Technical Documentation For 03 2047 52 PDF

Technical Documentation
Deck Machinery - Compressors - Steering gears
Technical Documentation
for HATLAPA
Compressors
V150 W55 L9 HSC22
Start Start Start Start

V-Line Water cooled
Compressor
Electro-mechanical Model
V105, V150, V200, V250, V375
PCH 1540
Uetersener Maschinenfabrik GmbH & C0. KG Discovery Court Business Centre

Tornescher Weg 5-7 . D-25436 Uetersen 551-553 Wallisdown Road,
Poole, Dorset BH12 5AG, England
Phone: +49-4122-7 11-0 . Telex: 218510 htlu d
Mobile: +49-172-9 81 32 92 . Cable Hatlapa Uetersen Phone: +44 (0)1202 853180
Fax.: +49-4122-7 11-104 Sales Fax Spare Parts Enquiries: +44 (0)1202 853190
-7 11-330 Service Fax General Sales: +44 (0)1202 853191
Internet http://www.hatlapa.de
E-mail: info@hatlapa.de
Page 2
WARNING
1. The following manual must be read before proceeding with installation, operation and maintenance of
this equipment.
2. Health & Safety Act Compliance. Before working on this equipment personnel should be made aware
of, and ensure compliance with, the Health and Safety Regulations appropriate to this class of work.
3. The handling points are indicated on the unit and must be used. The hooks of slings must be fitted to
lifting eyebolts using shackles.
4. Before proceeding with maintenance on the unit, or making adjustments to its connections and fittings,
it must be stopped and isolated electrically and mechanically and the outlet valves closed. Some units
on automatic standby duty, or isolators are remote from the unit and extra care is then necessary to
ensure that isolation is complete.
Hamworthy reserves the right to make changes to the design of the machine without prior notice.
NOTE: Where the compressor has been supplied with an electronic controller, the operating and
maintenance information detailed in supplement 1540A should be read in addition to this instruction
manual.
Page 3
Page 4
CONTENTS
SECTION 1 - INSTALLATION ........................................................................................................................ 1-1

1.1 LOCATION ....................................................................................................................................... 1-1
1.2 MOUNTING ...................................................................................................................................... 1-1
1.3 COMMISSIONING............................................................................................................................ 1-1
1.3.1 Commissioning Procedure ........................................................................................................ 1-1
SECTION 2 - OPERATING PROCEDURE .................................................................................................... 2-1
2.1 DESCRIPTION ................................................................................................................................. 2-1
2.2 CONTROL AND OPERATING PHILOSOPHY................................................................................. 2-1
2.3 NORMAL RUNNING PROCEDURE (AUTOMATIC CONTROL)..................................................... 2-1
2.4 MANUAL MODE RUNNING ............................................................................................................. 2-2
2.5 GENERAL......................................................................................................................................... 2-2
SECTION 3 - MAINTENANCE........................................................................................................................ 3-1
3.1 GENERAL......................................................................................................................................... 3-1
3.2 MAINTENANCE INSTRUCTIONS ................................................................................................... 3-2
3.2.1 Lubrication Oil Checking ........................................................................................................... 3-2
3.2.2 Lubrication Oil: Changing .......................................................................................................... 3-3
3.2.3 Air Suction Filter/Silencer Removal and Replacement ............................................................. 3-3
3.2.4 First Stage Concentric Valve Removal/Servicing/Replacement ............................................... 3-3
3.2.5 Final Stage Concentric Valve Removal/Servicing/Replacement .............................................. 3-7
3.2.6 First Stage Cylinder and Piston Removal ............................................................................... 3-10
3.2.7 First Stage Cylinder and Piston Reassembly.......................................................................... 3-11
3.2.8 Final Stage Cylinder and Piston Removal............................................................................... 3-12
3.2.9 Final Stage Cylinder and Piston Reassembly......................................................................... 3-13
3.2.10 Cooler Tubenest and Header Removal................................................................................... 3-14
3.2.11 Tubenest Clean/Examine/Replace.......................................................................................... 3-14
3.2.12 Cooler Tubenest and Header Assembly to Compressor ........................................................ 3-15
3.2.13 Cooler box end cover .............................................................................................................. 3-16
3.2.14 Connecting Rod Big End Bearing Removal ............................................................................ 3-16
3.2.15 Bearing Removal and Reassembly to Connecting Rods ........................................................ 3-16
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 .................... 3-20
3.2.20 Flywheel and Drive End Oil Seals Removal from Compressor .............................................. 3-20
3.2.21 Flywheel and Drive End Oil Seal Reassembly to Compressor ............................................... 3-21
3.2.22 Crankshaft and Main Bearing Removal from Compressor ..................................................... 3-22
3.2.23 Crankshaft and Main Bearings Reassembly to Compressor .................................................. 3-23
3.2.24 Oil Level Switch Remove/Clean/Replace................................................................................ 3-23
3.2.25 Air and Water Safety Valves ................................................................................................... 3-24
3.2.26 Separator Bowl Removal, Spider Examination and Removal................................................. 3-24
3.2.27 Spider Fitting and Separator Bowl Reassembly...................................................................... 3-24
3.3 WATER CIRCULATING PUMP (if supplied) .................................................................................. 3-25
3.3.1 General Overhaul .................................................................................................................... 3-25
3.3.2 Service Information ................................................................................................................. 3-25
3.3.3 Dismantling.............................................................................................................................. 3-25
3.3.4 Reassembly............................................................................................................................. 3-25
3.4 ELECTRICAL MAINTENANCE ...................................................................................................... 3-26
3.5 FAULT FINDING CHART ............................................................................................................... 3-27
3.6 TOOLS REQUIRED FOR COMPRESSOR MAINTENANCE ........................................................ 3-28
SECTION 4 - TECHNICAL DATA................................................................................................................... 4-1
4.1 GENERAL......................................................................................................................................... 4-1
4.2 PERFORMANCE.............................................................................................................................. 4-1
4.3 OTHER DATA .................................................................................................................................. 4-1
4.4 CRANKCASE LUBRICANTS ........................................................................................................... 4-3
4.4.1 Approved Oils............................................................................................................................ 4-3
4.4.2 Oil Company Equivalents .......................................................................................................... 4-3
4.4.3 Additional Maintenance for Machines Lubricated with Synthetic Oils....................................... 4-3
SECTION 5 - DRAWINGS .............................................................................................................................. 5-1
Page 5
FIGURES
Figure 3.1 First Stage Concentric Valve V150............................................................................................... 3-5

Figure 3.2 First Stage Concentric Valve V200/250/375................................................................................. 3-6
Figure 3.3 Final Stage Concentric Valve V150/200/250/375......................................................................... 3-8
Figure 3.4 Cooler Header V150 ................................................................................................................... 3-15
Figure 3.5 Cooler Header V200/250/375 ..................................................................................................... 3-15
Figure 3.6 Connecting Rod : V150............................................................................................................... 3-17
Figure 3.7 Connecting Rod : V200/250/375................................................................................................. 3-17
Figure 3.8 Coupling...................................................................................................................................... 3-19
Figure 3.9 Gap Between Coupling and Flywheel......................................................................................... 3-19
Figure 3.10 Location of Angle Steel on Crankcase Rails ............................................................................ 3-21
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 5.4 First Stage Cylinder and Piston .................................................................................................... 5-5
Figure 5.5 Final Stage Cylinder and Piston ................................................................................................... 5-6
Figure 5.6 Separator ...................................................................................................................................... 5-7
Figure 5.7 Gauges ......................................................................................................................................... 5-8
Figure 5.8 Cover Assembly for Electronic Controller Model .......................................................................... 5-9
Figure 5.9 V375 Drive Coupling Element and Coupling Hub (Drawing 641600, Issue 1) ........................... 5-10
Figure 5.10 V375 Flywheel (Drawing 3416300401, Issue 1).......................................................................5-11
TABLES
Table 3.1 Fastener Torque Settings .............................................................................................................. 3-1

Table 3.2 Maintenance Schedule .................................................................................................................. 3-2
Table 3.3 First Stage Concentric Valves - Items List..................................................................................... 3-7
Table 3.4 Final Stage Concentric Valves - Items List .................................................................................... 3-9
Table 3.5 Fixtures to Assist Flywheel Removal ........................................................................................... 3-20
Table 3.6 Switch Settings............................................................................................................................. 3-26
Table 3.7 Fault Finding Chart....................................................................................................................... 3-27
Table 3.8 Tools Required for Compressor Maintenance ............................................................................. 3-28
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 Oil Company Equivalents............................................................................................................... 4-3
Table 5.1 List of Parts for Figure 5.1.............................................................................................................. 5-2
Table 5.2 List Of Parts – V-Line Compressors ............................................................................................ 5-12
Page 6
Spare Parts and Service
Spare Parts can be ordered direct from the following address:

Hamworthy KSE Ltd. Telephone: +44 (0)1202 662600
Fleets Corner Facsimile: +44 (0)1202 665444
Poole, Dorset Email: poolespares@hamworthykse.com
BH17 0JT, England
or from any Hamworthy office or agency throughout the world.

When ordering spare parts, the following information is required to ensure that correct parts are supplied:
Type and serial number of machine: Obtained from machine nameplate
Item Number and full description of part required: Obtained from details in this publication
Technical Service and Advice:

Technical service and advice can be obtained during normal working hours from the above address, on the
following contact numbers
Telephone: +44 (0)1202 662663
Facsimile: +44 (0)1202 662622
Email: pooleservice@hamworthykse.com
or via any of our overseas companies or offices
Outside normal working hours a 24 hour emergency facility is available. Initial telephone contact number is
England +44 (0)1202 662663.
Overseas Hamworthy Offices

Canada Hamworthy Canada Ltd., Norway Hamworthy KSE A/S,
113 Cushman Road, Unit 8, Joseph Kellers vei 20
St. Catherines, Ontario. L2M 6S9 Tranby
Tel. +1 905 688 4922 PO Box 83, N-3401 Lier, Norway
Fax. +1 905 688 9028 Tel. + 47 32 85 92 00
Fax. + 47 32 85 21 93
China Hamworthy KSE Shanghai Representative Office, Singapore Hamworthy KSE PTE Ltd,
Room 7-D Yi Dian Plaza, 15 Benoi Crescent
No. 746 Zhao Jia Bang Road, Singapore 629978
Shanghai 200030 Tel. + 65 261 6066
Tel. + 86 21 64455665 Fax. + 65 261 6011
Fax. + 86 21 64459875
Dubai C/O Aqua Tech, South Africa Hamworthy Engineering Africa (Pty)
DY 160/1 Al Jadaf, PO Box 62073 Ltd
Dubai, UAE P.O. Box 50435,
Tel. + 971 4324 0335 Randburg 2125, Johannesburg.
Fax. + 971 4324 0336 Tel. + 27 11 7923886
Fax. + 27 11 7923889
Holland Hamworthy KSE BV, U.S.A. Hamworthy KSE Inc.,
Bristolstraat 1, 3047 A.B., Georgia 1129 Hospital Drive, Suite 3C,
Rotterdam, Netherlands Stockbridge, Georgia 30281.
Tel. + 31 10 462 4777 Tel. +1 770 507 8900
Fax. +31 10 415 9046 Fax. +1 770 507 8989
India Hamworthy KSE Pvt Ltd New Jersey 187 Route 34
C-155 Mittal Court, Nariman Point, Matawan, NJ 07747
Mumbai 400 021 India New Jersey
Tel. + 91 22 2872394 Tel: + 732 583 5115
Fax. + 91 22 2872394 Fax: + 732 583 5116
Korea Hamworthy KSE Korea Ltd. New Orleans 1418 Edwards Avenue
14th Floor Hyundai Building #1193-5 Suite B
Choryang 3 dong, Dong-gu, New Orleans
Pusan, Korea (601-013) Louisiana 70123
Tel: + 8251 465 8461 Tel: +1 504 734 5525
Fax: + 8251 463 7498 Fax: +1 504 734 5716
Page 7
Hamworthy Agents Worldwide
Abu Dhabi Ali & Sons Co. Egypt International Marine Center Sultanate Trans-Oceanic Trading Est.
Ali & Sons Co. Building PO Box 95 (21321) of Oman PO Box 4892
Tourist Club, PO Box 915 Imbrahimieh Postal Code 112, Ruwi
Abu Dhabi, U.A.E. Alexandria, Egypt Sultanate of Oman
Tel. + 971 2 723900 Tel. + 203 483 6959 Tel. + 968 798503
Fax. + 971 2 723901 Fax. + 203 483 7969 Fax. + 968 702981
Argentina Neptune S.A. France Etablissements Tiano Pakistan United Traders
Calle Mendoza 3185 - 5° - B 2 Bis Rue de la Baume Haroon Chambers
1428 - Buenos Aires Paris 75008, France Altaf Hussain Road,
Argentina Tel. + 33 1 4561 9932 Karachi 74000, Pakistan
Tel. + 54 1 322 6041 Fax. + 33 1 4225 6962 Tel. + 92 21 241 4916
Fax. + 54 1 322 5790 Fax. + 92 21 241 6862
Australia Caba (Aust.) Pty. Ltd. Germany Wilhelm Rump KG Poland Romac Ltd.
41 Barry Avenue Buchheisterstrasse 6 80/463 Gdansk,
Mortdale, N.S.W. 2223 20457 Hamburg, Germany Ciolkowskigo 7A/25
Australia Tel. + 49 40 317842-0 Poland
Tel. + 61 29 534 2100 Fax. + 49 40 3194841 Tel. + 48 58 347203
Fax. + 61 29 533 5332 Fax. + 48 58 3463694
Bangladesh Marinetec Ltd. Greece Alpha Marine Engineering Ltd. Qatar Al Ahed Trading &
30 Agrabad Commercial Area, 38 Salaminos Contracting Company
PO Box 2018 GR 16674 GLYFADA, PO Box 3266, Doha, Qatar
Bandar, Chittagong Athens Greece Tel. + 974 414022
Bangladesh Tel: + 301 89 43 220 Fax. + 974 414021
Tel. + 880 31 502834 Fax. + 301 96 80 210
Telex: 66466
Brazil Tridente Brazil Italy S.I.R.N. s.r.l. Spain Aries Industrial Y Naval S.A.
Rua Visconde de Inhuama, Genoa 22/1 Via Casaregis, 16129 Parque de las Naciones
134 – GR 1513 Genoa Edificio Germania
Centro - Rio de Janeiro – RJ Tel. + 39 0 10 586771 Guzman el Bueno 133
20091-100, Brazil Fax. + 39 0 10 542678 Madrid 28003, Spain
Tel. + 55 21 233 1489 Tel. + 34 91 533 9200
Fax. + 55 21 233 7187 Fax. + 34 91 534 7402
Bulgaria Dawcul Ltd. Cherni Vrah Bul, Trieste 22/1 Via Del Lazzaretto Venezuela Oficini Maritima PI. C.A.
BL NO 4VH A, 1421 Sofia, Vecchio, Edif Torre La Previsora
Bulgaria 9.34123, Trieste Piso 7, Sabana Grande
Tel. + 359 2 963 0156 Tel. + 39 0 40 304247 Aptdo 60710, Caracas 1060A
Fax. + 359 2 962 5217 Fax. + 39 0 40 308196 Venezuela
Tel. + 58 2 7817897
Fax. + 58 2 781 9457
Chile Lanz Y Cia Ltda Israel B. Sofer & Co. Ltd.
Calle Dr. Barros Borgono 233. PO Box 221,
Casilla 16389 Avichail 42910 Israel
Santiago, Chile Tel. + 972 9882 2319
Tel. + 56 2 235 2707 Fax. + 972 9862 5211
Fax. + 56 2 235 7329/1070
Columbia Consul Naval Ltda Kuwait The Trading & Industrial
Edificio Colseguros Equipment Co. (WLL)
Oficina 501 (TIECO),
Calle Cochera del Gobernador PO Box 2159,
Cartagena, Columbia S.A. 13022, Safat, Kuwait
Tel. + 575 664 6413 Tel. 00965 4810385
Fax. + 575 664 1640 Fax. + 965 4810387
Denmark Berendsen PMC A/S, Malta Thos. C. Smith & Co. Ltd.
Telefonvej 6, 12 St Christopher Street
DK 2860 Soborg, Denmark Valetta, Malta
Tel. + 45 70 21 21 21 ext 421 Tel. + 356 625071
Fax. + 45 39 54 85 11 Fax. + 356 247182
Ecuador Sertemar Ltd. El Oro 1303 Y New Caba (New Zealand) Ltd
Guaranda, PO Box 5899 Zealand 37 Clyde Street
Guayaquil, Ecuador S.A. Whangarei, New Zealand
Tel. + 593 4 345105/340325 Tel. + 64 94 383661
Telex. 043741 AM BU SL Fax. + 64 94 30854
V11
Page 8
SECTION 1 - INSTALLATION
1.1 LOCATION
The suction inlet should be installed in a well ventilated position so that air drawn into the compressor is as
cool and dry as possible and there is 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
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, take appropriate 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 15°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

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-line.
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 shutdown and optional pre-alarm
- high compressor motor current shutdown only
- high water pump motor current shutdown only (of water circulating pump supplied)
- emergency stop button operation 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 S1 to AUTO.
Set local/remote switch S2 as required.
Set drain switch S3 to AUTO (S3 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
- 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 during this cycle brings the compressor back
on line to recharge the system.
6. If the START button is pressed while the air system is fully charged, the compressor starts as
described in 2. The compressor is then controlled by the air system pressure switch as in 3 and 4
above.
2.4 MANUAL MODE RUNNING
Energise the starter panel by operating the main isolator.
Set mode switch S1 to MAN.
Set local/remote 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
SECTION 3 - MAINTENANCE
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 Loctite should be thoroughly
degreased using a Loctite activator. If cured Loctite 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.
Table 3.1 Fastener Torque Settings

M6 M8 M10 M12 M16
6 Nm 16 Nm 32 Nm 53 Nm 132 Nm
Page 3-1
Table 3.2 Maintenance Schedule

Commissioning Normal Operating Services
Period
Every 6 months
or 5000 hours.
Time required
Daily or every
Daily or every
or 2000 hours
Every 2 years
Every 5 years
for operation.
or 500 hours.
At 50 hours
10 hours
10 hours
1. Check oil level on dipstick. ! !
2. Drain and refill lubricating oil. ! !
3. Replace air inlet filter. !
4. Clean and inspect delivery line ! 30 mins
non-return valve.
5. Clean first stage valve and ! 4 hours
replace seals. Renew final
stage valve and O-rings.
6. Renew first stage valve and ! 2 hours
O-rings.
7. Check settings of all ! 1 hour
pressure safety valves,
replace as necessary.
8. Remove inter/after coolers and ! 4 hours
clean.
9. Dismantle and measure moving ! 6 hours
parts for wear.
st
10. Check condition of spider in 1 ! 6 hours
nd
and 2 stage separators
11. Replace bearings ! 1 hour
A complete overhaul, including bearing replacement, is recommended every 5 years or 5,000 running hours.
After a major service, follow the commissioning procedure detailed in section 1.
3.2 MAINTENANCE INSTRUCTIONS
3.2.1 Lubrication Oil Checking
Refer to Technical Data section for oil capacities and recommended lubricants.
1. Remove filler/dipstick and check oil level.
2. Fill/top up crankcase oil level if necessary with lubricating oil to full level on dipstick.
Periodically examine oil in crankcase and ensure that it is not contaminated with condensate. If the oil is
emulsified (creamy in colour) it must be changed and the crankcase cleaned. 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), ‘O’ 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 ‘O’ rings (48) fitted to valve cage (45) and ‘O’ 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 (50B).
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
10 12
12
1
13
6 9
13
8
15 15
14 15
2
16
Figure 3.1 First Stage Concentric Valve V150
Page 3-5
Figure 3.2 First Stage Concentric Valve V200/250/375
Page 3-6
Table 3.1 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 Self locking nut 1 1 1
11 Dome nut 1 1 N/a
12 Dome nut 4 4 8
13 Lift washer 2 2 2
14 Locating pin 1 1 1
15 Locating pin 3 3 3
16 Back peg 1 1 1
17 ‘O’ – ring (between 1 and N/a N/a N/a
7, not shown on Figure
3.2)
3.2.5 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 (B1) using screws (not supplied) in the two
tapped jacking holes.
3. Cover bores on cylinder.
4. Remove dome nuts (B2) and joint washers (78) from concentric valve studs.
5. Separate concentric valve from valve cage.
Page 3-7
Figure 3.1 Final Stage Concentric Valve V150/200/250/375
Page 3-8
Table 3.1 Final Stage Concentric Valves - Items List

Quantity
Item Description V150/V200/250 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 Stud 3 6
11 Dome nut 4 7
12 Locating pin 1 1
13 Screw 3 n/a
14 Back peg 1 1
15 Lift washer (below 8, not N/a 1
shown on Figure 3.1)
Dismantling
1. Unscrew the three socket head cap screws (13) (Not applicable on V375). Unscrew the centre nut
(V200/250 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 ‘O’ rings (71 and 72) fitted to valve cage (70) and ‘O’ 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 turn 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 internals and crankcase. Remove piston and pin.
13. Cover the crankcase aperture.
14. Examine removed components replacing worn/damaged parts as necessary. For wear allowances see
section 4 - Technical Data.
NOTE: If required connecting rod small end needle roller bearing (17) may be removed and refitted without
dismantling compressor any further. Section 3.2.15 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 header and 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
brush.
4. 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
by the internal chamfer on the taper faced ring.)
c. 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 Loctite Activator. With locknut fitted, coat cap head
screw with Loctite 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
on the gudgeon pin end face in line with the piston axis pointing away from the cylinder.
12. 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 pipework/hose to cylinder.
20. Refit guard (170) to crankcase.
3.2.8 Final Stage Cylinder and Piston Removal
1. Drain compressor of all cooling water. Remove water inlet connection from cylinder.
2. Remove concentric valve (B1) 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 turn over the compressor until the second stage piston (60) is at the top of its stroke in the
cylinder.
NOTE: If the first stage cylinder has been removed, take precautions to protect exposed first stage
components in the crankcase.
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 internals 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 internal chamfer on the taper faced ring.)
c. Both rings are to be fitted with the face marked “Top” facing towards the piston crown.
d. S.O.C. ring bottom groove.
6. Fit piston and gudgeon pin to connecting rod small end orienting piston and pin markings 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
joint faces.
16. 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 (V200/250/V375 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.
Figure 3.1 Cooler Header V150
Figure 3.2 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 smooth joint 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 fitted to the connecting
rod in accordance with the following sketch ensuring that the NON CIRCLIP SIDE of the bearing
is flush with the face shown.
Figure 3.1 Connecting Rod : V150
Machined dimple ref.
Figure 3.2 Connecting Rod : V200/250/375

Clearance fit:
Fit as for an interference fit but support the bearing in position to ensure that the NON CIRCLIP 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 fitted, 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) refitting
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
For V375, see Section 3.2.19.
1. Isolate compressor.
2. On compressors fitted 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 fitted 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
For V375, 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 assembled in 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 not twisted. A small
amount of grease should be applied under the head of the screw before fitting. 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-load. 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-load is thus increased. The axial bores in the
rubber element should be smeared lightly with grease beforehand to allow the socket bolts to slide
easily in the inserts.
Figure 3.1 Coupling

1. 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 3.2 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.
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 Oil Seals Removal from Compressor
1. Remove drive motor and coupling as detailed in section 3.2.17. Note drive pins (190B) 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 3.1 Fixtures to Assist Flywheel Removal

Machine Fixture
V150 J31974
V200/250 J32032
V375 J32244
Page 3-20
Figure 3.1 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 ‘O’ 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 ‘O’ 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 turning 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 turns and check, by trying to rock the assembly,
that the taper roller main bearings are seated correctly (i.e. little or no up and down movement of any
part of the assembly).
6. Attach a dial test indicator 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 turns. 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 V150/200/250 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.
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
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. Using a mild steel drift (not supplied), drift the outer bearing cup of the drive end main bearing (5) into
position in the crankcase.
4. Lightly oil the non drive end main bearing location bore in the crankcase.
5. Fit non drive end main bearing (4) outer race in position as described in operation 3.
6. Preheat non drive end main bearing inner race assembly to 140°C.
7. Lightly oil crankshaft non drive end bearing journal location.
8. Fit the heated inner race assembly on to the crankshaft journal and allow to cool before gently tapping
home against shoulder with a mild steel sleeve drift (not supplied).
9. 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 safety 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 safety 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 Safety Valve (145)

Located on the cooler box behind the first stage cylinder. Associated joint washer (146). When replacing the
water jacket safety valve ensure the outlet port is pointing downwards by using up to 3 joint washers.
First Stage Air Pressure Safety 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 Safety 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
(E1).
Separate bowl from the header by gently tapping the bowl with a soft headed mallet.
Note:It is advisable to leave 2 opposite corner 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 smooth faces, use Loctite ‘Chisel’ or similar.
st nd
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 (E1) using 6 bolts (E6) and washers (E7).
4. Tighten the corner bolts and then the central ones progressively until they are torqued correctly.
5. Fit separator drain pipes (if fitted).

Page 3-24
6. Fit solenoid coil ‘Din’ plugs (129).
3.3 WATER CIRCULATING PUMP (if supplied)
NOTE: The pump rotation is anti-clockwise 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 Dismantling
Pump Head
Close isolating valves, loosen the screws fastening the pump cover to the casing and lift the pump head
assembly out of the pump casing.
Impeller
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.
Impeller
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 turned by
hand.
Casing
Remove any significant volume of water from the casing. Use a new ‘O’ 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
3.4 ELECTRICAL MAINTENANCE
It is recommended that switch settings are periodically checked. Refer to the separate data sheet for
settings:
Table 3.1 Switch Settings

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 3.1 Fault Finding Chart
FAULT POSSIBLE CAUSE REMEDIAL ACTION
Final stage air safety valve
blowing.
Whilst in automatic (default) Air system charged signal and final Reset signal pressure settings lower than safety valve set
mode stage air pressure shutdown settings pressure (Note: maximum working pressure of compressor
greater than safety valve set pressure is 33 bar g)
Whilst running in manual Stop valve closed in final air delivery Open all stop valves in pipework
mode pipework
Non-return valve installed incorrectly. Correct installation.
Air system pressure safety devices set Correct safety device pressure settings as appropriate.
higher than safety valve setting.
First stage air safety valve The first stage air safety valve is unlikely to operate when the compressor is running automatically as
blowing. the compressor will be shut down by the high first stage air pressure transducer first. See below.
High first stage pressure Intercooler blocked Remove cooler header and tubenest. 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, clean/inspect/renew.
Delivery side of final stage valve Remove valve, clean/inspect/renew.
leaking
Delivery side of final stage valve Remove valve cage, renew O-rings and check joint washers
leaking to suction side under dome nuts.
Internal knocking noise from Worn big or small end bearings Strip down compressor for inspection, renew worn parts.
compressor.
Worn main bearings. Strip down compressor, check crankshaft end float. Renew
worn parts.
Damaged concentric valve. Remove valves, clean inspect and renew if necessary.
Piston slap. Remove cylinders, check clearances, renew worn parts
(cylinder, piston rings.)
Worn drive element. Renew drive coupling element.
Compressor will not achieve Concentric valves damaged or dirty. Remove valves, clean inspect and renew if necessary. (note
operating pressure or is reduced capacity normally indicates first stage fault)
operating at a reduced
capacity.
Solenoid drain/unload valve faulty. Check solenoid valve function, renew parts as necessary.
Worn or damaged piston rings/ piston. Remove cylinders, check rings are free in piston groove,
renew worn, distorted or damaged rings, piston as
appropriate.
Excessive cylinder component wear Remove cylinders, renew cylinder, piston, rings as necessary
Suction filter/silencer blocked. Renew element.
Concentric valves require Non-recommended grade of lubricating Drain lubricating oil, replace with recommended grade.
frequent cleaning. oil used.
Concentric valves overheating. Ensure concentric valves, cylinder components (cylinder,
piston, rings) and cooling water system is maintained in good
working order.
Excessive moisture in final Solenoid drain/unload valve faulty. Check solenoid valves function, renew components as
air delivery pipe work and/or necessary.
final stage cylinder/
intercooler.
Unload drain cycle incorrect for Reprogram solenoid drain/unload valves “dwell” and “spit”
operating conditions. 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 Excessive cooling water inlet pressure. Reduce inlet pressure to 7 bar g maximum that compressor is
blowing. suitable for.
Intercooler/aftercooler tube failure. Remove cooler header and tubenest. Renew/refurbish
tubenest.
Excessive oil consumption. Worn cylinder components. Remove cylinders, check cylinder, piston, rings. Renew
components as appropriate.
Page 3-27
3.6 TOOLS REQUIRED FOR COMPRESSOR MAINTENANCE
Table 3.1 Tools Required for Compressor Maintenance

TOOL V150 V200/250 V375
C spanner 2" - 6" ✓ ✓ ✓
Fly press ✓ ✓ ✓
D.T.I. and magnetic base ✓ ✓ ✓
3
13mm a/f x /8" square drive flank adaptor ✓ ✓ ✓
19 mm a/f x ½" square drive crowsfoot ✓ n/a n/a
24 mm a/f x ½" square drive crowsfoot n/a ✓ ✓
8" screwdriver ✓ ✓ ✓
Water pump pliers ✓ ✓ ✓
2 ½ lb steel lump hammer ✓ ✓ ✓
12" adjustable spanner ✓ ✓ ✓
Feeler gauges (0.02 - 1.0mm) ✓ ✓ ✓
24mm a/f combi spanner n/a ✓ ✓
19mm a/f combi spanner ✓ ✓ n/a
13mm a/f combi spanner ✓ ✓ ✓
24mm a/f ½" square drive socket n/a ✓ ✓
19mm a/f ½" square drive socket ✓ ✓ n/a
13mm a/f ¼" drive socket ✓ ✓ ✓
3mm a/f hexagon key ✓ ✓ ✓
4mm a/f hexagon key ✓ ✓ ✓
6mm a/f hexagon key ✓ ✓ n/a
8mm a/f hexagon key n/a n/a ✓
3mm a/f hexagon key x ¼" square drive ✓ ✓ ✓
4mm a/f hexagon key x ¼" square drive ✓ ✓ ✓
3
6mm a/f hexagon key x /8" square drive ✓ ✓ n/a
8mm a/f hexagon key x ½" square drive n/a n/a ✓
¼" square drive torque wrench (4 - 20 Nm) ✓ ✓ ✓
3
/8" square drive torque wrench (8 - 54 Nm) ✓ ✓ n/a
½" square drive torque wrench (30 - 150 Nm) ✓ ✓ ✓
14mm a/f hexagon key x ½" square drive ✓ ✓ n/a
17mm a/f hexagon key x ½" square drive n/a n/a ✓
¾" square drive torque wrench (up to 500 Nm) n/a n/a ✓
¾" square female x ½" square drive adaptor n/a n/a ✓
Page 3-28
SECTION 4 - TECHNICAL DATA

4.1 GENERAL
Compressor Type V150/V200/V250/V375
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 80 100 120 150 110 132 166 200 137 165 207 250 208 250 310 375
3
M /hour
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

V150 V200/250 V375
Maximum air inlet temperature 50°C
Maximum air outlet temperature 20°C over cooling water inlet
Maximum water inlet pressure 7 bar g
Maximum water inlet temperature 45°C
Minimum water inlet temperature 5°C
Cooling water outlet temperature 10°C above water inlet temperature
Nominal cooling water flow rate 20/25 litres/minute 60/70 litres/minute 115/120
litres/minute
Lubrication system Splash
Sump capacity min. 3.5 litres min. 7 litres min. 9 litres
max. 4.5 litres max. 8 litres max. 12 litres
Page 4-1
Table 4.3 Recommended Maximum Wear Clearances

Feature Feature Measured Renew when
Note: All dimensions are in millimetres. V150 V200/250 V375
First stage cylinder
(Nominal bore V150 Ø180 / V200/250 Ø200 / V375 Ø260)
Piston A Skirt Ø measured 15mm up from ≤ 179.600 ≤ 199.600 ≤ 259.6
base
Cylinder bore B Maximum diameter at any point ≥ 180.250 ≥ 200.250 ≥ 260.25
Piston to cylinder bore C Clearance between measured > 0.520 > 0.520 > 0.52
values A & B
Top and second D Piston ring width < 3.335 < 3.335 < 4.835
piston rings, piston ring
grooves.
E Piston ring groove width > 3.730 > 3.730 > 5.225
F Clearance between measured values > 0.200 > 0.200 > 0.200
D and E
G Piston ring gap when fitted to bore > 1.07 > 1.150 > 1.450
Conformable slotted oil H Piston ring width < 4.850 < 4.850 < 7.85
control ring, piston ring
groove
I Piston ring groove width > 5.194 > 5.194 > 8.184
J Clearance between measured
> 0.250 > 0.250 > 0.250
values H and I
K Piston ring gap when fitted to bore > 1.07 > 1.150 > 1.450
Gudgeon pin and small L Gudgeon pin Ø < 24.892 < 31.892 < 34.892
end bearing
Final stage cylinder
(Nominal bore V150 Ø75 / V200/250 Ø85 / V375 Ø110)
Piston M Skirt Ø measured 15mm up from
≤ 74.830 ≤ 84.830 ≤ 109.730
base
Cylinder bore N Maximum Ø at any point ≥ 75.164 ≥ 85.164 ≥ 110.164
Piston to cylinder bore O Clearance between measured > 0.210 > 0.210 > 0.210
values M & N
Top and second P Piston ring width < 2.350 < 2.350 < 2.850
piston rings. piston ring
grooves
Q Piston ring groove width > 2.660 > 2.660 > 3.160
R Clearance between measured > 0.200 > 0.200 > 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 Piston ring groove width > 5.194 > 5.194 > 5.194
V Clearance between measured > 0.250 > 0.250 > 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 Ø < 24.892 < 31.892 < 34.892
end bearing
Page 4-2
4.4 CRANKCASE LUBRICANTS
4.4.1 Approved Oils
Shell Corena Oils P100

Castrol Aircol SN100
Extensive tests have been carried out on the V-Line compressor using Shell Corena P100 (mineral) and
Castrol Aircol SN100 (synthetic) lubricants. These oils have been found to give good results over extended
service and Hamworthy recommend their use to ensure satisfactory operation of the compressor.
4.4.2 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.
Table 4.1 Oil Company Equivalents

Mineral Oils
Supplier Oil Type
BP Energol RC 100
Castrol Aircol PD 100
Esso Exxcolub 100
Mobil Rarus 427
Texaco R & O 100
Synthetic Oils
Supplier Oil Type
BP Enersyn RX 100
Esso Synesstic 100
Mobil 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
Page 4-4
SECTION 5 - DRAWINGS
1 4 8 9
10
11
13
12
7
Figure 5.1 Typical Arrangement of V-Line Water Cooled Compressor with Gauges
Page 5-1
Table 5.1 List of Parts for Figure 5.1

Ref Description
1 Gauge panel
2 Suction filter silencer
3 First stage safety valve
4 Final stage safety valve
5 Dual level oil switch
6 Oil drain plug
7 Oil filler/dipstick
8 Final air delivery
9 Motor terminal box
10 Lifting lugs
11 Inter and final stage separator
12 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 electro-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
Figure 5.2 Cooler
Page 5-3
(V150 ONLY)
Figure 5.3 Crankshaft and Flywheel

See Notes on page 5-2
Page 5-4
F8 (V150) 168 (V200/V250/V375)

F7 (V150) 169 (V200/V250/V375)
F6 (V150)
F5 (V150)
165
F4 (V150)
F3 (V150)
F2 (V150) 167 (V200/V250/V375)
F10 (V150) F2 (V200/V250/V375)
F11 (V150) F3 (V200/V250/V375)
F1 166
F9 (V150)
A2
56
57
43 46
54 53
55
32
45
48
145 (V150)
52
146 (V150)
54
50 132
300 (E.M.)
51 133
298 (E.M.)
100
39
145 (V200/V250/375)
146 (V200/250/375)
38
37
36
35
42
41
40
17
15
16
Figure 5.4 First Stage Cylinder and Piston
Page 5-5
79
80
73
70
71
72
77
B2
75
78
81
76
67
105
66
152
151
60
65
63
62
61
19
21
64
20
Figure 5.5 Final Stage Cylinder and Piston
Page 5-6
(E.M.) (C)
(E.M.) (C)
(C)
(C)
Figure 5.6 Separator
Page 5-7
Figure 5.7 Gauges

See Notes on page 5-2
Page 5-8
Figure 5.8 Cover Assembly for Electronic Controller Model
Page 5-9
Figure 5.9 V375 Drive Coupling Element and Coupling Hub (Drawing 641600, Issue 1)
Page 5-10
Figure 5.10 V375 Flywheel (Drawing 3416300401, Issue 1)
Page 5-11
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 Description Quantity

1 Crankcase 1
2 Crankshaft 1
3 Pin spring tension 1
4 Bearing taper roller 1
(main non drive end)
5 Bearing taper roller 1
(main drive end)
6 Oil seal 1
7 ‘O’ ring (adjusting sleeve 1
to bearing & crankshaft)
8 Flywheel 1
9 Bush cone clamping elements 1
10 Bearing adjusting sleeve 1
11 Socket set screw 1
15 Connecting rod (1st stage) 1
16 Bearing - big end cylindrical roller 1
17 Bearing - small end needle roller 1
18 Spacer - connecting rod/crankshaft 1
19 Connecting rod. (2nd stage) 1
20 Bearing - big end cylindrical roller. 1
21 Bearing - small end needle roller. 1
22 Clamping washer - c/shaft-conn. Rod 1
23 Set screw 1
24 Tab washer 1
30 Hose connector (not V375) 1

32 Hose (crankcase breather) (not V375) 30 cm
35 Piston (first stage) 1
36 Piston ring SOC 1
37 Piston ring taper faced 1
38 Piston ring barrel faced 1
39 Cylinder (first stage) 1
40 Gudgeon pin (first stage) 1
41 Hexagon socket set screw 2
42 Locknut 1
43 Stud (first stage cylinder 4
assembly to crankcase)
45 Valve cage (first stage) 1
46 Hose connector (not V375) 1
48 ‘O’ ring (first stage valve 1
cage to cylinder)
50 Concentric valve (first stage) 1
assembly A
51 ‘O’ ring (first stage concentric 1
valve outer groove to cylinder)
52 ‘O’ ring (first stage concentric 1
valve top face to valve cage)
53 Joint washer 4 (8)
54 Stud connector (not V375) 1
55 Bright washer (not V375) 1
Page 5-12
Table 5.2 List Of Parts – V-Line Compressors (Cont’d)

56 Nut 4
57 Bright washer 4
59 Socket set screw (V375 only) 2
60 Piston (second stage) 1
61 Piston ring S.O.C 1
62 Piston ring taper faced 1
63 Piston ring barrel faced 1
64 Gudgeon pin (second stage) 1
65 Socket set screw 2
66 Cylinder (second stage) 1
67 Stud (second stage cylinder 4
Assembly to crankcase)
70 Valve cage (second stage) 1
71 ‘O’ ring (second stage valve 1
Cage top groove to cylinder)
72 ‘O’ ring (second stage valve cage 1
Bottom groove to cylinder)
73 Plug 1
75 Concentric valve (second stage) 1
Assembly B 1
76 ‘O’ ring (second stage concentric 1
Valve outer groove to cylinder) 1
77 ‘O’ ring (second stage concentric 1
Valve top face to valve cage) 1
78 Joint washer 4
79 Nut 4
80 Bright washer 4
81 Anti-extrusion ring (V375 only) 1
85 Cooler box assembly C 1
86 Eyebolt 1
87 Set screw/bolt 4/3
88 Spring washer 4/3
90 Gasket (tubenest to cooler box) 1
91 Tubenest assembly 1
92 Gasket (tubenest to cooler header) 1
93 Cooler header 1
94 Bolt/adjusting screw 13
95 Bright washer 13
100 Gasket (cooler header to first 1

Stage cylinder)
101 Bolt 3/4
102 Bright washer 3/4
105 Gasket (cooler header to
Second stage cylinder) 1
106 Bolt 3
107 Bright washer 3
110 Separator assembly E 1
111 Gasket (separator /header -- 1
cooler box
112 Bolt 3
113 Bolt/stud 1
114 Bright washer 4
115 Nut (not V200/250) 1
116 Gasket (separator assembly to 1
Second stage cylinder)
Page 5-13

117 Set screw 2
118 Bright/spring washer 2
120 Joint washer 3
121 Adaptor 1
122 Joint washer 1
123 Solenoid valve body 1

First stage drain/unload
125 Washer (V375 only) 3
126 Nipple 1
127 Nipple 1
128 Solenoid valve 1
Final stage drain/unload
140 Oil level switch - crankcase 1
141 ‘O’ ring (oil switch ) 2
142 Set screw 1
143 Bright washer 1
145 Safety valve (air 1st stage cylinder) 1
146 Copper washer 3
147 Safety valve (water jacket safety) 1
148 Copper washer 3
149 Safety valve 1
(Air final stage cylinder)
150 Copper washer 3/1
151 Plug 2
152 Joint washer 2
153 Plug 2
154 Joint washer 2
155 Inspection cover 1
156 Cable clip 2/3
157 Set screw 4/6
158 Bright washer 4/6
160 Magnetic drain plug with seal 1
161 Oil filler/dipstick 1
165 Studding 1
166 Suction filter/silencer assembly F 1
167 Filter element (V200/250/375 only) 1
F2 Filter element (V150 only) 1
168 Wing nut (V200/250/375 only) 1
169 Bright washer (V200/250/375 only) 1
170 Guard – crankcase 1
171 Screw 1
172 Spring washer 1
Page 5-14

181 Badge (not shown) 1
190 Drive coupling sub-assembly G 1
191 Bolt/set screw 4/8
194 Motor packing piece (V200/250 only) 2
195 Mounting plate drive motor 1
196 Mounting plate drive motor 1
(Water circulating pump models only)
197 Bolt 2
198 Nut 2
199 Spring washer 2
200 Water circulating pump 1
201 Bolt 4
202 Spring washer 4
203 Bolt (not shown) 2
204 Spring washer (not shown) 2
209 Straight male union
Connector 1
210 Joint washer 1
212 Packing piece (V150 only) 2
213 Anti-vibration mount 2
214 Bolt 2
215 Spring washer 2
216 Anti-vibration mount 1
217 Screw 1
218 Spring washer 1
222 Flexible hose (water inlet)
To final stage cylinder/
Circulating pump * 1
224 Joint washer (hose to 1
cylinder/circulating pump)
225 Flexible hose (water outlet
from first stage cylinder) * 1
227 Joint washer (hose to cylinder) 1
228 Flexible hose (final air delivery) * 1
229 Joint washer (hose to separator) 1
230 Nameplate (not shown) 1
231 Hammer drive screw (not shown) 4
247 Electrical terminal box 1
266 Bolt 1
273 Plug 1
274 Joint washer 1
Page 5-15

COMPRESSOR WITH GAUGES
280 Pressure gauge (direct mount) 0 – 10 bar 1
281 Pressure gauge (direct mount) 0 – 60 bar 1
282 Adaptor 2
283 Joint washer 2
284 Pressure gauge (panel mount) 1
0 –10 bar
285 Pressure gauge (panel mount) 1
0 – 60 bar
286 Gauge panel 1
287 Set screw 2
288 Bright washer 2
289 Legend plate 1
290 Legend plate 1
291 Drive screw 4
292 Copper pipe assembly 50/60 cm
293 Copper pipe assembly 50/60 cm
294 Male stud coupling 2
295 Female stud coupling 2
296 Leather washer 2
298 Joint washer 4(1)
300 Plug 2
COMPRESSOR WITH MANUAL DRAINS

301 3 way equal tee 1
302 Adaptor 1
304 Hex adaptor 1

305 Ball valve 1
306 Ball valve 1
307 Joint washer 1
311 3 way equal tee 1
312 Adaptor 1
315 Ball valve 1
317 Joint washer 1
320 Temperature switch 1

321 Joint washer 1
CONCENTRIC VALVE (1ST STAGE) ITEM 50

A1 Concentric valve body assembly 1
A2 Dome nut 4(8)
CONCENTRIC VALVE (2ND STAGE) ITEM 75

B1 Concentric valve body assembly 1
B2 Dome nut 4(6)
Page 5-16

COOLER BOX SUB-ASSEMBLY ITEM 85
C1 Cooler box 1
C2 Cover cooler box end 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
C8 Plug 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 separator bowls) 1
E6 Bolt 6
E7 Plain washer 6
DRIVE COUPLING SUB-ASSEMBLY ITEM 190

G1 Drive coupling element (V200) 1
G1 Drive coupling element (V250) 1
G2 Drive pin (not V375) 4
G3 Drive coupling hub 1
G4 Hexagon socket cap screw (not V375) 4
SEALANTS/RETAINERS
J1 Loctite 603 high strength 1
Retainer 10ml size
J2 Loctite 243 thread locker 10 ml size 1
J3 Loctite 573 flange sealant 50 ml size 1
J4 Loctite 574 multi gasket 50 ml size 1
Page 5-17
ELECTRONIC CONTROLLER MODEL

130 Temperature sensor 0 - 100°C 1
Final air delivery (cooler box)
131 Joint washer 1
132 Temperature sensor 0 - 60°C 1
Water out (first stage cylinder)
133 Joint washer 1
135 Pressure transmitter 1
(First stage air)
137 Pressure transmitter 1
(Second/final stage air)
175 Cover/electrical sub assembly 1
176 Cover base 1
178 Set screw/bolt 4
179 Bright washer 4
182 Cover assembly 1
187 Plastic screw 4
188 Plastic washer 4
236 Joint washer 1
241 Joint washer 1
245 Set screw 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 P clip 1
259 Screw 1
262 P clip (V200/250/375 only) 2
263 Screw (V200/250/375 only) 1
Page 5-18
Instruction manual
Piston compressor
W55
Type Instruction manual
W55 Piston Compressors
INTRODUCTION:
This Instructions Manual contains a brief technical description and important instructions
on commissioning, maintenance and servicing of the compressor.
We recommend to read this manual carefully in order to be able, in case of trouble, to
detect the cause quickly and care for remedy and, in case of repairs, to make provisions for
proper mounting acc. to the instructions.
This manual assumes a general technical knowledge of piston compressors and does not
claim to be complete. If repairs become necessary, only original HATLAPA spare parts
must be used in order to maintain the operational reliability and efficiency of the machine.
For identification and supply of spare parts, an order must contain the following
information:
1. Serial No. and type designation (see name plate).

2. Ident No. from the spare parts list.
3. Method of the required dispatch, as well as consignee and address for the invoice.
4. Name of the vessel (ex-name), Yard No., and Shipyard.
In order to receive spare parts with the least possible delay, get in touch direct with
Uetersener Maschinenfabrik GmbH & Co.

Tornescher Weg 5-7 · D-25436 Uetersen / Germany
D-2549 Uetersen / Germany
Phone: (+49) 4122 / 711- 0
Telex: 218510 htlu d
Cable: HATLAPA Uetersen
Fax: (+49) 4122 / 711 - 330
Internet: http://www.hatlapa.de
or with our accredited agents, after-sales service stations or licensees/co-operators as per

attached list.
We wish to point out that repairs and/or modifications to the compressor which are carried
out without our approval during the guarantee period, will release us from our guarantee
obligations. The manufacturer cannot be rendered liable for damage to the compressor
which can be shown to have been caused by the use of unsuitable lubricants or failure to
comply with the operating instructions.
Reprint of the text or illustrations, or even extracts therefrom is prohibited.
Subject to alterations at all times due to technical development.
TABLE OF CONTENTS:
2 Rev.: 15.04.1999
Instruction manual Type
Piston Compressors W55
Page:
Introduction....................................................................................................................2
1 Description ..................................................................................................................4
1.1 Design .......................................................................................................................4
1.2 Specifications ............................................................................................................4
1.3 Working method ........................................................................................................5
1.4 Cooling ......................................................................................................................5
1.5 Lubrication of Working Parts .....................................................................................5
1.6 Cylinder lubrication ....................................................................................................6
1.7 Condensate Separation .............................................................................................6
1.8 Starting without Back-Pressure .................................................................................6
2 Setting-up and installation.........................................................................................7
3 Commissioning...........................................................................................................8
3.1 Safety References .....................................................................................................8
3.2 Before Starting...........................................................................................................9
3.3 After Starting..............................................................................................................9
3.4 During Operation .......................................................................................................9
3.5 After Stopping..........................................................................................................10
4 Servicing and Maintenance .....................................................................................11

4.1 General Servicing Instructions.................................................................................11
4.2 Servicing Schedule ..................................................................................................12
4.3 Overhaul of Valves ..................................................................................................14
4.4 Overhaul of Pistions and Cylinders..........................................................................14
4.5 Overhaul of crankshaft and connecting rod .............................................................17
4.6 Protection against Corrosion during prolonged Shut-Down .....................................18
5 Trouble Shooting ......................................................................................................19
6 Spare Parts................................................................................................................20
7 Instructions for Correctly Ordering Spare Parts....................................................21
Rev.: 15.04.1999 3
1 Description
1.1 Design
The compressor W55 is a single-cylinder, two-stage, water-cooled differential

compressor with upright cylinder.
Direction of rotation of the crankshaft – looking towards the flywheel – is clockwise

in standard design (see arrow indicating direction of rotation).
The equalization of mass of the crank mechanism guarantees low vibrations during
operation and enables a resilient mounting without any problems.
1.2 Specifications
Typ W55
Cylinder Bore 1st Stage [mm] 114
Cylinder Bore 2nd Stage [mm] 98
Piston Stroke [mm] 78
Crankshaft-Axial Clearance [mm] 0,2-
0,3
Quantity of Lub. Oil min. [l] 0,75
Quantity of Lub. Oil max. [l] 1,25
Weight without E-Motor [approx. kg] 100
4 Rev.: 15.04.1999
1.3 Working method
The compressor compresses the ambient air sucked in through the air-intake filter
with silencer in two stages to the selected final pressure. Concentric ring plate
valves with large flow cross-sections control automatically the gas exchange in the
compression chambers. After every stage the heated compressed air flows through
a large-dimensioned cooler. To monitor the correct functioning of the compressor
pressure gauges are installed after each compression stage. Safety valves,
installed, prevent the pressure from rising above the admissible limit.
1.4 Cooling
The heat created in the compressor by air compression and mechanical friction, is
dissipated to the cooling water. Check immediately after starting whether sufficient
cooling water is delivered to the compressor. This is done at the cooling water
inspection glass or at the discharge funnel.
Under regular operating conditions and with the prescribed cooling water supply as
well as with clean cooling chambers, the temperature rise between cooling water
inlet and outlet is 10 to 15° C.
The temperature of the cooling water must not exceed 50° C at its outlet. A
thermometer and a temperature control switch should be provided for controlling
the temperature of the discharged cooling water at the outlet pipe.
1.5 Lubrication of Working Parts
Only compressor oils according to the enclosed oil specification chart may be used.
The lubrication of all working parts is carried out automatically by a lubricating pin
fitted to the lower part of the connecting rod. This dips into an oil bath and splashes
the oil upwards..
Rev.: 15.04.1999 5
1.6 Cylinder lubrication
The first stage of the cylinder is lubricated by oil mist. The oil mist passes through a
connecting pipe between crankcase and suction chamber, and is sucked through
the combined suction and pressure valve into the cylinder. Faultless oil mist
lubrication is guaranteed with a closed crankcase only.
1.7 Condensate Separation
Together with the moist ambient air which is sucked in, water enters the
compressor in form of vapour. By compression and subsequent cooling of the
compressed air, this water vapour condenses. The water separated from the
compressed air blends with the oil which is entrained in very small quantities from
the lubricated working surfaces of the cylinders. This water-oil mixture is extracted
from the compressed-air stream after the 1st and 2nd stage in special condensate
collector chambers.
At regular intervals – after every 15 min. for about 10 sec. - as well as on starting
and stopping of the compressor, the collector chambers must be drained by
opening the manual valves or optionally by automatic devices. Such condensate
separation reduces wear and tear due to corrosion in the compressor components,
and in the connected pipelines and prevents the compressor from damage due to
water shocks. Disposal of the condensate has to be carried out according to the
locally valid prescriptions.
1.8 Starting without Back-Pressure
During starting-up, the driving motor must be unloaded by opening the drain valves.
In automatically controlled compressors, unloading is effected by time-lagged
closing of these valves.
6 Rev.: 15.04.1999
2 Setting-up and installation
The compressor is driven by a directly-coupled electric motor through a flexible

coupling, the shaft centres of motor and compressor must lie in exactly the same
axis. Under no circumstances may the shaft centres be offset.
The common baseplate for motor and compressor is torsion-free and must be
properly aligned to the ships foundation and fully supported at all points. If the
foregoing instructions are disregarded and if there are differences caused by
modifications to the ship´s foundation or the common baseplate or due to other
causes, this may result in inadmissible strain on the shafts due to incorrect
alignment.
In case of resilient mounting there must be sufficient room for movement. All
pipelines must then be connected to the consumer system by flexible hoses, strictly
adhering to the installation instructions.
All drain pipelines are to be laid with constant descent and must discharge into an
open funnel after the shortest possible distance. Each compression stage needs a
separate drain pipeline in order to guarantee perfect drainage of the individual
stages; stop valves are to be installed as closely as possible to the compressor.
Further instructions on the installation of valves, pipelines, and control equipment

are to be taken from the enclosed piping diagrams with their respective
descriptions.
Rev.: 15.04.1999 7
3 Commissioning
3.1 Safety References
The compressor has been produced according to the State-of-art and is

operationally reliable.
The compressors are a source of danger if inexpertly or improperly used.
• Only authorised and trained persons are allowed to operate and repair the
machine or to do maintenance work. Make sure that these persons have read
and understood the complete operating instructions and safety instructions.
• The compressor may only be used for compressing air.
• The compressor may not be operated without safety or protecting devices.
• Only sealed safety valves may be used, readjustment is not allowed. They
have to be replaced immediately when defective.
• Before starting any maintenance work it is necessary to stop the compressor
system and to prevent it from re-starting. The system has to be voltage–free,
all parts containing compressed air have to be depressurized.
• The compressor system may only be operated in perfect working condition.
It must be free of foreign parts.
• Rebuilding or any other changes to the compressor system that may
influence the safety are strictly prohibited.
8 Rev.: 15.04.1999
At initial commissioning, after a several months` interruption in operation, or

after extensive repair work the operator must observe the following points (see
also 4.6 Protection against corrosion during prolonged Shut-Down).
3.2 Before Starting
• The compressor must be filled to the upper oil level mark with prescribed
compressor oil (see list of recommended oils).
• Check that the crankshaft is moving easily by turning over the flywheel by
hand; but make sure that the compressor set cannot be started
unintentionally.
• Open the shut-off valve in the pipeline leading to the compressed-air
receiver.
• Open drain valves.
• Open the shut-off valves in the cooling water pipes.
3.3 After Starting
• Check the direction of rotation of the shaft (see also arrow).

• Check the cooling water flow.
• Close the drain valves and check for leakage.
3.4 During Operation
• Once the final pressure is attained, check the safety valves for proper
functioning: Slightly turn the knurled nut until the valve blows off. After
closure, check for leakage.
• After fitting of new working parts (repair), run in the compressor for about
one hour at low final pressure (5 to 10 bar).
Rev.: 15.04.1999 9
3.5 After Stopping
• Open the drain valves at the condensate separators.

• Check that the automatic drain valves open properly.
• Check the non-return valve in the pipe to the compressed-air receiver for
leakage.
10 Rev.: 15.04.1999
4 Servicing and Maintenance
For trouble-free operation, it is necessary to check regularly and carefully the

safety devices and the wear and tear parts of the compressor as well as the
functioning of fitted valves and instruments. Regularly check the stock of spare
parts and seals which must be protected against corrosion, and stock up to the
specified quantity again after any servicing and overhaul work.
The following maintenance and overhaul instructions must be adhered to.
However, they do not claim to be complete.
Observance of the servicing intervals as mentioned below guarantees great
reliability and long service life of the compressor.
In this connection, reference is made to the requirements of the rules of the
classification societies and seafarer unions.
4.1 General Servicing Instructions
a) Check the oil level daily. Fill the crankcase with the prescribed compressor oil,
however, not exceeding the top oil level mark. Too much oil results in foaming
due to immersion of rotating parts, with the compressor at extremely inclined
position. Intense misting of the oil and uncontrolled cylinder lubrication would
result in increased oil consumption and coking of the working valves.
b) Drain off the lub. oil at the prescribed intervals - when the compressor is still hot
from running - and fill in fresh compressor oil .
c) Regularly and carefully check the the air pressure of all stages. Varying
operating pressure values indicate anomalies in the valves, as well as leaks in
the piping system.
d) At regular intervals dismantle and strip down the combined suction and
pressure valves and clean all parts. Packing rings between valve and cylinder
head must be replaced in sets only. For details, see „4.3 Overhaul of Valves„.
e) Check the safety valves on the compressor by slightly turning the knurled nut at
short intervals.
Rev.: 15.04.1999 11
4.2 Servicing Schedule
After first commissioning, after a general overhaul, and after repairs to the crank
mechanism or cylinder, the following maintenance work should be done:
After 100 working hours
1.) Change the oil.

2.) Check the safety valves.
3.) Check the bolts and nuts on crankcase, cylinders, and pipelines for
tightness (See list of tightening torques).
4.) Check the drainage system.
After that the following intervals are to be kept:
After every 500 working hours:
1.) Check the safety valves

2.) Check and clean the cooling water chambers and pipes
3.) Check and – if necessary – replace the zinc protection
4.) Check the drainage system
After every 1000 working hours (however, at least once a year):
1.) Change the oil.

2.) Clean the air-intake filter
12 Rev.: 15.04.1999
1.) Clean the combined suction and pressure valves and check for wear.
2.) Check parts which come into direct contact with hot compressed air, such
as valves, cylinder heads and compressed-air pipelines for carbon residues
and, if necessary, clean them with solvents.
The admissible servicing intervals of the valves are determined above all by the
operating conditions and by the properties of the lubricant used. We
recommend to reduce the servicing intervals in case of severe operating
conditions.
Rev.: 15.04.1999 13
4.3 Overhaul of Valves
The suction and pressure valves of the compressor require conscientious care and
maintenance. Their springs and plates are the most intensely stressed parts of the
compressor.
For cleaning, the concentric valves have to be dismantled by removal of the fitting
bolt. Soaking of the components in paraffin facilitates removal of coked deposits.
Care should be taken that the ground sealing surfaces, and valve plates are neither
scratched nor damaged. Springs and valve plates should be checked for damage
and wear and replaced, if necessary. For reassembly, adhere strictly to the
assembly diagram (parts list). Parts of different valves must not be mixed. Tighten
the fitting bolt with the prescribed torque. After reassembling check the soft
running of the valve plates against the spring pressure using a rounded pin. Valves
or valve parts must be clamped in a vice with smooth jaws only. When fitting the
valves, use new packing rings in sets and see that they are properly positioned.
4.4 Overhaul of Pistions and Cylinders
All components must first be marked so as to maintain pairings (assignment of

pistons and cylinders) and the positioning of the parts for reassembly.
To measure clearance and wear, first of all, all parts must be cleaned and checked
for damage. The measurement of the cylinder diameter is carried out using a
precision internal gauge applied in the operational way of the piston rings.
To check the joint clearance, the piston rings should be inserted at a right angle
into the upper cylinder aperture and positioned at a location where the cylinder liner
shows no signs of wear. The joint clearance is measured using a feeler gauge.
Parts, which have reached or exceeded their service life (see List of Wear Limits),
should be replaced.
When re-installing the cylinder liner, the overflow bore holes in the area of the 2nd
stage valve must match.
14 Rev.: 15.04.1999
When fitting the cylinder liner the bearing surfaces in the cylinder block must be
cleaned and applied with sealing grease so that the liner slides into the cylinder
without dislodging the O-rings. Only grease may be used which is non-aggressive
to the O-rings. Do not grease the cylinder liner, otherwise the grease will be pushed
up when fitting the liner, preventing correct contact at the cylinder recess.
When fitting the piston observe Fig. Piston Assembly.

Clean the piston again after having removed the piston rings by means of piston
ring pliers. Oil must be applied to piston and piston rings before the piston is fitted
back into the cylinder. The piston must be installed with mounted connecting rod.
When fitting the piston proceed as follows:

Before fitting make sure that the joints of the rings are staggered and that they are
on alternate sides, outside the overflow bore holes for the valves 2nd stage. Take
care that the piston rings, particularly those of the 2nd stage, are placed centrically
in the piston. Regular radial projection is absolutely necessary, when assembling
see detail at "A" of Fig. "Piston Assembly" .
Insert the well-oiled piston with its rings and connecting rod from the top of the
cylinder liner. Once the piston rings 1st stage have been introduced, the piston has
to be pushed downwards until the first ring of the 2nd stage touches the chamfer C.
By applying slight pressure to the piston head, the piston can now be twisted about
15° to the left and right and worked easily ring by ring into the cylinder runway of
the 2nd stage.
Do not introduce the piston with force in order to avoid jams or breaking of piston
rings. If the piston jams, it must to be removed again and the piston rings centered
again exactly.
After fitting of piston and connecting rod turn the compressor by hand to see that
nothing jams.
Rev.: 15.04.1999 15
16 Rev.: 15.04.1999
4.5 Overhaul of crankshaft and connecting rod
Connecting rods and bearing covers are identified by punched figures. The location
of the covers must not be changed. Mark the individual parts to maintain correct
positions during reassembly.
After disassembly, clean all parts, check all bearings and bearing pins for wear and
damage. Check the clearance of the connecting rod by means of a precision gauge
(see List of Wear Limits).
Refitting of the crankshaft
Thoroughly oil the bearings and bearing pins as well as the associated components
before assembly. Insert the crankshaft in the crankcase first without shaft seals and
then screw on the housing cover with its gasket. Check wether the axial clearance
of the crankshaft is within the admissible clearance . Fit the shaft seal and tighten
the housing cover screws to the prescribed torque.
Refitting of the connecting rods
Oil the crank pin and bolt threads.

Place the upper part of the connecting rod with bearing shell on the crank pin and
see that the shell is correctly positioned in the connecting rod.
Put the lower part of the connecting rod with bearing shell from the opposite side,
pass through the fitting bolts and screw them into the upper part of the connecting
rod.
After pretensioning both bolts to approx. 30 Nm using the torque wrench tighten to
the prescribed torque.
Rev.: 15.04.1999 17
4.6 Protection against Corrosion during prolonged Shut-Down

Compressors must be stored in a dry room. In case of long storage a protection
of all inner components should be carried out according to the manual at least
every 8 months. Before first commissioning, the compressors must be checked
by a trained engineer for damage which may result from long storage. A report
of inspection must be sent to HATLAPA. Noticed damage during this check are
not covered by our guarantee. The date of commissioning or supply of the
vessel to owner must be advised to us.
Compressors which will be put out of operation for several months must be
protected against corrosion.
Internal protection:
• Open drain valves of 1st and 2nd stage under pressure.
• Run the compressor without pressure while the drain valves are open.
• Close the drain valves.
• Remove the air-intake filter-and pour about 250 cm³ of anti-corrosion oil into the
air-intake socket within approx. 2 minutes.
• Shut down the compressor and open the drain valves.
External protection:
• After cleaning, apply rust-preventive paint to all parts.
• Components made of light alloy, copper or brass need no treatment.
18 Rev.: 15.04.1999
5 Trouble Shooting
The following details are intended to provide a brief guide to determining the
cause of abnormal operation. We do not claim that this information is complete.
It only deals with the faults most frequently encountered, as known from
experience.
a) Intermediate pressure too low after 1st stage:

Leaking suction/pressure valve 1st stage
Leaking drain valve 1st stage
b) Intermediate pressure too high after 1st stage (safety valve blowing off):
Leaking suction valve 2nd stage
c) Compressed-air delivery too low:

Still open or leaking drain valves.
Combined suction/pressure valve damaged or leaking.
Leaking cooler or compressed-air delivery line.
Clogged cooler or compressed-air delivery line (at the same time, pressure at
the compressor considerably higher than in the compressed-air receiver).
d) Safety valve blowing off although pressure is normal:

Defective safety valve.
e) Safety valve of final stage blowing off, final pressure too high :
Closed valve on compressed-air receiver / non-return valve does not open.
Blockage of cooler or of compressed-air delivery line .
Defective pressure control switch (of the automatic system).
Rev.: 15.04.1999 19
6 Spare Parts
We recommend to keep some spare parts in stock in order to allow quick

remedy of minor failures due to the natural wear and tear.
1 set of valve plates and valve springs for each stage

1 set of piston rings incl. oil scraper ring for each stage
1 set of sealing rings and gaskets for each stage
If the compressor is intended for continuous operation, in addition stock:

1 combined suction and pressure valve for each stage
1 set of crankshaft bearings and connecting-rod bearings
1 piston with wrist pin and piston rings for each stage
20 Rev.: 15.04.1999
7 Instructions for Correctly Ordering Spare Parts
When ordering spare parts, the following details must be given:

1.) Serial No. and type designation (see name plate).
2.) Ident. No. from the spare parts list.
3.) Method of the required dispatch, as well as consignee and address for the
invoice.
4.) Name of the vessel (ex-name), Yard No., and Shipyard.
In order to receive spare parts with the least possible delay, get in touch direct
with

Phone: (+49) 4122 / 711- 0
Fax: (+49) 4122 / 711 - 330
or with our accredited agents, after-sales service stations or licensees/co-

operators as per attached list.
Rev.: 15.04.1999 21
ENGLISH
INSTALLATION AND
MAINTENANCE INSTRUCTIONS
FOR ELECTRIC MOTORS
0280.1400
ENGLISH
In case the motors are stored for more than

READ CAREFULLY THIS MANUAL
two years, the bearings must be replaced or the
BEFORE INSTALLING THE MOTOR
lubrication grease must be totally removed after
cleaning.
RECEIVING CHECK Single phase motors when kept in stock
for 2 years or more must have their capacitors
Check if any damage has occured during
replaced (if any).
transportation.
We recommend to turn the shaft (by hands)
üCheck nameplate data.
at least once a month, and to measure the
üRemove shaft locking device (if any) before
insulation resistance before installing it, in cases
operating the motor.
of motors stored for more than 6 months or when
üTurn the shaft with the hand to make sure it
subject to high humidity areas.
is turning freely. If motor is fitted with space heaters, these
HANDLING AND TRANSPORTATION should be switched on.
1 - General Insulation Resistance Check

MOTORS MUST NOT BE LIFTED BY Measure the insulation resistance before
THE SHAFT, BUT BY THE EYEBOLTS operating the motor and/or when there is any
sign of humidity in the winding.
Lifting devices, when supplied, are
designed only to support the motor. If the motor The resistance measured at 25ºC must be:
has two lifting devices then a double chain must
be used to lift it. Ri ≥ (20 x U) / (1000 + 2P) [MΩ]
Lifting and lowering must be done gently (measured with a MEGGER at 500 V d.c.)
without any shocks, otherwise the bearings can where U = voltage (V); P = power (kW).
get damaged.
If the insulation resistance is less than 2
DURING TRANSPORTATION,
megaohms, the winding must be dried
MOTORS FITTED WITH ROLLER OR
according to the following:
ANGULAR CONTACT BEARINGS
Warm it up inside an oven at a minimum
ARE PROTECTED AGAINST
temperature of 80ºC increasing 5ºC every hour
BEARING DAMAGES WITH A
until 105ºC, remaining under this temperature
SHAFT LOCKING DEVICE.
for at least one hour.
Check if the stator insulation resistance
THIS LOCKING DEVICE MUST BE
remains constant within the accepted values. If
USED ON ANY FURTHER MOTOR
not, stator must be reimpregnated.
TRANSPORTATION, EVEN WHEN
THIS MEANS TO UNCOUPLE
THE MOTOR FROM THE DRIVEN
MACHINE. INSTALLATION
STORAGE 1 - Safety
If motors are not immediately installed, All personnel involved with electrical
they must be stored in dry places, free of installations, either handling, lifting, operation
dust, vibrations, gases, corrosive smokes, or maintenance must be well informed and
under constant temperature and in normal updated concerning safety standards and
position free from other objects. principles that govern the work and carefully
Motor storage temperature must remain follow them.
between 5ºC to 60ºC, with relative humidity not We strongly recommend that these jobs
exceeding 50%. are carried out by qualified personnel.
MAKE SURE THAT ELECTRIC designed in such a way to stop any vibration
MOTORS ARE SWITCHED OFF originated from resonance.
BEFORE STARTING ANY
MAINTENANCE SERVICE. 4 - Drain Holes
Motors must be protected against acci- Make sure the drains are placed in the
dental starts. lower part of the motor when the mounting
When performing any maintenance configuration differs from that specified on the
service, disconnect the motor from the power motor purchase order.
supply. Make sure all accessories have been
switched off and disconnected. 5 - Balancing
In order to prevent from penetrating dust
and/or water into the terminal box, cable glands WEG MOTORS ARE DYNAMICALLY
or threaded pipe in the lead holes must be BALANCED WITH HALF KEY, AT NO
installed. LOAD AND UNCOUPLED.
Do not change the regulation of the
protecting devices to avoid damaging. Transmission elements such as pulleys,
couplings, etc must be dynamically balanced
2 - Operating Conditions with half key before installation.
Use always appropriate tools for installation and
Electric motors, in general, are designed removal.
for operation at an altitude of 1000m above sea
level for an ambient temperature between 0ºC 6 - Alignment
and 40ºC. Any variation is stated on the
ALIGN THE SHAFT ENDS AND
nameplate.
USE FLEXIBLE COUPLING,
COMPARE THE CURRENT, VOLTAGE, WHENEVER POSSIBLE.
FREQUENCY, SPEED, OUTPUT AND
Ensure that the motor mounting devices
OTHER VALUES DEMANDED BY THE
do not allow modifications on the alignment and
APPLICATION WITH THE DATA GIVEN
further damages to the bearings.
ON THE NAMEPLATE.
When assembling a half-coupling, be sure
Motors supplied for hazardous locations to use suitable equipment and tools to protect
must be installed in areas that comply with that the bearings.
specified on the motor nameplate. Suitable assembly of half-coupling:
Check that clearance Y is less than
KEEP AIR INLET AND OUTLET FREE 0.05 mm and that the difference X1 to X2 is less
AND CLEAN. THE AIR BLOWN OUT than 0.05 mm, as well.
BY THE MOTOR SHALL NOT ENTER
AGAIN. THE DISTANCE BETWEEN
THE AIR INLET AND THE WALL
MUST BE AROUND ¼ OF THE
INLET OPENING DIAMETER.
3 - Foundation
Note: Dimension X1 and X2 must be
Motors provided with feet must be installed 3mm minimum
on solid foundations to avoid excessive Figure and alignment tolerances
vibrations.
The purchaser is fully responsible for the 7 - Belt Drive
foundation.
Metal parts must be painted to avoid When using pulley or belt coupling, the
corrosion. following must be observed:
The foundation must be uniform and suf- Belts must be tighten just enough to avoid
ficiently tough to support any schock. It must be slippage when running, according to the
specifications stated on the belt supplier Make sure to use the correct cable
recommendation. dimension, based on the rated current stamped
on the motor nameplate.
WARNING:
Excessive tension on the pulleys will BEFORE ENERGIZING THE
damage the bearings and lead to a TERMINALS, CHECK IF THE
probable shaft rupture. GROUNDING IS MADE
ACCORDING TO THE CURRENT
STANDARDS. THIS IS ESSENTIAL
8 - Connection AGAINST ACCIDENT RISKS.
WARNING: When the motor is supplied with

Voltage may be connected at standstill protective or monitor temperature device such
inside the terminal box for heating elements or as thermostats, thermistors, termal protector, etc,
direct winding heating. connect their terminals to the corresponding
devices on the control panel.
WARNING:
The capacitor on single-phase motors 10 - Start-Up
can retain a charge which appears across the
THE KEY MUST BE FASTENED OR
motor terminals, even when the motor has
REMOVED BEFORE STARTING THE
reached standstill.
MOTOR.
A WRONG CONNECTION CAN a) The motor must start and operate
BURN THE MOTOR. smoothly. In case this does not occur, turn it off
and check the connections and the mounting
before starting it again.
Voltage and connection are indicated on
b) If there is excessive vibration, check if
the nameplate. The acceptable voltage the fastening screws are correctly fastened.
variation is ±10%; the acceptable frequency Check also if the vibration comes from a
variation is ±5% and the total acceptable neighbour machine. Periodical vibration checks
variation is ± 10%. must be done.
c) Run the motor under rated load for a
9 - Starting Methods short period of time and compare if the running
current is equal to that stamped on the
The motor is rather started through direct nameplate.
starting. In case this is not possible, use
compatible methods to the motor load and MAINTENANCE
voltage.
The rotation direction is clockwise if the WARNING:
motor is viewed from DE side and if the SAFETY CHECK LIST
phases are connected according to the
sequence L1, L2, L3. 1 - General Inspection
To change the rotation direction, inter-
change two of the connecting leads. üCheck the motor periodically.
üKeep the motor clean and assure free air flow.
THE CONNECTION TO THE POWER üCheck the seals or V Ring and replace them, if
SUPPLY MUST BE DONE BY required.
QUALIFIED PERSONNEL AND WITH üCheck the connections as well as supporting
FULL ATTENTION TO ASSURE A SAFE screws.
AND PERMANENT CONNECTION. üCheck the bearings and observe: Any excessive
AFTER CONNECTING THE MOTOR, noise, vibration, bearing temperature and grease
CHECK FOR ANY STRANGE BODY condition.
INSIDE THE TERMINAL BOX. THE üWhen a change, under normal conditions, is
CABLE INLETS NOT IN USE MUST BE detected, check the motor and replace the
CLOSED. required parts.
The frequency of the inspections depends 2 - Machines Fitted with Grease Nipples
on the motor type and on the application
conditions. It is strongly recommended to grease the
machine while running. This allows the grease
LUBRICATION renewal in the bearing housing. When this is
not possible due to turning parts by the grease
FOLLOW THE REGREASING device (pulleys, bushing, etc) that offer some
INTERVALS. THIS IS FUNDAMENTAL risk to the physical integrity of the operator,
FOR PROPER MOTOR OPERATION. proceed as follows:
üClean the area near the grease nipple.
1 - Machines without Grease Nipples üPut approximately half of the total grease and
run the motor for 1 minute at full speed.
Motors up to frame 200 are normally fitted Then turn off the motor and insert the rest of the
without grease nipples. In these cases the grease.
regreasing shall be done at the preventive üThe injection of all the grease with the motor in
maintenance job observing the following standstill can make the grease penetrate into the
aspects: motor, through the inner seal of the bearing
housing.
üDisassemble carefully the motors.
üTake all the grease out. FOR LUBRICATION USE ONLY
üWash the bearing with querosene or diesel. MANUAL GREASE GUN.
üRegrease the bearing immediately.
RELUBRICATION INTERVALS
TABLE 1 - BALL BEARINGS - Series 62/63

Relubrication intervals (running hours horizontal position)
II pole IV pole VI pole VIII pole X pole XII pole Grease
Serie 62
Bearing 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz (g)
6209 18400 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 9
6211 14200 16500 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 11
6212 12100 14400 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 13
Serie 63
6309 15700 18100 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 13
6311 11500 13700 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 18
6312 9800 11900 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 21
6314 3600 4500 9700 11600 14200 16400 17300 19700 19700 20000 20000 20000 27
6316 - - 8500 10400 12800 14900 15900 18700 18700 20000 20000 20000 34
6319 - - 7000 9000 11000 13000 14000 17400 17400 18600 18600 20000 45
6322 - - 5100 7200 9200 10800 11800 15100 15100 15500 15500 19300 60
TABLE 2 - ROLLER BEARINGS - Series NU 3

NU 309 9800 13300 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 13
NU 311 6400 9200 19100 20000 20000 20000 20000 20000 20000 20000 20000 20000 18
NU 312 5100 7600 17200 20000 20000 20000 20000 20000 20000 20000 20000 20000 21
NU 314 1600 2500 7100 8900 11000 13100 15100 16900 16900 19300 19300 20000 27
NU 316 - - 6000 7600 9500 11600 13800 15500 15500 17800 17800 20000 34
NU 319 - - 4700 6000 7600 9800 12200 13700 13700 15700 15700 20000 45
NU 322 - - 3300 4400 5900 7800 10700 11500 11500 13400 13400 17300 60
NU 324 - - 2400 3500 5000 6600 10000 10200 10200 12100 12100 15000 72
Note: The stator grips must be applied over the
üThe ZZ bearings from 6201 to 6307 do not side face of the inner ring to be disassembled or
require relubrication as its life time is about over an adjacent part.
20,000 hours. It is essential that bearings assembly be
üTables 1 and 2 are intended for the lubrication done under cleanning conditions to ensure
period under bearing temperature of 70°C (for good operation and to avoid damages. New
bearings up to 6312 and NU 312) and bearings shall only be taken out from their cases
temperature of 85°C (for bearings 6314 and NU when assembling them.
314 and larger). Before installing a new bearing it is
üFor each 15°C of temperature rise, the required to check the shaft fitting for any sharp
relubrication period is reduced by half. edge or strike signals.
üThe relubrication periods given above are For bearing assembly warm their inner
for those cases applying Polyrex® EM grease. parts withsuitable equipment - inductive pocess
ü When motors are used on the vertical - or use suitable tools.
position, their relubrication interval is reduced SPARE PARTS
by half if compared to horizontal position
motors. When ordering spare parts, please specify
WE RECOMENDED TO USE BALL the full type designation and product code as
BEARINGS FOR MOTORS DIRECTLY stated on the motor nameplate. Please also
inform the motor serial number stated on the
COUPLED TO THE LOAD. nameplate.
WARNING: MOTORS FOR HAZARDOUS
EXCESS OF GREACE CAN CAUSE
BEARNING OVERHEATING LOCATIONS
RESULTING IN COMPLETE Besides the recommendations given
DAMARGE. previously, these ones must be also followed:
Compatibility of Polyrex® EM grease with THE SPECIFICATION OF THE MOTOR

other types of grease: INSTALLATION PLACE IS FOR
CUSTOMER’S RESPONSIBILITY,
Containing polyurea thickener and mineral WHO WILL ALSO DETERMINE THE
oil, the Polyrex® EM grease is compatible with ENVIRONMENT CHARACTERISTICS.
other types of grease that contain:
üLithium base or complex of lithium or polyurea Motors for hazardous locations are
and highly refined mineral oil. manufactured according to specific standards
üInhibitor additive against corrosion, rust and for such environments and they are certified by
anti-oxidant additive. worldwide certifying entities.
Notes: 1 - Installation
üAlthough Polyrex® EM is compatible with types
of grease given above, we do not recommended The complete installation must follow
to mix it with any other greases. procedures given by the local legislation in effect.
ü If you intend to use a type of grease different
than those recommended above , first contact THE INSTALLATION OF HAZARDOUS
WEG. LOCATION MOTORS MUST BE
üOn applications (with high or low temperatures, CARRIED OUT BY SKILLED PEOPLE,
speed variation, etc), the type of grease and
relubrification interval are given on an additional AND THE THERMAL PROTECTION
nameplate attached to the motor. MUST BE ALWAYS INSTALLED,
EITHER INSIDE OR OUTSIDE THE
THE USE OF STANDARD MOTORS
MOTOR, OPERATING AT THE RATED
IN SPECIFIC AREAS OR SPECIAL
CURRENT.
APPLICATIONS MUST BE DONE BY
CONSULT TO THE GREASE 2 - Maintenance
MANUFACTURER OR WEG
Maintenance must be carried out by repair
shops authorized by WEG.
DISASSEMBLY AND ASSEMBLY Repair shops and people without Weg’s
authorization who will perform any service on
Disassembly and assembly must be done hazardous location motors will be fully
by qualified personnel using only suitable tools responsible for such service as well as for any
and appropriated methods. consequential damage.
üLower efficiency.
ANY ELECTRICAL OR MECHANICAL
üHigher vibration.
MODIFICATION MADE ON
üHigher noise level.
HAZARDOUS LOCATION MOTORS üHigher rated current.
WILL VOID THE CERTIFICATION. ü Higher temperature rise.
When performing maintenance, üReduced motor insulation.
installation or relubrication, follow these üReduced bearing life.
instructions:
1- Standard Motors
üCheck if all components are free of edges,
knocks or dirt.
üMake sure all parts are in perfect conditions. üVoltages lower than 440V do not require filter.
üLubricate the surfaces of the endshield fittings üVoltages equal or higher than 440V or lower
with protective oil to make the assembly easier. than 575V require filter for motor power supply
üUse only rubber hammer to fit the parts. cables longer than 20 meters.
üCheck for correct bolts tightening. üVoltages equal or higher than 575V require
üUse clearance calibrator for correct T-box fitting filter for any size of power supply cables.
(smaller than 0.05mm).
DO NOT REUSE DAMAGED OR IF SUCH RECOMMENDATIONS ARE
WORN PARTS. REPLACE THEM BY NOT FOLLOWED ACCORDINGLY,
NEW ONES SUPPLIED BY THE MOTOR WARRANTY WILL BE VOID.
FACTORY.
2- Inverter Duty Motors:
MOTORS DRIVEN BY VFD üCheck power supply voltage of the forced
Applications using VFD´s without filter cooling set.
can affect motor performance as follows: üFilters are not required.
WARRANTY TERMS
Weg warrants its products against defects in This warranty does not include disassembly
workmanship and materials for twelve (12) services at the purchaser facilities,
months from the invoice date issued by the transportation costs with product, tickets,
factory, authorized distributor or agent limited accomodation and meals for technical personnel
to eighteen (18) months from manufacturing date when requested by the customer.
independent of installation date as long as the The warranty service will be only carried out at
following items are fulfilled accordingly: Weg Authorized Repair Shops or at Weg’s
facilities.
- Proper transportation, handling and storage;
- Correct installation based on the specified Components whose useful life, under normal
ambient conditions and free of corrosive use, is shorter than the warranty period are not
gases; covered by these warranty terms.
- Operation under motor capacity limits; The repair and/or replacement of parts or
- Observation of the periodical maintenance components, when effected by Weg and/or any
services; Weg Authorized Repair Shop, will not give
- Repair and/or replacement effected only by warranty extension.
personnel duly authorized in writing by Weg;
- The failed product be available to the supplier This constitutes Weg’s only warranty in
and/or repair shop for a required period to connection with this sale and the company will
detect the cause of the failure and have no obligation or liability whatsoever to
corresponding repair; people, third parties, other equipment or
- Immediate notice by the purchaser about installations, including without limitation, any
failures accured and that these are accepted claims for consequential damages or labor costs.
by Weg as manufacturing defects.
WEG EXPORTADORA S.A.
AV. PREF. WALDEMAR GRUBBA, 3000
89256-900 JARAGUÁ DO SUL, SC - BRAZIL
PHONE (55) (47) 372-4002
FAX (55) (47) 372-4060
http://www.weg.com.br
FOR FURTHER INFORMATION PLEASE CONTACT YOUR NEAREST WEG SALES OFFICE
Instruction manual
Piston compressor
L9 - L14
L9 - L14 Piston Compressors
INTRODUCTION:
This Instructions Manual contains a brief technical description and important instructions
on commissioning, maintenance and servicing of the compressor.
We recommend to read this manual carefully in order to be able, in case of trouble, to
detect the cause quickly and care for remedy and, in case of repairs, to make provisions for
proper mounting acc. to the instructions.
This manual assumes a general technical knowledge of piston compressors and does not
claim to be complete. If repairs become necessary, only original HATLAPA spare parts
must be used in order to maintain the operational reliability and efficiency of the machine.
For identification and supply of spare parts, an order must contain the following
information:
1. Serial No. and type designation (see name plate).

2. Ident No. from the spare parts list.
3. Method of the required dispatch, as well as consignee and address for the invoice.
4. Name of the vessel (ex-name), Yard No., and Shipyard.
In order to receive spare parts with the least possible delay, get in touch direct with

Phone: (+49) 4122 / 711- 0
Fax: (+49) 4122 / 711 - 330
or with our accredited agents, after-sales service stations or licensees/co-operators as per

attached list.
We wish to point out that repairs and/or modifications to the compressor which are carried
out without our approval during the guarantee period, will release us from our guarantee
obligations. The manufacturer cannot be rendered liable for damage to the compressor
which can be shown to have been caused by the use of unsuitable lubricants or failure to
comply with the operating instructions.
Reprint of the text or illustrations, or even extracts therefrom is prohibited.
Subject to alterations at all times due to technical development.
2 Rev.: 15.09.1999
Piston Compressors L9 - L14
TABLE OF CONTENTS:
Page:
1 Description ..................................................................................................................4
1.1 Design .......................................................................................................................4
1.2 Specifications ............................................................................................................5
1.3 Working method ........................................................................................................5
1.4 Cooling ......................................................................................................................5
1.5 Lubrication of Working Parts .....................................................................................6
1.6 Condensate Separation .............................................................................................6
1.7 Starting without Back-Pressure .................................................................................6
2 Setting-up and Installation.........................................................................................7
3 Commissioning...........................................................................................................8
3.1 Safety References .....................................................................................................8
3.2 Before Starting...........................................................................................................9
3.3 After Starting..............................................................................................................9
3.4 During Operation .......................................................................................................9
3.5 After Stopping............................................................................................................9
4 Servicing and Maintenance .....................................................................................10

4.1 General Servicing Instructions.................................................................................10
4.2 Servicing Schedule ..................................................................................................11
4.3 Overhaul of Valves ..................................................................................................13
4.4 Overhaul of Pistons and Cylinders ..........................................................................13
4.5 Overhaul of Crankshaft and Connecting Rods ........................................................14
4.6 Protection against Corrosion during prolonged Shut-Down .....................................15
5 Trouble Shooting ......................................................................................................16
6 Spare Parts................................................................................................................17
7 Instructions for Correctly Ordering Spare Parts....................................................18
Rev.: 15.09.1999 3
1 Description
1.1 Design
This two-stage compressor has 2 cylinders with trunk piston and a single-throw
crankshaft. The 1st and 2nd stage cylinders are of 90°V-arrangement. All bearings
of crankshaft and connecting rods are anti-friction bearings. These bearings as well
as the working surface of the cylinders are splash lubricated by means of an oil
splash pin
The use of trunk pistons at all stages guarantees low wear and safe lubrication with
high service life expectancy for pistons and cylinders.
The equalization of mass of the crank mechanism and the special arrangement of
the two cylinders together with the use of trunk pistons guarantee low vibrations
during operation. They allow 3-point resilient mounting without any problems.
4 Rev.: 15.09.1999
1.2 Specifications
Type L9 L14
Number of Cylinders 2 2
st
Cylinder Bore 1 Stage [mm] 85,5 85,5
nd
Cylinder Bore 2 Stage [mm] 40 40
Piston Stroke [mm] 42 42
Crankshaft-Axial Clearance [mm] 0,2- 0,2-
0,3 0,3
Quantity of Lub. Oil min. [l] 1,1 1,1
Quantity of Lub. Oil max. [l] 1,5 1,5
Weight without E-Motor [appox. kg] 83 83
1.3 Working method
The compressor compresses the ambient air sucked in through the air-intake filter
with silencer in two stages to the selected final pressure. Lamellar valves
automatically control the gas exchange in the compression chambers. After every
stage the heated compressed air flows through a large-dimensioned cooler. To
monitor the correct functioning of the compressor a pressure gauge is installed
after each compression stage. Safety valves, installed after every compression
stage, prevent the pressure from rising above the admissible limit.
1.4 Cooling
The heat generated in the machine by air compression and mechanical friction is
led off to the atmosphere. A radial-flow fan fixed directly on the shaft and a
streamlined hood guide the cooling air at high speed over the ribbed cylinders,
valves and cylinder heads and over the ribbed cooler of the first and second stages
installed on the circumference.
Rev.: 15.09.1999 5
1.5 Lubrication of Working Parts
Only compressor oils according to the enclosed oil specification chart may be used.
The crankshaft and connecting rod bearings are splash lubricated by means of a
pin fixed to the connecting rod of the 1st stage.
1.6 Condensate Separation
Together with the moist ambient air which is sucked in, water enters the
compressor in form of vapour. By compression and subsequent cooling of the
compressed air, this water vapour condenses. The water separated from the
compressed air blends with the oil which is entrained in very small quantities from
the lubricated working surfaces of the cylinders. This water-oil mixture is extracted
from the compressed-air stream in special condensate collector chambers.
At regular intervals – after every 15 min. for about 10 sec. - as well as on starting
and stopping of the compressor, the collector chambers must be drained by
opening the manual valves or optionally by automatic devices. Such condensate
separation reduces wear and tear due to corrosion in the compressor components,
and in the connected pipelines and prevents the compressor from damage due to
water shocks. Disposal of the condensate has to be carried out according to the
locally valid prescriptions.
1.7 Starting without Back-Pressure
During starting-up, the driving motor must be unloaded by opening the drain valves.
In automatically controlled compressors, unloading is effected by time-lagged
closing of these valves.
6 Rev.: 15.09.1999
2 Setting-up and Installation
The compressor is driven by a directly-coupled electric motor through a flexible

coupling. Motor and compressor are fastened to the common base frame distortion-
free before being put into operation.
In case of resilient mounting there must be sufficient room for movement. All
pipelines must then be connected to the consumer system by flexible hoses, strictly
adhering to the installation instructions.
All drain pipelines are to be laid with constant descent and must discharge after the
shortest possible distance into an open funnel . Each compression stage needs a
separate drain pipeline in order to guarantee perfect drainage of the individual
stages; stop valves are to be installed as closely as possible to the compressor.
For sufficient supply of cooling air, the minimum distance to the cooler must be
observed (see final drawing). The air inlets may not be influenced by the warm
exhaust of other machinery.
Further instructions on the installation of valves, pipelines, and control equipment

are to be taken from the enclosed piping diagrams with their respective
descriptions.
Rev.: 15.09.1999 7
3 Commissioning
3.1 Safety References
The compressor has been produced according to the State-of-art and is

operationally reliable.
The compressors are a source of danger if inexpertly or improperly used.
• Only authorised and trained persons are allowed to operate and repair the
machine or to do maintenance work. Make sure that these persons have read
and understood the complete operating instructions and safety instructions.
• The compressor may only be used for compressing air.
• The compressor may not be operated without safety or protecting devices.
• Only sealed safety valves may be used, readjustment is not allowed. They
have to be replaced immediately when defective.
• Before starting any maintenance work it is necessary to stop the compressor
system and to prevent it from re-starting. The system has to be voltage–free,
all parts containing compressed air have to be depressurized.
• The compressor system may only be operated in perfect working condition.
It must be free of foreign parts.
• Rebuilding or any other changes to the compressor system that may
influence the safety are strictly prohibited.
8 Rev.: 15.09.1999
At initial commissioning, after a several months` interruption in operation, or

after extensive repair work the operator must observe the following points (see
also 4.6 Protection against corrosion during prolonged Shut-Down).
3.2 Before Starting
• The compressor must be filled to the upper oil level mark with prescribed
compressor oil (see list of recommended oils).
• Check that the crankshaft is moving easily by turning over the flywheel by
hand; but make sure that the compressor set cannot be started
unintentionally.
• Open the shut-off valve in the pipeline leading to the compressed-air
receiver.
• Open drain valves.
3.3 After Starting
• Check the direction of rotation of the shaft (see also arrow).

• Close the drain valves and check for leakage.
3.4 During Operation
• Once the final pressure is attained, check the safety valves for proper
functioning: Slightly turn the knurled nut until the valve blows off. After
closure, check for leakage.
• After fitting of new working parts (repair), run in the compressor for about
one hour at low final pressure (5 to 10 bar).
3.5 After Stopping
• Open the drain valves at the condensate separators.

• Check that the automatic drain valves open properly.
• Check the non-return valve in the pipe to the compressed-air receiver for
leakage.
Rev.: 15.09.1999 9
4 Servicing and Maintenance
For trouble-free operation, it is necessary to check regularly and carefully the

safety devices and the wear and tear parts of the compressor as well as the
functioning of fitted valves and instruments. Regularly check the stock of spare
parts and seals which must be protected against corrosion, and stock up to the
specified quantity again after any servicing and overhaul work.
The following maintenance and overhaul instructions must be adhered to.
However, they do not claim to be complete.
Observance of the servicing intervals as mentioned below guarantees great
reliability and long service life of the compressor.
In this connection, reference is made to the requirements of the rules of the
classification societies and seafarer unions.
4.1 General Servicing Instructions
a) Check the oil level daily. Fill the crankcase with the prescribed compressor oil,
however, not exceeding the top oil level mark. Too much oil results in foaming
due to immersion of rotating parts, with the compressor at extremely inclined
position. Intense misting of the oil and uncontrolled cylinder lubrication would
result in increased oil consumption and coking of the working valves.
b) Drain off the lub. oil at the prescribed intervals - when the compressor is still hot
from running - and fill in fresh compressor oil.
c) Regularly and carefully check the air pressure of all stages. Varying operating
pressure values indicate anomalies in the valves, as well as leaks in the piping
system.
d) At regular intervals dismantle and strip down combined suction and pressure
lamellar valves and clean all parts. For details, see 4.3 „Overhaul of Valves„.
e) Check the safety valves on the compressor by slightly turning the knurled nut at
short intervals.
10 Rev.: 15.09.1999
4.2 Servicing Schedule
After first commissioning, after a general overhaul, and after repairs to the crank
mechanism or cylinder, the following maintenance work should be done:
After 100 working hours
1.) Change the oil.

2.) Check the safety valves.
3.) Check the bolts and nuts on crankcase, cylinders, and pipelines for
tightness (See list of tightening torques).
4.) Check the drainage system.
After that the following intervals are to be kept:
1.) Check the safety valves

2.) Check the drainage system
3.) Clean the air-intake filter
After every 1000 working hours (however, at least once a year):
1.) Change the oil.

2.) Clean the ribbed coolers, the ribbed cylinders and the radial-flow fan
Rev.: 15.09.1999 11
1.) Clean the combined suction and pressure lamellar valves and clean all parts
2.) Check parts which come into direct contact with hot compressed air, such
as valves, cylinder heads and compressed-air pipelines for carbon residues
and, if necessary, clean them with solvents.
The admissible servicing intervals of the valves are determined above all by the
operating conditions and by the properties of the lubricant used. We
recommend to reduce the servicing intervals in case of severe operating
conditions.
12 Rev.: 15.09.1999
4.3 Overhaul of Valves
The combined suction and pressure lamellar valves need no special maintenance.
During general servicing as per the servicing schedule, the valves should be
inspected only and checked as to whether there are breaks on the lamellar.
Cleaning must be done very carefully in order to prevent dirt particles from getting
between the sealing surfaces of the lamellar. Defective valves cannot be repaired,
but must be replaced completely. When installing the valves, only complete sets of
packing rings may be used and correctly positioned.
Cylinder head nuts and bolts for pipes should first be tightened by hand. Then nuts
should be initially tightened cross-wise using a torque wrench at approx. 10 Nm
(1 kpm) and then tightened securely in the same sequence to the necessary torque.
4.4 Overhaul of Pistons and Cylinders
Pistons and cylinders can be removed for cleaning and checking of wear without
dismantling the connecting rod and crankshaft. All components must first be
marked so as to maintain pairings (assignment of pistons and cylinders) and the
positioning of the parts for reassembly.
To dismantle the pistons after pulling out the cylinders, firstly remove each of the
retainer rings of the wrist pins using a pair of circlip pliers, and then push the wrist
pin out of the piston with a set bolt or other suitable device.
Heating the piston to between approx. 60°C and 80°C facilitates insertion of the
wrist pin. Piston rings should be removed and inserted only using piston-ring
pliers. Observe that the piston rings are correctly positioned (see parts list) and
stagger the joints when fitting. On inclined cylinders, the oil scraper ring joint
should point upwards when fitting.
To measure clearance and wear, first of all, all parts must be cleaned and checked
for damage. The measurement of the cylinder diameter is carried out using a
precision internal gauge applied in the operational way of the piston rings.
The nominal diameter of the piston is stamped on top of the piston head. The actual
diameter should be checked at the bottom end of the piston stem, at right angles to
the wrist pin axis. For fitting clearances and wear limits refer to the attached list.
Rev.: 15.09.1999 13
To check the joint clearance, the piston rings should be inserted at a right angle
into the upper cylinder aperture and positioned at a location where the cylinder liner
shows no signs of wear. The joint clearance is measured using a feeler gauge.
Before fitting the pistons and cylinders, the seat face on the crankcase and
underside of the cylinder must be carefully cleaned. Use new cylinder foot gaskets.
Apply oil to pistons and cylinders. Compress piston rings with a tensioning band
and slip the cylinders over the pistons by hand.
Take care that the cylinder head bolts do not touch the cooling ribs of the cylinders.
Parts, which have reached or exceeded their service life (see List of Wear Limits),
must be replaced.
4.5 Overhaul of Crankshaft and Connecting Rods
The crankshaft and the connecting rod are supported by anti-frictions. Axial and
radial clearance of the crankshaft can be checked at the shaft when fitted. There
must be no radial clearance. Axial clearance of 0.2 to 0.3 mm is admissible. Any
perceptible radial clearance and excessive axial clearance indicates beginning of
damage to the bearings and the bearings should be replaced.To this purpose the
mechanism of the compressor has to be dismantled: The crankcase cover and the
flywheel housing can be forced out by means of pressure screws. After the inner
bearing ring on the fan wheel side has been drawn off and the circlip (together with
its thrust washer) of the connecting rod bearing on the crank pin has been
loosened, the crankshaft can be drawn out of the needle bearings of the connecting
rod bearings to the flywheel side. New inner bearing rings are to be pushed on to
the shaft without violence after it has been warmed up to approx. 80° C.
Proceed in the reverse manner for re-assembly. When refitting the flywheel casing
and the gearcase cover use one new gasket each. Should the axial clearance not be
sufficient, further gaskets can be fitted to obtain the required clearance as stated
before.
14 Rev.: 15.09.1999
4.6 Protection against Corrosion during prolonged Shut-Down

Compressors must be stored in a dry room. In case of long storage a protection
of all inner components should be carried out according to the manual at least
every 8 months. Before first commissioning, the compressors must be checked
by a trained engineer for damage which may result from long storage. A report
of inspection must be sent to HATLAPA. Noticed damage during this check are
not covered by our guarantee. The date of commissioning or supply of the
vessel to owner must be advised to us.
Compressors which will be put out of operation for several months must be
protected against corrosion.
Internal protection:
st nd
• Open drain valves of 1 and 2 stage under pressure.
• Run the compressor without pressure while the drain valves are open.
• Close the drain valves.
• Remove the air-intake filter-and pour about 250 cm³ of anti-corrosion oil into the
air-intake socket within approx. 2 minutes.
• Shut down the compressor and open the drain valves.
External protection:
• After cleaning, apply rust-preventive paint to all parts.
• Components made of light alloy, copper or brass need no treatment.
Rev.: 15.09.1999 15
5 Trouble Shooting
The following details are intended to provide a brief guide to determining the
cause of abnormal operation. We do not claim that this information is complete.
It only deals with the faults most frequently encountered, as known from
experience.
a) Intermediate pressure too low and / or Compressed-air delivery too low:

Leaking lamellar valve(s)
Leaking piston rings
Leaking cooler
Leaking drain valve
b) Intermediate pressure too high and / or Compressed-air delivery too low:

Leaking lamellar valve(s)
Clogged cooler
c) Safety valve blowing off although pressure is normal:

Defective safety valve.
st
d) Safety valve 1 stage blowing off, intermediate pressure is too high:
sea b)
e) Safety valve of final stage blowing off, final pressure too high :
Closed valve on compressed-air receiver / non-return valve does not open.
Blockage of cooler or of compressed-air delivery line .
Defective pressure control switch (of the automatic system).
16 Rev.: 15.09.1999
6 Spare Parts
We recommend to keep some spare parts in stock in order to allow quick

remedy of minor failures due to the natural wear and tear.
1 lamellar valve for each stage

1 set of piston rings incl. oil scraper ring for each stage
1 set of sealing rings and gaskets for each stage
If the compressor is intended for continuous operation, in addition stock:

1 set of crankshaft bearings and connecting-rod bearings
1 piston with wrist pin and piston rings for each stage
Rev.: 15.09.1999 17
7 Instructions for Correctly Ordering Spare Parts

1.) Serial No. and type designation (see name plate).
2.) Ident. No. from the spare parts list.
3.) Method of the required dispatch, as well as consignee and address for the
invoice.
4.) Name of the vessel (ex-name), Yard No., and Shipyard.
In order to receive spare parts with the least possible delay, get in touch direct
with

Phone: (+49) 4122 / 711- 0
Fax: (+49) 4122 / 711 - 330
or with our accredited agents, after-sales service stations or licensees/co-

operators as per attached list.
18 Rev.: 15.09.1999
Ersatzteil-Verzeichnis
List of spare parts
Liste des pièces de rechange
Kolbenkompressor
Piston compressor
Compresseur à piston
L 9 - L 14
zum Ersatzteilverzeichnis
to the list of spare parts
vers la liste des pièces de rechanges

Ersatzteilverzeichnis Kompressor L9 / L14
List of spare parts Compressor L9 / L14
Liste des pièces de rechange Compresseur L9 / L14
Benennung / designation / désignation Tafel / table / planche
Schnittzeichnung / sectional drawing / plan de coupe
Kurbelgehäuse / crank case / carter.............................................................. 1-199-010
Kurbelwelle / crankshaft / arbre manivelle.................................................... 2-501-010
Fußschienen / supports / supports................................................................ 3-199-010
Zylinder und Zylinderköpfe / cylinders and cylinder heads /

cylindres et culasses ...................................................................................... 1-199-020
Ventile / valves / soupapes ............................................................................. 2-199-020
Kolben / pistons / pistons............................................................................... 3-199-020
Pleuelstangen / connecting rods / bielles ..................................................... 4-199-020
Kühlsystem / cooling system / système de refroidissement....................... 1-199-030
Armaturen / fittings / robinetterie................................................................... 1-199-040
Schwungrad und Kupplung / flywheel and coupling /

volant et accouplement................................................................................... 1-199-014
Ansaugsystem / suction system / système d’aspiration ............................. 1-199-032
Starre Lagerung / rigid mounting / suspension rigide ................................. 1-199-043
Elastische Lagerung / resilient mounting / suspension élastique.............. 1-199-044
Automatische Entwässerung / automatic drainage /

vidange automatique....................................................................................... 1-303-053
Stand: 26.03.2003
L9 / L14
Kurbelgehäuse
Crank case Tafel / Table / Planche
Carter 1-199-010
Teil-Nr. / Part-No. Ident-Nr. / Ident-No. Benennung / Designation Menge / Qty.
No. de pièces No. d´identific Désignation Qté.

1 10.10.10 Kurbelgehäuse 1
Crank case
Carter
2 10.10.20 Ölstandsauge 1
Oil level inspection glass
Verre de niveau d’huile
3 10.10.30 Verschlußschraube 1
Screw plug
Vis de fermeture
4 10.10.40 Dichtring 1
Packing ring
Rondelle de joint
5 10.10.50 Schwungradgehäuse 1
Flywheel housing
Carter-volant
6 10.10.60 Wellendichtring 1
Radial packing ring
Bague d’étanchéité
7 10.10.70 Sechskantschraube 4
Hexagon head bolt
Vis à tête hexagonale
8 10.10.80 Sicherungsring 4
Securing ring
Segment de sécurité
9 10.10.90 Dichtung 2
Gasket
Joint
10 10.10.100 Gehäusedeckel 1
Housing cover
Couvercle du carter
Hexagon head bolt
Vis à tete hexagonale
L9 / L14
Kurbelgehäuse
Crank case Tafel / Table / Planche
Carter 1-199-010

Securing ring
13 10.10.130 Wellendichtring 1
Radial packing ring
Bague d’étanchéité
14 10.10.140 Oeleinfüllstutzen 1
Filler tube for oil
Tuyau de remplissage d’huile
15 10.10.150 Gegenmutter 1
Counter nut
Contre-écrou
16 10.10.160 Tragösenverschlußschraube 1
Eye bolt/ screw plug
Boulon à oeillet/ vis de fermeture
17 10.10.170 Dichtring 1
Packing ring
Rondelle de joint
18 10.10.180 Dichtring 1
Packing ring
Rondelle de joint
L9 / L14
Kurbelwelle
Crankshaft Tafel / Table / Planche
Arbre manivelle 2-501-010

1 10.20.10.10 Kurbelwelle 1
Crank shaft
Arbre manivelle
2 10.20.10.20 Paßfeder 1
Fitting key
Clavette d’ajustage
3 10.20.10.30 Paßfeder 1
Fitting key
Clavette d’ajustage
4 10.20.20 Zylinderrollenlager 1
Cylinder roller bearing
Palier à rouleaux cylindriques
5 10.20.30 Zylinderrollenlager 1
Cylinder roller bearing
Palier à rouleaux cylindriques
6 10.20.40 Paßscheibe 1
Fitting disk
Disque d‘ajustage
L9 / L14
Fußschienen
Supports Tafel / Table / Planche
Supports 3-199-010

1 10.30.10 Fußschiene 1
Support
Support
Hexagon head bolt
Vis à téte hexagonale
Securing ring
Segmant de sécurité
4 10.30.40 Fußschiene 1
Support
Support
Hexagon head bolt
Vis à téte hexagonale
6 10.30.60 Distanzstück 1
Distance piece
Pièce d‘écartement
L9 / L14
Zylinder und Zylinderköpfe
Cylinders and cylinder heads Tafel / Table / Planche
Cylindres et culasses 1-199-020

1 20.10.10 Zylinder 1.Stufe 1
st
Cylinder 1 stage
Cylindre 1er étage
2 20.10.20 Dichtung 2
Gasket
Joint
3 20.10.30 Zylinderkopf 1. Stufe 1
st
Cylinder head 1 stage
Culasse 1er étage
4 20.10.40 Zylinder 2. Stufe 1
nd
Cylinder 2 stage
Cylindre 2 ème étage
5 20.10.60 Zylinderkopf 2. Stufe 1
nd
Cylinder head 2 stage
Culasse 2 ème étage
6 20.10.70 Stiftschraube 8
Stud bolt
Goujon prisonnier
7 20.10.80 Scheibe 8
Disk
Disque
8 20.10.90 Sechskantmutter 8
Hexagon nut
Écrou hexagonal
9 20.10.100 Stiftschraube 4
Stud bolt
Goujon prisonnier
10 20.10.110 Distanzring (nur bei L9) 1
Distance ring (for L9 only)
Bague d‘écartement (seulement pour L9)
L9 / L14
Ventile
Valves Tafel / Table / Planche
Soupapes 2-199-020

1 20.20.10 Lamellenventil 1. Stufe 1
st
Reed-type valve 1 stage
Soupape à lamelles 1er étage
2 20.20.20 Dichtung 1
Gasket
Garniture
Packing ring
Rondelle de joint
4 20.20.40 Lamellenventil 2. Stufe 1
nd
Reed-type valve 2 stage
Soupape à lamelles 2ème étage
5 20.20.50 Dichtung 1
Gasket
Garniture
Packing ring
Rondelle de joint
L9 / L14
Kolben
Pistons Tafel / Table / Planche
Pistons 3-199-020

1 20.30.10 Kolben 1. Stufe kompl. 1
st
Piston 1 stage, complete
Piston 1er étage, complet
2 20.30.10.20 Kolbenbolzen 1
Wrist pin
Axe du piston
3 20.30.10.30 Sicherungsring 2
Securing ring
4 20.30.10.40 Minutenring 1
Taper-faced compression ring
Segment compresseur à face conique
5 20.30.10.50 Nasenreing 1
Stepped scraper ring
Segment à talon
6 20.30.10.60 Schlauchfederring 1
Oil scraper ring
Racleur d’huile
7 20.30.20 Kolben 2. Stufe, kompl. 1
nd
Piston 2 stage, complete
Piston 2ème étage, complet
8 20.30.20.20 Kolbenbolzen 1
Wrist pin
Axe du piston
9 20.30.20.30 Sicherungsring 1
Securing ring
10 20.30.20.40 Nasenring 2
Stepped scraper ring
Segment à talon
11 20.30.20.50 Minutenring 1
Taper-faced compression ring
Segment compressuer à face conique
L9 / L14
Pleuelstangen
Connecting rods Tafel / Table / Planche
Bielles 4-199-020

1 20.40.10 Pleuelstange 1. Stufe, kompl. 1
st
Connecting rod 1 stage, complete
Bielle 1er étage, complet
2 20.40.10.10.20 Nadelhülse 1
Needle bearing
Palier à aiguilles
3 20.40.10.10.30 Nadellager 1
Needle bearing
Palier à aiguilles
4 20.40.20 Pleuelstange 2. Stufe, kompl. 1
nd
Connecting rod 2 stage, complete
Bielle 2ème étage, complet
5 20.40.20.10.20 Nadelhülse 1
Needle bearing
Palier à aiguilles
6 20.40.20.10.30 Nadellager 1
Needle bearing
Palier à aiguilles
7 20.40.30 Distanzring 1
Distance ring
Bague d’écartement
Securing ring
L9 / L14
Kühlsystem
Cooling system Tafel / Table / Planche
Système de refroidissement 1-199-030

1 30.10.10 Kühler 1. Stufe 1
st
Cooler 1 stage
Refroidisseur 1er étage
2 30.10.20 Kühler 2.Stufe 1
nd
Cooler 2 stage
Refroidisseur 2ème étage
3 30.10.30 Gerade Einschraubverschraubung 4
Straight male stud coupling
Union simple mâle
4 30.10.40 Aramturenträger 1
Fitting support
Support de robineterie
5 30.10.50 Dichtung 1
Gasket
Garniture
Hexagon head bolt
Securing ring
Screw plug
Vis de fermeture
Packing ring
Rondelle de joint
10 30.10.100 Luftauslaß 1
Compressed-air outlet
Sortie sur l‘ air comprimé
11 30.10.110 Zylinderschraube 2
Cylinder head bolt
Vis à tête cylindrique
L9 / L14
Kühlsystem

Screw plug
Vis de fermeture
13 30.10.130 Dichtring 2
Packing ring
Rondelle de joint
14 30.10.140 Befestigungsschelle 1
Double clamp
Agrafe double de serrage
15 30.10.150 Senkschraube 1
Countersunk head screw
Vis à tête fraisée
16 30.10.160 Sicherheitsmutter 1
Locking nut
Écrou de blocage
17 30.10.170 Sechskantmutter 1
Hexagon nut
Écrou hexagonal
18 30.10.180 Radial-Lüfterrad 1
Radial fan wheel
Roue de ventilateur radiale
19 30.10.190 Scheibe 1
Disc
Disque
Hexagon head bolt
21 30.10.210 Frontplatte 1
Front cover
Couvercle avant
22 30.10.220 Lüfterhaube 1
Air blast housing
Carter du ventilateur
L9 / L14
Kühlsystem

23 30.10.230 Nietmutter 4
Rivet nut
Écrou à river
Hexagon head bolt
Hexagon head bolt
26 30.10.260 Scheibe 5
Disc
Disque
27 30.10.270 Scheibe 3
Disc
Disque
28 30.10.280 Gerade Einschraubverschraubung 1
Union simple mâle
L9 / L14
Armaturen
Fittings Tafel / Table / Planche
Robinetterie 1-199-040

1 40.10.10 Manometer 1. Stufe 1
st
Pressure gauge 1 stage
Manomètre 1er étage
2 40.10.20 Manometer 2. Stufe 1
nd
Pressure gauge 2 stage
Manomètre 2ème étage
3 40.10.30 Anschlußstück 2
Fitting
Raccord
4 40.10.40 Wika-Dichtring 2
Wika sealing ring
Rondelle de joint wika
Packing ring
Rondelle de joint
6 40.10.60 Sicherheitsventil 1. Stufe 1
st
Safety valve 1 stage
Soupape de sûreté 1er étage
7 40.10.70 Sicherheitsventil 2. Stufe 1
nd
Safety valve 2 stage
soupape de sûreté 1er étage
Packing ring
Rondelle de joint
9 40.10.100 Handventil 1
Manual drain valve
Soupape de vidange
10 40.10.110 Gerader Einschraubstutzen 1
Union simple mâle
11 40.10.120 Einstellbare Winkelverschraubung 1
Adjustable elbow coupling
Equerre orientable
L9 / L14
Schwungrad und Kupplung
Flywheel and coupling Tafel / Table / Planche
Volant et accouplement 1-199-014

1 14.10.10 Kupplungshälfte 1
Coupling half
Demi-accouplement
2 14.10.20 Elast. Zahnkranz 1
Flexible gear rim
Couronne dentée élastique
3 14.10.30 Kupplungshälfte 1
Coupling half
Demi-accouplement
4 14.10.40 Gewindestift 1
Threaded pin
Cheville filetée
5 14.20 Scheibe 1
Disc
Disque
6 14.30 Sechskantschraube 1
Hexagon head bolt
7 14.40 Sicherungsring 1
Securing ring
L9 / L14
Ansaugsystem
Suction system Tafel / Table / Planche
Système d’aspiration 1-199-032

1 32.10 Dämpferfilter 1
Air-intake filter with silencer
Filtre d‘ aspiration
2 32.20 Schlauch 1
Hose
Tuyauterie
3 32.30 Schlauchschelle 2
Hose clip
L9 / L14
Starre Lagerung
Rigid mounting Tafel / Table / Planche
Suspension rigide 1-199-043

1 43.10 Fußschiene 2
Support
Support
Hexagon head bolt
3 43.30 Distanzstück 1
Distance piece
Pièce d‘ échartement
Hexagon head bolt
L9 / L14
Elastische Lagerung
Resilient mounting Tafel / Table / Planche
Suspension élastique 1-199-044

1 44.10 Platte 1
Plate
Plaque
2 44.20 Schwingmetallpuffer 2
Rubber to metal bonded foot
Pied en caoutchouc-métal
Hexagon head bolt
4 44.40 Schwingmetallpuffer 1
Rubber to metal bonded foot
Pied en caoutchouc-métal
5 44.50 Platte 1
Plate
Plaque
6 44.60 Sechskantmutter 1
Hexagon nut
Ecrou hexagonal
L9 / L14
Automatische Entwässerung
Automatic drainage Tafel / Table / Planche
Vidange automatique 1-303-053

1 53.10.1 2/2-Wege-Magnetventil 1. Stufe 1
st
2/2-way solenoid valve 1 stage
Soupape électro-magnetique a 2/2 orifices 1er étage
53.10.2 2/2-Wege-Magnetventil 2. Stufe 1
2/2-way solenoid valve 2nd stage
Soupape électro-magnetique a 2/2 orifices 2ème étage
ENGLISH
INSTALLATION AND
MAINTENANCE INSTRUCTIONS
FOR ELECTRIC MOTORS
0280.1400
ENGLISH
In case the motors are stored for more than

READ CAREFULLY THIS MANUAL
two years, the bearings must be replaced or the
BEFORE INSTALLING THE MOTOR
lubrication grease must be totally removed after
cleaning.
RECEIVING CHECK Single phase motors when kept in stock
for 2 years or more must have their capacitors
Check if any damage has occured during
replaced (if any).
transportation.
We recommend to turn the shaft (by hands)
üCheck nameplate data.
at least once a month, and to measure the
üRemove shaft locking device (if any) before
insulation resistance before installing it, in cases
operating the motor.
of motors stored for more than 6 months or when
üTurn the shaft with the hand to make sure it
subject to high humidity areas.
is turning freely. If motor is fitted with space heaters, these
HANDLING AND TRANSPORTATION should be switched on.
1 - General Insulation Resistance Check

MOTORS MUST NOT BE LIFTED BY Measure the insulation resistance before
THE SHAFT, BUT BY THE EYEBOLTS operating the motor and/or when there is any
sign of humidity in the winding.
Lifting devices, when supplied, are
designed only to support the motor. If the motor The resistance measured at 25ºC must be:
has two lifting devices then a double chain must
be used to lift it. Ri ≥ (20 x U) / (1000 + 2P) [MΩ]
Lifting and lowering must be done gently (measured with a MEGGER at 500 V d.c.)
without any shocks, otherwise the bearings can where U = voltage (V); P = power (kW).
get damaged.
If the insulation resistance is less than 2
DURING TRANSPORTATION,
megaohms, the winding must be dried
MOTORS FITTED WITH ROLLER OR
according to the following:
ANGULAR CONTACT BEARINGS
Warm it up inside an oven at a minimum
ARE PROTECTED AGAINST
temperature of 80ºC increasing 5ºC every hour
BEARING DAMAGES WITH A
until 105ºC, remaining under this temperature
SHAFT LOCKING DEVICE.
for at least one hour.
Check if the stator insulation resistance
THIS LOCKING DEVICE MUST BE
remains constant within the accepted values. If
USED ON ANY FURTHER MOTOR
not, stator must be reimpregnated.
TRANSPORTATION, EVEN WHEN
THIS MEANS TO UNCOUPLE
THE MOTOR FROM THE DRIVEN
MACHINE. INSTALLATION
STORAGE 1 - Safety
If motors are not immediately installed, All personnel involved with electrical
they must be stored in dry places, free of installations, either handling, lifting, operation
dust, vibrations, gases, corrosive smokes, or maintenance must be well informed and
under constant temperature and in normal updated concerning safety standards and
position free from other objects. principles that govern the work and carefully
Motor storage temperature must remain follow them.
between 5ºC to 60ºC, with relative humidity not We strongly recommend that these jobs
exceeding 50%. are carried out by qualified personnel.
MAKE SURE THAT ELECTRIC designed in such a way to stop any vibration
MOTORS ARE SWITCHED OFF originated from resonance.
BEFORE STARTING ANY
MAINTENANCE SERVICE. 4 - Drain Holes
Motors must be protected against acci- Make sure the drains are placed in the
dental starts. lower part of the motor when the mounting
When performing any maintenance configuration differs from that specified on the
service, disconnect the motor from the power motor purchase order.
supply. Make sure all accessories have been
switched off and disconnected. 5 - Balancing
In order to prevent from penetrating dust
and/or water into the terminal box, cable glands WEG MOTORS ARE DYNAMICALLY
or threaded pipe in the lead holes must be BALANCED WITH HALF KEY, AT NO
installed. LOAD AND UNCOUPLED.
Do not change the regulation of the
protecting devices to avoid damaging. Transmission elements such as pulleys,
couplings, etc must be dynamically balanced
2 - Operating Conditions with half key before installation.
Use always appropriate tools for installation and
Electric motors, in general, are designed removal.
for operation at an altitude of 1000m above sea
level for an ambient temperature between 0ºC 6 - Alignment
and 40ºC. Any variation is stated on the
ALIGN THE SHAFT ENDS AND
nameplate.
USE FLEXIBLE COUPLING,
COMPARE THE CURRENT, VOLTAGE, WHENEVER POSSIBLE.
FREQUENCY, SPEED, OUTPUT AND
Ensure that the motor mounting devices
OTHER VALUES DEMANDED BY THE
do not allow modifications on the alignment and
APPLICATION WITH THE DATA GIVEN
further damages to the bearings.
ON THE NAMEPLATE.
When assembling a half-coupling, be sure
Motors supplied for hazardous locations to use suitable equipment and tools to protect
must be installed in areas that comply with that the bearings.
specified on the motor nameplate. Suitable assembly of half-coupling:
Check that clearance Y is less than
KEEP AIR INLET AND OUTLET FREE 0.05 mm and that the difference X1 to X2 is less
AND CLEAN. THE AIR BLOWN OUT than 0.05 mm, as well.
BY THE MOTOR SHALL NOT ENTER
AGAIN. THE DISTANCE BETWEEN
THE AIR INLET AND THE WALL
MUST BE AROUND ¼ OF THE
INLET OPENING DIAMETER.
3 - Foundation
Note: Dimension X1 and X2 must be
Motors provided with feet must be installed 3mm minimum
on solid foundations to avoid excessive Figure and alignment tolerances
vibrations.
The purchaser is fully responsible for the 7 - Belt Drive
foundation.
Metal parts must be painted to avoid When using pulley or belt coupling, the
corrosion. following must be observed:
The foundation must be uniform and suf- Belts must be tighten just enough to avoid
ficiently tough to support any schock. It must be slippage when running, according to the
specifications stated on the belt supplier Make sure to use the correct cable
recommendation. dimension, based on the rated current stamped
on the motor nameplate.
WARNING:
Excessive tension on the pulleys will BEFORE ENERGIZING THE
damage the bearings and lead to a TERMINALS, CHECK IF THE
probable shaft rupture. GROUNDING IS MADE
ACCORDING TO THE CURRENT
STANDARDS. THIS IS ESSENTIAL
8 - Connection AGAINST ACCIDENT RISKS.
WARNING: When the motor is supplied with

Voltage may be connected at standstill protective or monitor temperature device such
inside the terminal box for heating elements or as thermostats, thermistors, termal protector, etc,
direct winding heating. connect their terminals to the corresponding
devices on the control panel.
WARNING:
The capacitor on single-phase motors 10 - Start-Up
can retain a charge which appears across the
THE KEY MUST BE FASTENED OR
motor terminals, even when the motor has
REMOVED BEFORE STARTING THE
reached standstill.
MOTOR.
A WRONG CONNECTION CAN a) The motor must start and operate
BURN THE MOTOR. smoothly. In case this does not occur, turn it off
and check the connections and the mounting
before starting it again.
Voltage and connection are indicated on
b) If there is excessive vibration, check if
the nameplate. The acceptable voltage the fastening screws are correctly fastened.
variation is ±10%; the acceptable frequency Check also if the vibration comes from a
variation is ±5% and the total acceptable neighbour machine. Periodical vibration checks
variation is ± 10%. must be done.
c) Run the motor under rated load for a
9 - Starting Methods short period of time and compare if the running
current is equal to that stamped on the
The motor is rather started through direct nameplate.
starting. In case this is not possible, use
compatible methods to the motor load and MAINTENANCE
voltage.
The rotation direction is clockwise if the WARNING:
motor is viewed from DE side and if the SAFETY CHECK LIST
phases are connected according to the
sequence L1, L2, L3. 1 - General Inspection
To change the rotation direction, inter-
change two of the connecting leads. üCheck the motor periodically.
üKeep the motor clean and assure free air flow.
THE CONNECTION TO THE POWER üCheck the seals or V Ring and replace them, if
SUPPLY MUST BE DONE BY required.
QUALIFIED PERSONNEL AND WITH üCheck the connections as well as supporting
FULL ATTENTION TO ASSURE A SAFE screws.
AND PERMANENT CONNECTION. üCheck the bearings and observe: Any excessive
AFTER CONNECTING THE MOTOR, noise, vibration, bearing temperature and grease
CHECK FOR ANY STRANGE BODY condition.
INSIDE THE TERMINAL BOX. THE üWhen a change, under normal conditions, is
CABLE INLETS NOT IN USE MUST BE detected, check the motor and replace the
CLOSED. required parts.
The frequency of the inspections depends 2 - Machines Fitted with Grease Nipples
on the motor type and on the application
conditions. It is strongly recommended to grease the
machine while running. This allows the grease
LUBRICATION renewal in the bearing housing. When this is
not possible due to turning parts by the grease
FOLLOW THE REGREASING device (pulleys, bushing, etc) that offer some
INTERVALS. THIS IS FUNDAMENTAL risk to the physical integrity of the operator,
FOR PROPER MOTOR OPERATION. proceed as follows:
üClean the area near the grease nipple.
1 - Machines without Grease Nipples üPut approximately half of the total grease and
run the motor for 1 minute at full speed.
Motors up to frame 200 are normally fitted Then turn off the motor and insert the rest of the
without grease nipples. In these cases the grease.
regreasing shall be done at the preventive üThe injection of all the grease with the motor in
maintenance job observing the following standstill can make the grease penetrate into the
aspects: motor, through the inner seal of the bearing
housing.
üDisassemble carefully the motors.
üTake all the grease out. FOR LUBRICATION USE ONLY
üWash the bearing with querosene or diesel. MANUAL GREASE GUN.
üRegrease the bearing immediately.
RELUBRICATION INTERVALS
TABLE 1 - BALL BEARINGS - Series 62/63

Serie 62
6209 18400 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 9
6211 14200 16500 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 11
6212 12100 14400 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 13
Serie 63
6309 15700 18100 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 13
6311 11500 13700 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 18
6312 9800 11900 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 21
6314 3600 4500 9700 11600 14200 16400 17300 19700 19700 20000 20000 20000 27
6316 - - 8500 10400 12800 14900 15900 18700 18700 20000 20000 20000 34
6319 - - 7000 9000 11000 13000 14000 17400 17400 18600 18600 20000 45
6322 - - 5100 7200 9200 10800 11800 15100 15100 15500 15500 19300 60
TABLE 2 - ROLLER BEARINGS - Series NU 3

NU 309 9800 13300 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 13
NU 311 6400 9200 19100 20000 20000 20000 20000 20000 20000 20000 20000 20000 18
NU 312 5100 7600 17200 20000 20000 20000 20000 20000 20000 20000 20000 20000 21
NU 314 1600 2500 7100 8900 11000 13100 15100 16900 16900 19300 19300 20000 27
NU 316 - - 6000 7600 9500 11600 13800 15500 15500 17800 17800 20000 34
NU 319 - - 4700 6000 7600 9800 12200 13700 13700 15700 15700 20000 45
NU 322 - - 3300 4400 5900 7800 10700 11500 11500 13400 13400 17300 60
NU 324 - - 2400 3500 5000 6600 10000 10200 10200 12100 12100 15000 72
Note: The stator grips must be applied over the
üThe ZZ bearings from 6201 to 6307 do not side face of the inner ring to be disassembled or
require relubrication as its life time is about over an adjacent part.
20,000 hours. It is essential that bearings assembly be
üTables 1 and 2 are intended for the lubrication done under cleanning conditions to ensure
period under bearing temperature of 70°C (for good operation and to avoid damages. New
bearings up to 6312 and NU 312) and bearings shall only be taken out from their cases
temperature of 85°C (for bearings 6314 and NU when assembling them.
314 and larger). Before installing a new bearing it is
üFor each 15°C of temperature rise, the required to check the shaft fitting for any sharp
relubrication period is reduced by half. edge or strike signals.
üThe relubrication periods given above are For bearing assembly warm their inner
for those cases applying Polyrex® EM grease. parts withsuitable equipment - inductive pocess
ü When motors are used on the vertical - or use suitable tools.
position, their relubrication interval is reduced SPARE PARTS
by half if compared to horizontal position
motors. When ordering spare parts, please specify
WE RECOMENDED TO USE BALL the full type designation and product code as
BEARINGS FOR MOTORS DIRECTLY stated on the motor nameplate. Please also
inform the motor serial number stated on the
COUPLED TO THE LOAD. nameplate.
WARNING: MOTORS FOR HAZARDOUS
EXCESS OF GREACE CAN CAUSE
BEARNING OVERHEATING LOCATIONS
RESULTING IN COMPLETE Besides the recommendations given
DAMARGE. previously, these ones must be also followed:
Compatibility of Polyrex® EM grease with THE SPECIFICATION OF THE MOTOR

other types of grease: INSTALLATION PLACE IS FOR
CUSTOMER’S RESPONSIBILITY,
Containing polyurea thickener and mineral WHO WILL ALSO DETERMINE THE
oil, the Polyrex® EM grease is compatible with ENVIRONMENT CHARACTERISTICS.
other types of grease that contain:
üLithium base or complex of lithium or polyurea Motors for hazardous locations are
and highly refined mineral oil. manufactured according to specific standards
üInhibitor additive against corrosion, rust and for such environments and they are certified by
anti-oxidant additive. worldwide certifying entities.
Notes: 1 - Installation
üAlthough Polyrex® EM is compatible with types
of grease given above, we do not recommended The complete installation must follow
to mix it with any other greases. procedures given by the local legislation in effect.
ü If you intend to use a type of grease different
than those recommended above , first contact THE INSTALLATION OF HAZARDOUS
WEG. LOCATION MOTORS MUST BE
üOn applications (with high or low temperatures, CARRIED OUT BY SKILLED PEOPLE,
speed variation, etc), the type of grease and
relubrification interval are given on an additional AND THE THERMAL PROTECTION
nameplate attached to the motor. MUST BE ALWAYS INSTALLED,
EITHER INSIDE OR OUTSIDE THE
THE USE OF STANDARD MOTORS
MOTOR, OPERATING AT THE RATED
IN SPECIFIC AREAS OR SPECIAL
CURRENT.
APPLICATIONS MUST BE DONE BY
CONSULT TO THE GREASE 2 - Maintenance
MANUFACTURER OR WEG
Maintenance must be carried out by repair
shops authorized by WEG.
DISASSEMBLY AND ASSEMBLY Repair shops and people without Weg’s
authorization who will perform any service on
Disassembly and assembly must be done hazardous location motors will be fully
by qualified personnel using only suitable tools responsible for such service as well as for any
and appropriated methods. consequential damage.
üLower efficiency.
ANY ELECTRICAL OR MECHANICAL
üHigher vibration.
MODIFICATION MADE ON
üHigher noise level.
HAZARDOUS LOCATION MOTORS üHigher rated current.
WILL VOID THE CERTIFICATION. ü Higher temperature rise.
When performing maintenance, üReduced motor insulation.
installation or relubrication, follow these üReduced bearing life.
instructions:
1- Standard Motors
üCheck if all components are free of edges,
knocks or dirt.
üMake sure all parts are in perfect conditions. üVoltages lower than 440V do not require filter.
üLubricate the surfaces of the endshield fittings üVoltages equal or higher than 440V or lower
with protective oil to make the assembly easier. than 575V require filter for motor power supply
üUse only rubber hammer to fit the parts. cables longer than 20 meters.
üCheck for correct bolts tightening. üVoltages equal or higher than 575V require
üUse clearance calibrator for correct T-box fitting filter for any size of power supply cables.
(smaller than 0.05mm).
DO NOT REUSE DAMAGED OR IF SUCH RECOMMENDATIONS ARE
WORN PARTS. REPLACE THEM BY NOT FOLLOWED ACCORDINGLY,
NEW ONES SUPPLIED BY THE MOTOR WARRANTY WILL BE VOID.
FACTORY.
2- Inverter Duty Motors:
MOTORS DRIVEN BY VFD üCheck power supply voltage of the forced
Applications using VFD´s without filter cooling set.
can affect motor performance as follows: üFilters are not required.
WARRANTY TERMS
Weg warrants its products against defects in This warranty does not include disassembly
workmanship and materials for twelve (12) services at the purchaser facilities,
months from the invoice date issued by the transportation costs with product, tickets,
factory, authorized distributor or agent limited accomodation and meals for technical personnel
to eighteen (18) months from manufacturing date when requested by the customer.
independent of installation date as long as the The warranty service will be only carried out at
following items are fulfilled accordingly: Weg Authorized Repair Shops or at Weg’s
facilities.
- Proper transportation, handling and storage;
- Correct installation based on the specified Components whose useful life, under normal
ambient conditions and free of corrosive use, is shorter than the warranty period are not
gases; covered by these warranty terms.
- Operation under motor capacity limits; The repair and/or replacement of parts or
- Observation of the periodical maintenance components, when effected by Weg and/or any
services; Weg Authorized Repair Shop, will not give
- Repair and/or replacement effected only by warranty extension.
personnel duly authorized in writing by Weg;
- The failed product be available to the supplier This constitutes Weg’s only warranty in
and/or repair shop for a required period to connection with this sale and the company will
detect the cause of the failure and have no obligation or liability whatsoever to
corresponding repair; people, third parties, other equipment or
- Immediate notice by the purchaser about installations, including without limitation, any
failures accured and that these are accepted claims for consequential damages or labor costs.
by Weg as manufacturing defects.
WEG EXPORTADORA S.A.
AV. PREF. WALDEMAR GRUBBA, 3000
89256-900 JARAGUÁ DO SUL, SC - BRAZIL
PHONE (55) (47) 372-4002
FAX (55) (47) 372-4060
http://www.weg.com.br
FOR FURTHER INFORMATION PLEASE CONTACT YOUR NEAREST WEG SALES OFFICE
Bedienungsanleitung
Operating Manual
Schraubenkompressor
Screw Compressors
HSC 4 - 75
Operating instructions
HATLAPA Screw Compressors
Type
Serial number Date

Component overview
7
12 24 13 10 25 6 8 20 3 21 22 1
23 4 28 5 27 26 2 19 9 16 17 11 18 15 14
Fig. 1: Component overview
1 Compressor 15 Oil and condensation water drain valve

2 Compressed air / oil reservoir 16 Pressure reservoir name plate
3 Oil high-precision separator cartridge 17 Oil gauge
4 Electric motor 18 Oil filler neck
5 Fan 19 V-belt tensioning roller
6 PROCON control 20 Suction stop valve
7 Proportional controller (optional) 21 Control valve
8 Name plate 22 Relief valve
9 Drain line 23 Suction filter
10 Pressure detector 24 Oil filter
11 Safety valve 25 Compressed-air outlet with cut-off valve (op-
tional)
12 Switch box 26 Compressed-air aftercooler
13 Oil thermostat 27 Oil cooler
14 Temperature sensor 28 Super sound proofing hood
104482 HSC • 03/03

PROCON control
8 9 10 11 12 13 14
°C bar
20 00
.
4 5 6 7 1 2 3
Fig. 2: Operating elements
1 Power switch
2 Circuit-breaking key
3 Emergency stop
4 In the menu: One line up
Edit mode: Increase value
5 In the menu: One line down
Edit mode: Selection of the menu
6 In the menu: Call up information
Edit mode: Cancel value input
7 In the menu: Selection of the menu
Edit mode: Apply value
8 Permanent yellow: Base load sequencer operating mode
9 Permanent yellow: Remote operation
10 Permanent yellow: Automatic restart
11 Permanent green: Motor is running
Green flashing: Standby, motor can start automatically at any time
12 Blinking yellow: Maintenance
13 Blinking yellow: Warning
14 Red flashing: Type of malfunction
104482 HSC • 03/03 1

Table
PROCONof contents
control
Table of contents Technical annex
Component overview
PROCON control
1 Fundamental safety instructions....... 2

1.1 Designated use ........................................ 2
1.2 Fundamental measures.......................... 2
1.3 Description of symbols and notes ........ 2
2 Transport and storage ......................... 2

2.1 Transport .................................................. 2
2.2 Storage...................................................... 2
3 Mounting ................................................ 3
3.1 Mounting conditions............................... 3
3.2 Compressed-air port ............................... 4
3.3 Electrical connection .............................. 4
3.4 Checking the rotating direction ............ 5
4 Operation................................................ 7
4.1 Safety instructions .................................. 7
4.2 Switching the unit on ............................. 7
4.3 Start-up after an extended idle time..... 7
4.4 Weekly check ........................................... 7
4.5 Switching the unit off ............................. 7
4.6 Remote control ........................................ 8
4.7 Original HATLAPA accessories ............ 8
5 PROCON control .................................. 9

5.1 Operating elements ................................ 9
5.2 Display features....................................... 9
5.3 Input of parameters................................. 9
6 Inspection and servicing ................... 13

6.1 Safety instructions ................................ 13
6.2 Checking and topping up the oil level 13
6.3 Changing the oil .................................... 14
6.4 Changing oil filter.................................. 14
6.5 Draining the condensation water ....... 15
6.6 Cleaning the oil cooler and the
compressed-air aftercooler.................. 15
6.7 Checking safety valve ........................... 15
6.8 Changing oil high-precision separator
cartridge.................................................. 15
6.9 Checking and changing the suction
filter cartridge ........................................ 15
6.10 Clean proportional controller nozzle. . 16
6.11 Cleaning drain restrictor ...................... 16
6.12 Checking and adjusting the V-belt ..... 16
6.13 Notes on systems equipped with water
cooling system....................................... 17
6.14 Tighten the screw connections. .......... 17
6.15 Checking electric terminals................. 17
6.16 Relubricating / replacing motor
mounting ................................................ 17
7 Maintenance schedule....................... 18
8 Trouble shooting ................................ 20

8.1 Malfunction, compressor generally.... 20
8.2 Malfunction, PROCON control............ 24
8.3 Warnings, PROCON control ................ 25
104482 HSC • 03/03 1

Fundamental safety instructions
1 Fundamental safety instruc- 2 Transport and storage

tions
2.1 Transport
1.1 Designated use
Danger
The compressor system is intended exclu- Mortal danger caused by incorrect
sively for the generation of compressed air. transport.
Any other use shall be considered an undes- • Do not hold the compressor at its
ignated use. cladding elements as you lift it.
• Only use suitable lifting gear with the
corresponding weight-bearing capacity
1.2 Fundamental measures (for data on weight, please refer to
chapter “Technical annex”).
• Never point compressed air at persons. • Fasten and secure the system with
• Observe these operating instructions. belts at the corresponding points.
• Keep these operating instructions avail- • Secure swivelling and loose parts.
able at the location of use at all times. • Transport the compressor by means of
• Please observe the regular maintenance crane hooks, fork-lift truck and elevat-
intervals (refer to chapter 7 “Maintenance ing truck only.
schedule”). • Never remain under suspended loads.
• Use original HATLAPA parts and approved • Depressurise the compressor prior to
operating material only. any transport.
• Do not use compressed air for breathing
without corresponding treatment.
• Do not modify the system. 2.2 Storage
• Use mounting parts and devices down-
stream from the compressor which have Store the compressor in a dry location pro-
been designed for the maximum operating tected against weather influence. Ambient
overpressure of the compressor. temperature: -10°C to +50°C.
• In your capacity as proprietor, please en-
sure that all safety regulations are ob- Please order the HATLAPA conservation in-
served by the operating staff. structions in case of storage of over six
• Do not use the compressor as a climbing months.
aid.
For information on recommissioning
after an extended idle time, please re-
1.3 Description of symbols and fer to chapter 4.3.
notes
Danger
Mortal danger and risk of injury.
Caution
Damage to property.
Information and tips.
2 104482 HSC • 03/03

Mounting
3 Mounting Cooling and exhaust air
3.1 Mounting conditions Danger

Mortal danger and explosion hazard
! Check the compressor for damage during during suction.
transport. • Ensure that the compressor takes in
only clean air which is free from nox-
ious constituents. Noxious substances
Ambient conditions are liable to accumulate in the lubricat-
ing oil of the compressor. They may
Danger cause explosions in the system and
Mortal danger and explosion hazard heavy damages.
when caustic, inflammable or poison- • Do not allow objects or pieces of cloth-
ous gases are drawn in. ing of persons going past to be sucked
• Do not operate the compressor in ex- in by the intake air flow.
plosive surroundings or in the vicinity
of open flames and flying sparks.
1
B
Caution 2
Wrong mounting will cause damage to A
the compressor.
• Ensure sufficient ventilation of the
compressor room.
• Do not operate the compressor in the
open.
• Systems with a capacity exceeding 40
kW must be installed in such a way
that no combustible objects or materi- D
A
als are in the immediate proximity.
• Systems with a capacity exceeding 100
kW should be installed in a separate
room.
The space between the compressor and the C

wall has to be at least 60 cm (cf. Fig. 3: Loca- A
tion). The compressor has to be easily acces- E
sible from all sides. The ambient temperature
has to be between 3°C and 40°C.
Fig. 4: Room ventilation

> 60 cm
1 Intake air
2 Exhaust air
A Air inlet
B Air outlet
C Ventilation duct
D Exhaust fan
+3°C - +40 °C E Elastic connecting piece
Fig. 3: Location
104482 HSC • 03/03 3

Mounting
The overall length of all air intake and exhaust • Compressed-air lines, filters, aftercoolers
ducts must not exceed 4m; one baffle is per- and vessels must at their lowest spots be
missible. In case of conduits exceeding this equipped with an outlet for the condensa-
length or in case of several baffles, a booster tion water accumulated. These outlets
fan must be installed. In this case, please con- must allow to observe the draining con-
tact your technical adviser. densation water. Condensation water may
contain oil! In draining the condensation
For further information on the required venti- water, all applicable regulations on the
lation cross sections, please refer to the disposal of waste water must be complied
Technical Annex. with.
• Remove all securing devices before you
start to install the conduits.
Ground • Use only suitable connecting lines and
couplings which are designed for the in-
! Place the compressor on a horizontal and tended working pressure. Do not use any
plane surface. defect component.
• Supply lines must not be subjected to
The ground has to have a suitable load- stress or tension.
bearing capacity. HATLAPA offers special so-
lutions for inclined surfaces. Observe the technical data for the connection
of compressed air (cf. chapter “Technical an-
In order to reduce vibrations, HATLAPA rec- nex”).
ommends rubber-metal connections.
3.3 Electrical connection

3.2 Compressed-air port
The connection to the electrical power system
The connection to the compressed-air duct- may be carried out only by adequately trained
work system may be carried out only by expert.
trained experts or by staff members of
HATLAPA Company. Danger
Mortal danger caused by electric volt-
Danger age but also by rotating wheels, V-
Danger of injury by pressure in the belts, and fan blades.
pipes. • Test runs are permissible only if all
• Vent the pipes to which the compres- parts of the casing are closed (excep-
sor is connected. tion: check of the rotating direction).
Compressor systems have to be fitted with a

Use a flexible hose to connect the
power switch or a plug connection to interrupt
compressor to the supply network.
the power supply. Compressor systems with a
Thus, stress cracks and sound bridges
motor capacity of more than 3 kW or 16 Amps
are prevented.
have to be fitted with a lockable power switch
and upstream fuses.
In this respect, please refer to the cir-

cuit diagram in the chapter titled
“Technical annex” or in the switch
cabinet as well as to the following
connection conditions.
Check and retighten where appropriate

all electric terminals before first com-
missioning.
4 104482 HSC • 03/03

Mounting
3.4 Checking the rotating direction
Caution
Fire hazard and damage to compressor
in case of wrong polarisation of the
motor (5 revolutions maximum in the
wrong direction of rotation!).
• Carry out the check of the rotating di-
rection as described below:
! Open side cladding of the compressor.

! Please refer to chapter 4.2 titled “Switch-
ing the unit on”.
! Press the power switch, and immediately
after this the emergency stop (see fig. 2:
Operating elements). The correct rotating
direction of the fan has been marked by an
arrow on the fan cover.
! Change the poles of the electric connec-
tion of the motor in case of a wrong rotat-
ing direction.
104482 HSC • 03/03 5

Mounting
Electrical connection conditions
The connection to the electrical power system

may be carried out only by adequately trained
expert.
Caution
Overvoltages and undervoltages must not exceed the 10% mark.
This unit is intended for operation on a power supply network with a maximum system
impedance Zmax at the interconnection point (house service line), which is listed in the
table below in dependence of the performance. The user shall have to ensure that the
unit is operated only on a power supply network which meets these requirements. If and
when necessary, the local power supply company can provide information on the system
impedance.
400V-50Hz 3 ph 230V-50Hz 1 ph
Motor Motor Protection Protec- Motor Motor Protection Protec-
per- rated cur- – star- tion – di- per- rated cur- – star- tion – di-
formance rent delta rect start- formance rent delta rect start-
starting ing starting ing
kW A A A kW A A A
1.1 2.6 6 1.1 2.6 6

1.5 3.5/4.1 10 1.5 3.5/4.1 10
2.2 5.0/6.0 16 2.2 5.0/6.0 16
3.0 6.6/8.1 16 3.0 6.6/8.1 16
4.0 8.5 16 20 4.0 8.5 16 20
5.5 11.5 20 5.5 11.5 20

7.5 15.5 25 7.5 15.5 25
11.0 22.5 35 11.0 22.5 35
15.0 30.0 50 15.0 30.0 50
18.5 36.0 50 18.5 36.0 50
22.0 43.0 63 22.0 43.0 63
30.0 58.0 80 30.0 58.0 80
37.0 68 80 37.0 68 80
45.0 81 100 45.0 81 100
55.0 99 125 55.0 99 125
75.0 134 160 75.0 134 160
Tab. 1: Characteristic value for the electrical connection
The supply line cross sections provided are recommended values for a maximum 50m line
length at 30°C. For fuse protection, use “slow-to-blow” or “gL” fuses.
• 220/240 V systems require a three-core 1P/N/PE cable.
• 380/400 V systems require a four-core 3P/PE cable for direct start.
• 380/400 V systems require for star-delta starting a five-core supply line 3P/N/PE.
6 104482 HSC • 03/03

Operation
4 Operation 4.2 Switching the unit on
4.1 Safety instructions ! Check oil level through oil gauge and top
up the oil if and when necessary (refer to
chapter 6.2 “Checking and topping up the
Danger oil level”).
Mortal danger caused by sudden start- ! Switch on the power switch.
up of the system. ! Press power switch (see fig. 2: operating
• Systems which are in the standby op- elements).
erating mode are liable to start auto- ! Signal lamp indicates readiness for opera-
matically at any time. tion.
! Compressor starts and after approx. 10sec.
• All parts installed behind the check valve starts load operation.
(e. g. aftercooler, pressure switch) are not ! Open ball valve.
released automatically from pressure.
• Not all transmission lines are de-energised In case of faults, please refer to chapter 8 ti-
when the system is switched off! tled “Trouble shooting” for more help.
• Before commissioning, ensure that no
person can be injured by the starting
compressor. 4.3 Start-up after an extended idle
• Never point compressed air at persons. time.
• Do not use compressed air for breathing
without corresponding treatment. During an extended idle time, the complete oil
• Use mounting parts and devices down- content flows into the compressed air / oil
stream from the compressor which have reservoir. If this has happened, the screw
been designed for the maximum operating compressor is not any more lubricated.
pressure of the compressor.
• Do not reach into the rotating wheels ! Dismount intake regulator.
when the compressor is operational. ! Fill approx. 1 litre compressor oil into the
• Touch the compressor system at the on air intake fitting.
and off switch only during and shortly af- ! Mount intake regulator.
ter operation. Hot surface can cause se-
vere injuries. Do not mix different types of oil. In
• Switch the compressor off immediately in choosing the oil you want to use, refer
case of faults. to the corresponding HATLAPA speci-
• Keep combustible materials away from fications (refer to chapter 6.2 “Check-
the compressor system. ing and topping up the oil level“).
• Operate the compressor only with suction
filter and if all parts of the casing are
closed.
• Operate the compressor only at the per- 4.4 Weekly check
missible operating pressure of the pres-
sure reservoir. • Check oil level of the compressor (refer to
• Tighten the screw connections of the chapter 6.2 “Checking and topping up the
pressure pipes. oil level“).
• Wear tight-fitting work cloths when han-
dling the compressor.
• Wear goggles and ear muffs when working 4.5 Switching the unit off
with compressed air.
• Wear a hair net to protect long hair and ! Press circuit-breaking key “0” (see fig. 2:
remove any lose jewellery. operating elements).
• Check the cables for damage in regular ! Switch off power switch.
intervals.
• Keep domestic animals and children away
from the compressor system.
• Switch the compressor off when not
needed.
104482 HSC • 03/03 7

Operation
4.6 Remote control Top sound insulation
All systems which are equipped with remote To reduce noise emissions.
control must bear a clearly visible label read-
ing as follows: “Warning! This system is re-
motely controlled and is liable to start at any Base load sequencer
time." In addition, persons operating remotely
controlled systems must ensure that the sys- Intelligent higher-order control system to con-
tem is not started during maintenance or re- trol several compressors depending on the
pair work. For this, a corresponding informa- actual compressed air consumption.
tion sign must be affixed to the remote control
unit.
Speed regulator
! Open ball valve.
! Press power switch (see fig. 2: operating
Adapts speed and thus also energy consump-
elements).
tion of the screw compressor to the actual
! Signal lamp indicates readiness for opera-
compressed air consumption.
tion.
! System is now ready to be operated via
remote control.
Water-cooling system
For application conditions under which the

4.7 Original HATLAPA accessories standard fan cooling is not sufficient.
HATLAPA offers you the following accesso-
ries: For more information, please refer to the
HATLAPA price list or directly to HATLAPA. Heat exchanger
Free of charge energy derived from heat pro-

duced by the compressor during operation
Compressed-air filter which is then available to other consumers.
To clean the compressed air for special appli-
cations.
For more information on these and
other pneumatic accessories, please
Refrigeration or adsorption dryer refer to HATLAPA. Our address is on
the last page of these operating in-
structions.
To prevent faults of the compressed air duct-
work system, compressed-air tools, instru-
ments and controls caused by humid air.
Automatic condensation water drain
To spare you the daily draining of condensa-

tion water.
Oil and water separator
Is fitted downstream of the condensation wa-

ter drain. The separated water can be re-
moved directly into the sewer system.
Rubber-metal connection
To reduce vibrations.
8 104482 HSC • 03/03

PROCON control
5 PROCON control • Line 3:

Load operation hours. Load operation
5.1 Operating elements hours are indicated as five-digit figures.
“L.“ will appear on the left side of the dis-
See fig. 2 PROCON control play (e. g. “ L.12 345“ for 12345h).
• Line 4:
Air filter operating life. In the display “F1”
alternates with the corresponding operat-
5.2 Display features ing life value. In addition, the maintenance
LED flashes.
Basic display • Line 5:
Oil filter operating life. In the display “F2”
During normal operation, the display indi- alternates with the corresponding operat-
cates both network pressure and final com- ing life value. In addition, the maintenance
pression temperature as three-digit figures. LED flashes.
• Line 6:
In the event of pressure or temperature meas- Oil separator operating life. In the display
urement failure, the corresponding field “F3” alternates with the corresponding op-
shows “- - -”. The load operation of the system erating life value. In addition, the mainte-
is indicated through a dot following the net- nance LED flashes.
work pressure value. • Line 7:
Oil operating life. In the display “OIL” al-
In the event of malfunction reports or warn- ternates with the corresponding operating
ings occurring, these will alternate with the life value. In addition, the maintenance
analogue quantities in the pressure display LED flashes.
every three seconds. Malfunction reports in • Line 8:
the display start with an “E” followed by a V-belt operating life. In the display “BE.”
two-digit malfunction code (refer to chapter alternates with the corresponding operat-
8.2 “Malfunction, PROCON control” and chap- ing life value. This line will appear only in
ter 8.3 “Warnings, PROCON control”) whereas case the V-belt is activated in the option
warnings start with an “A”. In addition, in menu. In addition, the maintenance LED
case of malfunction a malfunction LED will flashes.
light up; in case of a warning a warning LED • Line 9:
will light up. Software version, e. g. “PRO 1.00“ for Ver-
sion 1.00.
Information menu
5.3 Input of parameters
! To call up the first line of the information
menu, keep key 6 (→) pressed for one sec-
Selection menu
ond.
! The keys 4 and 5 (↑/↓) allow you to navi-
! In order to enter parameters, keep key 7
gate within the menu structure.
(↵) pressed for three seconds. “COD.000”
! Press key 6 (→) to exit the menu; alterna-
will appear in the display.
tively, the menu is also exited if no key has
! Enter the code for the desired menu using
been pressed for 3 minutes.
the keys 4 and 5 (↑/↓).
! Confirm by pressing key 7 (↵), and the first
• Line 1:
parameter of the selected menu is dis-
System pressure indicator. The system
played.
pressure is displayed in place of the net-
! In case an invalid code has been entered,
work pressure. “P2” will appear on the left
or key 6 (→) has been pressed, the routine
side of the display. This line will appear
returns to the initial display.
only in case the system pressure input is
activated in the option menu. In case an
incorrect system pressure value has been
obtained, the display will show “- - -”. Selection of parameters within a
• Line 2: menu
Hours of operation. Hours of operation are
indicated as five-digit figures. “R.“ will ap- ! The keys 4 and 5 (↑/↓) allow you to navi-
pear on the left side of the display (e. g. gate within the menu structure in the dis-
“R.23 456“ for 23456h). play modus.
104482 HSC • 03/03 9

PROCON control
! Press key 6 (→) to exit the menu; alterna- Oil filter C2.# ### 0-9999h 500*
tively, the menu is also exited if no key has operating
been pressed for 5 minutes. life
Oil sepa- C3.# ### 0-9999h 2000
rator op-
Editing parameters within a menu erating
life
! Press key 7 (↵) to modify parameters. You Oil oper- C4.# ### 0-9999h 500*
are then in the edit mode. This is indicated ating life
by the corresponding parameter value
V-belt op- C5.# ### 0-9999h 0
flashing.
erating (inac-
! The keys 4 and 5 (↑/↓) allow you now to
life tive)
modify the value.
! Press key 6 (→) to return to the display Shutdown C6. # 0=No No
mode, and retain the previous value. mainte- 1=Yes
! Press key 7 (↵) to save the current value nance
and to enter the next value that can be Tab. 3: Maintenance menu
modified.
* only first maintenance interval; the re-
In the event values have been modified maining intervals are 2000h
within one menu, storage of the new
values is signalled through a horizontal The maintenance intervals can be specified
bar (for one second). between 0-9999h while the input „0“ means
that this interval should not be edited. In this
place only the target values of the mainte-
nance intervals are indicated; please infer the
Pressure control menu (Code 010) actual count from the information provided in
the initial display (refer to initial display in
Name Message Setting Factory chapter 5.2 “Display features”).
range setting
After a maintenance interval has been modi-
fied, the corresponding count is reset while
Minimum A1. ##.# Between 8.5 bar
the new set value is being applied. Thus the
network 5.0 bar
respective interval can start again, for in-
pressure and
stance after maintenance work has been
maxi-
completed.
mum
network
Use the “C6” parameter to decide whether the
pressure
compressor should be shut down after the
Maxi- A2. ##.# Between 10.0 maintenance interval has been exceeded by
mum mini- bar more than 100h. After the compressor has
network mum been shut down this way, the operator can
pressure network acknowledge this error message and start the
pressure compressor for another 100h.
and sys-
tem
pressure
Tab. 2: Pressure control menu
Maintenance menu (Code 020)
Name Message Setting Factory

range setting
Air filter C1.# ### 0-9999h 2000

operating
life
10 104482 HSC • 03/03

PROCON control
Operating parameter menu (Code The pressure control is effected via an exter-
030) nal contact during programmed operation of
the base load sequencer.
Name Message Setting Factory
In case the remote control is activated the
range setting
start-up is effected via an external contact.
The control system reacts only to the positive
Base load B1. # 0=No No signal edge for start-up of the device. If there
sequencer 1=Yes is no input signal this means that the com-
operating pressor is switched off. In this case you can-
mode not use the keyboard to switch on or off the
Conti- B2. # 0=No No device.
nuous 1=Yes
operation The “continuous operation” parameter allows
to operate the compressor in the no-load op-
Remote B3. # 0=No No
eration mode and thus to prevent it from be-
operation 1=Yes
ing switched off.
Re-starts B4. # 0=No No
automa- 1=Yes You can specify two periods if the automatic
tically af- restart after voltage breakdown has been acti-
ter power vated. The power failure time specifies the
failure maximum allowable period of voltage break-
Power B5. ## 0-60s 1s down after which it is permitted to restart the
failure device. If this value is set to “0”, the device
time can be restarted at any time. The re-start de-
Re-start B6. ## 0-60s 0s lay allows to prevent the compressor from re-
delay starting immediately after voltage recovery.
This may be necessary to prevent several
Tab. 4: Operating parameter menu compressors connected to the mains network
from starting simultaneously.
104482 HSC • 03/03 11

PROCON control
Menu structure, customer menu
Information Pressure control Maintenance intervals Operating parameter

°C bar °C bar °C bar °C bar
3s p2 00
. 3s cod 010 3s COD 020 3s Cod 030
System pressure (Option)
. r23 456 a1. 90

. c11
. 500 b1 . 0
Hours of operation Cut-in pressure
M
Air filter operating life Base load sequencer

operation
. L12 345 A2. 100

. c2. 500 b2. 0
Load operation hours Shut-off pressure Oil filter operating life Continuous operation
F1. 999 c31

. 500 b3. 0
Air filter operating life Oil separator operating life Remote operation
F2. 999 C4. 500 b4. 0

Oil filter operating life Oil operating life Automatic restart
F3. 999 C5. 0 b5. 1

Oil separator operating life V-belt operating life Power failure time
oil 999 C6. 0 b6. 0

Oil operating life Disable maintenance Re-start delay
Edit:
be 999 Edit mode
V-belt operating life
Increase values Cancel:
pro Decrease values

. 100 Return to the basic mode
Software version Apply value without retaining all previous values
Fig. 1: Menu structure, customer menu
12 104482 HSC • 03/03

Inspection and servicing
6 Inspection and servicing 6.2 Checking and topping up the oil

level
6.1 Safety instructions
Danger
The inspection and servicing may be carried Scalding hazard by draining hot oil.
out by experts or trained persons only. • Slowly open the oil filler neck.
• Avoid skin contact with hot oil
• Switch the compressor off for all servicing
work, and protect the unit against uninten-
tional operation.
• Prior to any servicing work set the power
switch to off or remove the mains plug.
• Use original HATLAPA parts and approved
operating material only. 2
• After having completed the servicing work
tighten all screws again.
• Depressurise the compressor prior to any
servicing work.
• Touch the compressor system at the on 1
and off switch only during and shortly af-
ter operation. Permit the compressor to
Fig. 5: Oil level indication
cool down prior to any servicing work. Hot
surfaces can cause severe injuries.
1 min. mark
2 max. mark
Before commencement of work, the following
steps must always be carried out.
! Close cut-off valve at compressed air out- Checking the oil level
let 25 (see fig. 1: component overview).
! Shut down the system. ! Switch the compressor off and depressur-
! Switch off power switch. ise.
! Open slowly the screw plug of the com- ! Drain off the condensation water before
pressed air aftercooler 26 to release air you check the oil level (refer to chapter 6.5
pressure. “Draining the condensation water”).
! Wait until no more air exits the post- ! Unscrew oil filler neck 18 (see fig. 1: Com-
cooler, and tighten the screw plug. ponent overview) by approx. 1 turn to
! Wait until the remaining system is re- check whether pressure has been released
leased from pressure and has cooled completely.
down. ! Check oil level through oil gauge 17 (see
! Unscrew oil filler neck 18 by approx. 1 turn fig. 1: component overview).
to check whether pressure has been re- ! The oil level has to be within the min. /
leased completely. max. level.
! Wait until no more air exits the oil filler ! Check whether the oil has a milky discol-
neck 18, and tighten again oil plug. oration or contains water drops (for meas-
ures, please refer to chapter 8 titled “Trou-
ble shooting / Milky colour of the oil, water
drops in the oil”).
104482 HSC • 03/03 13

Topping up oil 6.3 Changing the oil
Do not mix different types of oil. Exclu- Danger

sively use types of oil specified by Scalding hazard by draining hot oil.
HATLAPA. • Slowly open the oil filler neck.
• Avoid skin contact with hot oil
! Switch the compressor off and depressur-
ise.
Used oil has to be disposed of accord-
! Carry out the above steps as described in
ing to the local environmental regula-
the “Checking oil level” section.
tions.
! Remove oil filler neck 18.
! Slowly fill in the oil until the oil level as
indicated by the oil gauge 17 is within the
min. / max. range. ! Switch the compressor off and depressur-
! Screw on the oil filler neck. ise.
! Place a suitable collecting vessel under
Types of oil the oil and condensation water drain valve
15.
On account of the high stress the lubricating
! Open oil and condensation water drain
oil is exposed to in screw compressors with valve 15 while it is at operating tempera-
oil injection cooling, we recommend to use ture.
HATLAPA special purpose oils with AFS (anti
! Drain the oil into the vessel.
foam system) additives showing an extremely
! Close oil and condensation water drain
good aging and water-repellent behaviour; valve 15.
these oils do not foam, and they are anticorro-
! Open oil filler neck 18 and fill in the new
sive. oil slowly (refer to chapter 6.2 “Types of
oil”) until the oil level as indicated by the
The degree of viscosity of the oil chosen oil gauge 17 is within the min. / max.
should be based on the ambient temperature range.
according to ISO 3448.
! Screw on the oil filler neck.
Ambient temperature
6.4 Changing oil filter
0 up to +25°C Permanently
higher than
25°C Danger
Scalding hazard by draining hot oil.
• Carefully and slowly remove the oil fil-
Viscosity ISO VG 46 ISO VG 68 ter.
class • Avoid skin contact with hot oil
Viscosity at 41 up to 51 61 up to 75
40 °C mm²/s mm²/s
Use only new oil filters; you cannot
Point of igni- > 200°C
clean a used oil filter.
tion
If you replace the oil filter while the oil
Pour point At least 5°C below lowest circuit is filled, up to 2l oil can escape
ambient temperature. the system.
Tab. 5: Types of oil Dispose of the oil filter according to
the applicable local environmental
We assume no warranty unless the lu- regulations.
bricants used in our screw compres-
sors show these essential characteris-
tics.
14 104482 HSC • 03/03

! Place a suitable collecting vessel under 6.8 Changing oil high-precision

the oil filter 24. separator cartridge
! Turn the oil filter left using chain pliers to
screw it off.
! Clean the oil filter holder. Use only a new oil high-precision sepa-
! Screw down the new oil filter until the rator cartridge; you cannot clean a
gasket is firmly in place. used high precision separator car-
! Replace oil that has escaped by new oil tridge.
(refer to chapter 6.2 “Checking and top- A small amount of oil can escape as
ping up the oil level“). you change the oil high-precision
separator cartridge.
Dispose of the oil high-precision sepa-
6.5 Draining the condensation wa- rator cartridge according to the appli-
cable local environmental regulations.
ter
! Turn the oil high-precision separator car-
The condensation water contains oil tridge 3 (see fig. 1: Component overview)
and has to be disposed of according to left using chain pliers to screw it off.
the local environmental regulations. ! Clean the oil high-precision separator car-
tridge holder.
Drain the condensation water every week. ! Oil slightly the O-ring and the gasket of
the new oil high-precision separator car-
! Place a suitable collecting vessel under tridge.
the oil and condensation water drain valve ! Screw down the new oil high-precision
15. separator cartridge until the gasket is
! Open oil and condensation water drain firmly in place.
valve 15 while it is at operating tempera-
ture.
! Drain the condensation water into the ves- 6.9 Checking and changing the
sel until pure oil escapes. suction filter cartridge
! Close oil and condensation water drain
valve 15. ! Remove the cover of the suction filter 23
(see fig. 1: Component overview).
! In case of severe soiling, immediately re-
6.6 Cleaning the oil cooler and the place the suction filter (cf. list of
compressed-air aftercooler. HATLAPA spare parts in the chapter titled
“Technical annex”).
! Blow compressed air through the cooling ! Refit the cover of the suction filter.
fins of the oil cooler 27 and of the com-
pressed-air aftercooler 26 (see fig. 1: Com-
ponent overview) from the inside of the
machine until dust and deposits have dis-
appeared.
6.7 Checking safety valve
The safety valve 11 (see fig. 1: Compo-

nent overview) is secured with a seal
which must not be removed.
! Lift slightly the valve cap to check the

function.
104482 HSC • 03/03 15

6.10 Clean proportional controller 6.12 Checking and adjusting the V-

nozzle. belt
Applies only to systems equipped with HSC up to 7.5 kW

proportional control.
5
1 1
F
2 Fig. 7: Checking V-belt tension HSC up to 7.5

kW
Fig. 6: Proportional controller
! Apply a perpendicular force between 25 N
and 35 N in point 1 using a dynamometer.
1 Nozzle
! In doing so, the belt must give approx.
2 Hose connection
5mm.
! Remove plastic hose connection of the
proportional controller 7 (see. fig. 1: Com- 2
ponent overview). 3
! Unscrew the nozzle behind.
! Clean nozzle, controller and hose.
! Screw in the nozzle.
! Fix the hose connection again.
6.11 Cleaning drain restrictor

1
The drain restrictor is where the drain line 9
enters the casing of the compressor 1 (see fig. Fig. 8: HSC V-belt tensioning device up to 7.5
1: Component overview). kW
! Remove the drain line 9 from the drain re- 1 Motor flange screws
strictor. 2 Adjusting screw
! Unscrew the restrictor from the casing of 3 Lock nut
the compressor 1. 4 Nut
! Clean the hole of the restrictor.
! Mount and connect the restrictor again. ! Slightly loosen motor flange screws 1.
! Loosen lock nut 3 at adjusting screw 2.
! Adjust V-belt tension through adjusting
screw 2 and tighten lock nut 3 again.
! Tighten motor flange screws 1.
16 104482 HSC • 03/03

HSC up to 7.5 kW 6.14 Tighten the screw connections.
After first commissioning, check and –

if required – retighten all screws.
3
! Tighten all screw connections in regular
intervals.
4 ! In doing so, observe the torque (cf. Tab.: 6:
Torques).
2 Screw Maximum torque

1
M8 25 Nm
Fig. 9: HSC V-belt tensioning device over 7.5
M 10 50 Nm
kW
M 12 85 Nm
1 Bottom adjusting nut Tab. 6: Torques
2 Top adjusting nut
3 Lock ring
4 Square pin 6.15 Checking electric terminals
The V-belt tension must be corrected if the ! Check and – if required – tighten all elec-
lock ring 3 touches the square pin 4. tric terminals regularly.
! Loosen the bottom adjusting nut 1.
! Unscrew the top adjusting nut 2 until the
distance between the lock ring 3 and the
6.16 Relubricating / replacing motor
square pin 4 is 10-12mm. mounting
! Tighten the bottom adjusting nut 1.
! Relubricate or replace the motor mounting
as specified by the manufacturer (refer to
6.13 Notes on systems equipped the name plate of the motor).
with water cooling system
In water-cooled screw compressors, the oil /

air cooler is replaced by a plate heat ex-
changer, and the air-to-air cooler is replaced
by a tube bundle heat exchanger. You can use
fresh water as cooling water. It is recom-
mended to install a sand and a dirt filter be-
fore the cooling water preliminary flow.
104482 HSC • 03/03 17

Maintenance schedule
7 Maintenance schedule
The intervals mentioned are experimental values. They can differ considerably
depending on the application conditions.
Before first commissioning

After first commissioning
Every week
10 000 h1
4 000 h1
8 000 h1
Interval
2 000h1
6 000h1
500 h1
Application
Check the rotating direc-

! ! ! ! ! ! ! –
tion (cf. chapter 3.4).
Drain the condensation
! ! ! ! ! ! –
water (cf. chapter 6.5).
Check the oil level (cf.
! ! ! ! ! ! –
chapter 6.2).
Check the V-belt (cf.
! ! ! ! ! ! ! –
chapter 6.12).
Clean the proportional
controller nozzle (cf. " ! ! ! ! ! –
chapter 6.12).
Change oil (cf. chapter
6.3), mineral (factory- ! ! ! ! ! –
filled).
Change oil (cf. chapter
! ! ! –
6.3), synthetic.
Replace oil filter (cf.
! ! ! ! ! –
chapter 6.4).
Check safety valves (cf.
! ! ! ! ! –
chapter 6.7).
Clean the drain restrictor
! ! ! ! –
(cf. chapter 6.11).
Clean the oil-aftercooler
" ! ! ! ! –
(cf. chapter 6.6).
Check the suction filter
cartridge² (cf. chapter " ! ! –
6.9).
Change the suction filter
cartridge² (cf. chapter " ! ! –
6.9).
Change the oil high-
precision separator car- " ! ! –
tridge (cf. chapter 6.8).
Tighten the screw con-
nections (cf. chapter ! ! –
6.14).
18 104482 HSC • 03/03

Maintenance schedule
Check the electric termi-

! ! –
nals (cf. chapter 6.15)
Relubricate/replace mo-
tor mounting (cf. chapter ! –
6.16)
Measures carried out on

(date):
Measures carried out by

(name):
Key:
! Measure to be carried out:

" Measure to take whenever required.
– Check at the manufacturer's works.
1
The required maintenance and inspection measures must be carried out on a yearly basis if
the hours of operation provided are not reached within a year’s period.
2
Check daily in dusty conditions and replace, if and when necessary.
104482 HSC • 03/03 19

Trouble shooting
8 Trouble shooting
8.1 Malfunction, compressor generally
Danger
Trouble shooting may be carried out only by trained experts or by staff members of
HATLAPA Company. In all actions, please observe the fundamental safety instructions
(cf. chapter 1), the safety instructions for operation (cf. chapter 4), and the safety instruc-
tions for maintenance (cf. chapter 6).
The compressor does not start up.
Potential reasons Actions
No connection to network. • Check the connection to the mains.

Fuse has blown. • Check the electric cable, switching units
and the motor.
• Use time-lag fuses only.
• Replace the fuse.
Network pressure is over cut-in pressure. • Reduce the pressure in the network.
Defect in the pressure detector or cable • Check cable, or replace pressure detector.
break.
The motor has broken down. • Check the electric system and the cables.
• Replace the motor.
Temperature detector of the motor gives a • Refer to table “Temperature detector of
signal. the motor gives a signal”.
Temperature detector of the motor gives a signal.
Fault at the electric connection. • Check the electric connection for under-
voltage and phase failure.
• Check the conductor cross section.
Ambient temperature is too high. • Improve the room ventilation.
• Select a cooler location.
Damage on the compressor • Check bearing of the compressor and
gear set.
Motor gets too hot due to high switching fre- • Check the pressure switching points.
quency.
Pressure detector has been set wrongly. • Check the pressure switching points.
The clamping connections have come lose. • Retighten the clamping connections.
20 104482 HSC • 03/03

Trouble shooting
The switching frequency of the motor is too high.
The compressed-air reservoir is too small. • Use a larger compressed-air reservoir.

Too much condensation water in the com- • Drain the condensation water (refer to
pressed-air reservoir / compressed-air duct- chapter 6.5).
work system. • As a preventive measure, fit an automatic
condensation water drain system
(HATLAPA accessories).
Low delivery – the setpoint pressure is not made.
The suction filter is soiled. • Clean the suction filter.

• Change the filter cartridge.
Pipes and fittings are leaking. • Tighten the screws and fittings.
• Replace the seals.
The air demand is higher than the delivery • Check the air demand.
volume of the compressor. • Expand the compressed air supply.
The compressor turns too hot.
Ambient temperature is too high. • Improve the room ventilation.

• Select a cooler location.
The cooling air volume is not available or too • The space between fan and wall is to
low. small (cf. chapter 3.1 “Mounting condi-
tions”).
• Check cooler for dirt, and clean if neces-
sary.
The ultimate pressure is too high. • Check the pressure switching points.
Oil level too low. • Top up oil (refer to chapter 6.2 'Checking
and topping up the oil level').
Oil cooler is dirty. • Clean the oil cooler.
Oil thermostat / thermostat is defective (only • Replace oil thermostat / thermostat.
in case of water cooling)
104482 HSC • 03/03 21

Trouble shooting
Milky colour of oil, water drops in the oil.
Water accumulation in the oil vessel (operat- • Change the oil immediately.
ing temperature is not reached because of • Retrofit a standby heating (HATLAPA ac-
too short operation time) cessory item).
• Select warmer location.
• Check design of the compressor.
• Contact manufacturer as to oil specifica-
tions.
Water accumulation in the oil vessel • Change the oil immediately.
(caused by humid conditions). • Select dry location.
The oil consumption is too high.
The wrong oil has been used. • Check the type of oil (cf. chapter 6.2
“Types of oil”), and replace, if and when
necessary.
The compressor is too hot. • See Table “Compressor turns too hot”.
Oil escapes through oil high-precision separa- • Check suction – compressor stage.
tor cartridge. • Check oil grade.
Air escapes when the compressor is at rest
Pressure control valve is defective. • Replace pressure control valve.
The compressor is not relieved when switched off.
Pressure detector or relief valve is defective. • Check pressure detector and relief valve
at intake regulator and replace if neces-
sary.
The system shuts suddenly down
Oil level too low. • Refill oil (refer to chapter 6.2 'Checking
and topping up the oil level').
Oil filter is clogged. • Replace oil filter cartridge.
22 104482 HSC • 03/03

Trouble shooting
System fails to shift to no-load operation or fails to shut down.
Pressure control valve is defective. • Replace pressure control valve.
Safety valve blows off
Pressure detector is set at a too high rate. • Correct settings of pressure sensor.
Pressure sensor is defect. • Replace pressure sensor.
Safety valve is defective. • Replace safety valve.
Suction stop valve does not close completely. • Check springs of the suction stop valve.
Solenoid valve is defective. • Replace solenoid valve.
Oil high-precision separator cartridge is used • Replace oil high-precision separator car-
up. tridge.
Proportional controller nozzle is clogged • Clean proportional controller nozzle.
(only with proportional control).
System is operating but is producing no pressure
Membrane in the adjust cylinder of the reduc- • Replace membrane and check control
ing damper is defective (depending on the pressure in the pressure control valve.
type of compressor)
The relief valve is defective. • Replace relief valve.
Pressure control valve is leaky. • Replace pressure control valve.
Abnormal noises
“Whistling” sound caused by compressed air • Remedy leaking points.

escaping the supply network, fittings etc. • Replace the seals.
• Tighten the screw connections.
The safety valve is “crackling”. • Check pressure settings.
• Check and replace if necessary safety
valve.
Fan is knocking. • Check whether the fan does not scrape.
Grinding noises • Damage in the mounting, compressor
needs repair.
• Damage in the mounting, motor needs
repair (HATLAPA service).
104482 HSC • 03/03 23

Trouble shooting
8.2 Malfunction, PROCON control
Any malfunction will cause the compressor to shut down. This will last until the cause of
the malfunction is eliminated and the corresponding message is acknowledged:
• Press key 6 (→) to enter the basic mode.

• Keep then both keys 4 and 5 (↑/↓) pressed for at least 2 seconds.
Message Type of malfunction Cause
E01 Final temperature The value set under “Final temperature error” has
been reached or exceeded.
E02 Emergency stop Emergency stop key 4 has been pressed; or cable
break.
E03 Temperature of the motor. The temperature of the motor winding is too high; or
cable break.
E04 Direction of rotation Wrong direction of rotation; or cable break.
E05 Start temperature The final temperature is not higher than the value
set under “Start temperature”.
E06 Development of system The system pressure has not been developed within
pressure the set period. V-belt may have broken.
E07 Excess pressure The maximum allowable system pressure has been
exceeded.
E08 Temperature sensor Defect in the temperature sensor or cable break.
E09 Network pressure sensor Defect in the network pressure detector or cable
break.
E10 System pressure sensor When parameter “System pressure sensor” = 1 and
system pressure sensor is defective; or cable break.
E11 Shutdown maintenance At least one maintenance interval has been ex-
ceeded by more than 100h and parameter active.
ErE EEPROM parameter At least one parameter is outside the valid setting
range or EEPROM is defective.
ErA EEPROM adjustment Adjusted values of the analogue sensors are incor-
rect.
24 104482 HSC • 03/03

Trouble shooting
8.3 Warnings, PROCON control
In case of a warning, the compressor is not shut down automatically. The message is
acknowledged in the same fashion as with malfunction.
Message Type of malfunction Cause
A01 Final temperature The value set under “Final temperature error” (-5°C)
has been reached or exceeded. If Error final tem-
perature is active the warning is reset automatically.
A021 Air filter differential pres- Air filter is clogged; or cable break.
sure
A03 Oil filter differential pres- Oil filter is clogged; or cable break.
sure
A041 Separator differential Defect in the oil separator; or cable break.
pressure
A11 Air filter service life Maintenance interval for the air filter has elapsed.
A12 Oil service life Maintenance interval for the oil has elapsed.
A13 Oil filter service life Maintenance interval for the oil filter has elapsed.
A14 Separator service life Maintenance interval for the separator has elapsed.
A15 V-belt service life Maintenance interval for the V-belt has elapsed.
1
Optional
104482 HSC • 03/03 25

03/03 # We reserve the right for technical changes.
HATLAPA
Uetersener Maschinenfabrik
GmbH & Co.
Tornescher Weg 5 – 7,
25436 Uetersen
Telefon: ++49 4122 711- 0
Telefax: ++49 4122 711 - 104
104482 HSC •
eMail info@hatlapa.de
Internet www.hatlapa.de
Ersatzteil-Verzeichnis
List of spare parts
Liste des pièces de rechange
Schraubenkompressor
Screw compressor
HSC 18,5 - 22
Werkstoff / Halbzeug / DIN
Modell Nr. / Werkzeug Nr.
Buchstabe Änderung Datum Name

Maßstab Datum Name Zeichn.Nr.
Allgemeintoleranzen für Schweißkonstruktionen DIN 8570

Gez.
Gepr.
19.12.00 Küster 6990001
Diese Zeichnung darf nur zu den Zwecken Zerspanende Fertigung: Zulässige Abweichung für Maße ohne Toleranzangabe in mm DIN 2768
für Längenmaße l in mm Nennbereich l Winkelmaße a in ° und ' für Schenkellänge benutzt werden, wozu sie dem Empfänger Genauig- Nennbereiche (mm) der Freimaße über 30 über 120 über 400 über 1000
Paßmaß Abmaß Benennung
Compressor-motor cpl.
über 2000
keitsgrad über 0,5 bis 3 über 3 bis 6 über 6 bis 30 bis 120 bis 400 bis 1000 bis 2000 bis 4000
Genauig- über 30 über 120 über 315 über 1000 über 2000 über 315 anvertraut ist, sie darf weder
keitsgrad bis 30 bis 120 bis 315 bis 1000 bis 2000 bis 4000 bis 315 bis 1000 über 1000
vervielfältigt, noch dritten Personen, fein ±0,05 ±0,05 ±0,1 ±0,15 ±0,2 ±0,3 ±0,5 Oberflächenbehandlung Die Maße werden
A ±1 ±1 ±1 ±2 ±3 ±4 ±20' ±15' ±10' insbesondere Konkurenzfirmen ohne unsere mittel ±0,1 ±0,1 ±0,2 ±0,3 ±0,5 ±0,8 ±1,2 ±2 besonders geprüft
B ±1 ±2 ±3 ±4 ±6 ±45' ±30' ±20' Erlaubnis mitgeteilt oder zugänglich grob ±0,2 ±0,3 ±0,5 ±0,8 ±1,2 ±2 ±3 ±4 Ersatz für
C ±1 ±3
±2
±4 ±6 ±8 ±11 ±1° ±45' ±30' gemacht werden. sehr grob ±0,5 ±1 ±1,5 ±2,5 ±4 ±6 ±8
HSC 18,5/22
Pos. pcs Description Order No. Pos. pcs Description Order-No.
101 1 E-Motor 18,5kW 764040 137 1 Pin 69271371
101 1 E-Motor 22kW 764073 139 1 Fan belt disc 7,5bar 18,5/22kW 717647
102 4 vibration damper 757102 140 1 Fan belt disc 10bar 18,5/22kW 717648
103 4 Pin 18,5kW 66151039 141 1 Fan belt disc 13bar 18,5/22kW 717649
103 4 Hexagon bolt 22kW 700250 145 3 Fan belt 7,5bar 18,5kW 707598
104 4 Wheel disc 701407 145 3 Fan belt 10bar 18,5kW 707598
105 4 Under leg washer 703412 145 3 Fan belt 13bar 18,5kW 707593
106 4 Nut 703103 145 3 Fan belt 7,5bar 22kW 707593
107 1 Motor plate 6990107 145 3 Fan belt 10bar 22kW 707528
108 2 Hexagon bolt 700240 145 3 Fan belt 13bar 22kW 707519
109 2 Spring ring 7035070 151 1 Clamping 6927151
111 2 Nut 703106 155 1 Clamping roll 69141551
113 1 Fan belt disc 18,5kW 717606 155.9 1 Clamping roll complete 69141559
113 1 Fan belt disc 22kW 717605 156 2 Ball bearing 705063
115 8 Settling disk 18,5kW 6632115 157 1 Lock ring 704107
116 1 Fan hub 18,5kW 6985116 160 3 Nut 703104
116 1 Fan hub 22kW 6990116 161 1 Disc 705383
117 1 Fan complete 18,5kW 104747 162 1 Wheel disc 701409
117 1 Fan complete 22kW 104748 163 2 Under leg washer 703413
118 3 set screw 701253 164 1 Lock nut 703312
119 4 Fan blade 104749 165 1 Lock ring 704011
120 4 Hexagon bolt 700204 166 1 Lock ring 704018
121 4 Spring disc 703605 167 1 Lock ring 704004
130 1 screw compressor block 765034 168 1 Cylinder screw 700822
131 1 Clamping lever 69271311 169 1 Disc 703423
132 4 Cylinder screw 700839 170 1 Flange 6990170
134 1 Pin 6927134 172 4 Cylinder screw 701017
135 1 Compression spring 6637480 173 1 O-Ring 90x3 707680


Gez.
Gepr.
19.12.00 Küster 6990001
Compressor-motor cpl.
über 2000
C ±1 ±3
±2
HSC 18,5/22


Gez.
Gepr.
10/97 Küster 6990002
für Längenmaße l in mm Nennbereich l Winkelmaße a in ° und ' für Schenkellänge benutzt werden, wozu sie dem Empfänger Genauig- Nennbereiche (mm) der Freimaße über 120 über 400 über 1000
Frame and noise cover
über 30 über 2000
B ±1 ±2 ±2 ±3 ±4 ±6 ±45' ±30' ±20' Erlaubnis mitgeteilt oder zugänglich grob ±0,2 ±0,3 ±0,5 ±0,8 ±1,2 ±2 ±3 ±4 Ersatz für HSC 18,5/22
C ±1 ±3 ±4 ±6 ±8 ±11 ±1° ±45' ±30' gemacht werden. sehr grob ±0,5 ±1 ±1,5 ±2,5 ±4 ±6 ±8
Pos. pcs. Description Order-No. Pos. pcs. Description Order-No.
10 1 Shield 15030014 218 1 ventilation flap 6990218
201 1 Frame complete 6990201 219 1 cover plate 6990219
211 4 rubber base 708805 220 1 key to the control cubicle 770051
212 4 Cylinder screw 700820 221 1 protective grid 715814
210 1 Frame 6990210 222 6 Cylinder screw 700822
213 4 Cylinder screw 700822 223 6 Nut 703102
214 4 Spring ring 703604 224 1 Wall ring 18,5kW 104912
215 1 Sidpanel front 6990215 224 1 Wall ring 22kW 6985224
216 1 Sidepanel right 6990216 228 4 Cylinder screw 701004
217 1 Sidepanel left 6990217 230 1 Cable connection 760365


Gez.
Gepr.
10/97 Küster 6990002
Frame and noise cover
über 30 über 2000
B ±1 ±2 ±2 ±3 ±4 ±6 ±45' ±30' ±20' Erlaubnis mitgeteilt oder zugänglich grob ±0,2 ±0,3 ±0,5 ±0,8 ±1,2 ±2 ±3 ±4 Ersatz für HSC 18,5/22
C ±1 ±3 ±4 ±6 ±8 ±11 ±1° ±45' ±30' gemacht werden. sehr grob ±0,5 ±1 ±1,5 ±2,5 ±4 ±6 ±8
434
431
437
427
305 467
304
303
308
306
302 300
309
307

Gez. 17.12.97 Küster 6990003
für Längenmaße l in mm Nennbereich l Winkelmaße a in ° und ' für Schenkellänge
Diese Zeichnung darf nur zu den Zwecken
benutzt werden, wozu sie dem Empfänger
Zerspanende Fertigung: Zulässige Abweichung für Maße ohne Toleranzangabe in mm DIN 2768
Genauig- Nennbereiche (mm) der Freimaße über 120 über 400 über 1000
Paßmaß Abmaß
1:10 Gepr.
Benennung
Electric-control Procon
über 30 über 2000
B ±1 ±2 ±2 ±3 ±4 ±6 ±45' ±30' ±20' Erlaubnis mitgeteilt oder zugänglich grob ±0,2 ±0,3 ±0,5 ±0,8 ±1,2 ±2 ±3 ±4 Ersatz für
C ±1 ±3 ±4 ±6 ±8 ±11 ±1° ±45' ±30' gemacht werden. sehr grob ±0,5 ±1 ±1,5 ±2,5 ±4 ±6 ±8 HSC 18,5/22
3 1 Assembly control PROCON kpl. 775089 309 1 Sealing rubber profile 708825
300 1 Control cubicle 6980300 310 6 Cylinder screw 702012
302 1 Emergency stop 775105 311 6 Under leg washer 703412
303 1 PROCON control 775045 427 1 Temperature sensor 775050
304 1 Covering cap 7750451 431 1 Coupling 775073
305 1 Cable form 7750453 434 1 Screw connection 752003
306 1 Front foil for Procon control 7750452 437 1 Pressure detector 775048
307 1 Adhesive label 6970307 467 1 Reducer plug 6913467

Gez. 17.12.97 Küster 6990003
für Längenmaße l in mm Nennbereich l Winkelmaße a in ° und ' für Schenkellänge
Diese Zeichnung darf nur zu den Zwecken
benutzt werden, wozu sie dem Empfänger
Zerspanende Fertigung: Zulässige Abweichung für Maße ohne Toleranzangabe in mm DIN 2768
Genauig- Nennbereiche (mm) der Freimaße über 120 über 400 über 1000
Paßmaß Abmaß
1:10 Gepr.
Benennung
Electric-control Procon
über 30 über 2000


Gez.
Gepr.
10.12.97 Küster 6990004
für Längenmaße l in mm Nennbereich l Winkelmaße a in ° und ' für Schenkellänge benutzt werden, wozu sie dem Empfänger Genauig-
keitsgrad
Nennbereiche (mm) der Freimaße
über 0,5 bis 3 über 3 bis 6 über 6 bis 30
über 30
bis 120
über 120
bis 400
über 400
bis 1000
über 1000
bis 2000
über 2000
bis 4000 Paßmaß Abmaß Benennung
über 1000 anvertraut ist, sie darf weder
Armatures-tubing, Separation system, Cooling system
Genauig- über 30 über 120 über 315 über 2000 über 315
401 2 Screw 705517 470 1 Oil temperature controller compl. 6634470
402 1 Screw 705525 486 1 Screw connection 752003
408 1 Screw connection 102655 497 1 Pipe 6980497
409 1 Pressure control valve 711802 498 1 Pneumatic pipe 6990498
410 1 Separator 18,5kW 6990410 499 1 Pneumatic pipe 6990499
410 1 Separator 22kW 69274103 500 1 Pressure vessel 6990500
422 1 Flange 22kW 103052 526 1 Oil filler plug 6913550
425 1 Seal 22kW 6931538 527 1 Seal ring 703705
434 1 Screw connection 752003 535 4 Cover vessel 6990535
435 1 Hose 755237 543 1 Cone cock 751601
436 1 Hose otp. Oil gauge 101424 545 1 Angle 705833
438 1 Screw connection 752121 547 1 Screw 705526
440 1 Screw connection 752149 548 1 Screw connection 706610
445 1 Reducer plug 87629 549 1 Pneumatic hose 755009
446 1 Double nipple 706344 550 4 Hexagon bolt 700206
447 1 Pneumatic pipe 6990447 551 4 Disc 703423
456 2 Screw connection 752054 552 4 Spring disc 703604
459 4 Cylinder screw 700855 601 1 Combi-Cooler 790554
461 1 Seal 6619461 602 3 Hexagon bolt 720200
463 1 Pressure joint 6990463 603 3 Nut 703101
464 1 Flexmaster 706615 604 3 Under leg washer 703410


Gez.
Gepr.
10.12.97 Küster 6990004
keitsgrad
über 30
bis 120
über 120
bis 400
über 400
bis 1000
über 1000
bis 2000
über 2000
über 1000 anvertraut ist, sie darf weder
Armatures-tubing, Separation system, Cooling system
Genauig- über 30 über 120 über 315 über 2000 über 315
539
455
454
421
405 424
427
406 426
443
411
442
423
453
452 457
430 Werkstoff / Halbzeug / DIN
429
427 Modell Nr. / Werkzeug Nr.
426 Buchstabe Änderung Datum Name


Gez.
Gepr.
18.11.97 Küster 6990410
für Längenmaße l in mm Nennbereich l Winkelmaße a in ° und ' für Schenkellänge benutzt werden, wozu sie dem Empfänger Genauig- Nennbereiche (mm) der Freimaße über 30 über 120 über 400 über 1000 über 2000
Genauig-
keitsgrad
A
bis 30
±1
über 30
bis 120
±1
über 120
bis 315
±1
über 315
bis 1000
±2
über 1000
bis 2000
±3
über 2000
bis 4000
±4
bis 315
±20'
über 315
bis 1000
±15'
über 1000
±10'
anvertraut ist, sie darf weder
vervielfältigt, noch dritten Personen,
insbesondere Konkurenzfirmen ohne unsere
keitsgrad
fein
mittel
über 0,5 bis 3
±0,05
±0,1
über 3 bis 6
±0,05
±0,1
über 6 bis 30
±0,1
±0,2
bis 120
±0,15
±0,3
bis 400
±0,2
±0,5
bis 1000
±0,3
±0,8
bis 2000
±0,5
±1,2
bis 4000
±2
Oberflächenbehandlung Die
besonders geprüft
Maße werden Separator cpl.
C ±1 ±3
±2
HSC 18,5
410 1 Separator 6990410 430 1 Seal ring 703701
405 4 Cylinder screw 700924 442 1 Lock valve 751123
406 4 Wheel disc 701407 443 1 Seal ring 703702
411 1 Valve housing 6922411 452 1 Screw connection 752069
421 1 Lock ring 704013 453 2 Seal ring 703810
423 1 Seal 6922423 454 1 Double nipple 6922454
424 1 O-Ring 22x2,5 707754 455 1 Pipe 6922455
426 2 Screw 705500 457 1 Non-return valve 751206
427 2 Seal ring 703700 463 1 Screw connection 707372
429 1 Screw 705522 539 1 Air/oil separator box 758159


Gez.
Gepr.
18.11.97 Küster 6990410
für Längenmaße l in mm Nennbereich l Winkelmaße a in ° und ' für Schenkellänge benutzt werden, wozu sie dem Empfänger Genauig- Nennbereiche (mm) der Freimaße über 30 über 120 über 400 über 1000 über 2000
Genauig-
keitsgrad
A
bis 30
±1
über 30
bis 120
±1
über 120
bis 315
±1
über 315
bis 1000
±2
über 1000
bis 2000
±3
über 2000
bis 4000
±4
bis 315
±20'
über 315
bis 1000
±15'
über 1000
±10'
vervielfältigt, noch dritten Personen,
insbesondere Konkurenzfirmen ohne unsere
keitsgrad
fein
mittel
über 0,5 bis 3
±0,05
±0,1
über 3 bis 6
±0,05
±0,1
über 6 bis 30
±0,1
±0,2
bis 120
±0,15
±0,3
bis 400
±0,2
±0,5
bis 1000
±0,3
±0,8
bis 2000
±0,5
±1,2
bis 4000
±2
Oberflächenbehandlung Die
besonders geprüft
Maße werden Separator cpl.
C ±1 ±3
±2
HSC 18,5
539
455
454
405
421
406 424
463
411 449
443
442
423
427 Modell Nr. / Werkzeug Nr.

426 a Ermeto EVGE 28 für Druckluftabgang entfällt 10/01 Hall

Gez.
Gepr.
15.10.01 Küster 69274103
Separator cpl.
über 2000
C ±1 ±3
±2
HSC 22-55
410 1 Separator compl. 69274103 427 1 Seal ring 703700
405 4 Screw 700605 442 1 Emergency valve 751123
406 4 Wheel disc 701409 443 1 Seal ring 703702
411 1 Valve housing 6927411 449 1 Non-return valve 751206
421 1 Lock ring 704018 454 1 Double nipple 6927454
423 1 Seal 6931538 455 1 Pipe 6927455
424 1 O-Ring 30x2,5 707678 463 1 Screwing connection 707322
426 1 Screw connection 705500 539 1 Air/oil separator box 758164


Gez.
Gepr.
15.10.01 Küster 69274103
Separator cpl.
über 2000
C ±1 ±3
±2
HSC 22-55
482
485
493
488 472
473
481
483 480
483
494
490 495
477
476
484
479
478


Gez.
Gepr.
22.10.01 Küster 6634470
Oil-thermostat cpl.
über 30 über 2000
C ±1 ±3
±2
HSC 18,5/22/30/37
470 1 Oil temperature controller compl. 6634470 481 1 Piston 6613481
472 1 O-Ring 28x3 707703 482 3 Cylinder screw 701006
473 1 Set for oil temerature controller 757817 483 2 O-Ring 16x2,5 707753
476 1 Valve housing 6613476 484 4 Spring washer 703512
477 1 Double nipple 6633477 485 3 Spring disc 703605
478 1 Oilfilter 7,5/10bar 18,5/22kW 758101 488 1 Screw connection 752057
478 1 Oilfilter 13bar 18,5/22kW 758102 490 1 Screw connection 752054
478 1 Oilfilter 7,5/10bar 30/37kW 708500 493 1 Cap 6613493
478 1 Oilfilter 13bar 30/37kW 758104 494 1 Screw 705500
479 4 Cylinder screw 701020 495 1 Seal ring 703700
480 1 Compression spring 6613480


Gez.
Gepr.
22.10.01 Küster 6634470
Oil-thermostat cpl.
über 30 über 2000
C ±1 ±3
±2
HSC 18,5/22/30/37
741
734
724 732
729 709
733 731
745 738
730
737 728
738 727
735 726
719 707
725 720
731
721 708
739 710
725 717
722 703
702
755 716 705
730 714 706
730 704
713 712
711
756
701
718
750
752


Gez.
Gepr.
6.8.01 Küster 6633700
keitsgrad
über 30
bis 120
über 120
bis 400
über 400
bis 1000
über 1000
bis 2000
über 2000
Suction regulator without proportional control
Genauig- über 30 über 120 über 315 über 1000 über 2000 über 315
C ±1 ±3 ±4 ±6 ±8 ±11 ±1° ±45' ±30' gemacht werden. sehr grob ±0,5 ±1 ±1,5 ±2,5 ±4 ±6 ±8 HSC 18,5/22/30/37
700 1 Suction controller 6633700 726 1 Cap 66137254
701 1 Suction body 6633701 7261 1 Relief valve compl 66337261
702 1 Cylinder 6633702 727 1 Membrane 66137252
703 1 Holder 6633703 728 1 Relief valve 66137251
704 1 O-Ring 55x2,5 707670 729 4 Cylinder screw 701004
705 1 Compression spring 6633705 730 3 Screwing connection 707322
706 1 Seal 707878 731 2 Angle connection 707372
707 1 Seal 708440 732 1 Plastic pipe 757000
708 1 Piston 66337081 733 1 Plastic pipe 757000
709 1 Restrictor 6913709 734 1 Plastic pipe 757000
710 1 Compression spring 3173120 735 1 Plastic pipe 757000
711 1 Lock ring 704112 737 1 Sleeve 6633737
712 1 Valve cone 6633712 738 2 Seal ring 703700
713 1 Valve ring 6633713 739 1 Solenoid valve 7054071
714 1 O-Ring 707608 741 1 Tee coupling 707321
716 1 Steel cone 707304 745 4 Spring disc 703606
717 1 Lock ring 704109 750 1 Suction filter 708989
718 1 Feet seal 6996718 752 1 Filter cartridge 708501
719 4 Cylinder screw 701016 753 1 Filter cap 758027
720 4 Spring disc 703605 755 4 Wheel disc 701409
721 4 Hexagon bolt 700222 756 1 Screw 701601
722 4 Under leg washer 703413 Maintenance set incl.
790 1 66337901
724 1 Plug-in nipple 2707099 704,705,706,707,710,718,727
725 2 Double nipple 706340


Gez.
Gepr.
6.8.01 Küster 6633700
keitsgrad
über 30
bis 120
über 120
bis 400
über 400
bis 1000
über 1000
bis 2000
über 2000
Suction regulator without proportional control
C ±1 ±3 ±4 ±6 ±8 ±11 ±1° ±45' ±30' gemacht werden. sehr grob ±0,5 ±1 ±1,5 ±2,5 ±4 ±6 ±8 HSC 18,5/22/30/37


Gez.
Gepr.
25.3.03 Küster 66337001
keitsgrad
über 30
bis 120
über 120
bis 400
über 400
bis 1000
über 1000
bis 2000
über 2000
Suction regulator with proportional control
C ±1 ±3
±2
HSC 18,5/22/30/37
700 1 Suction controller compl. 66337001 7261 1 Relief valve 66337261
701 1 Suction body 6633701 727 1 Membrane 66137252
702 1 Cylinder 6633702 728 1 Relief valve 66137251
703 1 Holder 6633703 729 4 Cylinder screw 701004
704 1 O-Ring 55x2,5 707670 730 4 Screwing connection 707322
705 1 Compression spring 6633705 731 4 Angle connection 707320
708 1 Piston 66337081 734 1 Plastic pipe 100874
709 1 Restrictor 6913709 735 1 Plastic pipe 100874
710 1 Spring-pressure Nr. 39 3173120 736 1 Propotion controller 6633736
711 1 Lock ring 704112 737 1 Sleeve 6633737
712 1 Valve cone 6633712 738 2 Seal ring 703700
713 1 Valve ring 6633713 739 1 Solenoid vavle 7054071
714 1 O-Ring 10x2,5 707608 741 1 Adapter 6913741
716 1 Steel cone 707304 744 1 Plastic pipe 100874
717 1 Lock ring 704109 745 4 Spring disc 703606
718 1 Feet seal 6996718 750 1 Suction filter with cartridge 708989
719 4 Cylinder screw 701016 752 1 Filter cartridge 708501
720 4 Spring disc 703605 755 4 Wheel disc 701408
721 4 Hexagon bolt 700069 756 1 Screw connection 705500
722 4 Under leg washer 703414 757 1 Seal ring 703700
724 4 Plug-in nipple 2707099 Maintenance set incl.
790 1 66337901
725 2 Double nipple 706340 704,705,706,707,710,718,727
726 1 Cap 66137254


Gez.
Gepr.
25.3.03 Küster 66337001
keitsgrad
über 30
bis 120
über 120
bis 400
über 400
bis 1000
über 1000
bis 2000
über 2000
Suction regulator with proportional control
C ±1 ±3
±2
HSC 18,5/22/30/37
Service
Anleitung zur richtigen Bestellung von Ersatzteilen

Für die Bestellung sind folgende Angaben unbedingt erforderlich:
1) Schiffsname (Ex-Name), Neubau-Nr. und Bauwerft

2) Fabriknummer und Typenbezeichnung (siehe Typenschild)
3) Ersatzteilnummer entsprechend Ersatzteilliste
4) Gewünschte Versandart, Versandadresse und Rechnungsanschrift
Instructions for correctly ordering spare parts

1) Name of vessel (former name), Hull No. and building shipyard

2) Serial number and type of the machine (see name plate)
3) Part number from the Spare Parts List
4) Desired method of dispatch, invoice and consignee’s address
Instruction pour établir les commandes de pièces de rechange

Les indications suivantes seront indispensables pour la commande:
1° Nom du navire (ex-nom), No. du navire et chantier de construction

2° Numéro d’usine et type (voir plaque d’identité)
3° Numéro de pièce suivant liste des pièces de rechange
4° Mode de transport désiré, adresses du destinataire et de la facture
Instrucciones para pedir correctamente piezas de repuesto.

Cuando se piden piezas de repuesto, deben ser dados los –
siguiéntes datos:
1) Número de serie y tipo (ver placa) .

2) Número de la pieza según la Lista de Piezas de Repuesto.
3) Forma de despacho así como consignación y dirección para la facturación.
4) Nombre del buque (nombre antígúo) ‚ número de construción y Astilliero.
Service
Um Ersatzteile schnellstens zu erhalten, wenden Sie sich bitte direkt an
oder an unsere Vertretungen (x), Kundendienststellen (o) oder Lizenznehmer ( +) laut

anliegender Liste.
In order to receive spare parts with the least possible delay, please get in touch with us
directly
or with our representatives (x),service stations (o) or licensees/co-operators (+) as

indicated in the enclosed list.
Pour assurer une fourniture rapide, veuillez vous adresser á
ou á nos agences (x) , stations-service (o) ,licenciés/partenaires de cooperation (+)
Uetersener Maschinenfabrik GmbH & C0.
Tornescher Weg 5-7 . D-25436 Uetersen
Phone: +49-4122-7 11-0

Mobile: +49-172-9 81 32 92
Fax.: +49-4122-7 11-104 Sales
-7 11-330 Service
Internet http://http://www.hatlapa.de/
Service-Stations
Spare Parts
Agencies
Our manufacturing programme:

Deck Machinery . Compressors . Steering Gears
HATLAPA Uetersener Maschinenfabrik GmbH & Co. KG

Tornescher Weg 5-7 . D-25436 Uetersen
GERMANY
Phone: +49-4122-7 11-0 .
Mobile: +49-172-9 81 32 92 .
Fax.: +49-4122-7 11-104 Sales
-7 11-330 Service
Internet:http://www.hatlapa.de
SUBSIDIARY OFFICE
FOR HAMWORTHY TYPE COMPRESSORS
HATLAPA Hamworthy Marine Compressors Ltd
Discovery Court Business Centre
551-553 Wallisdown Road
POOLE, Dorset BH12 5AG
UNITED KINGDOM
Phone: +44-1202-85 31 80
Fax.: +44-1202-85 31 91 Sales
+44-1202-85 31 90 Spares
Vertretungen (x), Kundendienststellen (o) und Lizenznehmer (+)

Representatives (x), service stations (o) and licensees/co-operators (+)
agences (x), stations-service (o) et licenciés/partenaires de cooperation(+)
o Australia Moorabbin, Vic. 3189 Tel:+61-3-95 32 13 97/95 32 1386

CJA Marine Technology Pty Ltd Fax:+61-3-95 32 14 13
Unit 3, 136 Cochranes Road E-mail: cja@attglobal.net
x Belgium B-2710 Hoboken Tel.: +32-3-827 40 91/95

Marine & Industrie BVBA Fax: +32-3-827 40 95
Emile de Harvenstraat 50-52 Telex: 33672 mardus b
E-mail: mardus@pandora.be
o Belgium/ Antwerp 2030 Tel.: +32 3 546 40 80

Luxembourg Service Hydro n.v. Fax: +32-3 546 40 81
Boterhamvaartweg 2 E-mail: service.hydro@hydro.be
x Brazil Rio de Janeiro - RJ Tel.: +55-21-2211 50 50/-50 28

PML Petersen Matex Ltda Fax: +55-21-2518 22 20/-30 19
Av. Rio Branco 25/18° E-mail: Max.Herrmann@pml.com.br
Stand 03.06.2004 Seite / page 1

Service-Stations
Spare Parts
Agencies
o Brazil Santos SP 11013-030 Tel.: +55-13-3222 46 86

Metalock Brasil Ltda Fax: +55-13-3222 40 88
Rua Visconde do Rio Branco 20/26 E-mail: santos@metalock.com.br
x Bulgaria 9000 Varna Tel.: +359-52-23 21 74

Ecatdan ApS Fax: +359-52-23 21 74
3 “Angel Georgiev” Str.
x Canada St. Catherines, Ontario L2M 6S9 Tel.: +1-905-688-4922

o Marine & Offshore Inc Fax.: +1-905-688-9028
113 Cushman Road, Unit 60 E-mail: hcl@vaxxine.com
o Chile Concepcion Tel.: +56-41-25 32 75

Eurotecnica Ltda Fax: +56-41-25 32 76
Los Carrera No. 1056 E-mail: eurotec@entelchile.net
x P.R. of China Nanjing 210039 Tel.: +86-25-86 70 21 27

+ CSSC Lüzhou Machine Works Nanjing Telex: 34106 Fssnk
Zhong Hua Men Wai Fax: +86-25-86 71 15 43
E-mail: foreign_trade@luzhou.com.cn
x P.R. of China Shanghai 200023 Tel.: +86-21-53 01 49 51/52

Hatlapa Asia Pacific Pte Ltd Mobile: +86-137 01 74 73 14
No. 600 Lu Ban Road Fax: +86-21-53 01 49 57
Room 1702, Jiangnan Shipyard Building E-mail: hatlapa@online.sh.cn
x Croatia 21000 Split Tel.: +385-21 385 267

o Nava International d.o.o. Fax.: +385-21-385 267
Planciceva 4 E-mail : mirko.nava@inet.hr
x Cyprus 3032 Limassol Tel.: +357-25-34 53 19

M.I.E. Services Ltd. Fax: +357-25-34 56 39
124 Gladstonos Str. E-Mail: adamos@mieserv.cy.net
The Hawk Building
x Denmark DK-2605 BrØndby Tel.: +45-77 33 66 33

Northrop Grumman Sperry Marine B.V. Fax: +45-77 33 66 11
Industrivej 16-18 E-mail: dk@sperry-marine.com
x Egypt/UAR Alexandria Tel.: +20-3-58 58 570

Alexandria Maritime Fax: +20-3-5 82 85 87
Consultative Office Telex: 54539 AMCO
10 Ahmed Yehya Pasha St. E-mail: amco.alex@amcoegypt.com
Gleem P.O. Box 1424

Service-Stations
Spare Parts
Agencies
x Finland FIN-00811 Helsinki Tel.: +358-9-75 59 81

Oy Tapiro Ab Cable: Tapiro
Pikkupurontie 11 Fax: +358-9-75 59 87 00
E-mail: tapiro@tapiro.fi
x France F-92100 Boulogne Tel.: +33-1-41 10 23 30

Wenex S.A. Telex: 633106 wenex
6, Rue de l’Est Fax: +33-1-41 10 23 45
E-mail: Wenex.equip@wenex.fr
o Germany D-47119 Duisburg-Ruhrort Tel/Fax.: 0203-8 28 98

Fr. Jung
König-Friedrich-Wilhelm-Str. 20
o Great Britain Staines/Middlesex TW18 4AX Tel.: +44-1784-41 04 15

for London and Saville Marine Fax: +44-1784-41 03 15
all U.K. ports Centurion House E-Mail: savmar@btinternet.com
London Road
x Greece 185 37 Piraeus Tel.: +30-210-41 85 301

o M.I.E. Co. Ltd. Fax: +30-210-45 39 234
Kanari 1 Telex: 241256
E-mail: commercial@mie.gr
o Greece 18863 Perama – Piraeus Tel.: +30-210-43 23 600/1-2

Inje Cov Ltd. Fax: +30-210-43 12 770
463, Dimokratias Ave Telex: 213306 Ingv gr
E-mail: injegov@ath.forthnet.gr
x India Bombay - 400 021 Tel.:+91-22-22823704/22842200

o Nicol & Andrew Engineering (Pvt.) Ltd. Fax: +91-22-2285 06 24
Suite 7, 2nd Floor “Arcadia” Telex: 1183677 kash in
Nariman Point E-mail: ksananda@bom4.vsnl.net.in
x Indonesia Jakarta 12160 Tel.: +62-21-7 25 55 41

o PT API, P.T. Assindo Fax: +62-21-7 25 55 46
Perniagaan Internasional E-mail: ptapijak@indo.net.id
Victoria Centre 3rd Fl.
Jl. Sultan Hasanuddin No. 47-51
+ Indonesia Bandung 42028 Tel.: +62-22-7 20 73/7 20 76

PT. Pindad (Persero) Telex: 28572 Pindad
Jl. Jend. Gatot Subroto Fax: +62-22-46 12 22

Service-Stations
Spare Parts
Agencies
x Iran Tehran 19139 Tel.: +98-21-260 13 02/200 00 08

o Iran Imexen Co. Fax: +98-21-20 04 849
No. 38 Koye Sh. Yazdanian, Gholhak Telex: 226041 imex
E-mail: Irimexen@rasaneh.com
x Italy I-29015 Castel San Giovanni (Piacenza) Tel.: +39-0523-84 30 46

o Realizzazioni Tecniche Cable: Ratenav
Navalmeccaniche Srl (R.T.N. Srl) Fax: +39-0523-84 30 40
Via Mozza 15 E-mail: info@retenav.it
x Korea Nam Gu, Pusan 608-743 Tel.: +82-51-6 10 12 33

o Dong Sung Co. Telex: 53115, Ext. No. 53
Room 1725, “21” Century City Building Fax: +82-51-6 10 12 32
55-1, Daeyeon 3-dong E-mail:ds_service@dongsungco.com
x Lebanon 3032 Limassol, Cyprus Tel.: 00357-25-34 66 26

Sheerlines Services Ltd Fax.: 00357-25-34 08 56
124 Gladstonos Street E-mail: c.petrou@sheerline.com.cy
The Hawk Building
x Mexico 01010 Mexico,D.F. Tel.:+52-55-5651 97 40/56 80 21 04

o Nautica S.A. de C.V. Fax: +52-55-56 51 28 25
Condor No 31 E-mail: nautica@prodigy.net.mx
Col. Alpes
x Middle East 3032 Limassol, Cyprus Tel.: +357-25-36 60 77

Saudi Arabia, Oman M.I.E. Services (Middle East) Ltd Fax.: +357-25-36 60 88
U.A.E., Qatar, Yemen Gladstonos 124 E-mail: simon@mieserv.cy.net
th
Bahrain, Kuwait, The Hawk Bldg., 4 Floor
Jordan
x Netherlands 3084 CC Rotterdam Tel.: +31-10-46 24 777

o Hamworthy KSE B.V. Fax.: +31-10-41 59 046
Aploniastraat 33 E-mail: talders@hamworthykse.nl
x Norway 6019 Aalesund Tel.: +47-70 17 29 80

o Tøssebro AS Fax: +47-70 17 29 90
Vestre Olsvikvej 25 E-mail: mail@tossebro.no
x Poland 70-672 Stettin Tel.:+48-91-462 3383/462 30 25

o Sanger Metal Sp-ka z.o.o.. Mobile: +48-0602-337 999/338 030
ul. Mostnika 10 Fax: +48-91-462 33 45
E-mail: sanger@olszewski.szczecin.top.pl
o Poland 80-958 Danzig Tel.:+48-58-301 56 51

for deck machinery Hydroster Ship Machinery Works Ltd Fax.:+48-58-301 17 23
steering gears Ul. Szafarnia 10 E-mail: office@hydroster.com.pl

Service-Stations
Spare Parts
Agencies
x Portugal 1101 Lisbon Codex Tel.: +351-21-3 42 00 21

Gellweiler Soc. de Equip. Fax: +351-21-3 42 00 26
Maritimos e Industriais Lda E-mail: mail@gellweiler.pt
Travessa do Alecrim, 3-2°
x Romania 6200 Galati Tel./Fax: +40-236-46 20 56

Xerex S.R.L. E-Mail: ilniczky@yahoo.com
1, Closca St.,
Bl.PS11, Suite 4
X Singapore Singapore 609916 Tel.:+65-65 62 80 86/65 62 80 88

o Hatlapa Asia Pacific Pte Ltd Mobile: +65-96 33 93 81
German Centre, Unit 02-25 Fax: +65-65 62 80 99
25 International Business Park, E-Mail: hatlapa@singnet.com.sg
Jurong
x South Africa Kraaifontein ZA 7569 Tel.: +27-21-86 32 466

o DMG Engineering (Pty) Ltd. Fax: +27-21-86 33 629
4 Karee Street
x Spain Madrid-28006 Tel.: +34-91-6 76 65 99

o for compressors Comercial Tecnica Diesel S.A. Telex: 27262 ctd e
(Cotedisa) Cable: Cotedisa
Principe de Vergara 86 Fax: +34-91-6 77 17 71
E-mail : cotedisa@modipesa.com
x Spain Madrid-28033 Tel/Fax: +34-91-3 83 15 77

for deck machinery Javier López-Alonso Morán E-mail: javlopez@wanadoo.es
steering gears Avda. San Luis 166 - 8° E
x Sweden SE-400 40 Gothenburg Tel.: +46-31-42 63 00

o A.B. Pegol Cable: Pegol
Djurgardsgatan 9 Fax: +46-31-12 77 39
P.O. Box 4093 E-mail: process@pegol.se
x Syria Cyprus Tel.: 00357-25-34 08 56

Sheerlines Services Ltd Fax.: 00357-25-34 66 26
124 Gladstonos Street E-mail: c.petrou@sheerline.com.cy
The Hawk Building
x Taiwan/R.O.C. Taipei Tel.: +886-2-25 06 36 88

MPC Hanteh International Ltd. Fax: +886-2-25 06 39 99
15F, 87 Sung Chiang Road

Service-Stations
Spare Parts
Agencies
x Turkey 34903 PENDIK/Istanbul Tel.:+90-216-392 69 92

Senak Marine Ind. & Trade Co Fax:+90-216-392 65 05
Güzelyali Mah E-mail: senak@senak.com
Sahilyolu Cad 61/2
o United Arab Sharjah Tel.: +971 6-56 90 770

Emirates TurboMot Marine Eng. Co. Fax: +971-6-56 90 802
P.O. Box 3178
x U.S.A. Clermont, Florida 34711 Tel.: +1-352-243 94 55

o Diesel Impex Corp. Fax: +1-352-243 00 38
11227 Marseilles Blvd E-mail: dieselic@aol.com
o U.S.A. Orange, Ca. 92665 Tel.: +1-714-9 74 56 84

CS Controls Inc. Fax.¨+1-714-9 74-56 85
1820 N. Lincoln St. E-mail: cscontrols@aol.com
Houma, La. 70363 Tel.: +1-985-8 76 60 40

CS Controls Inc. Fax.: +1-985-8 76 07 51
101 Dickson Rd. E.mail: info@cscontrols.com
o U.S.A. Ft. Lauderdale, Florida 33315 Tel.: +1-954-7 63 36 60

Motor Services Hugo Stamp Inc Fax: +1-954-7 63 28 72
3190 SW 4th Ave E-mail: service@mshs.com
x Venezuela Caracas Tel.: +58-212-285 23 44/7822/7631

TENAVAL Fax: +58-212-285 77 76
Av. Fco. De Miranda E-mail: tenaval@hotmail.com
Edif. Bco del Orinoco
2°, Piso Ofic 2-B

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Technical Documentation

Deck Machinery - Compressors - Steering gears

V150 W55 L9 HSC22

Start Start Start Start

Uetersener Maschinenfabrik GmbH & C0. KG Discovery Court Business Centre

SECTION 1 - INSTALLATION ........................................................................................................................ 1-1

Figure 3.1 First Stage Concentric Valve V150............................................................................................... 3-5

Table 3.1 Fastener Torque Settings .............................................................................................................. 3-1

Spare Parts can be ordered direct from the following address:

or from any Hamworthy office or agency throughout the world.

Technical Service and Advice:

or via any of our overseas companies or offices

Overseas Hamworthy Offices

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

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.

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

WARNING: TAKE PRECAUTIONS TO PREVENT INJURY TO PERSONNEL WHILST OBSERVING

11. Check the operation of the system pressure switch.

SECTION 2 - OPERATING PROCEDURE

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

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

2.3 NORMAL RUNNING PROCEDURE (AUTOMATIC CONTROL)

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

2.4 MANUAL MODE RUNNING

Energise the starter panel by operating the main isolator.

Set mode switch S1 to MAN.

Set local/remote switch S2 to LOCAL.

Press RESET push button.

- oil level switch overridden.

1. BEFORE PROCEEDING WITH MAINTENANCE OR OVERHAUL, THE COMPRESSOR MUST BE

WHEN MAINTAINING THE EQUIPMENT PROTECTIVE GLOVES SHOULD BE WORN.

Table 3.1 Fastener Torque Settings

Table 3.2 Maintenance Schedule

3.2 MAINTENANCE INSTRUCTIONS

3.2.1 Lubrication Oil Checking

1. Remove filler/dipstick and check oil level.

3.2.2 Lubrication Oil: Changing

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

2. Remove wing nut (F8) on top of filter.

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

6. Renew element if necessary.

3.2.4 First Stage Concentric Valve Removal/Servicing/Replacement

5. Cover open bores on cylinder and breather hose.

8. Separate concentric valve from valve cage.

1. Unscrew and remove nut (10).

4. Tighten stud connector (54) and dome nuts (50B).

6. Fit studding (165) to stud connector and tighten.

7. Reassemble suction filter silencer assembly to valve cage as described in 3.2.3.

Figure 3.1 First Stage Concentric Valve V150

Figure 3.2 First Stage Concentric Valve V200/250/375

Table 3.1 First Stage Concentric Valves - Items List

3.2.5 Final Stage Concentric Valve Removal/Servicing/Replacement