OPERATION & MAINTENANCE

MANUAL
PET
COMPRESSOR TYPE WH40H3N

Doc. Ref:WH40H3N
Important
This Instruction Manual covers Installation & Commissioning, Operation and Maintenance of
the Gardner Denver Belliss & Morcom ‘PET’ range of compressors.
It is ESSENTIAL that this document is read and understood by everyone who will work with
this equipment, as failure to do so may result in death, injury or damage to the compressor or
its associated equipment.

Disclaimer
While every care was taken in the preparation of these instructions, it cannot be guaranteed
that every aspect has been covered. Gardner Denver Belliss & Morcom cannot, therefore,
accept liability for direct or consequential damage that may arise resulting from non-
conformity with this Manual, from repairs carried out improperly, from using other than
original spare parts, and from non-observance of good operating and maintenance
engineering practices. Should there be any doubt whatsoever, or should any further
information or explanation be required, Gardner Denver Belliss & Morcom must be
contacted.
This information is given in good faith, no warranty or representation is given concerning
such information, which must not be taken as establishing any contractual or other
commitment binding upon Gardner Denver Belliss & Morcom.
Gardner Denver Belliss & Morcom reserve the right to make changes to any information
contained within this manual without prior notice.

Warranty Statement
The compressor(s) and ancillary equipment supplied by Gardner Denver Belliss & Morcom
are covered under Warranty for the period agreed in the Supply Contract.
The equipment provided is well designed to afford many years of trouble free service.
However, should the need arise to implement a warranty claim then this can be done using
Warranty Claim Form Document No.CM4F2 obtainable from Gardner Denver Belliss &
Morcom Service Department. A copy of this form is provided in Appendices located at the
end of this manual.
It should be noted that consumable parts that require replacement during normal compressor
operations are not normally covered under Warranty. Similarly, the Warranty does not cover
running adjustments.
Point of Contact

Gardner Denver Belliss & Morcom Ltd

Chequers Bridge,
Gloucester,
GL1 4LL,
England
Tel: +44 (0) 1452 338198 Email: service@belliss.co.uk
Fax: +44 (0) 1452 338317 Web: www.belliss.com

This document contains confidential information of Gardner Denver Belliss & Morcom Ltd (The Company). The copyright,
design right and/or other intellectual property rights in the document belongs to (The Company). All rights conferred by law and
by virtue of International Copyright and other conventions are reserved to The Company. This document and the information
contained therein or any part thereof must not be reproduced, disclosed or used for any other than those for which the prior
written consent of The Company has been given.
 Gardner Denver Belliss & Morcom Ltd
Foreword
Gardner Denver Belliss & Morcom are well known in the market place for the design,
manufacture and supply of high-quality air compressor equipment. This Instruction Manual is
produced for the ‘PET' range of compressors. These compressors are constructed from the
highest quality materials and are designed and built according to the latest manufacturing
techniques. The compressor design will give good service providing that it is operated and
maintained in accordance with the information contained within this Manual.
The information and notes presented in the 'Ancillary Devices’ Instruction Manuals will
provide operational and maintenance information for the control and instrumentation system,
motor/drive unit and where appropriate, any other device associated with the compressor
package.
Targeted Personnel
This document is designed to provide competent operatives, who are fully conversant with
compressor operating and maintenance techniques, with an understanding of the
compressor elements and their operation and subsequent maintenance. It should be noted
that the term 'competent' implies that the operative is a compressor engineer suitably trained
in the installation, operation and maintenance of the Gardner Denver Belliss & Morcom
product.
This Instruction manual is not intended to supersede or take the place of the Gardner
Denver Belliss & Morcom product-training course. For further information regarding training
courses or to book a place, please contact Gardner Denver Belliss & Morcom Service
Department. The address, telephone/facsimile number is provided at the start of this
documentation.
How to Use this Instruction Manual
The Instruction Manual is designed to enable speedy location of relevant information. To this
end the document is divided into six chapters, each of which covers an individual topic.
Cross-references between topics and illustrations are identified within the text using bold
characters i.e. (Refer to Chap 2 Section 4.1) or see Fig 3.
At appropriate locations within this document you will see 'Information Boxes'. It is VERY
IMPORTANT that the information contained within these boxes is adhered to, as failure to do
so may result in death, injury or damage to the compressor or its associated equipment. The
following outlines the philosophy applied to each of the three levels of boxed notation.
WARNING!
This pictogram with the remark "WARNING!" identifies a potential dangerous
hazard. Non-compliance will put the operator or a third party at risk of death or
injury.

CAUTION!
This pictogram with the remark “CAUTION!” identifies the possibility that if non-
compliant the compressor and/or its associated equipment can be damaged.

This pictogram marks important Notes, which identifies supplementary information

for the competent and economic use/operation of this compressor package.

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Foreword
Documentation Storage
Always store this Instruction Manual near the compressor so that it is available for reference
at all times. If the instruction manual is lost, Gardner Denver Belliss & Morcom can supply
a new copy for a small fee. When requesting new or additional copies, of this document,
please include your compressor details with your order.
Comments and Suggestions
We would welcome comments and suggestions for improvements to this Instruction Manual.
If you decide to comment, make a copy of the page or pages concerned and add your
comments. Then send your response to Gardner Denver Belliss & Morcom. Please do not
forget to include your name and the name of your company, your company address and your
telephone and facsimile numbers.

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COMPRESSOR TYPE WH40H3N Date: May 2002
CONTENTS Page: 5 of 145

1 TECHNICAL DATA & COMPRESSOR DESCRIPTION.....................................9

1.1 Technical Data..................................................................................................... 9
1.1.1 Operating Data....................................................................................................9
1.1.2 Compressor Data ..............................................................................................10
1.1.3 Tightening Torques (Dry Threads) .....................................................................13
1.1.4 Materials of Construction ...................................................................................14
1.2 Technical Description of the Compressor .......................................................... 15
1.2.1 Purpose of the Equipment .................................................................................15
1.2.2 Compressor Identification ..................................................................................15
1.2.3 Compressor Operation ......................................................................................16
1.2.4 Crankcase and Lower Motion Work ...................................................................16
1.2.5 Cylinders, Pistons and Piston Rod Packings......................................................18
1.2.6 Valves ...............................................................................................................19
1.2.7 Motor and Couplings .........................................................................................19
1.2.8 Control Panel and Controls................................................................................19
1.2.9 Safety Equipment and Systems .........................................................................20
2. SAFETY INFORMATION..................................................................................22
2.1 Safety Policy...................................................................................................... 22
2.1.1 Commonplace Hazards .....................................................................................22
2.1.2 Proper Use ........................................................................................................22
2.1.3 Organisational Measures...................................................................................23
2.1.4 General Safety Precautions for Compressors ....................................................23
2.1.5 Installation, Commissioning and Operation ........................................................24
2.1.6 Maintenance......................................................................................................24
3 INSTALLATION & COMMISSIONING .............................................................27
3.1 Safety Precautions............................................................................................. 27
3.2 Installation Requirements .................................................................................. 27
3.2.1 Location ............................................................................................................27
3.2.2 Ventilation .........................................................................................................27
3.2.3 Foundations ......................................................................................................28
3.2.4 Pipework Installation..........................................................................................28
3.2.5 Cooling Water ...................................................................................................31
3.2.6 Electric Cabling .................................................................................................32
3.3 Handling and Unpacking.................................................................................... 32
3.3.1 Stability .............................................................................................................32
3.3.2 Slinging Instructions ..........................................................................................33
3.3.3 Lifting Instructions .............................................................................................34
3.3.4 Unpacking .........................................................................................................34
3.4 Installation Procedure ........................................................................................ 35
3.4.1 Safety Precautions ............................................................................................35
3.4.2 Mounting Arrangements - Anti-Vibration Mounts ................................................35
3.4.3 Levelling and Alignment - Flange Mounted Motors.............................................36
3.5 Preparation for Commissioning.......................................................................... 36
3.5.1 Cleaning the Compressor ..................................................................................36
3.5.2 Preparing the Compressor.................................................................................36
3.5.3 Preparing the Motor...........................................................................................38
3.5.4 Motor Rotation Check........................................................................................38
3.6 Commissioning the Compressor ........................................................................ 38
3.6.1 Trial Run ...........................................................................................................38
3.6.2 Completion of Commissioning ...........................................................................39

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COMPRESSOR TYPE WH40H3N Date: May 2002
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4 OPERATING INSTRUCTIONS.........................................................................41
4.1 Controls and Indicators...................................................................................... 41
4.1.1 Starter System...................................................................................................41
4.1.2 Load Control System Functions .........................................................................42
4.2 Preparation for Starting...................................................................................... 43
4.2.1 Before Operating the Machine (Pre-Start Checks) .............................................44
4.3 Starting the Compressor .................................................................................... 44
4.3.1 Under Normal Conditions ..................................................................................44
4.3.2 After An Emergency Stop ..................................................................................45
4.4 Running ............................................................................................................. 45
4.4.1 Running Checks ................................................................................................45
4.4.2 Automatic Operation..........................................................................................45
4.4.3 Faults/Hazards ..................................................................................................45
4.5 Stopping the Compressor .................................................................................. 46
4.5.1 Normal Stopping................................................................................................46
4.5.2 Emergency Stopping .........................................................................................46
4.6. Fault Indications ................................................................................................ 46
4.6.1 Fault Finding .....................................................................................................47
5 COMPRESSOR MAINTENANCE.....................................................................51
5.1 Preventive Maintenance .................................................................................... 51
5.1.1 Maintenance Schedule ......................................................................................51
5.2 Maintenance Instructions ................................................................................... 56
JOB No. 001 CRANKCASE OIL CHANGE.....................................................................57
JOB No. 002 FIT PISTON ROD CLAMPS......................................................................59
JOB No. 003 CYLINDER TOP COVERS - REMOVE & REFIT.......................................60
JOB No. 004 PISTON RINGS - REMOVE & REFIT .......................................................62
JOB No. 005 PISTON/CYLINDER END CLEARANCES - INSPECTION........................68
JOB No. 006 PACKING GLAND ASSEMBLY - REMOVE & REFIT................................70
JOB No. 007 PACKING GLAND ASSEMBLY - OVERHAUL ..........................................74
JOB No. 008 PISTON ROD OIL SHEDDER - REMOVE & REFIT ..................................76
JOB No. 009 OIL SCRAPER GLAND - REMOVE & REFIT............................................78
JOB No. 010 SUCTION & DELIVERY VALVES - REMOVE & REFIT.............................79
JOB No. 011 SUCTION & DELIVERY VALVES - OVERHAUL.......................................81
JOB No. 012 SUCTION VALVE UNLOADER ACTUATORS - REMOVE & REFIT..........83
JOB No. 013 PISTON RODS - REMOVE & REFIT ........................................................85
JOB No. 014 OIL FILTER - REMOVE & REFIT..............................................................86
JOB No. 015 OIL PRESSURE RELIEF VALVE - ADJUSTMENT ...................................86
JOB No. 016 LUBRICATING OIL PUMP AND DRIVE - INSPECT & OVERHAUL ..........87
JOB No. 017 INTERCOOLER - INSPECT & OVERHAUL ..............................................87
5.3 Lists of Tools ..................................................................................................... 88
5.3.1 Commercially Available Tools List......................................................................88
5.3.2 Specialist Service Tools List ..............................................................................89
5.4 Waste Products ................................................................................................. 90
5.4.1 Oil - After Oil Changes.......................................................................................90
5.4.2 Coolant .............................................................................................................90

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CONTENTS Page: 7 of 145

6 SPARE PARTS ................................................................................................92

6.1 Ordering Spares and Spares to be Held in Stock............................................... 92
6.2 Spares List......................................................................................................... 93
6.3 Illustrated Parts List - Main Component Location View ...................................... 95
Fig 1 Crankcase Assembly (2-03-288)...........................................................................96
Fig 2 Connecting Rod Assembly (2-76-426)...................................................................97
Fig 3 Crankshaft Assembly (2-06-383)...........................................................................98
Fig 4 Main Guide Assembly (2-07-280)..........................................................................99
Fig 5 Bearing End Cover Assembly (2-25-121) ............................................................100
Fig 6 Flywheel End Cover Assembly (2-25-123) ..........................................................101
Fig 7 Second Stage Piston Rod Assembly (2-30-144)..................................................102
Fig 8 Third Stage Piston Rod Assembly (2-30-202)......................................................102
Fig 9 Crosshead Assembly (2-31-066).........................................................................103
Fig 10 Oil Pump and Cooler Assembly (2-34-562) .......................................................105
Fig 11 Piston Rod Scraper Assembly (2-63-047) .........................................................106
Fig 12 Crosshead Assembly (2-31-067).......................................................................107
Fig 13 First Stage Piston Rod Assembly (2-30-252).....................................................108
Fig 14 First Stage Cylinder Assembly (2-01-908) .........................................................110
Fig 15 First Stage Top Cover Assembly (2-04-467)......................................................111
Fig 16 Distance Piece Assembly (2-07-414) ................................................................112
Fig 17 First Stage Piston Assembly (2-28-660) ............................................................113
Fig 18 First Stage Packing Box Assembly (2-64-285)...................................................114
Fig 19 First Stage Suction Valve Assembly (2-70-489).................................................115
Fig 20 First Stage Delivery Valve Assembly (2-70-490)................................................116
Fig 21 Second Stage Cylinder Assembly (2-01-531) ....................................................118
Fig 22 Second Stage Top Cover Assembly (2-04-274).................................................119
Fig 23 Distance Piece Assembly (2-07-281) ................................................................120
Fig 24 Second Stage Piston Assembly (2-28-481) .......................................................121
Fig 25 Second Stage Packing Box Assembly (2-64-286) .............................................122
Fig 26 Second Stage Suction Valve Assembly (2-70-503)............................................123
Fig 27 Second Stage Delivery Valve Assembly (2-70-504)...........................................124
Fig 28 Third Stage Cylinder Assembly (2-01-481)........................................................126
Fig 29 Third Stage Top Cover Assembly (2-04-305) ....................................................127
Fig 30 Distance Piece Assembly (2-07-281) ................................................................128
Fig 31 Third Stage Piston Assembly (2-28-523) ...........................................................129
Fig 32 Third stage Packing Box (PSB032-060) ............................................................130
Fig 33 Third Stage Suction Valve Assembly (2-70-236) ...............................................131
Fig 34 Third Stage Delivery Valve Assembly (2-70-237) ..............................................132
Fig 35 First Stage Interstage Pipework Assembly (2-71-780) .......................................134
Fig 36 Second Stage Intercooler Assembly (2-71-781) ................................................136
Fig 37 Cooling Water Assembly (2-45-2515)................................................................138
Fig 38 Pressure Gauge Assembly (2-46-1250) ............................................................141
Fig 39 Unloader Assembly (2-68-642) .........................................................................144
Fig 40 Ancillaries (2-150-055)......................................................................................145

APPENDICES
Appendix 1 Safe Working Limits
Appendix 2 Warranty Authorisation Claim Form
Appendix 3 Compressor Log Sheet

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 CHAPTER 1
TECHNICAL DATA &
COMPRESSOR DESCRIPTION

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 OPERATION & MAINTENANCE MANUAL Issue: 1
COMPRESSOR TYPE WH40H3N Date: May 2002
CHAPTER 1 - TECHNICAL DATA & Page: 9 of 145
COMPRESSOR DESCRIPTION

1 TECHNICAL DATA & COMPRESSOR DESCRIPTION

The information contained in this section is intended for the use of the engineer
responsible for the operation and maintenance of the plant. It is essential that any
necessary adjustments, servicing or overhaul work should be carried out by competent
persons who are familiar with the installation, operation and maintenance of this
product and who have the appropriate authorisation.
When communicating with the Gardner Denver Belliss & Morcom on matters relating
to the compressor always quote the compressor type and serial number
(e.g.WH40H3N Serial No. 8759).
This manual is written using SI Units of measurement. The three basic units used
herein are: the metre, the kilogram and the second. All measurements in this manual
are expressed using these units unless otherwise stated.
Standards and Legislation
The compressor is manufactured in accordance with the European Economic
Community Directive: BS EN 1012-1: 1997, and is tested in accordance with British
Standard: BS 1571 Parts 1 and 2.

1.1 Technical Data

1.1.1 Operating Data
Normal Operating Conditions

Instrument Pressure Gauge Range Pressure Range

(Normal Operation)

Air Delivery - 1st stage 0 - 7 Bar G 2.3 - 2.9 Bar G

Air Delivery - 2nd stage 0 - 30 Bar G 11.8 - 13.2 Bar G

Air Delivery - 3rd stage 0 - 76 Bar G 45.0 Bar G

Oil Pressure ** 0 - 10 Bar G 3 - 4.8 Bar G

**Oil pressure will fluctuate with ambient conditions, compressor loading and with the
type and viscosity of the oil being used. Also; oil pressure peaks during start-up before
settling back as the oil achieves its operating temperature.
This machine is fitted with over-temperature monitoring safety switches for final air from
both the third stage cylinder and the aftercooler. Details of the settings for these
devices are given in Section 1.1.2 Compressor Data.

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COMPRESSOR TYPE WH40H3N Date: May 2002
CHAPTER 1 - TECHNICAL DATA & Page: 10 of 145
COMPRESSOR DESCRIPTION

Flows and Capacities

Cooling Water
Flow** 36 m3/h (nominal) ** The cooling water flows are design
24 m3/h (min) estimates and may need to be adjusted at
site to meet the exact cooling requirements.
Pressure 7 Bar G (max)
4 Bar G (min) It is recommended that the compressor is
Temperature 38 ºC. (max) monitored during its initial running period and
Inlet 16 ºC. (min) that a record is kept of the flows and
temperatures for future reference.
Compressed Air Data Crankcase Data
Gas being compressed AIR Oil Sump Capacity 91 litres
Delivery Pressure 45.0 Bar G
Air Capacity 2220 m3/h
Inlet Temperature 0-45 ºC
Relative Humidity 0 - 100%

1.1.2 Compressor Data

Installation Data
Instrument Air: Component Weights
Normal Operating Range 7 bar g Compressor Weight 9000 kg.
minimum (without motor).
Maximum Pressure 10 bar g Service/ 1000 kg
Maintenance Lift
Vibration:
Vibration on the compressor may exceed 2.5 mm/s2, but there is no bodily contact with
the operator.
Mechanical Data
Cylinder Data Bumping Clearance (On All Cylinders)
1st Stage Cylinder Bore 515.00 mm Piston Top to Top Cover 2.8 - 3.1 mm
2nd Stage Cylinder Bore 287.75 mm Piston Bottom to Cylinder 1.2 - 1.8 mm
3rd Stage Cylinder Bore 165.10 mm
Piston Stroke 165.10 mm

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