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INSTRUCTION MANUAL AIR COMPRESSOR HLF2/77

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Sole suppliers of genuine spare parts

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INSTRUCTION MANUAL FOR AIR-COOLED AIR COMPRESSOR HLF2/77
IMPORTANT The following information must be given when ordering spares: (A) Compressor type, HLF2/77 (B) Compressor number, e.g. 70007 (C) Quantity, description and parts number of the spares required (A) and (B) are stamped on the compressor rating plate which is fixed to the side of the crankcase and (C) will be found in the spare parts list at the back of this instruction book. SPERRE INDUSTRI A/S reserves the right to amend technical specifications without prior notice and disclaims all legal liability in connection such amendments. PERSONAL SAFETY Whenever work is to be carried out on the compressor, the electric current must be switched off, and the compressed air delivery pipe valve must be closed.
SPERRE INDUSTRI A/S 6057 ELLINGSY - NORWAY Phone : + 47 70 16 11 00 Fax : + 47 70 16 11 10 Telex : 42 509 SPAIR N [email protected] E-mail: Web: www.sperre.com

CONTENTS
General Description -----------------------------------------------------------------Installation ------------------------------------------------------------------------------Starting up------------------------------------------------------------------------------Operation -------------------------------------------------------------------------------Stopping --------------------------------------------------------------------------------Maintenance, Overhaul, Repairs -------------------------------------------------Valves -----------------------------------------------------------------------------------Piston and Connecting Rod--------------------------------------------------------Bearings - Dismantling and Assembly ------------------------------------------Multi-finned tube coolers -----------------------------------------------------------Gaskets ---------------------------------------------------------------------------------Lubricating Oil -------------------------------------------------------------------------Table of Normal Pressures and Temperatures in Service -----------------Maintenance Schedule--------------------------------------------------------------Fault Tracing Chart-------------------------------------------------------------------Tolerances - Wearing Limits-------------------------------------------------------Automatic Relief Mechanism ------------------------------------------------------Replacements Parts List------------------------------------------------------------Illustrations for replacement parts list -------------------------------------------

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Air-Cooled Air Compressor

Type : HLF2/77

Page - 1

GENERAL DESCRIPTION
This is a two-stage 90 vee compressor. Cylinders and compressed air coolers are air-cooled. Supply pressure is determined by adjusting the safety valve. The compressor and motor are supplied as a single unit. The compressor and motor are connected by means of a flywheel. All the materials used are of first class quality, thoroughly tested and in accordance with the requirements of the classification societies. Instrumentation is supplied in accordance with classification society requirements and if desired the compressor can be fitted with equipment for fully automatic operation. Bearings and cylinder walls are splash lubricated. The oily level in the sump can be checked through a sight glass. An automatic low oil level alarm can be supplied as an optional extra. The compressors is normally supplied without a relief mechanism for the L.P. cylinder suction valve. However, a relief mechanism can be ordered from SPERRE if required. The compressor set can be supplied either for bolting direct to the foundation or for flexible installation by means of resilient mountings fitted under the bedplate.
o

INSTALLATION
The compressor and motor are normally supplied ready-fitted to a bedplate. In cases where the motor is installed separately, alignment must be carried out with great care. In order to ensure trouble-free operation it is important that the foundation should be well stiffened and free from vibrations from other installed machinery. This applies to rigid mounting and flexible mounting alike. A well-dimensioned fresh air duct must be provided to the location where the compressor is to be installed. The mouth of the duct should be as close as practically possible to the suction side of the cooling fan. The ambient temperature should o not exceed 45 C. In principle the pipe from the compressor to the air reservoir should be arranged as shown in the installation diagram supplied with the compressor. A non-return valve of strong construction and offering little air resistance should be installed after the compressor. If the compressor set is installed with resilient mountings, a flexible connection (hose) must be installed in the compressor air supply line after the compressor. A water/oil separator should be fitted at some distance from the compressor, and so arranged that the line slopes downwards from the compressor to the separator. This will prevent condensate from damaging valves and cylinders. It is recommended to provide the water separator with manual and automatic draining. Equipment for automatic draining is available as an optional extra. If the pipe from compressor to reservoir is longer than about 10 metres the dimensions shown in the installation diagram supplied with compressor should be somewhat increased to ensure the lowest possible air resistance. Care should be taken to arrange the piping so that condensate cannot collect in pockets. All piping must be well clamped and free from vibration.

STARTING UP
Before initial starting up and after long periods out of use, carry out the following operations in the sequence given: 1.Check out the oil level (sight glass). 2.If the unit has been unused for more than 6 months, remove valves and lubricate cylinder walls. 3.Open air line cocks and start the unit. 4.Check that all components are running normally. Inspect instruments, check and repair any leaks.

Air-Cooled Air Compressor

Type : HLF2/77

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OPERATION
During operation, pressures and temperatures must be within the given limits. Any deviation is abnormal and its cause should be ascertained by means of the fault tracing chart. In the case of pressure or temperature deviations it is recommended first to check the values with new thermometers and pressure gauges in order to ensure that the fault is not to be found in the instruments.

STOPPING
No special adjustment or the like are required before stopping the compressor. If the compressor is to remain unused for a long period, lubricate valves and cylinder walls with oil. The compressor should be turned over from time to time

MAINTENANCE - OVERHAUL - REPAIRS

Only ORIGINAL SPERRE REPLACEMENT PARTS must be used in connection with overhauls and repairs. Before ordering spare parts, please read the instructions given on page 1.

VALVES
L.P. Valve To dismantle the valve, proceed as follows: 1. Loosen pipe connections. 2. Loosen and remove cylinder head. 3. Loosen the bolts holding the valve in place on the cylinder head. Carefully separate the upper and lower sections of the valve body. IMPORTANT! THERE ARE MILLED SLOTS IN THE UPPER AND LOWER SECTIONS OF THE VALVE BODY. WHEN CORRECTLY FITTED THESE SLOTS CORRESPOND. Clean the valves, carbon deposits can best be removed by means of a good solvent, carbon remover or the like, then flush with fresh water. IMPORTANT! SEALING SURFACES MUST NOT BE SCRAPED WITH SHARP TOOLS: USE A WAIRE BRUSH IF NECESSARY. Worn and damaged parts and gaskets should be replace. Valve assembly sequence is the opposite of the above. IMPORTANT! THE VALVE MUST BE CORRECTLY FITTED UNDER THE CYLINDER HEAD. THE SUCTION SIDE MUST FACE FORWARDS (TOWARDS THE FILTER) AND THE PRESSURE SIDE MUST FACE BACKWARDS (TOWARDS ELECTRIC MOTOR). H.P. Valve To dismantle he valve, proceed as follows: 1. Loosen pipe connections. 2. Loosen cylinder head nuts and remove cylinder head. 3. The valve can now be lifted out of the cylinder. Clean the valve in the same way as the L.P. valve. Assembly sequence is the opposite of the above. IMPORTANT! ONLY ORIGINAL SPERRE COPPER RINGS MUST BE USED AS VALVE SEATING GASKES. EXACT DIMENSIONS AND CORRECT HARDNESS ARE OF DECISSIVE IMPORTANCE FOR GOOD OPERATING RESULTS. Cylinder head nuts should be tightened a little at a time, in sequence, to avoid torsional strain on the valve.

Air-Cooled Air Compressor

Type : HLF2/77

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PISTON AND CONNECTION ROD

The procedure for dismantling and assembling the piston and connecting rod is as follows: 1. 2. 3. 4. 5. 6. Dismantle the electric motor, coupling, and intermediate piece from the compressor. Loosen and remove the L.P. cylinder head. Remove the crankcase cover from the crankcase and detach the counterbalance at the end of the crankpin. Loosen the bearing end shield and pull it axially together with the crankshaft, far enough to bring the connecting rods clear of the crankpin. Pull the L.P. piston with the rod out of the top of the cylinder. Pull down the H.P. piston with rod out through the crankcase.

Assembly sequence is the opposite of the above.

BEARINGS - DISMANTLING AND ASSEMBLY

Work on bearings requires great care and scrupulous cleanliness.

Crankshaft bearings
These are needle bearings. IMPORTANT! WORN OR DAMAGED CRANKSHAFT BEARINGS MUST BE REPLACED COMPLETE. REPLACEMENT OF PARTS OF THE BEARINGS IS NOT SATISFACTORY. BEARINGS DISMANTELED FROM SHAFT AND/OR CONNECTINGS ROD MUST ALWAYS BE REPLACED BY NEW BEARINGS. 1. Remove the outer ring from the connecting rod, using pressing tools. 2. Remove the inner ring from the crankpin by heating it rapidly with a welding torch, then push it off the pin by means of a screw driver or the like. If necessary, rapidly cool the ring so that it cracks, or grind a notch in it to reduce its tension. 3. Fit a new outer ring to the connecting rod by means of a pressure tools. o 4. To fit the inner ring, heat it in an oil bath or on an electric hotplate to 80 - 100 C before pressing it onto the pin. IMPORTANT! DO NOT USE AN OPEN FLAME TO HEAT THE NEW RING.

Gudgeon pin bearings

The gudgeon pin bearings are needle bearings. Dismantle as follows: 1. Remove seeger rings. 2. Press out the gudgeon pin. If necessary, heat the piston slightly and rapidly. 3. Use pressing tools to remove and re-install the connecting rod bearing outer ring. IMPORTANT! CHECK THAT THERE IS SLIGHT AXIAL PLAY BETWEEN CONNECTING ROD AND PISTON AFTER INSTALLATION.

Crankshaft bearings
Dismantling and replacement procedure is as follows: 1. 2. 3. 4. 5. Remove the crankcase cover from the crankcase and detach the counterbalance at the end of the crankpin. Dismantle the electric motor, coupling piece, coolers and flywheel. Dismantle cylinder heads, pistons and connecting rods as described under "PISTON AND CONNECTING ROD". Pull the bearing housing and crankshaft clear of the crankcase. Pull the crankshaft clear of the bearing housing, remove seeger ring and carefully tap the bearings off the shaft and bearing housing respectively.

Assembly sequence is the opposite of the above. The largest bearing is locked to the shaft with Loctite.

Air-Cooled Air Compressor

Type : HLF2/77

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MULTI-FINNED TUBE COOLERS

To ensure trouble-free operation it is of the greatest importance to ensure that the coolers are kept clean and free of foreign matter at all times. If the coolers are not kept properly clean, high air temperatures will result, with a consequent reduction of working life of valves and cylinders. The coolers can be externally cleaned by spraying on a good grease solvent and then blowing them clean with compressed air. In the case of heavy deposits of dirt the coolers should be dismantled for external and internal cleaning. Any carbon deposits in the tubes can be removed by placing them in a bath of carbon remover or similar solvent overnight, and then flushing with hot fresh water.

GASKETS
In order to achieve satisfactory operation it is recommended to replace gaskets at every overhaul. Worn or damaged gaskets will reduce compressor capacity and cause faulty operation. Use only original SPERRE gaskets.

LUBRICATING OIL
The crankcase lub. oil volume is 1,8 litres. The following lubricating oils are recommended: MOBIL RARUS 427 MOBIL RARUS 827 BP ENERSYN RX 100 BP ENERGOL RC 68 CALTEX RPM COMPR. OIL 68 CASTROL AIRCOL SN 100 CASTROL AIRCOL PD 100 CHEVRON HD COMPR. OIL 100 ELF PRIMERIA SG 100 ESSO/EXXON ZERICE S 100 ESSO/EXXON SYNTESSTIC 68 FINA EOLAN AC MITSUBISHI COMPR. OIL 100 NIPPON OIL CO. FAIRCOL SA100 NYNS COMPR. OIL 68 PHILLIPS COMPR. OIL 68 SHELL CORENA P 68 STATOIL COMPWAY S 100 TEXACO SYN STAR DE 100 DAPHNE MARINE COMPRESSOR 100

Ask SPERRE for advice before using lubricating oil of any other type.

Air-Cooled Air Compressor

Type : HLF2/77

Page - 5

TABLE OF NORMAL PRESSURES AND TEMPERATURES IN SERVICE

Temperatures in service, with shaft speed 1450 rpm. o The given values are for intake temperature (ambient temperature) 35 C and supply pressure 30 bars. Pressure after L.P. cylinder: Temperature after L.P. cylinder: Temperature after L.P. cooler: Temperature after H.P. cylinder: Temperature after H.P. cooler: 2-3 bars o 125 C o 115 C o 210 C o 80 C

At lower or higher intake temperatures the temperatures at the points indicated above will be approximately an equal number of degrees lower or higher. Temperatures will be lower at lower shaft speeds.

MAINTENANCE SCHEDULE
The following is a guideline for a normal maintenance schedule. However, compressor operating conditions vary widely from installation to installation and it is therefore important to adapt the maintenance schedule to the experience of the individual operator. The following schedule applies to automatically monitored and manually operated installations alike. Daily inspection: Make a quick general inspection of the whole compressor (in normal operation) and specially check the following: 1. Lubricating oil level. 2. Compressed air temperature and pressure. After the first 200 hours' operation: Change lubricating oil. Drain the sump while the oil is hot, clean the sump thoroughly before filling with fresh oil. Further maintenance can suitably be effected in accordance with the following plan (The scope of each maintenance routine is given in the notes). Total running time from installation of the new unit 1000 hours 2000 hours 3000 hours 4000 hours 5000 hours 6000 hours 7000 hours 8000 hours 9000 hours 10 000 hours Maintenance routine Routine A Routine A Routine A Routine A Routine B Routine A Routine A Routine A Routine A Routine C

From 10 000 hours begin from the top of the schedule again, repeating Routine A at 11 000 hours Routine B at 15 000 hours Routine C at 20 000 hours and so on.

Air-Cooled Air Compressor

Type : HLF2/77

Page - 6

ROUTINE A
1. Change lubricating oil. 2. Remove the valves from both cylinders. Check for carbon deposits. Use a stick or similar object to check whether springs, plates or the like have been broken. Dismantle the valve for cleaning and/or repair if necessary. 3. Inspect the flexible coupling between compressor and motor. 4. Check bed bolts. Also check vibration dampers and hose connections if the unit is flexibly mounted. Check that no oil has come into contact with the rubber elements in the vibration dampers. 5. Function-test the safety valve. Close the stop valve on the pipe to the receiver. The safety valve should blow at maximum working pressure + 10%. If necessary, dismantle safety valve, clean and readjust. 6. Check all pipe connections (compressor running). 7. Check that all automatic equipment is functioning correctly. 8. Clean air filter. 9. Check all bolts and nuts for proper tightness.

ROUTINE B
1. Change lubricating oil. 2. Remove the valves from both cylinders. It is recommended to dismantle the valves for full inspection and cleaning or replacement as necessary. 3. Carry out Routine A, items 3,4,5,6,7 and 8. 4. Dismantle compressor cooler tubes and clean internally as described on page 5.

ROUTINE C
1. Change lubricating oil. 2. Remove the valves from both cylinders. It is recommended to dismantle the valves for full inspection and cleaning or replacement if necessary. 3. Dismantle cylinders, pistons and connecting rods. Inspect cylinder walls, pistons and piston rings. Clean and replace any damaged or worn parts. Inspect big end and little end bearings. 4. Dismantle compressor cooler tubes and clean internally as described on page 5. 5. After dismantling cylinders, pistons, cooler tubes etc., check wear on crankshaft frame bearings by testing crankshaft lateral play. The life of ball and roller bearings may vary considerably. 6 Carry out Routine A, items 3,4,5,6,7 and 8.

Air-Cooled Air Compressor

Type : HLF2/77

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FAULT TRACING CHART

1.Compressor capacity is low, or compressor not supplying full pressure. Possible causes Dirty, damaged or worn valves Remedy Clean and check all valve plates, springs and gaskets. Replace defective parts. Piston compression rings worn. Replace. Unsuitable lubricating oil. Change. Loosen and remove rings. Clean grooves and rings. (after long periods out of use the cylinder will be dry and it may therefor easily be scored when the compressor is started up. This is indicated by a sharp increase of blow-off through the crankcase cover relief valve). Clean filter. Inspect components and circuits.

Safety valve damaged or defective (causing it to blow at lower pressure).

Overhaul safety valve.

3. Valves require maintenance too frequently Possible causes Overheating Remedy High ambient temperature. Improve fresh air supply. Carbon deposits in coolers. Clean coolers. Air filter damaged. Clean or replace. Clean.

Carbon deposits on valves

Piston rings have stuck

Dirt or foreign matter in intake air Cooler tubes dirty

4. Bearings and bearing housings running hot. Lubricating oil overheating. Noise from bearings. Possible causes Damaged or worn bearings Uneven wear on crankshaft bearings Low oil level 5. Piston running hot Possible causes Remedy Check little end bearing, piston rings and piston clearance. Check fresh air supply to cooling fan. If the piston has completely seized, wait a while before turning over the compressor. Clean cylinder thoroughly and clean off piston, fit new piston if necessary. Remedy Replace bearings. Check crankshaft for straightness. Replenish sump.

Air filter blocked Faulty automatic control equipment 2. Safety valve blows off Possible causes Supply line stop valve closed Carbon deposits in non-return valve Faulty adjustment of automatic system: Compressor does not stop when air reservoir is full.

Remedy Open valve.

Worn little end bearing Piston and/or rings binding in cylinder

Clean valve. Check automatic circuitry.

Air-Cooled Air Compressor

Type : HLF2/77

Page - 8

TOLERANCES - WEARING LIMITS

1. End tolerances for piston rings Push a piston without rings halfway into the cylinder from below, and place the piston ring in the cylinder bore so that it presses against the top of the piston. Withdraw the piston and using a feeler gauge measure the clearance between the ends of the piston ring. Piston Diameter Clearance for new rings in cylinder without wear Maximum permissible clearance (approx.) 0.7 mm 0.8 mm 3. Clearance between pistons and cylinders Measure the clearance by means of a dial gauge, taking the cylinder and piston separately. Alternatively the piston can be placed in the cylinder and the clearance measured with thickness gauges. If the latter method is chosen, two gauges should be used, one inserted at either side of the piston, opposite each other. The piston clearance should be measured in the area above the upper ring groove. The sums of clearance on both sides should be as follows: Piston diameter cylinder 50 mm 77 mm Clearance for new piston in new clearance 0.20 mm 0.25 mm Maximum permissible (approx.) 0.6 mm 0.65 mm

50 mm 77 mm

0.2-0.35 mm 0.3-0.45 mm

2. Height clearance in piston ring grooves Clean piston rings and ring grooves. Fit ring in groove and using a feeler gauge measure the height clearance of the ring in the groove. Clearance for new rings in piston without wear Maximum permissible clearance (approx.) 0.06 mm 0.04 mm

4. Clearance between piston crown and cylinder head. The clearance between the piston crown and the cylinder head should be not less than 0,75 mm.The normal gasket thickness is ca. 1,0 mm, and thus the piston crown may project a maximum of 0,25 mm above the cylinder at top dead centre

Top ring All other rings

0.015-0.04 mm 0.00-0.025 mm

These values apply to both piston diameters.

AUTOMATIC RELIEF MECHANISM

To order complete pressure relief equipment, quote Part No. 3428. In addition, the Part No. and voltage of the solenoid coil must be quoted. Note! The solenoid valve (4688) should be located away from the compressor. The control air pressure for the solenoid valve must be maintained within the following limits. Maximum control air pressure: 10 bars Minimum control air pressure: 4 bars When fitting the gripper (3436) in the cylinder head (1283), it is very important to set correctly the distance between the gripper and the valve. Adjustment is effected by means of the adjustment screw (3438) on the upper face of the cylinder head. When the gripper is correctly fitted, its pins should project 3 mm from the plane lower surface of the cylinder head.

Air-Cooled Air Compressor

Type : HLF2/77

Page - 9

COMPRESSOR TYPE HLF2/77

Qty 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 2 1 1 1 1 1 1 2 2 1 1 2 2 2 2 1 1 2 2 1 1 1 1 1 Description Crankcase Crankcase cover Cylinder head H.P. Cylinder head L.P. Drive coupling Piston rod Crankshaft Flywheel Bearing housing Counterbalance Spacer Bracket Valve, L.P. Valve, H.P. Valve plate, L.P. Valve plate, H.P. Valve plate, H.P. Washer Valve bolt Valve nut Valve spring H.P. Valve spring H.P. Guide ring Plain nipple Oil scoop Tubular pin Piston, H.P. Piston, L.P. Catch plate, lower H.P. Catch plate, upper H.P. Gudgeon pin, H.P. Gudgeon pin, L.P. Compression ring,stepped,H.P. Compression ring,stepped,L.P. Compression ring, plain, H.P. Oil ring, H.P. Oil ring, L.P. Safety valve seat Safety valve spindle Ball Spring, H.P. Spring, L.P. Regulating nut Lifting lug Inspection glass Intercooler, complete Aftercooler, complete Key Air relief valve Part No. 1022 1070 1281 1283 1371 1428 1436 1444 1446 1520 1991 2046 3036 3037 3122 3123 3124 3131 3203 3236 3279 3280 3298 3345 3347 3350 3352 3354 3432 3433 3451 3452 3487 3488 3501 3528 3529 3560 3572 3576 3580 3581 3599 3608 3634 3657 3658 3682 3700 Qty 1 1 1 4 1 1 2 2 1 1 2 1 1 1 7 1 1 5 1 1 1 1 1 2 2 4 4 4 12 2 1 1 1 2 1 1 3 3 3 1 1 1 3 1 1 1 1 1 Description Air filter Pressure gauge, H.P. Seeger ring Seeger ring Seeger ring Ball bearing Needle bearing Needle bearing Ball bearing Valve sealing ring Valve sealing ring Copper gasket Copper gasket Copper gasket Copper gasket Spring washer Serrated washer Bolt Gasket Gasket Gasket Gasket Set of gaskets Lock nut Lock nut Stud bolt Stud bolt Stud bolt Nuts Set screw Nipple muff Threaded plug Threaded plug Bolt Safety valve, L.P.. Safety valve, H.P. Unbraco screws Double male end union Double male end union Elbow Tee piece Tee piece Connecting bolt Clamp Flexible coupling insert Male/female nipple Bolt Bolt Part No. 3711 3773 3806 3813 3815 3872 3877 3878 3881 3918 3919 3925 3926 3929 3930 3937 3939 3946 3998 4075 4095 4096 4127 4131 4133 4193 4194 4199 4238 4268 4283 4293 4297 4401 4421 4422 4445 4457 4460 4466 4472 4473 4484 4514 4519 4590 4605 4618

Air-Cooled Air Compressor

Type : HLF2/77

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