn/damaged parts as necessary. For-wear allowancessee
section 4 - Technical Data.
•
NOTE: If required connecting rod small end needle roller bearing (17) may be removed and refilled without
dismantling compressor any further. Section 3.2.15 refers. •
•
•
•
Page 3-10
•
•
•
•
• 3.2.7 First Stage Cylinder and Piston Reassembly
• 1. Before commencing reassembly ensure that sufficient Loctite sealant and retainer is available to seal
the cylinder to the crankcase and retain the cap head screws in the piston.
• a. The minimum amount of Loctite flange sealant number 573 required is 50 millilitres
• b. The minimum amount of Loctite nutlock 243 required is 10 millilitres
• 2. 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. Remove all traces of gasketing on joint faces of cylinder to cooler headerand ensure faces are grease free.
• Do not smooth joint faces. Do not use emery cloth or a metal scraper to abrade or clean them. It is
recommended that a chemical such as Loctite 'Chisel' is used in conjunction with hand brushing with a wire
• 4.
brush.
Remove Loctite from threads in piston using a tap. If the cap head screws are to be re-used, clear
• threads using a die.
• 5. If new piston rings are being fitted gap rings to cylinder to a closed gap of 0.175/0.300mm (V150),
0.20/0.33 (V200/250) or 0.26/0.39mm (V375). Ensure rings are fitted as follows to the piston.
• a. Barrel faced ring top groove.
• b. Taper faced ring second groove (this ring can be readily identified against the barrel faced ring
• c.
by the internal chamfer on the taper faced ring.)
Both rings must be fitted with the face marked "Top" facing towards the piston crown.
• d. S.O.C. ring bottom groove.
• 6. Align adjacent ring gaps on piston at 180' to each other.
• 7. Clean piston threads and cap head screw with Loclite Activator. With locknut fitted, coat cap head
• screw with Loclite 243 and screw into piston until the cup end is 4 mm below the gudgeon pin bore.
•
8. Assemble piston and ring assembly into cylinder bore exercising caution in fitting the rings around the
cast scallop on the cylinder.
• 9. Using suitable lifting tackle and exercising caution so that the piston does not drop out of the cylinder,
align cylinder assembly on to studs.
• 10. Lower cylinder gradually with piston gudgeon pin hole visible until the hole and small end bearing are
• aligned. 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.
• 11: Position gudgeon pin ends equally distant in from the piston side faces and align the machined mark
• 12.
on the gudgeon pin end face in line with the piston axis pointing away from the cylinder.
Torque cap screw and lock nut as appropriate. Refer to torque table Section 3, General Notes.
• 13. Coat underside of cylinder (joint face to crankcase) with Loctite flange sealant 573.
• 14. Lower cylinder into contact with crankcase
• 15. Fit new gasket (100) between cylinder and cooler header. Do not grease gasket or faces.
• 16. Fit bolts (101) and bright washers (102) through cooler header into cylinder and tighten finger tight.
• 17.· Fit concentric valve and cage assembly to cylinder as detailed in section 3.2.4.
• 18. Torque bolts (101) to the appropriate level. Refer to torque table, Section 3 General Notes.
• Page 3-11
•
•
•
•
19. Reconnect water outlet pipeworklhose to cylinder.
•
20.
3.2.8
Refit guard (170) to crankcase.
Final Stage Cylinder and Piston Removal •

•
•
1. Drain compressor of all cooling water. Remove water inlet connection from cylinder.
2. Remove concentric valve (81) and valve cage (70) assembly from cylinder (66) as detailed in
section 3.2.5.
•
3. Remove guard (170) from crankcase.
•
4. Using a bar tum 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.
•
5. Remove the 2 screws (117) and washers (118) securing the separator assembly to the cylinder.
Remove the separator from the cooler box by removing the bolts (112) and stud (113) securing the •
separator header (E1) to the cooler box (C1).
•
6. Remove the bolts (106) securing the cooler header (93) to the cylinder.
•
7. Fit an eyebolt (not supplied) into the tapping in the top of the cylinder and connect to suitable lifting
tackle.
•
8. Using lifting tackle and by striking the cylinder gently with a soft headed mallet, break the seals
•
between the cylinder and crankcase, cylinder and separator, cylinder and cooler header.
•
9. 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.
•
10. Identify with non-destructive marker, orientation of piston side and gudgeon pin end towards front of
compressor.
11. Remove the two socket set screws (65) from the underside of the piston (60) which lock the gudgeon
•
•
pin (64) in position.
12. Supporting piston push gudgeon pin out of piston and connecting rod (19) taking care when pin frees
connecting rod to prevent damage of rod striking piston intemals and crankcase. Remove piston and
gudgeon pin. •
13. Cover the crankcase aperture, connecting rod small end bearing, and passage ways on separator and •
cooler header.
•
14. Examine removed components replacing worn/damaged parts as appropriate. For wear allowances
see Section 4 - Technical Data. •
NOTE: If required connecting rod small end needle roller bearing (21) may be removed and refitted without •
dismantling compressor any further. Section 3.2.15 refers to the procedure.
•
•
•
Page 3-12 •
•
•
•
• 3.2.9 Final Stage Cylinder and Piston Reassembly
• 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 50 millilitres.
• Minimum amount Loctite nutlock 243 required is 10 millilitres.
•
2. Remove all traces of sealant on joint faces of cylinder to crankcase and ensure surfaces are grease
free.
• 3. Remove all traces of gasketing on joint faces of cylinder to cooler header, cylinder to separator and
separator to cooler box, and ensure surfaces are grease free. Do not smooth joint faces.
• 4. Remove Loctite from threads in piston using a tap. If grub screws are to be re-used clean the threads
• using a die.
• 5. If new piston rings are being fitted gap rings to cylinder to a closed gap of 0.075/0.200mm (V150),
0.10/0.23 (V200/250) or 0.11/0.24 mm (V375). Ensure rings are fitted as follows to the piston.
• a. Barrel faced ring top groove.
• b. Taper faced ring second groove (this ring can be easily identified against the barrel faced ring
• by the intemal chamfer on the taper faced ring.)
• c. Both rings are to be fitted with the face mar1<ed "Top" facing towards the piston crown.
s.a.c. ring bottom groove.

•
d.
6. Fit piston and gudgeon pin to connecting rod small end orienting piston and pin mar1<ings to 'front of
• compressor. •
• 7. Position gudgeon pin ends equally distant in from the piston side and align machined mark on
gudgeon pin end face in line with piston axis pointing towards the crankcase.
• 8. Clean threads and screws with Loctite Activator.

"
• 9. Coat thread of one socket set screw (65) with Loctite nutlock 243 and fit to piston by gently pushing
• pin in from either end ensure screw engages in the counterbore in the pin.
• NOTE: Loctite nutlock 243 may not cure on components under oily conditions - see General Notes,
Section 3.
• 10. Coat thread of second socket set screw (65) with nutlock and fit to piston.
• 11. Align adjacent piston ring gaps on piston at 180' to each other.
• 12. Using suitable lifting tackle align cylinder over studs (67) and onto piston, compressing rings to guide
• into cylinder.
• 13. Coat underside of cylinder (joint face to crankcase) with Loctite flange sealant 573.
• 14. Lower cylinder into contact with crankcase.
•
15. Fit new gasket (105) between cylinder and cooler header (93), gasket (116) between cylinder and
separator header (E1) and gasket (111) between separator and cooler box. Do not grease gasket or
• 16.
joint faces.
Fit bolts (106) and bright washers (107) through cooler header (93) into cylinder and tighten finger
• tight.
• Page 3-13
•
•
•
•
17. Fit screws (117) and washers (118) through separator header into cylinder, tighten finger tight.
•
18. Adjust gap between final stage cylinder and cooler header using feeler gauges, to give the best
parallel flange seal. This can be achieved by rotating the cylinder to give an equal gap each end.
•
19. Fit concentric valve and cage assembly to cylinder as detailed in section 3.2.5. Torque bolts (106 and
•
117).
•
20. Reconnect water inlet connection to cylinder.
•
21. Refit guard and tighten fasteners.
•
3.2.10 Cooler Tubenest and Header Removal
•
1. Drain compressor of all cooling water.
•
•
2. Remove gauge pipes.
•
3. Remove the bolts (101) and washers (102) securing the cooler header (93) to the first stage cylinder
(39).
4. Remove the bolts (106) and washers (107) securing the cooler header to the second stage cylinder.
•
Fit 2 x M12 eyebolts (V2001250N375 only) (not supplied) in the top of the cooler header and suspend
the header using a sling. •
5. Remove the remaining bolts (94) securing the cooler header. •
6. Remove cooler header (93) from tubenest (91) and cylinders by gently tapping with a soft headed •
mallet if necessary to separate the gaskets between the cooler header and tubenest, header and first
stage cylinder, header and second stage cylinder. •
7. Remove tubenest (91) from cooler box by gently tapping tubeplate with a soft headed mallet to •
separate the gasket between the tubenest and cooler box.
•
3.2.11 Tubenest Clean/Examine/Replace
•
1. Remove tubenest assembly.
•
2. Clean the outside of the cooler tubes to remove all traces of scale or other foreign bodies taking care
not to damage the cooler tube surface.
•
3. Chemically clean the tube internals by 'ARDROX' or similar chemical cleaner.
•
4. Examine tubes for signs of damage/reduction in tube wall thickness. If there is any doubt in the
•
condition of the tubenest Hamworthy recommend replacement of the tubenest assembly.
•
Faulty cooler tubes that are part of a 'U' tube nest formation cannot be removed individually, the
complete tubenest assembly must be replaced.
•
•
•
•
•
•
Page 3-14 •
•
•
•
• 3.2.12 Cooler Tubenest and Header Assembly to Compressor
• NOTE: The following procedure assumes that the first and final stage cylinder assemblies have been
assembled to the crankcase.
• 1. To assist alignment of gaskets, tubenest and header insert 2 lengths of studding (not supplied) into the
• top 2 outermost tapped holes in the cooler box front face.
• 2. Ensure all the joint faces are clean and grease free. Do not smooth joint faces.
• 3. Fit tubenest to cooler box gasket (90) over studs. Do not grease gasket.
• 4. Fit tubenest (91) over studs.
• 5. Fit cooler header to tubenest gasket (92) over studs. Do not grease gasket.
• 6. Fit cooler header (93) over studs.
• 7. Insert gasket (100) between header and first stage cylinder, loosely fit the bolts (101) and washers
(102) through the header. Do not grease gasket.
• 8. Insert gasket (105) between header and final stage cylinder, loosely fit the 3 bolts (106) and washers
•
(107) through the header. Do not grease gasket.
9. Loosely fit all but 2 of the bolts (94) and washers (95) through the cooler header and tubenest to the
• cooler box.
• 10. Remove the lengths of studding used for guidance and insert the remaining 2 bolts and washers.
• 11. Tighten the bolts (101 and 106) cooler header to cylinders. The bolts should be tightened to a torque
of 170 Nm. This overrides the value in Table 3.1.
• 12. Tighten the bolts (94) in the cooler header progressively in alphabetical order as shown until they are
• torqued correctly. The bolts should be tightened to a torque of 170 Nm. This overrides the value in
Table 3.1.
• 13. Re-connect the gauge pipes.
• H F M c
• D K A L G
• +++++ +
• 8 J E
• d- -b<-L----'-"
• Figure 3.4 Cooler Header V150
c
• F J
• A G
• + + +
• 8
d-
H E
-b'-'----'-"
• Figure 3.5 Cooler Header V200/250/375
• Page 3-15
•
•
•
•
3.2.13 Cooler box end cover
•
Removal
•
1. Remove cooler drain plug (C6).
•
2. Remove the bolts (C4) and washers (C5) and release cooler box end cover (C2).
•
3. Clean and remove all traces of gasket (C3) from joint faces on end cover and cooler box. Ensure joint
faces are grease/oil free. Do not smoothjoint faces.
•
Re-assembly
•
4. Assemble gasket (C3) between cover and cooler box. Note: Do not grease gasket or joint faces.
•
5. Secure cover to cooler box with bolts (C4) and plain washers (C5). Fit cooler drain plug (C6) to cover.
•
3.2.14 Connecting Rod Big End Bearing Removal
•
1. Drain compressor of cooling water.
•
2. Drain oil and dispose of in accordance with local regulations.
•
3. Remove the first and final stage cylinders and pistons as detailed in Section 3.2.6. and 3.2.8
•
4. Remove the screws (157) and washers (158) securing the crankcase inspection cover.
•
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 second stage connecting rod (19) big end withdraw rod off crankshaft complete •
with cylindrical roller (big end) bearing (20).
•
8. Remove spacer (18) from crankshaft.
•
9. Using a puller as in 8 withdraw first stage connecting rod (15) complete with cylindrical roller (big end)
bearing (16). •
3.2.15 Bearing Removal and Reassembly to Connecting Rods •
NOTES: 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.
•
If the existing big end bearings are to be refitted, the inner race, rolls and bearing cage must be
replaced in the original position.
•
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, clean/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 resultant fit is interference
or clearance and fit accordingly as follows: •
Page 3-16 •
•
•
•
• 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.
• b. Cold press the big end bearing into the connecting rod. Bearing must be filted 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.
•
•
• 'L _ 100-----'?
• Figure 3.6 Connecting Rod: V1S0
•
•
•
• Machined dimple ret.
•
• Clearance fit:
Figure 3.7 Connecting Rod: V200/2S0/37S
• 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 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.
• NOTE: On a V200/250/375 compressor only, the bearing is supplied as a matched pair and must be
• assembled as SUCh.
• 3.2.16 Connecting Rod Assembly Fitment to Compressor
• NOTE: When the connecting rod has been filted, it must be free to slide through the bearing range of side
clearance, from shoulder to circlip. If this is not easily achieved the connecting rod must be removed,
• the bearing pressed out and the bore cleaned thoroughly prior to re-assembly.
•
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 first stage connecting rod (15) 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 final stage connecting rod (19) until the assembly is pushed solidly
• against the shoulder on the crankshaft. Remove studding, nut and retaining washer.
• Page 3-17
•
•
•
•
5. Assemble retaining washer (22), new tab washer (24) and screw (23) to pintle. Tighten screw.
•
6. Assemble first stage cylinder components to compressor as detailed in 3.2.7.
•
7. Assemble second stage cylinder components to compressor as detailed in 3.2.9.
•
8. Fit drain plug (160) to crankcase.
•
9. Clean joint faces of crankcase inspection cover and crankcase. Apply loctite flange sealant 574 to
cover joint face. Fit cover to crankcase and secure with the 4 screws (157) and washers (158) refilling •
the 2 cable clips between washer and cover.
•
10. Recommission compressor as detailed in section 1.
•
3.2.17 V150, V200, and V250 Drive Motor and Coupling Removal from Compressor
•
ForV375, see Section 3.2.19.
•
1. Isolate compressor.
•
2. On compressors filled with water circulating pumps only, drain the cooling water.
•
3. Place a suitable support under the crankcase close to its connection to the drive motor.
•
4. For compressors mounted on anti vibration mounts, remove the fasteners securing the mount under
the drive motor to the ship's deck, and for those compressors filled with anti vibration mounts and a
•
•
water circulation pump disconnect the water inlet connection to the pump and separate the male union
nut on the connector (205) on the pump.
5. For compressors not mounted on anti-vibration mounts remove the fasteners securing the drive motor
to the ship's deck. •
6. Remove the bolts (191) and washers (192) securing the drive motor to the crankcase. •
7. Using suitable lifting tackle, lift and slide the drive motor complete with drive coupling element (G1), •
coupling hub (G3), hexagon socket cap screws (G4) out of the crankcase.
•
8. If required, remove drive coupling element (G1) from coupling hub (G3) by removing the hexagon cap
screws (G4). •
9. If required, remove drive pins (G2) from flywheel. •
3.2.18 V150, V200, and V250 Drive Motor and Coupling Assembly to Compressor •
ForV375, see Section 3.2.19. •
Important notes for fitting Coupling
•
In addition to the operational sequence 1 to 9 listed below the coupling must be assembledin accordance
•
with the following notes: ' . .. . .
•
a. The screws connecting the rubber element to the hubs must be tightened to the torque stated.
Tightening torques which are too low will cause damage to the coupling.
•
Ensure that on tightening the screws the aluminium bushes in the rubber part are notlwisted. A small
•
amount of grease should be applied under the head of the screw before filling. Prevent twisting of the
rubber part dUring tightening of the screws. This is particularly important with the radial screws. If the
•
•
coupling is supplied in a pre-assembled state, do not dismantle it, but fit it in this condition.
Page 3-18 •
•
•
•
• b. Fit the hubs onto the motor shaft and lock using the grub screw. The radial bolt holes should be
nearest the motor shaft face. Fit the axial bolts onto the flywheel. Position the element with the side
• having the rubber free face of the axial aluminium inserts towards the flywheel 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, carefully sliding 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-Ioad 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.
,...,J'.-
•
lightlygrease
• @J~--=-
• ~ a'G
• ~
• 1.
Figure 3.8 Coupling
If removed, reassemble drive coupling pins (G2) to flywheel.
• Tighten coupling pins to a torque of 220 Nm. .
• 2. If removed, assemble drive coupling hub (G3) 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 a 1 - 2 mm gap between the coupling extremes (not the hub) and
the flywheel, dimension (A).
•
•
•
•
•
•
•
•
•
• Figure 3.9 Gap Between Coupling and Flywheel
• 3. If removed assemble drive element (G1) onto hub (G3) with hexagon socket cap screws (G4). Tighten
screws to a torque of 220 Nm (M16) or 500 Nm (M20).
• 4. Lightly grease the coupling pins. 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.
• 5. Fit bolts (191) and spring washers (192) through drive motors flange onto crankcase.
• 6. Fit holding down bolts to drive motor or anti vibration mount.
•
• Page 3-19
•
•
•
•
7. On compressors on anti vibration mounts and fitted with water circulating pumps, reconnect union nut
and male connector (205) on the circulating pump and water inlet pipework. •
8. Remove support placed under crankcase. •
9. Recommissi6n compressor as detailed in section 1. •
3.2.19 V375 Drive Motor and Coupling Removal from, and Assembly to, Compressor •
See Figure 5.3, Figure 5.9, Figure 5.10. •
3.2.19.1 V375 Drive Motor and Coupling Removal from Compressor
•
Follow Steps 1 to 6 in Section 3.2.17. Then:
•
7. Using suitable lifting tackle, lift and slide the drive motor complete with coupling hub (G3) out of the
•
crankcase.
•
8. If required, remove drive coupling element (G1) from flywheel (8) by removing the M10 screws.
•
3.2.19.2 V375 Drive Motor and Coupling Assembly to Compressor
•
1. If removed, assemble drive coupling element (G1) onto flywheel (8) with M10 screws.
•
2. Using suitable lifting tackle, lift and slide the drive motor whilst aligning the coupling hub with the drive
coupling element, slide the coupling hub to engage into the drive coupling element and the motor
•
•
flange location diameter onto the crankcase.
•
Then follow Steps 5 to 9 in Section 3.2.18.
•
3.2.20 Flywheel and Drive End 011 Seals Removal from Compressor
.•1
1. Remove drive motor and coupling as detailed in section 3.2.17. Note drive pins (1908) need not be
removed from the flywheel.
2. Slacken the 7 clamp screws on drive bush (9).
3. lay two lengths of 3mm mild steel or similar angle (not supplied) of maximum leg length 30mm on the
2 rails in the crankcase under the flywheel. Alternatively, a fixture can be supplied by Hamworthy. •
See sketch.
•
Table 3.5 Fixtures to Assist Flvwheel Remova
•
•
Machine Fixture
J31974
•
V150
V2001250 J32032
_ . V375 J32244 •
•
•
•
•
•
Page 3-20 •
•
•
•
•
•
•
•
•
•
•
• Figure 3.10 Location of Angle Steel on Crankcase Rails
• 4. 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 and ease the flywheel onto the two pieces of angle (operation
•
3 refers.)
•
5. Using suitable lifting tackle remove flywheel from crankcase.
(Note tapped hole in periphery of flywheel is M12).
• 6. Remove the screw (157) and washer (158) securing the crankcase inspection cover (155).
• 7. Using a soft headed mallet gently tap the side faces of the crankcase inspection cover (155) to break
its seal with the crankcase. Remove cover.
• 8. Wedge a piece of clean bar (not supplied), through the front of the compressor between the crankshaft
• balance weight and one of the cast webs behind the balance weight to prevent the crankshaft from
rotating.
• 9. Remove grub screw (11). 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) exercising, caution not to
damage the housing bore in the crankcase.
• 11. Remove '0' ring (7) from crankshaft.
• 3.2.21 Flywheel and Drive End Oil Seal Reassembly to Compressor
• 1. Fit new radial shaft seal (5) to crankcase.
• 2. Fit new '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 one of the cast webs to prevent the crankshaft from tuming and 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 tums 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 to the end face of the crankcase resting on the end of the crankshaft.
• Page 3-21
•
•
•
•
7. Push or pull the crankshaft balance weight 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. Replace grub
screw (11). •
9. Position the pieces of angle along the rails in the crankcase (refer to section 3.2.19 operation 3). Using •
suitable lifting tackle locate flywheel onto the pieces of angle and ease the flywheel onto the
crankshaft.
•
10. Loosen the drive element clamping screws a couple of tums. Lightly oil the clamping element.
•
11. Slide the clamping element onto the crankshaft and locate in the flywheel. Remove the screws from
•
the release threads and screw into the clamping holes.
•
12. Tighten the clamping screws diagonally by hand while aligning the hub. With a torque wrench tighten
the clamping screws diagonally across with half the tightening torque (see below). Continue tightening
•
but with the full torque. (35 Nm V15012001250 or 71 Nm V375)
•
•
13. Tighten the clamping screws one after the other, repeat several times. The tightening process is only
completed when none of the screws can be tightened any further.
14. Remove the pieces of angle or fixture placed over the rails in the crankcase.
•
15. Check the flywheel alignment with a dial test indicator does not exceed 0.125mm. If this alignment is
not achieved release the clamping screws, adjust the flywheel and re-tighten screws as above. Re- •
check flywheel alignment.
•
16. Reassemble drive motor and coupling to compressor as detailed in section 3.2.18.
•
17. 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.
•
18. Recommission compressor as detailed in section 1.
•
3.2.22 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 3.2.6. 3.2.8, 3.2.14, 3.2.17 or 3.2.19, and 3.2.20 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.
•
•
Page 3-22 •
•
•
•• SECTION 3 - MAINTENANCE
• 3. Gently tap the drive end of the crankshaft with a soft headed mallet and tighten the nut as in operation
2, drive 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) 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.
• 3,2.23 'Crankshaft and Main Bearings Reassembly to Compressor
• 1. Before reassembly ensure crankcase internals and crankshaft are clean.
• 2. Lightly oil the drive end main bearing location bore in the crankcase.
•• 3.
4.
Using a mild steel drift (not supplied), drift the outer bearing cup of the drive end main bearing (5) into
position in the crankcase.
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. Preheat drive end main bearing inner race assembly to 140·C.
• 10. 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.
• 11. Lightly oil the crankshaft drive end main bearing journal.
• 12. Fit the heated inner race assembly onto the crankshaft and into the bearing outer race.
• 13. Refit oil seal and flywheel as detailed in section 3.2.20.
• 3.2.24 Oil Level Switch Remove/Clean/Replace
• 1. Drain compressor of lubricating oil as detailed in section 3.2.2.
• 2. Remove the DIN connector.
• 3. Remove screw (142) and washer (143) securing dual oil level switch (140) to crankcase.
• 4. Lever switch out of crankcase.
• 5. Remove screws (2) and slide sleeve off body.
• 6. Clean switch by removing all metallic particles.
• 7. Reassemble switch, fit new O-rings (141), replace DIN connector and re-fill compressor with oil, refer
to section 3.2.2.
• Page 3-23
•
•
••
3.2.25 Air and Water Safety Valves
•
These valves are all pre-set at the factory to suit the maximum working pressure duty 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 pulses found with the compressor.
•
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.
•
Water Jacket Safely Valve (145)
•
located on the cooler box behind the first stage cylinder. Associated joint washer (146). When replacing the
water jacket safely valve ensure the outlet port is pointing downwards by using up to 3 joint washers.
•
First Stage Air Pressure Safely Valve (147)
•
•
located on the front face of the first stage cylinder on the V200/250/375 and the rear face of the cylinder on
the V150. Associated joint washer (148).
Final Stage Air Pressure Safely Valve (149)

located on the inlet to the final stage separator. Associated joint washer (150).
3.2.26 Separator Bowl Removal, Spider Examination and Removal

••
1. Disconnect the 'Din' plug from the solenoid coils (129). •
2. Disconnect the drain pipes from the bottom of the separators (if fitted). •
3. Remove the bolts (E6) and washers (E7) holding the separator bowl (E2) to the separator header •
(El).
•
Separate bowl from the header by gently tapping the bowl with a soft headed mallet.
•
Note:lt is advisable to leave 2 opposite comer bolts (E6) screwed into the bowl when splitting this
assembly as this will take the weight of the bowl when it is free. •
4. Remove separator bowl. •
5. Clean and remove all traces of gasket from the joint faces of the header and bowl. Ensure faces are •
grease/oil free. Do not smoothfaces, use loclile 'Chisel'or similar.
•
6. Inspect 1" and 2"" Stage separator spiders for looseness (E3 and E4).
•
7. If the spiders are not solidly held in position, remove them by knocking them out with a bar placed
through the bottom hole of the bowl.
•
8. If the spiders are fixed solidly, re-assemble separator components as in 3.2.27.
•
3.2.27 Spider.Fitting and Separator Bowl Reassembly .
•
1. Tap the spider tabs into the location grooves in the bow. Knock the spider from the bottom to
•
straighten the tabs and ensure the spider is firmly positioned in the bowl.
•
•
2. Position gasket (E5) over bowl (E2). do not grease gasket. Ensure faces are grease/oil free.
•
3. Fit bowl (E2) to separator header (El) using 6 bolts (E6) and washers (E7).
•
4. Tighten the comer bolts and then the central ones progressively until they are torqued correctly.
•
5. Fit separator drain pipes (if fitted).
Page 3-24
•
•
•• SECTION 3 - MAINTENANCE
• 6. Fit solenoid coil 'Din' plugs (129).
•• 3.3 WATER CIRCULATING PUMP (if supplied)
NOTE: The pump rotation is anti-elockwise looking on motor fan.
•
3.3.1 General Overhaul
• After 3 - 4 years service the pump should be overhauled, to include changing the mechanical seal and motor
bearings and cleaning. Check for wear and change worn pump parts. Always use new gaskets on re-
• assembly.
3.3.2 Service Information
•
•
WARNING: BEFORE DOING ANY MAINTENANCE OR REPAIRS MAKE SURE THAT THE ELECTRICAL
SUPPLY TO THE MOTOR IS ISOLATED AND CANNOT BE ACCIDENTALLY RECONNECTED.
PREFERABLY PADLOCK THE ISOLATOR OR REMOVE THE FUSES. IF IN DOUBT CONSULT A
• QUALIFIED ELECTRICIAN.
•• 3.3.3
Pump Head
Dismantling
• Close isolating valves, loosen the screws fastening the pump cover to the casing and lift the pump head
assembly out of the pump casing.
• Impel/er
• Remove impeller circlip and remove impeller and tolerance ring.
• Mechanical Seal
• Remove rotating part of seal. Unscrew motor flange bolts and remove the cover. Remove seat from cover.
• 3.3.4 Reassembly
• Mechanical Seal
• Important: Mechanical seals are precision products and should be treated with care. Do not touch the faces
• with fingers - use a paper tissue.
• Clean seal recess in pump cover. Use a soap solution (do not use oil) on the rubber seal and press into the
pump cover. Make sure that the shaft is clean and smooth and free from sharp edges. Fasten the pump
• cover to the motor flange. Mount the seal face ring on the bellows unit, taking care that the grooves in the
face ring are in line with dimples in the retainer sleeve. Slide the assembly into place.
• Impel/er
• Fit the tolerance ring onto the shaft. Push the impeller onto the shaft and fit the retaining circlip. The impeller
will have pushed the rotating seal partly against the stationary part. Check that the impeller can be tumed by
• hand.
• Casing
• Remove any significant volume of water from the casing. Use a new '0' ring and refit the motor head
assembly, tightening the screws evenly. Turn the shaft by hand to make sure that nothing is catching.
•
•
• Page 3-25
•
•
SECTION 3 • MAINTENANCE
••
3.4 ELECTRICAL MAINTENANCE
•
It is recommended that switch settings are periodically checked. Refer to the separate data sheet for
settings:
Table 3.6 Switch Settinas

••
SWITCH SETTINGS
•
•
Oil level switch Activates when oil level falls below fill mark.
High air temperature switch 60·C alarm
80·C shutdown
•
•
•
•
••
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Page 3-26 •
•
•
•• 3.5 FAULT FINDING CHART

Table 3.7 Fault Finding Chart
•• FAULT
Final stage air safety valve
blowing.
Whilst in automatic (default)
POSSIBLE CAUSE
Air system charged signal and final

REMEDIAL ACTION
Reset signal pressure settings lower than safety valve set
•e mode
Whilst running in manual

mode
stage air pressure shutdown settings
greater than safety valve set pressure
Stop valve closed in final air delivery
pipework
pressure (Note: maximum working pressure of compressor
is 33 bar g)
Open all stop valves in pipework
• Non-return valve installed incorrectly.

Air system pressure safety devices set
Correct installation.
Correct safety device pressure settings as appropriate.
•• First stage air safety valve

blowing.
High first stage pressure
higher than safety valve setting.
The first stage air safety valve is unlikely to operate when the compressor is running automatically as
the compressor will be shut down by the high first stage air pressure transducer first. See below.
Intercooler blocked Remove cooler header and tube nest. Clean cooler tubes and
•
(First stage air safety valve first stage air passageways in header, cooler and first stage
blowing) separator.
Suction side of final stage valve leaking Remove valve, dean/inspect/renew.
•• Delivery side of final stage valve

leaking
Delivery side of final stage valve
leaking to suction side
Remove valve, deanlinspectlrenew.
Remove valve cage, renew O-rings and check joint washers

under dome nuts.
• Intemal knocking noise from

compressor.
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, clean inspect and renew if necessary.
Remove cylinders, check clearances, renew wom parts
• Wom drive element.

(cylinder, piston rings.)
Renew drive coupling element.
• Compressor will not achieve

operating pressure or is
Concentric valves damaged or dirty. Remove valves, clean inspect and renew if necessary. (note
reduced capacity nonnally indicates first stage fault)
• operating at a reduced
capacity.
• Solenoid drain/unload valve faulty.

Wom. or damaged piston ringsl piston.
Check solenoid valve function, renew parts as necessary.
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 filterlsilencer blocked. Renew element.
• Concentric valves require

frequent cleaning.
Non-recommended grade of lubricating
oil used.
Drain lubricating oil, replace with recommended grade.
• Concentric valves overheating. Ensure concentric vatves, cylinder components (cylinder,

piston, rings) and cooling water system is maintained in good
working order.
• Excessive moisture in final

air delivery pipe work and/or
Solenoid drain/unload valve fautty. Check solenoid valves function, renew components as
necessary.
• final stage cylinder/

intercooler.
• Unload drain cycle Incorrect for

operating conditions.
Reprogram solenoid drain/unload valves -dwell- and -spit"
times to suit operating conditions.
• Oil seeping out from Drive end lip or o-ring seal adjustment Remove flywheel adjustment sleeve and drive lip seal and
underside of crankcase near sleeve to crankshaft leaking. o-ring. Renew seal and o-ring. Refer to Section 3.2.15.
drive motor.
• Water jacket safety valve

blowing.
Excessive cooling water inlet pressure. Reduce inlet pressure to 7 bar 9 maximum that compressor is
suitable for.
• Intercooler/aftercooler tube failure. Remove cooler header and tubenest Renew/refurbish

tubenest.
• Excessive 011 consumption. Wom cylinder components. Remove cylinders, check cylinder, piston, rings. Renew
components as appropriate.
• Page 3-27
•
•
SECTION 3 • MAINTENANCE
•
•
3.6 TOOLS REQUIRED FOR COMPRESSOR MAINTENANCE
•
C spanner 2" - 6"
Table 3.8 Tools Reauired for Comaressor Maintenance
TOOL V150
,/
V200/250
,/
V375
,/
••
•
Fly press ,/ ,/ ,/
D.T.I. and magnetic base ,/ ,/ ,/
13mm aff x 3 /." square drive flank adaptor ,/ ,/ ,/

•
•
19 mm aff x Yz" square drive crowsfoot ,/ nla nla
24 mm aff x Yz" square drive crowsfoot nla ,/ ,/
8" screwdriver ,/ ,/ ,/
•
•
Water pump pliers ,/ ,/ ,/
2 Yz Ib steel lump hammer ,/ ,/ ,/
12" adjustable spanner

.Feeler gauges (0.02 - 1.0mm)
,/
,/
,/
,/
,/
,/ •
24mm aff combi spanner
nla
,/
,/
,/
,/
,/
,/
nla
,/
••
24mm aff Yz" square drive socket nla ,/ ,/
•
19mm aff Yz" square drive socket
13mm aIf X" drive socket
,/
,/
,/
,/
nla
,/ •
3mm aIf hexagon key ,/ ,/ ,/
•
4mm aff hexagon key
6mm aIf hexagon key
,/
,/
,/
,/
,/
nla •
8mm aIf hexagon key nla nla ,/
•
3mm aff hexagon key x X" square drive
4mm aff hexagon key x X" square drive
,/
,/
,/
,/
,/
,/ •
6mm aIf hexagon key x 3/." square drive ,/ ,/ nla
•
8mm aIf hexagon key x Yz" square drive
X" square drive torque wrench (4 - 20 Nm)
nla
,/
nla
,/
,/
,/
•
3 /s' square drive torque wrench (8 - 54 Nm) ,/ ,/ nla
•
•
Yz" square drive torque wrench (30 - 150 Nm) ,/ ,/ ,/
14mm aIf hexagon key x Yz" square drive ,/ ,/ nla

17mm aIf hexagon key x Yz" square drive nla nla ,/
•
•
%" square drive torque wrench (up to 500 Nm) nla nla ,/
X" square female x y," square drive adaptor nla nla ,/
•
•
•
•
•
•
Page 3-28 •
•
•
• SECTION 4 - TECHNICAL DATA
• SECTION 4· TECHNICAL DATA
• 4.1 GENERAL
• Compressor Type V150fV200fV250fV375
• 4.2 PERFORMANCE
• Maximum working pressure 33 bar.
• 4.3 OTHER DATA
• Table 4 1 Capacity and Power at 30 Bar
• V150 V200 V250 V375
•
Nominal 1000 1200 1500 1800 1000 1200 1500 1800 1000 1200 1500 1800 1000 1200 1500 1800
Speed
R.P.M.
• Output
3/hour
80 100 120 150 110 132 166 200 137 165 207 250 208 250 310 375
•
M
Absorbed 17 20 25 30 22 26 33 39 28 33 41 49 40 48 60 72
• Power kW
• Outputs quoted are bottle charging rates.

Noise - 89 dB (A) at 1 Metre
• Table 4 2 Operating Parameters
• Maximum air inlet temperature

V150 I V200/250
50°C
I V375
..
•
Maximum air outlet temperature 15°C over cooling water inlet
Maximum water inlet pressure 7 barg
• Maximum water inlet temperature

Minimum water inlet temperature
45°C
5°C -
•
Cooling water outlet temperature 15°C above water inlet temperature
Nominal cooling water flow rate 20/25 litres/minute I60/70 litres/minute I 115/120
•
litres/minute
Lubrication system Splash
•
Sump capacity min.3.5 litres min. 7 litres min. 9 litres
max.4.5 litres I max. 8 litres I max. 12 litres
•
•
•
•
•
•
•
•
•
•
• Page 4-1
•
•
SECTION 4 - TECHNICAL DATA
•
•
Feature
Table 4 3 Recommended Maximum Wear Clearances
Feature Measured Renew when •
Note: All dimensions are in millimetres. V150 V200/250 V375
•
First stage cylinder
(Nominal bore V150 0180 1 V200/250 0200 1 V375 0260)
•
Piston A Skirt 0 measured 15mm up from
base
,,179.600 ,,199.600 " 259.6
•
Cylinder bore B Maximum diameter at any point " 180.250 " 200.250 " 260.25
•
Piston to cylinder bore C Clearance between measured
valuesA& B
> 0.520 > 0.520 > 0.52
•
Top and second
piston rings, piston ring
D Piston ring width < 3.335 < 3.335 < 4.835
•
grooves.
E Piston ring groove width > 3.730 > 3.730 > 5.225 •
F Clearance between measured values > 0.200 > 0.200 > 0.200
•
•
DandE
G Piston ring gap when fitted to bore > 1.07 > 1.150 > 1.450
Conformable slotted oil H
control ring, piston ring
Piston ring width < 4.850 < 4.850 < 7.85
•
groove
I Piston ring groove width > 5.194 > 5.194 > 8.184 •
J Clearance between measured
> 0.250 > 0.250 > 0.250 •
K
values H and I
Piston ring gap when fitted to bore > 1.07 > 1.150 > 1.450
•
Gudgeon pin and small L
end bearing
Gudgeon pin 0 < 24.892 < 31.892 < 34.892
•
Final stage cylinder
•
•
(Nominal bore V150 0751 V2001250 0851 V375 0110)
Piston M Skirt 0 measured 15mm up from
s 74.830 s 84.830 s 109.730
Cylinder bore N
base
Maximum 0 at any point " 75.164 " 85.164 " 110.164 •
Piston to cylinder bore 0 Clearance between measured
values M & N
> 0.210 > 0.210 > 0.210
•
Top and second P Piston ring width < 2.350 < 2.350 < 2.850
•
piston rings. piston ring
grooves
•
Q
R
Piston ring groove width
Clearance between measured
> 2.660
> 0.200
> 2.660
> 0.200
> 3.160
> 0.200 •
values P & Q
•
•
S Piston ring gap fitted to bore > 0.710 > 0.800 > 0.890
Conformable slotted oil T Piston ring width < 4.850 < 4.850 <4.850
control ring, piston ring
groove
•
U
V
Piston ring groove width
Clearance between measured
> 5.194
> 0.250
> 5.194
> 0.250
> 5.194
> 0.250 •
values T & U
•
•
W Piston ring gap fitted to bore > 0.710 > 0.800 > 0.890
GUdgeon pin and small X Gudgeon pin 0 < 24.892 < 31.892 < 34.892
end bearing
•
Page 4-2 •
•
•
• SECTION 4 - TECHNICAL DATA
•
• 4.4 CRANKCASE LUBRICANTS
• 4.4.1 Approved Oils
• Shell Corena Oils P100

Castrol Aireol SN100
•e 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.
• 4.4.2 Oil Company Equivalents
• The following lubricants have not been tested by Hamworthy with the V-Line compressor, but are offered as
equivalents by the oil companies.
• Tabe4.4
lOCiI omeanv Eauivalents
• Mineral Oils
•
Supplier Oil Type
BP Energol RC 100
• Castrol Aircol PD 100
• Esso
Mobil
Exxcolub 100
. Rarus 427
• Texaco R& 0 100
• Synthetic Oils
Supplier Oil Type
• BP Enersyn RX 100
• Esso
Mobil
Synesstic 100
Rarus 827
• Texaco Cetus, DE100
• 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.
• 4.4.3 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
•
•
•
•e 1 8 9
• 2
• ~bc----';-+-- 10
•
• 3
•
• 5
•
•
•
11
•
• 7
•
• 6
•
•
• Figure 5.1 Typical Arrangement of V-Line Water Cooled Compressor with Gauges
•
•
•
•
•
•
•
•
• Page 5-1
•
•
SECTION 5 - DRAWINGS
•
•
Table 51 L·IS t 0 f Parts for Fiaure 5.1
Ref Description •
1 Gauge panel
•
2
3
Suction filter silencer
First stage safety valve •
4 Final stage safety valve
•
5
6
Dual level oil switch
Oil drain plug •
7 Oil filler/dipstick
•
8
9
Final air delivery
Motor terminal box •
10 Lifting lugs
•
11
12
Inter and final stage separator
First stage solenoid drain valve •
13 Final stage solenoid drain valve
•
•
•
•
•
•
Notes on Figures
•
(C) Parts fitted to controller model only
•
(E.M.) Parts fitted to electra-mechanical model only
•
Where parts are specific to a particular model, applicable model numbers are shown next to the item
number. •
Figure 5.3 Crankshaft and Flywheel: •
For V375, the Drive Coupling SUb-assembly (190) is detailed in Figure 5.9, and the flywheel (8) is shown in
Figure 5.10 •
Figure 5.7 Gauges: •
For V150, copper pipe links adaptors (282), via ball valves (298), to gauges.
For other models, copper pipe runs from adaptors beneath the cooler header (93), via ball valves (298), to •
gauges.
•
•
•
•
•
•
Page 5-2 •
•
• • • • • • • • • • • • • • • • • • • • • • • • • • 0 • • • • • • •
C4
86 C3 C5
148 CIO C2
147 Cll
Cl
90
273
131 (V37i!iq
"
cS'
c 91 13QlIJ376CI
iil
C/l
N 92
111
n 87
8iD 300
... 101 88
298
102
130
(Vl&lCI
131
lVl50C)
131
('1200/250 Cl
130 en
('1200/250 Cl m
n
-f
5
J
93
~
Z
C/l
106 C
;0
"tJ
Dl
<0
<D
95
~
Z
,
01 Cl
en
'"
en
m
0
-l
G3
0Z
190 '"C
8
11
~
Z
G>
10 en
6
7
5 0
247
248
249
250
251
252
253
161
254
214 255
215
212 (V150 ONLY)
213 245
246
•
•
• ~_-"F",8,,"'" 168 (V2Ol)'V25llI\I75)
~_-,F7:.LO!J'>!!l 169(V2OCW2SQNJ15)
• F8 ,
•
•e
F4 "
F3cv150)
F2 V150 167 (V2OO'V25CW31S)
•
• ~~~~~~========~F1~':":SO
• ~~
F1 166
F3 (V2OMI25OIIIJ75)
• F9 (VlSO)
•
•
57
43 48
• 54 53
• 55
45
32
• 48
~
• 52
54
~t'.'
• 50
• 51
2981E.M,)
•
• 145 (V2OCW25OI375)
•
146 (VlOl:rnIn75)
38
•
37
36
• 35
•
42
41
• 40
17
• 15
•
18
• Figure 5.4 First Stage Cylinder and Piston
•
•
• Page 5-5
•
•
•
•
79 •
80
•
73
•
70
•
•
71
72
77
•
75
•
•
___---!8!l1 fVS1~ ON.'ll
76
67
•
•
•
105 •
66
•
•
•
•
•
•
•
60
•
•
65
63
62
•
•
61
•
19
•
•
21
64
20
•
Figure 5.5 Final stage Cylinder and Piston
•
•
Page 5-6 •
•
•
•
• 149
320
(Ut)
•
321
(E .....)
150
E6
• 135
E7
~
(0)
• 236
(0) 117
• 118
•
114
116 113
•
•
• E4
E3
172
•
114
• El
• E5
• 125
• 314
•
• 110 E2
•
• 120 0
•
C
~
304 315
•
301 317
302
•
312
~
311
• 126
• ~
127
•
128
121 129
• 122
• 123
• 129
• Figure 5.6 Separator
•
• Page 5-7
•
•
• SECTION 5 • DRAWINGS
•
• 166 (cl
• 162 (cl
167 lcl
•
•
•
•
•
•
•
•
• 1751<1
•
•
•
•
•
•
•
•
•
•
•
• 176 (cl
• 1761C1
• 179 lcl
• Figure 5.8 Cover Assembly for Electronic Controller Model
•
•
•
• Page 5-9
•
m
go
TI
cD' 8 HOLES 125 z
e'"
c ITEM NO. PART NO. EQU ISPACED ,
ill AS SHOWN, 90
'"U>
CS
I
2
BX80 FLE 10"
BX80-PB i
z
"'"C Gl
m
~. MANUFACTURERS PART NO.
CD
oo 3010/080/055-756094 20
c
"2- 19.925 '&
S' MIO
!Cl 19.978
m
ii
THREAD r-,
~ .o .
:a
DI
''\I
=
Cl.
r-, (T)
oo N
c U) LO
"2- U) OI
:;-
!Cl
::I:
.
OI-
'
N
'&
N
'&
N
N
c 0I0
0- f"-CO '\I
B (T)
~ '&
=
!Cl
...
~
en
rf, 75.000
o
!"
YJ 75.019
..
iii
c
KEYWAY DETAIL 2
-...
CD
•••• • • ... • • • • • • • • • • • • • • • • • • • • • • • •••
Z HOLES OR ILL AND TAP 0.1. 0.1.
WIZ X 1.75-SH X ZZ
DEEP F"ULL THRE"-D.
TAPPING DRILL 3.
DEEP TO PO 1Nl . --------=:::::::,-h~:::.~_

--x
\
lJ
\ \ \~ ~I I I
'--\ !.;
I 1
"
-1+-----
I
---K--- ----.-1-
r -
,
N
e
--'
1\ "-- "
1 \
I \ 1).7~
\
\
\
\
\
,..:/ r,."'
~\
I I
i I
\ \
f 1
...-:& x ." en
m
"HOLES ORII.!. ~lS EOUI·$P.t.CEO
o
AS $HOWN.tJlILL J4.5 DEEP TO POINT ::j
0.1 ..
oz
NOTES,- 1.JrU. IMSP£CtF'U:O SI.RF'-et rlMISl€S TO lE M3
l.1oIl.X OJT Of" ~AHCt IIW>S TO BE 1.5J 0 U In.s ... rtt.01US
].INERTlA IPo..NII "8ClJT AllIS fT ROTATlO'l' 1.11C0 Wl •• '"
c
'0'
~
0.1 A
Z
C)
en
•
•
•
Table 5.2 List Of Parts - V-Line Compressors
•
NOTE: Where two numbers are shown in the quantity column the first quantity is for the V150 compressor,
the second refers to the V200/250/375 compressor. Where the quantity for the V375 is different it is
•
•
shown in brackets. Items shown in italics apply only to the electronic controller model, and are listed
at the end.
Ref Descriotion QuantitY

•
•
1 Crankcase 1
2 Crankshaft 1
3
4
Pin sorina tension
Bearing taper roller
1
1
•
•
(main non drive end)
5 Bearing taper roller 1
•
(main drive endl
6 Oil seal 1
'0' ring (adjusting sleeve
•
7 1
to bearina & crankshaft)
8 Flvwheel 1
9
10
Bush cone clarnplnq elements
Bearina adiustina sleeve
1
1 •
11
15
Socket set screw
Connectino rod (tst staael
1
1 •
16
17
Bearin~ - bia end cylindrical roller
Bearina - small end needle roller
1
1 •
18
19
Soacer - connectina rodIcrankshaft
Connectinq rod. (2nd staqe)
1
1 •
20
21
Bearina - bia end cvlindrical roller.
Bearina - small end needle roller.
1
1 •
22
23
Clamoino washer - c/shaft-conn. Rod
Set screw
1
1 •
24 Tab washer 1
•
30 Hose connector (not V375l
Hose (crankcase breather) (not V375l
1
•
•
32 30 cm
35 Piston (first staae) 1
Piston rina SOC
•
36 1
37 Piston rino taoer faced 1
Piston rin!:! barrel faced
•
38 1
39 Cvlinder (first staqe) 1
40 Gudaeon Din (first staoe) 1
41
42
Hexaoon socket set screw
Locknut
2
1 •
43 Stud (first stage cylinder
assemblv to crankcase)
4
•
45
46
Valve caae (first stace)
Hose connector (not V375l
1
1 •
48 '0' ring (first stage valve
caceto cvlinder)
1
•
50 Concentric valve (first stage)
assembly A
1
•
51 '0' ring (first stage concentric
valve outer groove to cylinder)
1
•
52 '0' ring (first stage concentric
valve top face to valve cage)
1
•
53 Joint washer 4 (8)
•
54
55
Stud connector (not V375)
Bright washer (not V375)
1
1 •
Page 5-12
•
•
•
•
• Table 5.2 List Of Parts - V-Line Comoressors Cont'dl
Ref Descriotion Quantitv
• 56
57
Nut
Briaht washer
4
4
• 59
60
Sacket set screw N375 onlvl
Piston (second staOe\
2
1
• 61
62
Piston rina S.O.C
Piston rina taoer faced
1
1
• 63
64
Piston rina barrel faced
GUdcleon oin Isecond staael
1
1
• 65
66
Socket set screw
Cvlinder (second staoe)
2
1
• 67 Stud (second stage cylinder

Assemblv to crankcase)
4
• 70
71
Valve caae (second staael
'0' ring (second stage valve
1
1
• 72
Caae too croove to cvlinderl
'0' ring (second stage valve cage 1
• 73
Bottom oroove to cvlinder)
Pluo 1
• 75 Concentric valve (second stage)

Assemblv B .
1
1
• 76 '0' ring (second stage concentric

Valve outer nroove to cvllnder)
1
1
• 77 '0' ring (second stage concentric 1

Valve ton face to valve cane1 1
•
78 Joint washer 4
79 Nut 4
•
80 Bnaht washer 4
81 Anti-extrusion rinn N375 onlv) 1
•
85 Cooler box assemblv C 1
86 Evebolt 1
•
87 Set screwlbolt 4/3
88 snrina washer 4/3
•
90 Gasket (tubenest to cooler box) 1
91 Tubenest assemblv 1
•
92 Gasket Ilubenest to cooler headerl 1
93 Cooler header 1
•
94 Bolt/aiifustina screw 13
95 Briaht washer 13
• 100 Gasket (cooler header to first

Staae cvlinderl
1
• 101
102
Bolt
Briaht washer
3/4
3/4
• 105 Gasket (cooler header to

Second staae cvlinderl 1
• 106
107
Bolt
Bnaht washer
3
3
• 110
111
Senarator assemblv E
Gasket (separator /header -
1
1
• 112
cooler box
Bolt 3
• 113
114
Bolt/stud
Bnaht washer
1
4
• 115
116
Nut Inot V200/250l
Gasket (separator assembly to
1
1
• Second stace cvlinder)
• Page 5-13
•
•
•
•
Table 5.2 List Of Parts - V-Line ComDressolS Cont'dl
Ref Description Quantitv
•
117
118
Set screw
Briahllsorina washer
2
2
•
120
121
Joint washer
Adaotor
3
1
•
122 Joint washer 1
•
123 Solenoid valve body
First stace drain/unload
1
•
125
126
Washer lV375 onlvl
Nioole
3
1
•
127
128
Nioole
Solenoid valve
1
1
•
140
Final stace drain/unload
Oil level switch - crankcase 1
•
141
142
'0' rina (oil switch l
Setscrew
2
1
•
143
145
BriQht washer
SafelY valve (air 1st slaae cvlinderl
1
1
•
146
147
Coooer washer
SafelY valve (water iacket safetvl
3
1
•
148
149
Copper washer
Safety valve
3
1
•
150
lAir final staae cvlinder)
Coooer washer 3/1
•
151
152
Plua
Joint washer
2
2
•
153
154
Plua
Joint washer
2
2
•
155
156
Inspection cover
Cable CIiD
1
213
•
157
158
Set screw
Briaht washer
4/6
4/6
•
160
161
MaQnelic drain pluQ with seal
Oil filler/dipstick
1
1
•
165
166
Studdina
Suction filter/silencer assemblv F
1
1
•
167
F2
Filter elementlV2001250/375 onlv)
Filter element lV150 onlv)
1
1
•
168
169
Wino nut N2001250/375 onIv)
Briaht washer N200/250/375 onlv)
1
1
•
170
171
Guard - crankcase
Screw
1
1
•
172 Sorina washer 1
•
•
•
•
•
•
•
Page 5-14 •
•
•
•
• Table 5.2 List Of Parts - V-Line Compressors Cont'dl
Ref Description Quantitv
• 181
190
Badae (not shown)
Drive coupllnqsub-assernblv G
1
1
• 191
192
Bolt/set screw
serine washer
4/8
4/8
• 194
195
Motor packinq piece (V200/250 onlv)
Mountina plate drive motor
2
1
• 196 Mounting plate drive motor

(Water circulatina ourno models onlv)
1
•
197 Bolt 2
198 Nut 2
• 199
200
sormo washer
Water circulating pump
2
1
• 201
202
Bolt
serine washer
4
4
• 203
204
Bolt (not shown)
SDrina washer (not shown)
2
2
• 209 Straight male union

Connector 1
• 210
212
Joint washer
Packina niece (V150 onlv)
1
2
•
213 Anti-vibration mount 2
214 Bolt 2
•
215 SorinQ washer 2
216 Anti-vibration mount 1
•
217 Screw 1
218 SDrina washer 1
•
222 Flexible hose (water inlet)
To final stage cylinder/
Circulatina oumo • 1
• 224 Joint washer (hose to

cvlinder/circulatina DumD)
1
• 225 Flexible hose (water outlet

from first stage cylinder) • 1
• 227
228
Joint washer (hose to cylinder)
Flexible hose (final air deliverv) •
1
1
• 229
230
Joint washer (hose to seDarato[\
Nameolate (not shown)
1
1
• 231
247
Hammer drive screw (not shown)
Electrical terminal box
4
1
• 266
273
Bolt
Pluo
1
1
• 274 Joint washer 1
•
•
•
•
•
•
•
• Page 5-15
•
•
SECTION 5 • DRAWINGS
•
•
T a bl e 5.2 List Of Parts - V-Line ComDressors ICont'd)
Ref I Description Quantitv
•
COMPRESSOR WITH GAUGES
280 Pressureaauae (direct mount) 0 - 10 bar 1
•
281
282
Pressure gauge (direct mount) 0 - 60 bar
Adaptor
1
2
•
283
284
Joint washer
Pressure gauge (panel mount)
2
1
•
285
0-10 bar
Pressure gauge (panel mount) 1
•
286
0-60 bar
Gauae panel 1
•
287
288
Set screw
Bright washer
2
2
•
289
290
Leaend olate
Leoend plate
1
1
•
291
292
Drive screw
Coooer oioe assemblv
4
50/60 cm
•
293
294
Coooer oioe assembly
Male stud couplina
50/60 cm
2
•
295
296
Female stud couolina
Leather washer
2
2
•
298 Joint washer 4(1)
•
300 Plua 2
•
COMPRESSOR WITH MANUAL DRAINS
301 3 way eaual tee 1
•
302 Adaotor 1
•
304
305
Hex adaptor
Ball valve
1
1
•
306
307
Ball valve
Joint washer
1
1
•
311
312
3 way eaual tee
Adaptor
1
1
•
315
317
Ball valve
Joint washer
1
1
•
320 Temperature switch 1
•
321 Joint washer 1
•
CONCENTRIC VALVE (1ST STAGE) ITEM 50
Al Concentric valve body assembly I 1
•
A2 Dome nut I 4181
•
CONCENTRIC VALVE (2ND STAGE) ITEM 75
B1 Concentric valve body assembly I 1
•
•
B2 I Dome nut I 4161
•
•
•
•
Page 5-16
•
•
r
•
•
• Table 5.2 List Of Parts - V-Line Compressors (Cont'd)
• Ref I Description
COOLER BOX SUB-ASSEMBLY ITEM 85
Quantitv
• C1
C2
Cooler box
Cover cooler box end
1
1
• C3 Gasket (cover cooler box

end to cooler box) 1
•
C4 Bolt 11/9
C5 Plain washer 11/9
• C6 Plug 1
C7 Joint washer 1
•
CB PluQ 1
C9 Joint washer 1
•
C10 Bleed Valve 1
C11 Joint washer 1
• SEPARATOR SUB-ASSEMBLY ITEM 110
• E1 Separator header 1
E2 Separator bowls and spiders 1
• E3 Separator spider (first stage) 1

E4 Separator spider (second stage) 1
• E5 Gasket (separator header

to seoarator bowls) 1
E6 Bolt 6
• E7 Plain washer 6
• DRIVE COUPLING SUB-ASSEMBLY ITEM 190

G1 Drive coupling element (V200) 1
• G1
G2
Drive coupling element IV250l
Drive pin (notV375)
1
4
• G3
G4
Drive coupling hub
Hexacon socket cap screw (not V375)
1
4
• SEALANTS/RETAINERS
• J1 Loctite 603 high strength

Retainer 10ml size
1
• J2
J3
Loctite 243 thread locker 10 ml size
Loctite 573 flanqe sealant 50 ml size
1
1
• J4 Loctite 574 multi gasket 50 ml size 1
•
•
•
•
•
•
•
•
•
• Page 5-17
•
•
•
•
Table 5.2 List Of Parts - V-Line Compressors (Cont'd)
•
ELECTRONIC CONTROLLER MODEL
130 Temperature sensor 0 - 100·C 1
•
131
Final air delivery (cooler box)
Joint washer 1
•
132 Temperature sensor 0 - 60·C
Water out (first stage cylinder)
1
•
133
135
Joint washer
Pressure transmitter
1
1
•
•
(First staoe air)
137 Pressure transmitter 1
•
(Secondlfinal stage air)
175 Cover/electrical sub assemblv 1
•
176 Cover base 1
178 Set screw/bolt 4
•
179 Bright washer 4
182 Cover assemblv 1
•
187 Plastic screw 4
188 Plastic washer 4
236
241
Joint washer
Joint washer
1
1
•
245
246
Set screw
SprinQ washer
4/1
4/1
•
•
248 Brass stud 1
249 Brass washer 1
•
250 Hex nut 1
251 Brass washer 1
•
252 Lockwasher 1
253 Brass washer 1
•
254 Nut 1
255 Nut 1
•
258 PC/ip 1
259 Screw 1
•
262 P clip (V20012501375 only) 2
263 Screw (V20012501375 only) 1
•
•
•
•
•
•
•
•
•
•
•
Page 5-18
•
•

Installation, Operating and Maintenance Manual: Hamworthykse

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•

• ChiNA SHIPBUILDING CORP.

• HAMWORTHY KSE LIMITED

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

• Telephone: +44 (0)1202 662600

• Offices, Associate Companies and Agents throughout the world

• ensure that isolation is complete.

• 3.2.10 Cooler Tubenest and Header Removal.

• 3.2.12 Cooler Tubenest and Header Assembly to Compressor

• 3.2.21 Flywheel and Drive End Oil Seal Reassembly to Compressor

• 3.2.23 Crankshaft and Main Bearings Reassembly to Compressor

• 3.2.25 Air and Water Safety Valves

• 3.2.27 Spider Fitting and Separator Bowl Reassembly

• SECTION 5 - DRAWINGS 5-1

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

or via any Hamworthy KSE office or agency throughout the wortd.

• Type and serial number of machine:

•• Technical Service and Advice:

• Telephone: +44 (0)1202 662663

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

Korea HamwCll1lly KSE Korea Lld

HamwoIthyKSEAIS New Jersey

HamwCll1lly KSE Inc •

California Hamworthy KSE !ne

• 1340 Beunos Aires, Argenllna

• BRAZIL BULGARIA CANADA

• 134 - Gr 1513, Rio De Janeiro

CHILE COLUMBIA CZECH REP.

• Lanz Y Cia Uda ConsuJnaval Uda Mann.m~eTradingSRO

CROATIA CYPRUS ECUADOR

• Eurella ~ D,O.O SheeI1lne Marine Services sertemarUd

EGYPT FRANCE GERMANY

• InlernIIIIonal Marine Center Etabllssements T1ano SA WDhelm Rump KG

• GREECE ICELAND INDONESIA

• Marine & Industrial Systems Ud S stelaanson & Co Ud P.T Slools Intermarlne

• ISRAEL ITALY ITALY

• 11. sorer & Co Ud

MALTA NEW ZEALAND OMAN

PORTUGAL QATAR ROMANIA

SPAIN TAIWAN THAILAND

• compressor external surfaces.

• positions and weight of the compressor.

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

• 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.

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

• Replace plugs in cylinders.

• complete revolutions to ensure lubrication of the cylinder bores during initial

• 4. Remove guard covering barring over access aperture in crankcase.

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

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

The compressor starting method can be either star/delta or direct-on-Iine.

• The compressor may be supplied with a water circulating pump if required.

• 2.2 CONTROL AND OPERATING PHILOSOPHY

• - minimum oil level shutdown and optional pre-alarm

• 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

• 2.3 NORMAL RUNNING PROCEDURE (AUTOMATIC CONTROL)

• 1. Energise the starter panel by operating the main isolator.

• Press RESET push button.