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 “Hull’
HAM WORTHY
Pumps & Compressors

Hamworthy
2TM6 Series
Two-stage
Air Compressors

Publication No. PCH 1120/2 0891

HAMWORThY PUMPS & COMPRESSORS LIMITED

Fleets Corner, Poole, Dorset. BH17 7LA. England.
Tel: (0202) 665566. Fax: (0202) 665444 (Spares & Service).
Fax: (0202) 666363 (Sales). Telex: 41348 (KAMPAC G).

Offices in London & Troon (Scotland).

Offices or associate companies in Atlanta (GA.), Bombay, Johannesburg, Oslo, Osaka,

Rio de Janeiro, Rotterdam, Singapore, St. Cathariries (Ontario), Sydney,
and agents throughout the World.
 —

:.

v.t):k..

WARNING
PLEASE NOTE

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

2. Before lifting installing and operating the unit, the instructions detañed below, and also the accompanying
manual, must be read

3. Ensure that all equipment used for lifting the unit is adequate for the weight. The weight ‘s normally
stencilled on the unit and/or stamped on the machine nameplaca

4. The handling points are indicated on the unit and these must be used The hooks of slings must not be
fl fitted directly to lilting eyebolts or lugs. shackles must be used.

‘ 5. Before running the unit for the first time, the installation must be thoroughly checked and the
procedure detailed in Section 3 of the manual, unde, the heading “Checks 8efore Initial Run”. referred to.

6. The unit must not be run unless all protective guards supplied with the equipment are in position.
: 7 Before proceeding with maintenance on the unit. a, making adjustments to its connections and fittings.
it must be stopped and isolated electrically and mechanically and visible warning notices displayed.
Some units are on automatic standby duty, or isoletors are remote from the unit, and extra care is then
fl necessary to be sure that isolation is complete.

fl 8. Before commencing repair or owerhaul apreliminvy check at available spares must be made. e.g. rep lace
ment set of 0-rings. joints or jointing material

9. On compressors when work is to be proceeded with on wate, and/or air passages, the unit must be vented
of all pressurised air and drained of cooling water.

70. Pumps handle various fiquids sometimes not those for which the pump was initially supplied. Know the
properties of the liquids that have been pumpe4 and actions necessary to make handling safe and in the
event of an emergency.

77. Before commencing work on a pump, close the suction end discharge valves in the system pipelines and
remove the casing drain plug to ensure that the pump interior is at atmospheric pressure.

CAUTION
NOTICE TO AU. USERS OF tMM WORTh’? PUMPS AND COMPRESSORS P04 1149

SPARE PARTS

EQUIPMENT FAILURES HAVE BEEN EXPERIENCED AS A DIRECT RESULT OF

CUSTObERS USING LOW QUALITY SPARE PARTS SUPMJED BY
OUR
COWANIES OTHER THAN HAMWORTHY (OR T1EIR APPOINTED AGENTS).

aEASE NOTE Ti-tAT WARRANTY CLAIMS MAY BE INVALiDATED AS A DIRECT

RESULT OF USING NON-ORIGmaAL SPARES.

STATUTORY RIGHTS ARE NOT AFFECTED.

 CONTENTS
WARNING; THIS EQUIPMENT CONTAINS ASBESTOS. BREATHING
ASBESTOS DUST IS DANGEROUS TO HEALTH. FOLLOWSAFETY SECTION 1 — TECHNICAL DATA
INSTRUCTIONS.
Page
GASKET JOINTING MATERIAL USED IN THIS EQUIPMENT MAY
INCLUDE ASBESTOS. REMOVE AFTER SOAKING WITH OIL OR Standard Performance Range.
1/1
WATER. PREFERABLY ASSISTED BY USE OF HAND TOOLS. Specrfication 1/I
POWER TOOLS SHOULD NOT BE USED UNLESS SUITABLE DUST Recommended Maximum Wear Clearances
EXTRACTION IS PROVIDED OR RESPIRATORY PROTECTIVE
EQUIPMENT (S WORN. SECTION 2— DESCRIPTION
PLACE WASTE MATERIALS IN HEAVY GAUGE PLASTiC SACKS General 2/1
AND DISPOSE OF AS ADVISED BYTHE LOCAL WASTE DISPOSAL ETAILED
AUTHORITY. 2/3
Crankcase 2/3
Cy,inder B)ock 2/3
Movtng Parts 2/3
Crankshaft 2/3
Connecting Rods .
2/3
Pistons 2/3
Cylinder Head and VaIv 2/3
Automatic VaIv 2/4
LJorLtion System 2/4
fl O;IPwnp 2/5
Relief Vaive 2/5
Oil Fiiter 2/5
Water Coclir.q System .
2/6
Water Circulating Pump-
2/6
Water Jacket Safety Valve 2/7
First Stage Cooler 2/7
Second Stage Cooler. 2/7
Air Pressure SafetyValve .2/7
Pressure Gauge, - . 2/7
Delivery Line Non Return Valve. 19
•t- Oil and Watw Separator (If Fitted) 2/9
—
Automatic Unloader Plunrr Operated (,en Fitted) 2/9
*4 Automatic Drain Trap (When Fined) 2/9
Air Govern (If Fitted) 2/10
Water Shut-off Valve 2111
-
Solenoid Operated Unloader/Cooler Drain Valv
4+ 2/11
Automatic Controls (When Fitted) 111

SECTION 3 — INSTALLATION
‘a
INSTALLATION OATA
COOLING WATER QUANTITY 3/1
RECOMMENDED COOLING PIPEWORK DIMENSIONS 3/1
COOLING WATER TEMPERATURE 311
RECOMMENDED LUBRICANTS
Cempressor CranKso Lubrir 3/2
Cooling Water Pump Lubricants 3/2
Motor Lubricants 3/2
fl Cooling Water Pressure 3/2
Compressor Weight and Dimensions 3/2
INSTALLATION PROCEDURE
General 3/4
fl Location 3/4
Sugted Marine nsmllatiodl Procedure 3/4

fl
a(a -—3
 Page
en
Ships Compressor Mounting Fage
3/4 en
Suggested Industrial Installation Procedure
3/6 Compressor Not in Use . . . .
Foundations 5/12
3/6 *fl OVERHAUL OR REPAIR OF COMPRESSOR
Alignment of Sets with Pin Type Buffer Coupling
3/7 Genera’
Alignment of Identical Half Couplings 5/12
3/8 Compssci’ Dismantiirç Procedjre
Elecrical Installation 5/13
3/8 Reoval of Seccnc Stage Cylinoer Head
Main Air Line 5,13
3/s Removal of FirstStage Cylinder Head :3
Automatic Unloader (When Fitted)
3/s erncval at Pstons ano Cor9ect.’lq c-ds
Pressure Switch and Solenoid Valve Connections 51t4
3/9 Second Stage Piston Assembly 5/14
Automatic Drain Trap (When Fitted)
3/9 First Stage Piston Assembly 5/14
Non-return Valve (When Fitted)
3)0 fl First Stage Cylinder ‘Wet” Liner 5/14
PaIy-V Belt Drive
.
3/9 Second Stage Butter ‘Wet’ Liner 5/14
Recommendations for Cooling Water
3/10 fl Second Stage Cylinder ‘Wet, Liner 5114
CoolingwatecTemoerature First Stage Cylinder 3Io
3/10 5/14
Cooling Water Pressure FIwheeI/Cranksnaft Assembly
Cooling Water Quantity
3/10 fl 5/IS
3/10 C;eanir.g and Insoectinri 5/15
Water Pipe Size and Layout Installation of Flywheel and Crankshaft Assembly
3/11 fl 5/16
. . . . . . -
STORAGE—COMPRESSOR. . Assembly of First Stage Cyflnder Block to Crankcase
3/12 5/16
SECTION 4— OPERATION fl First Stage Cylinder “Wet” Liner 5/17
Second Stage Buffer Wet’ Liner 5/17
PRINCIPLE OF OPERATION Second Stage Cylinder ‘Wet Liner 5/17
Compressor Fittirg Pistons arid Connecting od Assemblies
4/1 5/17
Automatic Valves First Stage Piston Assembly 5/7
Nan-return Valve 4/1
Second Stage Piston Assembly 5/18
4/1 Assembly ol Second Stage Cyiinder I-lead
-
Automatic Drain Trap (When Fitted) 5/18
Automatic Unloader When Fitted) 4/1 Sub-Assemblies and Ancillary Equipment
4/2 5/19
Air Governor General 5/19
Water Shut-off Valve 4/2 Lubricating Oil Pump
4/2 5/19
Automatic Controls Removal and Dismantling of Pump 5/20
OPERATING PROCEDURE 412 Aenbly and Installation of Pump 5/21
Checks Before Initial Run Oil Prure Relief Valve 5/21
• . . 4/4
Commissioning Procedure Water Pump (If Fitted) 5/21
• . 4/4
Starting (Manual Control Only) Rernal and Disn’antling of Pump 5/22
Starting the Compressor on Automatic Control 4/5 Assembly and Installation of Pump 5/22
Stopping the Compressor (Manual Control Only) 4/5 First Stage Air Cooler 5/24
Oil Level 4/5 Second Stage Air Cooler 5/24
• . 4/6 Automatic Valves
Oil Pressure 5/24
4/6 Waler Jacket Relief Valve 5/24
. .
CoolingWater System
.4/6 Automatic Drain Traps
. . 5/24
Air Pressure SafetyValves
.4/6
fl
Del ivery Line Non-Return Valve 5/25
fl Removal and Inspection of Delivry Valve 5/25
—
SECTION 5 MAINTENANCE Assembly and Installation of Delivery Valve 5/25
—
Automatic Delivery Line Unloader Plunger Operated
ROUTINE MAINTENANCE fl 5/26
Removal and Dismantling Procedure 5/26
General
514 fl Assembly and Installation of Unloader 5/27
Automatic Valves
514 “spection or Ren,ojal of Big End Shell Beatings 5/28
Sucti, Valves
5/4 Removal of First Stage Connecting Rod Big End Bearing Shells 5/28
Delivery Valves
5/6 Installation and Assembly of First Stage Co,ating Rod Big End Brings 5/28
Air Filter/Silencer
5(7 fl lpection or Renewal of Second Stage Connecting Rod Big End Being Shells 5/28
Topping lip Crankcase Sump with Lubriting Oil
First Stage Piston Assembly 5/28
Oil Filter and Crankcase Sump
5/7 Dismantling of Piston Assembly 5/29
Air Coolers (General) Assembly of Piston Components
First Stage Cooler 5/29
I: Second Stage Piston Assembly 5/29
Removal of First Stage Cooler Removing and Dismantling Air Governor
5/8 5/29
. . . -
Re-assembly of First Stage Cooler Aenbling arid ristalling Air Governs 5/31
Second Stage Cooler Removing and Dismantling Watw Shut-ott Valve 5/31
.
Removal of Second Stage Cooler Assembling and Installing Water Shut-off Valve
5/9 5/31
Re-assembly of Second Stage Cooler Spare Parts Ordering Procedure 5/33

4 5
to
 T
TABLES-

Page
‘WI-v
SECTION 1 —TECHNTCAL DATA
-V
RECOMMENDED MAXIMUM WEAR CLEARANCES 1/3
CCCLINGWATERQUANTITY 3/1 Standard Performance Range
-S
RECOMMENDED COOLING WATER PIPEWORK DIMENSIONS 3/1
RECOMMENDED LUBRICANTS Free Air Delivered 183 to 364 m3/h
3/2
MAINTENANCE SCHEDULE 5/1 Pressure 14 to 42 bar
FAULT FINDING CI-4ART -
5/2 Speed SOOto 970 rev/mm.
w
LIST OF PARTS 5/34
Specification
ST
ILLUSTRATIONS
Number of Stages Two
S V Number of Cylinders - Two, one per stage
Arrangement of 2TM6 Compressor 1/4
Cut-away View of 2TM6 Compressor 2/2 Suction Valves Low Lift low inertia plate type
Automatic Valve 2/4
fl Delivery Valves One per stage
Oil System and Flow Diagram 2/5 First Stage Cooler Single Pass Type
Air Flow Schematic Diagram - - 2/6 Second Stage Cooler Double Pass Typo
Principle of Flexible Rotor Water Pump 2/6 Air Pressure Safety Valves Two. One Fitted to Each Cooler Housing
Water Jacket Safety Valve 2/7 Relief Valves (Wateri One Fitted to First Stage Cylinder Head
2/8 Relief Valves (Oil) One Fitted in Crankcase Oil Pipework
Cut-awayView of First Stage Cooler
AirpressureSaletyValve . - 2/9 Crankshaft Two Crank, Three Bearing Shaft with
Non-Return Valve - . - 2/9 Integral B&an Wei9ht
—
Automatic Unloader Plunger Operated 2/10
fl Main Bearings Three Thin Wall Shell Type
Automatic Drain Trap 2/10 Thrust Washers Fitted to Centre Main Bearing
Air Governor 2/10
fl Connecting Rod Two
Water Shut-off Valve 2/11 Connecting Rod Bottom End Bearing Two Thin Wall Shell Type
General Arrangement of 2TM6 Compressor 3/3 Connecting Rod Top End Bearing Two Press Fit Bushes
Suggested Installation on Fabrited Mountings . - 3/5 Pistons One LP. Piston
Anti.vibration Pads for Marine Installation 3/6 One 1-IP. Piston
Foundation Template 3/6 With Integral Buffer Piston
—
Alignment of Couplings Pin Type 3/7 Oil Pump Rotary Gear Type. Chain Driven
—
Alignment of Couplings Identical Half Type - - -
3/8 Oil Filter Cartidge By-pass Type
Alignment of Belt Drive 3/10 Air Filter/Silencer Fitted to First Stage Air Inlet
Principle of Automatic Drain Trap 4/2 Water Pump Rotary Self-priming
Typical Compressor Installation with Automatic Control 4/3 Unloader Air Operated, Unloading on First
First and Second Stage Cooler Assemblies 5/10 and Second Stage Coolers
Sectional Arrangement of Oil Pump 5/20 ‘ If Fitted
Flexible Rotor Water Pump 5/23
Automatic Drain Trap 5/24 n Piston Ring Gap (New
Delivery Line Non-Return Valve 5/26
n -

Automatic Delivery Line Unloader 5/27 First Stage -

Air Governor 5/30 228.6 mm. Cylinder 0.406 to 0584 mm.

Water Shut-off Valve 5/32 fl 0,406 to 0,584 mm.
254,0 mm. Cylinder
AFr Pressure SafetyValve 5/33 Second Stage 0.254 to 0.330 mm.
Sectional Arrangement 2TM6 Compressor fl
Drawing No. 5247, Sheets 1 to 7. Crankshaft End Float 0,203 to 0,559 mm.
fl
Cylinder Head Clearance 0635 mm. (Minimum — Each Stage)
n Air Pressure Safety Valve Setting To Operate at 10% Above Design
Working Pressure
Water Relief Valve Setting STANDARD 2.8 bar
fl Oil System Relief Valve Setting 2,1 bar / 3,5 bar
Sump Capacity 15 Litres Minimum
fl 23 Litres Maximum
Fusible Plug FUSING TEMPERATURE 121°C

0
6 a I/i
 n
a
ci RECOMMENDED MAXIMUM WEAR CLEARANCES
Torque Settings
Valve Screw Item 270) 12,0 Kgm.
a
Va [ye Screw (I tern 324) 15 Kg.m. RECOMMENDED SIZE
ci ALL DIMENSIONS RECOMMENDED
Vaive Cao Screws !ten, 273 & 327) 10.4 Kg.m. CLEARANCE B ORE RENEWAL
Main Bearing oIt Nuts Item AS) 10,4 Kg.m. a AREM.M. BEFORE
ConiectEng Rod Bolt Nut (IRe— C3) 0,4 Kg.rn. RECffWAL MIN. MAX.
Cooler Cover Nuts (Item 184) 10,4 Xg.m. 157 STAGE PiSTON 0.660
a 253.39
Cylinder Head Nuts Stern 256 & 305) 20,8 Kg.rn. NOMINAL
BORE 254)
a SORE 254.33
Maximum Comprsor Weight or

3ar Carnoreor 1020 K9.

a 1ST STAGE ‘ISTO’ 228.
Basepiated Set NOMINAL I 0.580
3100 kg. n BORE 228) SORE 228.60

PISTON 101 09
2ND STAGE 0560
BORE 101.71
n SUFFER
BUFER PISTON 15194
a oses
BORE 15270
fl SMALL GUDGEON
END PIN 50.67
n 0.203
BUSH 5098
a
BIG END JOURNAL 82.37
n 0.254
BEARING 8270
a
MAINS JOURNAL 82.37
a 0.254
SEARING 82.70
a
‘ISTON 1ST STAGE 1.6
a 9 INC
GAP 2NDSTAGE 1.000
a
1STSTAGE RINGWIDTH 9.35
a RINGS & 0.254
GROOVES GROOVE WIDTH 915
a
2NDSTAGE RINGWIDTH 6.17
a RINGS& 0254
GRVES GROOVE WIDTH 6.58
a
a NM. All recommendations are supplied for guidan only. The criteria to be used for repIament should be
loss of perforrnance or materaI damage.
a
The above figur, ray however be of sane advantage for planned maintenan prcdtires,
n

•1.
1/3
1/2

‘1
 tIES

SECTION 2— DESCRIPTION
I
GENERAL

A oictor:aI lustration of :l,e tyce 2TM6 comessor is shown oocosite.

V The comoressor isa medium pressure two stage, two crank, single acting, water cooled nachin& It has been
desigrec ormarIy as a compact and rocust marine unit suitable for starting, cortroi air auties and yeiecal
servce air. However, its attrbutes make tie comorescr eoually suitabe for many industrial aopications.

The desgn is •n acccrdan with the best modn practice, the outstanding ‘eatur being ccmcactn and
ease of maintenan. The val.es e pa’tictjlarly accsibie s,d the air olers rrey be readiiy wizhar..n
fl complete units.

A combined fflter and siFenr on the air intake protects the machine from atmospheric impurities and also
redus the ambient noise level.

Each compressor 5 supplied complete with all the necessary fittings. These include first stage cooler. second
stage cooler, air and water pressure relief/safety valves, drain cocks and pressure gauges.

The air pres,ure gauges are mounted on an nstrument bracket together with an oil pressure gauge. This
instrument bracket is fitted at a convenient height on the non-drive end of the machine.

Lubrication is automatic, all bearing surfa being for fad byan integral gear pump, chain driven from
the crankshaft. The system is fined with a by-pass type filter and spring loaded relief valve. The lower cylinder
wails are lubricated by oil mist

A supply of cooling wate’ is required to provide a diff’enzial between the comprsor inlet and outlet
fl connection,, thus tisfy,i’g the flow requirenml’ts as detailed in Section 3. 1 dered a ‘ter circulating
punp, driven from the coo,ntsor aankshaft, can be supplied. A r&ial ive s fitted to the comr
fl jacket as a protrion ainst exie pressife developing in the event of an nternal lkage.

fl Baseplated uniI mpIete with electric rnaors, or otfra types of prime mo can be suoolied as required.
Autornatc control Systems, unloading equipment, drain trs, n,-refljrn valves and rroistixe serereta3 can
also be supplied on ruest.

n
A. Second Stage Cylinder r’eaa K. Cooler Hand Dram Valve
B. First Stage Cylinder Head L Cooling Water Inlet
C. Water Jacket Rele1 Valve M. Water Pump
0. Cylinder Block N. Auxiliary Drive End Cover fl
E. First Stage Cooler 0. Second Stage Cooler
F Crankcase Breather P. Cooler Relief Valve
6. Crankcase Door 0. Oil Pressure Gauge
—

H. Crankcase A. First Stage Pressure Gauge

I. Low Oil Pressure Switch S. Second Stage Pressure Gauge
J. Cooler Automatic Drain Valve T. High Air Temperature Switch

Arrangement of 2TMG Compressor

n
n

‘/4 2/1
 DETAILED
n A oart[aly sectioned pictorial illustration of the type 2TM6 comessor is shown.
cs Cr., kce.
0 The crankcase incorporates three main bearings each of which is fitted with main bearing
shells of the thin
0 walt type; in addition, the centre bearing is fitted with thrust half-washers. A [arge
inspection door is fitted
on each side of the crankcase giving complete accessibility to all working rts. Viewed
from the non-drive
0 end of the compressor the left-hand door incorrates a dipstick assembly and the
right-hand door a crankcase
breather.

The dipstick can be removed to facilitate topping up the rubricating oil.

n Cylind.e BIOdE
0 The cylinder block is fitted with repiaceasle ‘irst stage liner and second stage suffer
me, of the we! type.
0 The liners are a light drive fit in the cylinder bocx and are sealed by ‘0-ring seals; two
at the bottom, one at
the tap.
0
The cylinder block also carries the first and second stage coolers, arid is provided with drain valves to
facilitate
0 system drainage.

The block is located on the crankcase by locating buttons, and secured by studs and self locking nut.

Moving Pain

0 These mprise the crankaf;, connecting rods and pistons.

0 Cranksh.lt The ankshaft incaporates integral balanix weights and is drilled arid tapped at the non-drive
end for the oil pump drive sprocket attachment bolts, arid at the drive end lathe fiflel attachment bolt.
0 Connectng Rods. Two identical connecting rods are each fItted with thin wall big end bearing shells and
small end bushes.
0
0 Pistoru. The pistons are made of aluminium alloy. The first stage piston is fitted with two compression rings
and one slotted oil control ring. The second stage piston consists of a lower buffer’ piston and a second
A. First Stage Suction Valve Oil Pump
stage piston proper. This piston is fitted with compreion rings at its upper extremity but the buffer piston
I. 0
B. First Stage Delivery Valve has no rings fitted.
.1 Buffer Cylinder Liner
C. First Stage Cylinder Linsi K. Hand Drain Valve 0
0. First Stage Piston The gudgeon pins are retak,ed in each pistai by internal circlipe.
L Second Stage Cooler Tubeplate
E. First Stage Cooler Tubes M Second Stage Cylinder Liner 0
F By-pass Oil Filter Cylind.r H. and Vtva
R Second Stage Piston Assembly
G. Oil Pressure Relief Valve 0. Second Stage Suction Valve 0
H. Oil P,.jmp Inlet Strainer The first saga cylinder head is loQted on the cylinder block, at the non-drive end of the iachine, by means
P. Snd Stage Delivery Vale
of the lower end of the second stage cylinder liner. This liner s also of the wet’ type and s seatai on the
0 lower end by an 0-ring seal, and on the upper end by a copper washer.
Cut-awn View of 2TM6 Comprnso#
0 The second stage cylinder head is located on to the first stage cylinder head by the flanged top end of the
second stage cylinder liner. The cylinder head is sealed by a copper washer at this position. Both heads are
0 secured by studs and nuts.
0 First and second stage cylinder heads each rry their respective suction and delivery valves.
0 Each suction valve makes a metal to metal contact with its seat and is retained by a elve cage. The is
secured to the cylinder head and an C’-ring seal is used to seal the mating surfaces.

The delivery valves are eec], retained o4 its seat by a valve ca whici, in turn is held in place by a valve saew
and cover. The valve cover is sealed by an ‘O’-ring seeP and sacissi to the cylinder head, The valve saew it
sealed by a cap nut and copper joint.

2/2 213
 n
Automatic Valve,

the automatic valves open and remain open by differential pressure, and are closed by spring plat when
this differential pressure ceases,

n
n

n
A. Solit Pin
n
B. Castle Nut (or Alernatve Setf-lock.ng Nut!
n
C. Nut Washer
D. Valve Seat
L Lift Washer
n
F, Valve Plate
G. Damper Plate
n
H. Spring Plates
I. Lift Washer
n
J. Buffer Plate
K. Centre Bolt
n

Automatic VaIv.
n
n
C
A. Oil Feed Main Bearings
B. Oil Filter (By-pass Type)
C. lnet Strainer
D. Oi Pump
E. Pipe to Oil Pressure Gauge
Lubriation Svtein
n F. Oil Pressure Gauge Oil System and Flow Di..m
A schematic flow diagram of the compreor lubrition system is illustrated.
n Oil Pump. The gi puma comorises a body and a cover which together house a driving gear and a driven gear.
The main besirigs, oig and c-rqs and sr-all end cearings are fed by a rotaiy gear pump. This purno is chain
The gears are carried in bearir busties and the purno asserrtly secured to the Qank
driven from the antstatt
n
Raid V.1w. A soringloaced adjustable relief valve is fitted in the ankcase oil pipwork on the disctiarqe
Oi S arawn from inc ank-e reservoir through an inlet strainer into the oil pump. The oil is then fed to
n side of the oil pump and re)ieves through the oil filt assembly.
the three main bearings, and an oil filter. An oil pressure rehef valve. set to relieve at 2.8 bar, is also incorporated.
The filter is Ejteo wzn an outlet elbow throuçh wflich bv-p3ssed oil is reiur,d to t aankce reseoir.
n Oil Filter. The by-Da oil filyec of the tfrow away type is ovnted in th crankcase at the drkie end.

From each main bearing the Oil tlows through paages in the crankshaft to the big end bearings, and then n Not,: The operating cii preure may ,y between the I!mits indicated in Data. Section 7. dependent
through passages in the connecting rods to the small end bearings. On oil ten’pnwre and viscosity.
fl
a 215
2/4
ts
 a
Watt. Caolin System C a Water .I.ck.t Safety V.1w.. ‘his valve co’nists of a body whici, housesa bacxinq disc, spring, and soindle.
The tacKing disc an an ‘0-ring are 9eid against tl,eir seating by the spring, and locrned in the lve body by
A schematic crawng of the cooing water ‘low ano ar fow systems are snown the spindle.

The compressor cooi i’ig water inlet s situated at the Dottorr of the cylinder block and trie outlet on the
secora stage cylinoer head.
S.
Notc When the comprestr is fitted with a water circulating pump iris mounted at the non4riye end
of the machine The water inlet to the machine is then at the pump suction flange and the pump
delivery flange is connected to the cylinder block inlet by a copper pipe.

The :coling water circu:ates lhrcçh he cviiter block whch hous vie ‘‘st and second stage coojers. t
then passes into the first stage cylinder head and in turn, cools the lve pockets, befoi-e passing into the E
second stage Cylinder head.
S.

A. Cranked Spindle 0. Backing Disc

co// a. B. Body E. 0-ring
fl7 I C. Spring
1 C S
E t Wit., Jacket Safety VaN.

First Sag. Cool... This is a single pass oler in whid, the air passe from an niet cover through a bank of
L tubes to an outlet cover. The cooler is mounted in the cylinder block.

A tubeplate, into which the tubes are expanded, s secured to the inlet cover, and this in turn’s secured to
fl the cylinder block.
M M M
At the outlet end, the cooler tubes are exparded nb a similar tubeplate. This is attached to the outlet cover
with a thin brass diaphragm interposed between the mating faces. The outer edges of the diaphragm are
A. Air Flow G. Second Stage Cylinder clamped to the cylinder block by a sealing ring. This allows free moven’ent of the cooler assembly, due to the
B. Suction Filter H. First Stage Air Cooler thermal expansion of the cooler tubes, relative to the cylinder block.
C. Sucton Valve I. Second Stage Air Cooler n
D. Delivery Valve J. Non-return Valve The outlet Cover carries a drain valve for draining the cooler of any water deposited by the air. This can also
E. First Stage Cylinder L. Oil and Water Separator fl be used to unload the compressor during starling. The cover is fined with an air pressure safety valve to
F Cooling Water M. Condensate Extraction orotect tie air system ri event of any excess pressure. This valve ‘eseats automaccahy.

Air Flow Scbm, atic Diagram

n Second St. Cool.,. The second sThge cooler is a do.A,lo iss type in whid, the air pass from the deli.wy
cover orq the upper bank of toes and then returned to the delivwy cover tivoth a return co and the
Not.: The equi,ed cod big wata’ quantity, rnperatwe and p,n resa*tion, a give, in Date, lower bank of nca
Section 7. n Thermal expansion is allowed for as in the first sage cooler.
Not.: Pa, any particular installation the necessary cooling waw, qu.nfl’, p,euur, arid ten’perawre n The delivery cover is fitted with a drain valve and an air pressure safety valve similar to the first stage
rnD*Dom a,. thovw, in Dew, Section 7. outlet cover
Water Circulating Pump. The water circulating ourno is of the flexible rotor, po&tive displamait type. Al, Pvaaa Safety Vav.. The safety valve fitted to the first outlet cover and to the secono stage delivery
It comprises a body and an end cover whici-. bou a rotor and a m for operating the flexible blad. The n ccver ccmcrises a body, caD, aria seat which together house a plunger and wring. The spring pressure
rotor is moun, on a shaft which is carried i two bad brrçs I itt in a separate bearing housing bolt set cy means of the aajtister. so nat the valve will ift at 10% above its associated stage ope’ating pressure.
to me body. Sealing ot t,e oump is achieved by —leans of a mechanical seal fitted to the pump shaft. n Ga-
n The first art second se pressure gaLqa, :ogettwr the oil pressure gauge. e mounted on a suPØort
a secured to the first stage cylinder head.

a The first stage gauge is connected to the first stage cooler outlet cover and the second staic gauge is
connected to the second stage cooler delivery cover both by copper pipes and ssraight connections.

PHndp. of Water Pump n Gauge cocks are incorporated in the connecting pipe lines to the air gauges.
a
2/6
a 2??

a
 4-lw

0
0
0

1w
it Ii,

A. Cap A. Valve Cage

vie B. Adjuster B. Valve Housing
C. Body. C. Delivery Valve
vie 0. Spring
E. Non Return Valve
Plunger
‘tie F. Seat
vie
Air Prenure Safety VaIv.
e4w
Ddivey Liii. Nm,•Rfljm Valy.

The function of the non-return valve is to prevent the rewrse flow of air from the air rec&ver back to the
compressor. This is particularly important when a devory line unloader is fitted.

A practiI feature of the design is that the delivery velve n be removed for routine maintenance or replaca
n-mm without disturbirg the piliri. connections.
v-It The non-return valve consist of a valve housing and a valve rage which together house a low nerta tvp
TI. delivery valve. The deivsry valve is similar to that fitted in the cQmpror and refer,ca should be made to
U,e cornp,a automatic vlve illustration.
a* Oh and Wfl S.j.a,, (If Fitted)

The secerator is fittM i the aW delivery line to remGe impirities and rno4stse from the air. It comprises
a fabrirat body with an internal float asntly to facililateautorratic drainage.

n Aut.nDc Unload. - Plung. Op....t4 (Wt., flU4)

n The unloader compres a first and se.t 5mg. cir,ter. a disctwge ctwnber, a plunger 9uide. and a olunge
guide co’er which together hote di. first and sewnd smge .Iv, their elve seats, ana a plijnger. The valves
n are soring-led onto their whid also act valve guida.

n The ur.loada is mounted on the inlet filtw/,encer assently elbow and the exnaust air espes 10 atmowh1
thro{41 t[te siIen without usir excasjvt noe.
A. Frst Stage Cooler Inlet Cover C. Diaphran
B. Frst Stage Cooler Tube, 1-1. Air Pressure Safety Valve
n Auton.tic Draá Trw (Wh. Fiflad)
C. Tubeplato I. Second Stage Cooler Delivery Cover
0. Cooling Water Inlet Connection J. First Stage Air Pressure Gauge
n The automatic drain trap discharges condensate from the cornpr5or coolers and consists of a body, cap, and
E. Cooler Condensate Drain K. Second Stage Air Pressure Gauge
fl drain p which together house a disc arid saeen. ShUn, are fitted between the p and body, and the scan
F. irst Stage Cooler Outlet Cover
is retained by the drain p, All components are of stainl, steel.

Cut-eway View of First Stag. Coder The drain trap is normally mounted on a connecting block at the non-drive end of the machine.

2/8
2/9
 ti
CI Water Stun-off Van

The water shut-off valve is fined to the comprsor water acket inlet tapping. ;t is ocerateQ
pneumaticIiy
by air from a tapping in the first sta cooler, via an adjustabe air flow control valve, wr’ cn resRrcts the air
CI flow from ihe diaphragm chamber to provide slow closing of ihe valve. The valve consists of a gobe valve
body, valve assembly and valve cover. It is spring-loaded in the shut position and is operated by a diaphragm,
CI which is housed in an adapter flange assembly and top cover, through a push rod.

CI
CI A B o E

C.
A. Pu’ger Guide E Second Stage Char-ba
Guije C
9. Cover Second Stage Air In;ez
C. Discharge Chambar C. F:rst Stage Chamber
D. FirstStageAir Inlet A. Top Cover
C B. Diaphragm
AutQmatic Unloader — Plunger Operated C. Adapter Flange Assembly
D. Pushrod
E. G’obe Valve Body
C. F. Valve Cover
G. ComDrsion Svir.g
H. ValveAssernbly
A. Drain Cap
B. Silencer
C. Cap
D. Body
E. Adapter
War Shut.ff Valve
Automatic Drain Trap wHir
Soletiold Op.nt.d Cool., Drain Valv.,/Unloader (When Fitt.d
n
Solenoid operated cooler drain valves drain the condensate from the coolers whilst operating on a pressure
Air Gonmo. (If Fitted)
n switch controlled START—STOP cycle. The valv, being of normally open construction, vent the coolers
and preure spaces of the compressor whilst it is stationary and cro’4ide unloaded starting.
The air governor controls the operation of the main air delivery line unloader and is fitted to the air receiver;
cm
When the compror is stoned, adjustable timed contacts energisa and de-energise the solenoid operated
it is connected to the unloader by a pipe.
drain valves to bring the comprsor on load and to drain condensate horn the coolers. The frequency of
the condensate drainage and the drain period are independently adjustable.
BasilIy it consists of a body, a spring-loaded valve and spindle, and an upper and lower seat. Adjusting fl
collars are provided for setting the cut-out pressure and shims for adjusting the cutin pressure. The air from
Automatic Controls (Whet, Fitted)
the receiver passes through a mh filter. cm
Various methods of controls are available, depending on system requirements, for one, two or three
compressors.
A. Spindle
B. Adjuster n Visual alarm facilities with automatic compro, lockout and manual reset are also availabe.
C. Collar
• D. iJppe Seat
E. Shims
F. Body pp
G. Lower Seat
F-f. Adapter fl
Air Govemo. n
fl
2/10 2111
sp
 SECTION 3—INSTALLATION

INSTALLATION DATA
n
n COOLING WATER QUANTITY

a REQUIRED APPROXIMATE
COMPRESSOR * COOLING WATER PRESSURE DROP
a SPEED QUANTITY ACROSS COMPRESSOR
a
a rev.1,nin. 1./mi... bar

a 585 73 0.3
a 705 87 0.4
• 880 105 3.5
a 970 114 0.5
a
a ‘NOTE COMPRESSOR SPEEDS SHOWN ARE TYPICAL SPEEDS OBTAINED WHEN
USING AN ELECTRIC MOTOR AS PRIME MOVER.
a
a RECOMMENDED COOLING WATER PIPEWORK OIMEPIONS
a
NOMINAL PIPE
a MAXIMUM RECOMUEI’CED WATER FLOW
DIAMETER

a mm. 1./mi,
a 12
10.5
a 14 22
18 36
a 54
22
a 27 82
35 138
a 195
41,5
54 330
72 585
a 800
84
a
a COOLING WATER TEMPERATURE

a The ma,c’mum recommended cooling water temperature into the compreor is 38°C. If 1emperalur in exs5
of this figure re beriq cidered ocx TECHNICAL DEPARTMENT must be wnsut and t may be cossibie
n to make scec’al recomrrcndalinns

a
a 3/1

a
 n
RECOMMENDED LUBRICANTS

Compressor Crankcase Lubricant n

a A
Supplier Oil Type Supplier Oil Type
Agip Dicrea 68 Gulf Compres.or Oil 53
Ampol Darol. Oil 20 Lubrication Entri Monotec Compressor 0116222
Super Ardea C 68 Mobil Raru, 426 (Preferred)
Antar & Ocean Turbine T 68 Rams 427
Misola H 68 DTE Oil Heavy/Medium n
BP Energol AC 68 Pr rot na Solca AC 43
Caltex Aeial Oil PE R 80 Solco SAE 20/20W
Castrol AircolPO 100 Eden AC 34
Pert T 100 Shell Coren p es
Aircol SN 100 Turbo T 68
Chevron Refrigeration 68 Regal Oil R&O 68
GST Oil 68 Compreur Oil EP VOL —68 WV
Duckhams Deenal 20 Total Cortusa 68
Essa Zeric, S 68 Petro Canada Super Compressor Oil 68
Golden Fleece CIrcol 46 Wisura Ventura 42 T-V
(Australia) Circol 68 Hydroma 42
n
n
TIt
n
a B
n
Coaling Wit.. Pump Lubflcn

Shell Alvania Grease 3. Esso Beacon 3, Or equivalent grease.

n A. Lfting Eye Bolt Bare Compressor B. Utting Lug Basepated Set
fl
Motm Lubricant Maximum Weight: C. Clearance Required f or Dismantling Compressor

See dIanufactureq-s recommendatians. Bare Compressor 980 kg. Baseplated Set 3.1 X kg.
n
Engine Lub,icn
CAUTION ThE HOOKS OF SLINGS MUST NOT BE FIflED DIRECTLY TO LIFTING EYE BOLTS
OR LUGS. SHACKLES MUST ALWAYS BE USED.
See Manufacturers recommendations.
fl
ti.n.,a A. • _..,...t of 2TMO Caançnssc.
cooling Wat.. Pnuur. fl
The maximum allowable water inlet prezure to the compressors 2.8 bar for a standard machine. It is The standard DIRECTION OF ROTATION for the comprsor is clockwise, looking on the non-drive end
essential that the correct quantity of water is supplied when the machine is running and it is preferred of the machine. Non-standard direction of rotation can also be supplied on request. Reference must be
that this flow is shutoff when the compressor is stopped. made to the general arranqenlent drawing supplied with each ccmpreor. A direction of rotation arrows
fitted to the compressor at the drN-end on the cylinder block.
Conpna. W&t md O4mnniom
Note; The lifting positions to be employed for installation and ,wnowil of the comprnwr or th. complete
The ,‘ax’mum wtight ot n corrror and the comptete baseplated t. the overall dimensions, art the baseplated wt are indicated on the general arrangement draw/nt torthr with the maximum lifting
minimum cewenca for removai of paru are show., on the General A,ranment illusfltion. we/gha

Fr complete dimensional data on any particular installation, reference should always be n,ade to the
n
general arrangement drawings supplied with the equipment.

.t.
as
3/2 as 3/3

a.
 INSTALLATION PROCEDURE C
General -
a
The circulation of cooling water throuçh the corrpreor musi be positive and some torn,
of visual flow
indicator should be orovKled in the circuit. Recomrnendatior’.s for cooling water systems
are detaied in tns
sect,on anti flowrate requirements are supplien in Section 4A. C.
is recommended that an automatic plate type non-return valve is fitted in the ar delivery
line, as near to
the Compressor as possible. If automatic unloading equipment is fitted to the
compressor, titment of this
tyce of vaLve . essential.

Its of urcst °‘portanca that sjfficient space s proVded around the machine to aiiow
personne’ acss,
a.
and to facrlitate removal and installation of components during normal maintenan
roulines. Its advisable
to Leave ample headroom above the unit for crane joists or lifting tackle. Minimum required
clearance
a.
dimensions for component removal are shown in the general arrangement drawing supplied
with the com
resser ar &w in this Section.

Check the otation of te pri’ne “o’er befere CCup!ing jp to the nachine. The direction
of rotatlo,, rust e
a.
as shown in the general arrangement drawing of the machine being installed, and
by the direction arrow on
the compressor. The compressor must not be run in the wrong direction or damage may result.

Note: Before running the con1prear for the first time e installation mint be thoroughly
chaked and
the procedure indicated in Section 4 for initial Stan consulted.

Location
as
In order that the maximum efficiency can be obtained from an a!r compressor, careful
consideration must
5. given to its location. as
1Is mportant to ensure that the max{mum amount of air can be drawn into the cylinders and that the air as
Itritalce be as cod an dry as possible.
a.
Each machines fitted with a combined silencer and filter on the air intake, but it is
still important that the
initial air intake be clean. a.
Suggeitad Marine Installation Proc.dur.
a.
Compressor sets must, where ponible, be installed at engine room floor level. Where engine room
flats are
aS
utilised they are to be of strong cantilever constructon adequately tied at the outboard end. Plate
thickness aS
or seatings shouLd generally not be los than 15 mm. with adequate stiffening ribs provided
adjacent to the
baseclate holding down bela Under ck stiffening must extend from main frame to main frame
where
possible, to prevent vibration above any single frame.

Ship. Compr.*or Mounting

a.
A compressor isa reciprocating machine and consequentJy the seating should be of adequate strength F
to
prevent vibration. If the cocnp,or is mounted on a ‘fiat,it is recommended that flexible p.pe 0
ccnnectons a.
are used. A. ibs as Close as Possible to Each Holding Down Bolt
as 8. Deep Stiffening Ribs
NOTE: UnderdeCk stiffening rth Would. if pouJble, extend from main beam to main bnm
to prevent oscillation about any single beam.
C. Main Athwart Beam
D. Deep Frame Below
E. lee Sections
F. Framework Built on Top of Flat, Stiffening as for Above.

-V
Suqg.,t*d ln.t.llation on Fabriated Mountings
n
3/4
3/5
 a.
C.
ci
a. A. Baseptate
A. Baseplate B. Steel Wedges
B. Anti vibration bush a. C. Anchor Plate
C. Heavy steel washers D. Foundation Bolt
0. Anti vibration pads a. E. Soace Seneath Baseplate and Holes FiLl in wrrh Grourinq
E. Steel chock Foundat on Bolt •‘JjT arid Washer

Anti-vibntioq, Pad. for Maim. Installation a. bchin. in Position Ready for Groutin

a.
WI— Sat, with Pin Type Buffer Co.cling

With the corroessor set positioned on the stool, raise the unit apDroximateiy 25mm w tb the aid
Sund IndUnIIaI IrutMIaon Procedure of ‘acicirg
screws in the basiate or ste wedges inserted between the baseplate and the stooL Sit the baseplare nolcrg
down bolts but do not tighten them at this stage. Mount a clock gauge with a magnetic base on the Compressor
The provision of a good foumation is an ee’.tial requirerrnt to the tisfactory working of any n-achine.
flywheel and, with the gauge set at zero on the motor naif couolirig, adkist the jacking screws or wedges so
Concrete is the rmst tisfactcry ndiurn for foundations which must be sufficiently substantia’ to acsorb
WI-,’ tIt by tightening loosening the ho1dng down bolts the baseclate alignment is within 008mm. as ndited
any vibration, and to form a rigid support f or the baseplate. ‘enewr possible the fotindatiom of the
on the clock 4e, This should be done at lois p0mm on the upling, the points being 90° art. and
rnad,irie should not join the foundations of a boilding, otherwise vibraton rry be transmitt. by
flaring the flfl9hl and coupling together as one unit.
Wig

Foundadont
a. Check that the coupling and fhwheel facas are parallel with a taper gauye When correct alignment s achieved,
with a pair of inside cahpers msure the gap between the underside of the baseplaie and the stool at each
Generally spking the size of the concrete block should be aPproximately 300 mm. longer and wider than
as holding down bolt position. Make a sohd steel chock, slightly oversize, i or each posilpon and file them to make
the base of the machine. The depth can only be determined after excavation of the site, but it is important each one a light tap fit between the baseplate and the stool. As each chock is fitted the alignment should be
that the concete is carried down until a solid base is reached.
a. checked on the clock gauge. Fully tighten all holding down bolts and recheck for correct alignment.

The machine and prime mover are correctly aligned on their basaplates before shipment. The alignment,
as Not. I. The te of an appmved resin fitter in place of steel chocks is acceptable providetl that the respective
however, tiny be disturbed during flnsit or by incorrect levelling of the baseplate on its foundations. manufacturer, ir,, tells Won procedures am fully adopted.
a.
Adjt wedges to level the set using the machined under surfa at the sides of the baseplate for this purpose. Nat. 2. If the coupling a’ignmat derailed thrnt cannot be achieved, the best reading pomible should be
Remove the coupling bolt, and connect up the pipework. Pipa should line up naturally; under no circumstanoss
a. obtained before fining the chockt The motor dowels should then be removed, the motor moved
should they be ford into position. The pipes should also be supported independently. Consideration of the to suit the comprlsaor position, and the motor dowels refitted.
last two points wilt ensure that no external stains are applied to the unit. Now check the alignment as described
a.
in the accompanying illustration whichever is applicable.
•5 C
as

as I
A. Motor Shaft
as B. Dial Indicator
C. Flywheel
D. Coupling Bolt
E. Comprso, Crankthaft
P. Coupling Gap

AJi?,n,.nt of Set with Pin Type Boff., Coupling

at
a. 317
3/6
 t
IdenticaL HdI C041911fl9
C Prnn. Switch end Sdenod Valve Connection,

Check the alignment at the coupling by placing a straight edge across the coupling flanges. To avoid erratic operation of these control devices, it is preferable that they
This should be are attached to the receivers by
done at four points on the coupling, the points being 90° apart. The distance between separate pipework. If it is imperative that these connections are taken from
thi faces of the the common balance pipe, then it
coupling halves should also be checked at four points with a thickness gauge. They must be ensured that this pipe has a capacity in excess of 500 cm3. This
should be spaced far wiN prevent a sudden pressure drop
gnough aart so thai the sxLal ceararce between the compressor and prime —over affeaing the control devic when air is cassed to a compressor unicader.
cotolings is in exce
of their resoective end foats. AlV,wance sIoud also be made for wear in tie
thrust bearin.
Automatic Drain Trap (When Fitted)
WIT
A B
The trap should be fined wiib me a,sc vertical i.e. with ihe
cap on the horizontal centre line). If it is arranged
in a vertical me a must discharge downwards.
C HH
The piping particularly at low pressure, to and from (he trap should be the
maximum size with the minimum
of bends and fittings, which would cause restrictions. Pt is permissible to have
up to 300 mm. of piping on the
fl drain trap oulets. If a lorger p se re :s reu’red, the automatic drain trap
shouid be moved to the end of the
desired pioe. An seating valve should tier’ be fttec before trio trap to allow
trap maintenance.
C
Non-Return V.4w. (When Fitt*d!
D E F a
The non-return valve must be fitted as close as possible to the delivery side
A. Straight Edge of the compressor, It may be
0 -‘“‘Hnstalled in horizontal or vertil pipelines and orientated in any position
in the pipeline. Care must be taken
6. Normal Coupling Gap to ensure that the valve does nec act as a condensate trap, especially for condensate
0. from a compressor other
0,051 mm. Maxirum tie than the compre%cr o. wNch it is intended to act as a non-return
valve. The valve ‘9u51 be installed .n
D. Offset Misalionn’ent accordance with the direction of flow arrow st on the side of the valve
ld.ntical HaLf Coup1in housing, ;.e. from the Compressor to
E. Angular Misalignment — the re&ver or system. A non”ettrn waive “ltst be fitted when unloaders
F. are used to prevent the air recEiver
Perfect Aoignment discnarqirq on compres shtndown.
n Poly-V Belt Drive
_Ia.
When assembling the drive, the prime mover must be moved toward the Compressor to allow the belt to be
n fitted. The pulleys and their grooves must be cln arid free ol rust and “ounted
beernqs as possible. The drive and driven shafts must be allel and the pulleys
as near to the shalt support
in correct ahgnment. the
0 alignment n be checked with a straight edge by placing it across the faces of the
pulleys dnd ensuring that
the nw and far points on the face of ch pulley is touching.
EI.cticd Inetalledon 0
To tension the belt:
Each installation is to be wired to the relevant wiring diagram in accordance with recognised standards of
_Ia.
practice. Earth continuity roust be provided for all exposed metalwork of electrical apparatus, cable sheaths 1. Ensure thai the ribs are a snug fit in the pulley grooves and tighten the belt
sufficiently to prevent it
and armour. cable glands, conduit, ducts, trunking etc. Flexible conductors rjst be provided to earth sagging at the centre of the span.
resili&flly mounted uipnt.
fl 2. Mark two Iin on the back of the belt X5 mm. apart.
Ensure that overload r&ay are set to the correct current rating of the motor(s) they are protecting,
3. Tension the belt whilst slowly rotating the drive until the distance between the
lines is increased to
206A mm.
Mm Air Line
fl
4. Ensure that the belt is Protected by a well ventilated guard.
An efficient compressor plant is dependent upon a well designed air pipework system.
NO IT: Chak the be!r tnion frequently during the f/rn day, running a,d ad/un, if necIy, derailed
Condensate is geneated in the air system bY the compression/cooling cycle. This condente is removed at a
various stages of the compression pro. The amount of moistixe whic1, may eventoHy pan into the pricu
fl above. lnwfficienr tern/on will cauw the belt to and excndwe tension will ov&oad the belt
s’ip
and the b&n
rnatic plant can be reduced by correct drainage of the air supvv pipawok. A typ(I cOrne,mr nflLtaoon
incorporating automatic controls is shown in the illustration.
n
Vertical runs of pipework directly upward from the compressors 5hould be avoided, and horizontal runs should
dcend away from the compressor with a slope of approximately 1 in 12. This will prevent condente running
back to the machines and to pipeline relief valv.

Automatic Unlo.d.r (When Fittad)

n
The automatic unloader is fitted to the air inlet silencer/filter mounting bracket.
Pilot air must be piped away
from the air reiver to the unloader via a wolenoid valve or other control
device.

3)8 3/9
ts
 a

as Water Pipe Size and Layoyt

In order to avoid exssive friction l5 through piping,

it must always be kept as short as possible. The
DO Page 3/1 gives a guide to the pipe size required, table
it should be noted that the compressor
H not be used to tablish the final pipe size to connections must
be used, as the compressor has a wide range of
duties
as M’nor reouction, in pice #it:inqs size ae ecprabIe ol to the
compre%or. prov!des they ar kept to a
minimum. Should t system cloework lasses be high, a la-ger size oioe
ttn tie: o-s&nE ‘rcrn the :abie,
.1 the shcJld Ce js. The size of the oloework to be employed should
be set&’mired Dy the 4r’ct on oes aIcwab!e
-
n the system
n
The e of a corroressors own water pump is recomnr,ed : szed to give
-_ fl the or-act coohrg water
L. uanzity Even with a pressue cooling system it hel to e,stre that
ANGLED shafts not fl srne the units no; starved v other wits.
When more than one corrp.-essor is drawing off a sirle
OFFSET correct my mov,nq ANGLED shafts nbC parallel) 0,ej correct by resetting suction sine it must be sseo that one unit nnot
shafts in the same s1aw
fl starve the system of water, therefore it is :rrportant that tiE
either uIIey along fle shaft correct by settinq spafts mmon suctIon Oioe ‘las a greater c’oss-seczional
area than the teta. a’s-sectonal a’ of the Dipes to the individtl
until alqned. parallel Ensure no deflection comessors It incividua water cumcs
are titt to (he comprors in such a system, then eat), individual
-
is taKng place in supporting circuit mLt nclt4e a non-retsn valve,
as shcwn Ca crevent internal water re-crculation.
framework or shafts.

Non-return valves ar any other v&ves used in the system

must have low asses. If the comorsor is nan
n inverted loop of piDework. an ar vent ‘lust be fitted to avoid
the for—aton of air pockets.

yy

n
nw
n
CORRECT. Belt Temáon

Migm,wn of Bait Dii..

vi—
Reco.nmendadoe. foe Cooling War
1
n
CoollegWata Tenipennn. The n’exinMinl recommended cooling wat ternpature into th coOrew 5
38°C. If temperatures in excs of this are being considered, our TECHNICAL DEPARTMENT musc be
consulted and it may be possible to make special recommendation!.

Cecilri1 War Pr.wjn. The maximum allowible wat inlet pressure to the compressor is 2.8 bar for a
standard machine. a
Cooling Water Qeantity. the minimum quantity of cooling water required is show,, in a table on Page 311. a
The prasure drop auoss the compror is also shown.
a
The n,axin,urn temperature rise allowable for the cooling water for each compressor naturally varies but a
good average maximums 8°C. A temperature rise greater than this normally indicetes insufficient turbulence
through the compressor cylinder block, and resultant hot spots may occur in the machine.

The fitting of a water pump to a compressor coaling system is strongly recommended as it ensures that the
correct quantity of water is supplied when the machine is running, particularly if several units are supplied n
from a common suction main and discharging into a common main.

It is not recommended to have cooling water flow through the compressnr whilst the machine is stationary

Should water pumps not be required, Hamworthy Engineering Limited n supply water shut-off valves.
fitted to the machines. lobe actuated auornatilly.

at 3/Il
3/10
 as
STORAGE — COMPRESSOR
2. Refill the crankcase with lubricating 0t1 as reco
mmended in Technical Data,
The following recommendations are offered if compressors are not Section 1.
to be installed
immediately or if they are to be taken out of service for
a time. The 3. Run the compressor off—load for 15 minutes to
reco,mnendations are based on temperate climatic conditions and
the periods residual inhibiting oil.
circulate the oil and vent any
specified may be superseded by alternatives as appropriate for
the prevailing
conditions.
CAUTION: ENSURE tEAT OTHER EQUIPMENT IN ThE
SYSTE$ IS NOT
The principal objective when storing the compressor for eith CONTAMINATED WHEN TEE COMPRESSOR
er short or long IS PURGED OF
periods is to remove all traces of moisture from the machine and INHIBITING OIL.
to replace the
normal lubricating oil with a rust—preventing inhibiting oil.
Only Shell Easis
158 inhibiting oil must be used. 4. Operate the unit in accordance with the
overall installation requirements.
Shut—Down • Start—Up, After Long Ter. Inhibiting

After use, run the compressor for three minutes with all To prepare the unit for operation after a
condensate manual long—ten period of inhibiting:—
drains open. This purges the machine of hot, moist air and
will prevent internal
condensation. I. Remove compressor from storage container
.
If the unit is likely to be shut—down for more than four
weeks, it is advisable
I 2. Remove all plug. and tape from opening.
to carry out the following short—term inhibiting procedure.
fl 3. Reconnect the compressor into the overall inst
allation.
Short—Term Inhibiting
fl 4. Refill the crankcase with lubricating
oil as recoended in the Technical
The following recormnendations are offered for storing the Data, Section 1.
machine for short—term
periods of up to six months:— fl
5. Refer to ‘Checks Before Initial Run
V ’ and ‘Coriissioaing Procedure in Section
1. Drain off the lubricating oil whilst still warm. 4, Operation.

2. Remove alt the valve cages and wet the cylinder walls 6. Run the compressor off—load for 15 minu
and automatic valves residual inhibiting oil.
tes to circulate the oil and vent any
with Shell Ensis 158. Bar the compressor through
three complete revolution,
to ensure that the cylinder wall, are thoroughly coate t S
d. CAUTION: ENSURE THAT OTHER EQUIPMENT IN THE
-
SYSTEM IS NOT
3. If the compressor is to be removed from the installa CONTAMINATED WHEN TEE COMPRESSO
tion, seal all openings R IS PURGED OF
with plugs and tape. INHIBITING OIL.

CAUTION: DO NOT TURN THE CRANKSHAFT AFTER REMOVING 7. Operate the unit in accordance with
TUE INHIBITING the overall installation requirements.
OIL OR BEFORE CARRYING OUT THE START—UP
PROCEDURE OUTLINED
BELOW. a
Long—Tera Inhibiting
TI
The following recoendatiOn5 are offered when storing
the machine for long—ten
periods of over six months:—

I. Carry out the recoimuended short—term inhibiting

procedure as outlined above.
2. Place the complete compressor in a suitable long
—term storage container
together with a suitable desiccant such as silic
a gel. Ensure that a humidity
indicator is clearly visible for regular inspectio
n.
Start—Up, After Short—Term Inhibiting

To prepare the compressor for operation after a short—term period of

inhibiting:—

1. Remove all plugs and tape from opening.. as

as
2
a
S
 e

S
4 5
SECTION4—OPERAT,ON
SW
PRINCIPLE OF OPERATION
ST
Comprnioi
S V
The type 2TM6 is a positive displacement, two stage, piston operated type compressor
V T
On the suction stroke air is drawn through the first stage suction valve, via the combined air inlet silencer!
filter, into the first stage cylinder. Ihis occurs on the downward stroke of the first stage piston. As this piston
w + commenc its upward stroke, the spring plates of the suction valve seal the valve and aLr is compressed in the
cy[inder until the required air pressure is reached. At this pressure the first stage delivery valve opens and the
I compressed air is delivered to the first stage cooler by way of the inlet cover.

The air pas nrough the oler to the outlet wver and then to the send stage cyinder head via a cooper
pipe, where it is ,rawn into the socond stage cylinder through The suction valve. Suction and comoression
stroke are similar to that indicated for the first stage. The air passes through the second stage Gelivery valve.
into tile second stage cooa eLvery cover and along the upper bank of cooler tunes to the return cover. Its
then returned to the delivery cover through tite lower bank of cooler tubes and then elivaed to an ar
. receiver or system,

Automatic V.Ivn

The uQnatic valv open and remain open by differential pressure, and are closed by spring plates when this
fl differential pressure ceases.

The first stage suction valve will only open when the first stage cylinder pressure is below atmospheric pressure
and the discharge valve from this stage will only open when the pressure in the first stage cylinder is in excess
of that in the first stage to second stage air connecting pipework. Similarly the second stage suction valve only
opens when the air pressure in that cylinder is less than that in the interstage connecting pipework, The second
- s’tage detivery will open only whet, the cylinder pressure is in exc of final system or air receiver wessure.

5+
The pressure difference necssary for the opening of the valve, also for the air flow ihrou, the valves, is
caused by the movement of the compressor pistons. At the moment when the valves open, this pressure
difference has to oercop the inertia of the valve plates, the wring load, and friction losses.

In orcer to synchroriise the cycfe of valve mov1,t with piston stroke, the correct sØfng load is at paramount
importance- When flow ses. the spring load acting on the valve plate closes the salve without delay.

p Non Return Valve

p The operation of the non return valve assembly is similar to a compressor discharge automatic valve.

Automatic Drain Trap (When Fitted)

The thermodynamic drain traps automatically remove the condente which builds up in the first and second
stage cooler air passages due to the cooling of the compressed air.

The thermodynamic drain trap works on the principle that in a moving fluid, the total pressure is the sara at
all points. This total pressure is the sum of the dynamic and static pressures at any one point.

The flow of conde,,sate throvh the trap varies the static arid dynamic pressure acting on the d;sc. with the
result that it discrarges any condensate praont.

A complete cycle of the automatic drain trap is illustrated.

4/1
 The disc s raised from the seat rings C by
n
inccrirg ressure allowing instant dinarge n
of air aid condensate throLgh outlet B.

The qn velocity of following air aeates a

low pressure area under the disc wb ci, draws a
it towards the seat, and at the same time
n
builds up pressure in chamber D. n
Pressure in chamber D, acting on the fuN n
top area of the disc, forces it down against
the incoming pressure untit it seats on the n
inner ‘99 0, thus c’osing Ihe inle!. At ,he
sa’e ti’e the csc a,so seats on the outer n
rir.g C, tracprg Dressure in cPamcer D.

Tie pressure in chamoer D wiP be ‘eouced

n 8
after peod of t.rre due to very smal n
leakage across me outer ring C, and the disc
will be raised from the seat and the cycle n
repeated.

Principle of Automatic Drain trap

n
fl
Autom.tic Unloader (When Fitted) a
The unloader operates by venting the first and scona stage cooiers to atrrospnere. Each stage then delivers air
at nominal pressure so that the lajor’ty of work done s to overcame friction losses through valves and air
ssa9. The machine is therefore running “off load’ and is not delivering air to the dischai’ge air receive- oi ‘w-iw
system -

When the compressor is on load, the unloader valves are held on their seats bY the air pressure of the appropriate
Typical Compressor Installation with
stage. The springs only provide a light load sufficient to reseat the valves when no air loads are applied. T — Solenoid Operated Drains
These valves are lifted when air is supplied Wy some appropriate means e.g. three-way solenoid valve)
to the will.
plunger guide cover thus forcing down the plunge’. Air is vented from the first stage seat and second A. Air Receiver K. ‘Solenoid Operated Drain/Unloading
stage
discharge chamber to the suction filter/silencer assembly. B. Air Receiver Outlet Valves
C. soLating Valves L. No. 1 Compressor
D. No. 2 Compressor M. Oil/Water Separator (Below Machine
Air Governor a E. Compressor Discharge Level)
F. Tunepsh N. Air Line 1 in I 2 Slope Away trDm
With the compressor running, air oressure in the air receive- builds up until the load on the lower seat area of a G. Hand Drain Va!ves Compressors
the valve exceeds preset spring load in the gave-nor and the valve lifts and seats on the upper st allowing the H. Hand/Auto Drain Valve 0. To Pressure Switches
J. Non-return Valve - P.
receiver air pressure to pass through the valv, to actuate the automatic delivery line w,loader. When the air a Pressure Switches
pessure in the recei drops below the predetermined setting, the governor wring reseats the valve on the
lower seat and the air actuating the automatic delivery line unloader i vented to atmosphere to allow the n
compreor to come on load.

Water Shut-off Valve

When the compressor is running, air pressure from the tapping in the first stage cooler is greater than the valve Automatic controts also include solenocd operated unloader/cooler drainvalves and can incorporate aisofault protection
spring pressure and this actuates the diaphragm and push rod to lift the valve assembly off ts seat. This allows alarm systems when required.
water to flow through the valve in to the compressor. When the compressor stops and the air pressure drops, the
wring doses the valve and shuts off the ooling wate’ supply. Who,, the comessor starts up again, the cycle is pp Two modes of ooeralior are avaiabe HAND anc AUTOMATIC’ With the starler selector swTcn the ‘AND 3051101
repeated. tie compressor is startec by means ot the START’ butlon.

Compror automatic controllers are available for use with one, two or three compressors. They are used in
conjunclion with suitable starters to control the sequence of comprsor(s) operation.

4/2
. .
4/3
.
 The nader/CCcIer drain valves Deng ef crmaIIy open ConStrucoOn. vent the Coolers
and ressure spaces of 6. Check stop Iv a visI fI nditor (wn fin) Ofl cIing wat pipeiis. Vaty
compressor wh!0 S stat:orarj and p1ev de ;JrioaGea SZartirg. shId be
wj. on arE the nditor rister a flow.
When The STAT’ bultor’ s pressed a time delay relay comes into oQerat,cn and after
approximate’y two S8CQr1c
adjusrabie up to five seconds) of the comresscr running unloaded the soreno:d vaFves close bring,ig Not., If the cudling water Ifrmn form an inverted loop, ensure that the cwnpror water ween am
the compressor
on load. vented of all air.

After apprcxmatey 5 m’ns. running (adjustable between I and 10 rrins,) the saencid valves oen to
drain condensa 7. Check that the machine is free to rotate by barring the crankshaft through at east
from th inter and after cacrers, ThS cycle is repeated wit,l the compressor is stced one complete
by means of (he sePector revolution.
being tur,ed to he OFF Dosition.

Wit me $&ec:cr switch ir’ me ALTO ost:cn starting ard StOcDilg of the :cmpressor * 8. If a water crcu!ating puro is fitted, check that bring gr.secs (it
any) are filled with wease and
5 cor:’ollea Dy a pessre It ensure bearings are ub,ited.
swjlch fitted to the recer,er The operation of the SOlerOd valves s as prevIojsly
descr’bed ‘Sr -IA\D cDeratc
The se’ecz,r swi:cn s :jrrec :c :10 QFF ;esi:on o ClCSe dcwn no Cdrzressor
g. carry out ntIal start up check of pr•me mover as ecommended by the manufacturer.
For full delails of any Qartrcuar panel reference shouJd be made to the instructions suphed with
the unit.

Ills
OPERATING PROCEDURE Starting (Manual Conuol Only)
I
CAUTION 1. 00 NOT ATTEMPT TO START THE COMPRESSOR UNTIL THIS MANUAL HAS BEEN I 1. Start prime mover. t tisa riable speed unit run up to ftl speed siowly.
FULLY READ AND UNDERSTOOD.
V —
2 Check oil prsIse. Unde, no circun,slans must this be allowed to fall below 0.7 bar. Shauld there be
2. NO ADJUSTMENTS TO THE COMPRESSOR, ITS CONNECTIONS OR FITTINGS MUST
a stden drop of oil prse, stop the nchino mmediately and refa’ to the fault ffridir du’t for
BE CARRIED OIJTWHILST MACNINE IS RUNNING.
prthablc a, rerrejy.
3. THE COMPRESSOR SHOULD NEVER SE RUN UNLESS ALL. PROTECTIVE GUARDS ri—
ON THE MACHINE AND PRIME MOVER ARE FInED. 3. Close first stage and second stage cooler drains in that order,ard compressor will comrrence io
operate.
fl
4. HEALTH & SAFETY Act COMPliANCE. BEFORe OPERATING THIS EQUIPMENT 4. Mjust pressure gauge cocks to prevent vibraflon of the pointers.
USERS SHOULD BE MADE AWARE 0F AND ENSURE COMPLIANCE WITH. THE
HEALTh AND SAFETY REGULATIONS AflRQPrnATt TO This CLASS OF WORK, 5. If automatic drains are not fiuj to the comprsor, ensure that the code drain .ilv are just
sufficiently open to allow the moisture depos4ted in the olers to rn. Without atttion to this
Checks B.for. Initial Run point an nuIsian ot oil ar v,ter will form on the suction art disctwqe eIv with detrrrital
—
results.
Becre start(ng the r.peno icr me first time cc after rr ntenan the toiIcwng chocks mUSt be tfl3C€.
fl 6. Atte, compressor has been running on load for some time adjust cooling wat flow to that remmaid
in nslIation Data. Section 3.
1. Check that all pipework nstaflatfon is complete and all r&evant pipework has been hydrotested.
fl
2. If work has been rried out on the prime moer (art there s any doubt about dWection of rotation of
prime mover) re-check the direction of rotation with the drive disconnected. fl
Staiing di. Caiwc,.a on At,tm.t Co.m,I
3. 1 the machine Fas De.n lyirq idle or some considonble Wne. f cankse and/or 1me nowr nave
-

Den movea, re-check ignment as indicated n Section 3

1. When per supply is ntroducJ to the control neI after it has been isolat (tar any ‘easorI the
manual re-set button for lock out alarrm Ut fiu) mist rlorrNIly be p,eed. Fo, full details of any
Comminioqing Procidu,.
exctØtiocn to this. rela to the iflslnjcton nansl suppIi wiih the contro)Ia
1. Check oil evel in the sump. PHI or top up as required to the rrximum level mark on the dipst,ck.
2. Set control panel swrch to automatic control. In the Auto stop/start mode the machine will start
Use onIV recommended lubrints.
atitomatilIy if ai, demand is required. Or, aut&continuous control the start button of the compressor
must be pressed for initial start-up.
2. Remove one valve at a thne from each cylirter and pour na small quantity of oil. This will ensure
.
equats lubriton of the ciI(rd do nitiat , 3. Continue from Point 2 in Pr&OUS Para9raph (Manl Controfl.
3. Re-fit valv ar ct’eck afl Ive ages ve been tightened to recommalded torque settings.
See Data, Stoppà,q U.. Compraic. (M.nu.I Control Only)
Sectii 1).
1 Unload the machine by oning the first ar second stage cco& drait, vaiws.
4. Check manual cooler drain vaIv. These should be open. One is situated at the
bottom of the first flags
cooler outlet cover and the other at the bottom of the second stage oIe outlet
cDer. 2. Purge the compressor coolers of condensate by running the machine for two minutes ott-load.

5. Chec& gauge cocks. These should be partially

open and are immediately below their rpecttve pr€ssure 3. Stop compressor. reaving hand drains open.
gauges. This preuton will ensure gauq are not darmged by any sudden inase
n pressure on start
up. 4. If cnmprescr 3 to be stopoed fcc any engtb of tmo it is oreferabte to isolate the cooling wacer supply.

4/4 4!5
 a.
Oil L.nt
ap
SECTION 5— MMNTENANCE
The oil level in the crankcase surnp must be checked daily. Do not attempt to rry out this operation whilst
a
the compressor is running. For a list of recommended lubrints refer to Installation Data Section 3.
C. MAINTENANCE SCHEDULE
Occasionally ease the drain DIug, situated near he base or the aankse at me free end of the machine Run Coimnistioning
off any water which may nave gatnaed bertatn The oil- This wat accumuiates from roistin in tr air arc
a. Period Non’n.l Operationsi Servn
varies greatly with working conditions.
-
a. 101w,. 6wks. 3mdn. 6mttn. 1 yr. 2yrs. 4yn.
Oil Pr.nut. Operation 10 hrs. 50 hr.. or or or or or
a. or or
Daily 150 ho. 50 bri. 500 Fin. 1,000 Fin. 2,000 his. 4000 Firs.
The oi pressure valve must be set to relieve at the pressure indicated in Data, Section 1 when the oil is hot. Check oil level in
crankcase X X
To alter the system pressure the oil pressure relief valve situated in the crankcase must be adjusted. For details
a. Check oil and air
see Sector 5 (Auxiiiary Equipme,t. c’essures ana gat.qe
a. :oc< setI:ngs X X
Cooling War Sy,un.
Clean air met Flier X X
A cylinder cooling water jacket safety relief valve is fitted to the compresso, and will operate in the event of
a. Clean and inspect
a,, air leakage or excessive pressure in the water spaca The valve is provided with a handle and should be lifted automatic valves X X
periodilly to ensure that it is free on it seat.
Lift water jacket
a. relief valve X
CAUTION: IN COLD CLIMATES WHERE THE COOLiNG WATER IS LIABLE TO FREEZE IF TNE X
Cear ‘rsoect anD
COMPRESSOR IS NOT IN USE, DRAIN WATER WACES BY REMOVAL OF DRAIN eset ar pressure
safety valves -
PLUGS IMMEDIATELY AFTER SHUTDOWN. ENSURETHAT WATER COLLECTING
ON ThE COOLER DRAIN VALVES DOES NOT FREEZE ThUS PREVENTING THEM Ct,eck operating
FROM FuNCTIONINa
as pre5sures and -

temperatures of all
as automatic protection
Al, Pressure Safety Valves
devices (if titled) X X
the air safew valves ‘,tted to each stage are set durng assen,blv to blow at iO% above working oressure.
They
a. Check autanatic sequence
are of the Ion-freeze. SOD acuon type ana will rnmodiately reseat as soon as excess pressure is relieved It these ot compreor n all
valves operate for any unknown reason, stop the compressor and refer to the fault finding chart for robable 91eS :tapplcable) X X
‘aut aria rer’ecy.
Drain and- :nspect
crankce. Refill with
new oil X X
a. Clean and inspect
delivery line non-return
a. valve X X
C€an ana inspect all
valves, valve seats and
0-ring sis. ReØa
as as necessary X
a. Fit new fusible plug X
Fit new by-pass oil
a. filter X
Cck conoition of
holcinq own noits and
lLscas-9ecsary x
Check cDmpressorprime
mover alignment and
aS adjust as necessary X
aS Clean coolers and
water paca X
as SviD ano rflSure
moving carts for wear X
as
am
4$
a. 5/1
 n
FAULT FINDING CHART
n FAULT FINDING CHART (Cont’dj
n
FAULT PROBABLE CAUSE REMEDIAL ACTION
FAULT PROBABLE CAUSE REMEDIAL ACTION n
Excessive oil Carryover Ensure that oil control pision
2nd stage rerief valve Stop valve in compressor line Open stop valve. from 1st stage piston. ring at the base of 1st stage
blowing. cioseJ. n pston is not worn Cr slack in
n iTs gr-oov and tiat the oU noles
Reservorr system kjl. Stop consor. n :r grocve are not uocked.
n Renew parts as necessary.
Rd ef valve faulty. nspect valve.
Incorrect pressure switch Check setting. Excessive moisture in Check the oinls between
settrg. passages. cylinder biock and 1st and
n 2nd stage beads are tight, and
1st stage relief valve 2rd stage suction Cr delivery Cean and inspect valves. ..6e cocer drain cocks as
blowing- damaged or dirty. renew any broken parts. detailed in ‘Stariing Up’’
instructions.
Relief valve faulty. Inspect valve
n Din drawn into conloressor. Per4nrrn Routine Maintenance
Overheating of compressor. Cooling water flow incorrect. Chect cooling water flow.
n on air tIter.

Blockage of coolers. Clean and inspect coolers. Overheating at aIr delivery. Cooling system not function- Check flow indicaior. Open stop
n ing properly. valves, clear b’ockage or prime
Overheating of 1st stage. 1st stage valv damaged or Clean and inspect each valve. pump.
driy.
Overheat.rg in crankcase. Prolonged running with See Orev’OuS fault.
Ovwheating of 2nd stage. 2nd stage vaIv daraged or Qean and inspect each v&ve.
a previous fault.
dirty.
n Knock in motion work. Slack connecting rod or main Adjustor renew the bearing
Compressor will not operate Valves damaged or dirty CIn and inspect valve and bearings,
fl concerned.
at ?LI prure is reduced pacity indita renew all b,oken parts.
operating at reduced trouble with 1st stage vaIv. Low oil prure. Inlet strainer choked. Remove arid Gean by washing
pacity. n in petrol. Allow t to &ain.
then dry before replacing it.
Leaking piston rings. Ensure that rings are free in n
groov. Renew worn or Insufficient oil in crankse. Check oil Level, top up with
distorted rings.
n cart vade ci oil, if necs
y (see Recornm€fld
E,tcessive cylinoer wear. flachines fitted with liners. Li.trintS).
remove and renew liners,
pistons and rings as necessary.
—Hi• Pipe broken in oil system. Replace pipe.

Speed low. Chock comoror speed and

n Oil p&gro driving chain broker,. Replace chain.
adjust
n Oil pljcrp ‘equires overhaul. Overhaul pump (S* Section 4}.
Blocked suction filter. Clean filter.
Bearing clearance excessive Renew bearing(s).
Unloader faulty. Check operatIon of unloader
syst e rn Air delivery me Darriaged seat& Dsflan1Le, cean, and ‘.ap in
non-return valve leaking, valve faces and valve to valve
Frequency of vawe Overheaiin Keep valves, piston rings and n botsing seat.
neintenance excsiva cooling water system in good
working order.

Blocked si.ction. Inspect and c!ean suction fiIt.

n
n
I 5/3
5/2 -I
 n
n -I
ROUTINE MAINTENANCE
n >
WARNING 1. MAINTENANCE MUST NOT BE CARRIED OUT ON THE COMPRESSOR
I.
4 •10
WHILST IT IS IN MOTION. ‘ e o I- 0 —— — e
n 0
2. BEFORE CARRYING OUT ANY MAINTENANCE ON THE MACHINE, THE z-.
COFIWRESSOR MUST BE STOPPED AND ISOLATED MECHANICALLY AND
n
ELECTRICALLY. AND VISIBLE WARNING NOTICES DISPLAYED.
n 50
II
3. WHEN WORK IS TO BE CARRIED OUT ON WATER AND/OR AIR PASSAGES Iii W

THE COMPRESSOR MUST OE VENTED OF ALL PRESSURISED AIR AP

n La
DRAINED OF COOLING WATER.
n C <2
4. HEALTH & SAFETY ACT COMPLIANCE. BEFORE OPERATING ThIS : >
tiLut
‘ —
EOUPMENT USERS SHOULD BE MADE AWARE OF, AND ENSURE
n NO 00
“C)
COMPUANCE WITH. THE HEALTh AND SAFETY REGULATIONS zz g
APPROPRIATE TO THIS CLASS OF WORK.
n S 0
0< -J
e.tfl, v—— 0 :—t t
—‘I — C •
• Cuc)- -—
• 20002 —
Genni o U_..J-iC
a.>
o 0
n wz z
Rout:ne maintenance of the comoreo, shoula be carried out at the intervals isted in the %1aintenan E
. 0.
Scneaule, page 5/1. Procedur to Ce aoopt for routine maintenance are detailed Jnd the approiate
heading, in this section.

Before re-assembly at disrnant components, all pats must be thorot4ily ciear with k&osene or gasolene
I
,d all pars examineo for wea. corrion, cracks, distortion, or any otj,e damage and be renewed as ne&y.
Reference should be made to the wear ,olers given in Data. Section 1. f dimensions of the appropriate
n en
wearing ten’s are close to bun excess of these reco.rnrreaed it nay be aoproiate to reolace them at this
z—z S ,
-

ti me.
n
E E’t
All joints, gaskets, and ‘0-ring seass should be examined for sa-viceability and renewed as thoht nery. E 4w’’

n ..
S
When re-embIing comoressor oompon,ts ensure that all flat faced joints, solid copper rin and ‘O’in Ih
ace refitted. In any opaiton concerning the att great care riust be taken to ensure that they ale riot n • iaa3
o >>ODtn
damaged. If they are dar’aged in any ey durng semblv they must be renewed. Solid copw rirL, if in
0
gooa condition. can ne re-tied provided they are annealed ocsionaiIy by heating and quenching. z
n
It is ecy impocv2nt wt,en replacing joint apecially cy’inda hd joint) that the correct thickns and ty of
jointing is used to maintain the correct assembly ciearans.
n
n a
Automatic Valve.
2
When servtcing a suction or delivery valve, withdraw, clean, inspect and refit valve, one ala time. This will ensure n 2

that an valves and valve cages are refitted in thew correct valve pocket,, failure to ensure this may resuLt in the -

developmenc of a hazardous situation. n

II a
o
2
CE
CC
=
00
C
.9
Suction Valve (S.. lllwntlaM) a .Sz =3 SC C
.33
1. Remove cap head scrs (2) or (309) securing the valve cage (261 or (307). 0 ,cZ>-s,J

z0 C
S — N C4
2. Withdraw the valve cage taking care not to damage the 0-ring seal (2641 or (310).

3. Screw valve extractor tool to the prouuding end of valve centre bolt and withdraw the valve assembly C’, ‘—

(262) or (308) from its seating. n — ‘0

pp
Note: On cerln valves a wit locking nat/s us (a renh the manbly in place ate áotd nut arid wilt pin.

5/4 5/5
 n
Air Filter/Silencer
4. Take out the split Din. if fitted and. wsaew slotted or self-locking nut from the valve bolt.
To clean and lubrite the air tutor element 259).
5. Withdraw the washers and plates from the centre bolt. At the same time note the method
and order of
removal of each valve component to facilitate correct re-assembly. Reference should always be
made to 1. Remove the round headed screw at ar ntake end and withdraw the element.
the illustration of the valve being sembled to ensure that the components are rebuilt in their correct
order. This is essential to correct oparatioriot the valves. 2. Wash the element in a suitable solvent and allow to drain.

6. ‘
Clean all components thoroughly. Remove gene and carbon deposits with a soft briah usirg
a hot Immerse the ele—ent 9 li.tricating oil and acain allow to drain.
water and sods solution. Care must be taken during the cleaning operation as any surface scratch
may fl
use leakage and uItirrtely a breakage. Refit elenEnt ruo si err and secure with Strew.

7, Each component should be inspected and any items which appear defective, worn, or damaged Topping Up Crankcase Sump with Lubricating Oil
should
be renew.
1. Stop machine and allow oil level to settle.
The valve plate and valve seat can be lightly “lapped by means of a fine carborundum
ste. Before
re-assembly dean all ctmpor.nts and erure flat all traces of grinding pasta have been removed. 2 Drain any water accumulation in t crankcasa sump.

Not., The prdpn n,etflod of anying out thb ntkn ii to lIghWy “tw” the pth plate and 3. Cheoc oil level and fiN to r”ax,mum mark indicated on dip-stick.
vWbsnt sawin plate ltthooWbsaw.n,d that, Ms, this opration is complete, the
iu,facee ,e “tiar when un um., condition. Gil Filter and Cr.nkca. Sump

8. Assemble valve components in reverse order to their removal, fit the nut and tighten to the torque To drain and clean o-ankse sump, replace oil filter and refill sump with clean new oil.
setting shown in Data. Section 1. If nut is not of the self4ocking type fit a new split pin.
1. Remove drain plug (110) and washer (111) located at the bottom of auxiliary drive cover, and drain the
9. Check that the valve can function curactly sit that p’ate movement exist,. Extreme care must be oil from the sump whilst the machine swarm alter having been run ¶ot some time.
taken to emse that the valve plate not saaçed or damaged during this operation,
2. Remove ankcase doors (115) and joints (II 6)and clean out any residue in the sump.
10. The valve aently should be lightly larwied’ to it, ting in the valve pocket with a fine thccundum
a
3. Take out the inlet strainey 131 and wash in a suitable solvent. Allow to dry and refit. Ensure that the
—
paste. Clean valve assembly and valve seat thoroughly arid ensure all traces of grinding paste are removed.
joint washer is fitted and that all pipe connections are fully tightened.
11. Replace valve assembly (262) or (308) in cylinder head.
———

4. To change it,. oil filter disconnect the union nut (42) from the filter inlet connection. Loosen the filter
12. Place valve cage (281) or (301) in position, takinq care not to damage the O’.ing seal clamp screw nut (4) arid withdraw the filter from the damp ring.
(264) or (310).
Fit retaining cap l scran (263) or (34) arid tighan them uniformly to the recommende
d torque Trarsler the filt inlet nnection (40) and outlet elbow () to a new filter. Erse that the joint
settings (see Data Section 1).
fl washer is in position. Fit new filter (38) in the damp ring aM tighten nut and setscrew. Re-connect
DdLvery Valve (I.e llwfldaa) union nut to the filter inlet connection and a,sse all connectiom me tight.
fl
7. Remove valve cage screw cap nut (271) or (325) and joint washers (272) or 5. Position joint washer on drain plug and re-fit plug in the auxiliary drive cover.
(326) and relieve valve cage
screw (270) or (324) by several turns.
6. Fill the crankcase sump with clean new oil of the correct grade as indicated in the ta, Section 3.
2. Remove cap head soews (273) or (327) retaining the valve cover (268) or (322).
a
7. Check that crankcase door joints (116) are servic2ablo. re-fit doors (115) and secure with wring
3. Remove valve cover and velve cage taking e not to damage O’-ring seal
a
(2) or (323) on valve cove.
Proceed as for items(S) to (11) indttve, for nninteswnca
Air Coolest (General)
4. Place valve cage arid valve cover in position taking care not to damage fl
the ‘Orlng seal (269) or (323). Both first and second stage coolers are of the straight, through tubular ty and are housed in the cylinder
Fit retaining cap head soews (273) 0e (327) and tighten them uniformly
to the recomn,ended torque block. They are arranged for easy withdrawal to facilitate cleaning and inspection. It is important that the
settings (see Data. Section I).
elements are cleaned both inside and out at regular intervals, the frequency being dependent upon the
5, Tighten vatve cage screw (270) or (324) to the ro©mrnended torque condition of the coding water being used. Failure to maintain the coolers in a reasonably clean condition
setting and fit the joint washer fl can result in exceive temoeratures in the comprsar air pasga. Carbonition of the air passages will
(272) or (326) and cap not, (277) or (325). Tighten the wlve cage ew p
nut to the recommended cur with resultant damage to v,lv. cadets etc.
torgim setting (see Data. Section 1).
Scale on the outside of the coder tithes arid in the water jackets can be removed by a strong solution of hot
Nfl F&a cm ttflflltiancamme,dW that ii ca, heed damn are fidy ,jg, g.e. sa or a proprietary decaier. The internal surface of the cooJers can be cleaned with a tlexbte wre brush.
,slswnt anti-nm can,pou,fl

n sf7
516
 Defective tubes must be renewed: if cares taken when drilling out faulty tires it is possible to expand
Second Stag. Cool.,
repIacem-.ts nm the same tteplates. The ends of the tubes to be exçended must be annealed by heating
and ouenchng. After reo4ace’Nnt of any tubes, me tune banks with covers, must be hydraulically tted
Removal of Second Stag. Cooler. To withdraw the second stage cooler tube assembly
to rwi the stage working pressure of the comprsor, from the cyinder olock
oroceed as foilows:
First Stag. Cooler
1, Remove the flywheel guard.
it
Removal of First Stage Cooler. To withdraw the first stage cooler tube assembly from the cylinder block
2. Drain the cooling system by removing the drain plug (241) and washer (242)
situated on the sides of
proceed as follows:
the cylinder block.
Remove flywheel guard. 3. Disconnect the drain pipe (833) from the cooler drain block (815).

2. Drain the cooling syste- by removing me drain plug (241) and joint washe (242) situated on the & Disconnect the second stage gauge air ppe (912) from the cooler delivery covw
sice of the cylinder block (145). (210).
Ta 5. Remove nuts 336) and setsa-ews (334) securing the air pipe (331) to the second
3. Disconnect the drain pipe 828) from the coo4er drain block (815). stage cvlincer head
(302) to the secona stage cooler delivery cover (210).
4. Disconnect the L.P. gauge pipe (911) from the coa[er outlet cover (193). 6. Remove the pipe and joints (332).

5. Remove nuts 336) and setscrews (334) securing the air delivery pipe (331) from the first stage cooler 7. Disconnect the main air delivery pipe fton, the cooler delivery cover.
outlet cover, to the second stage cylinder head. Remove the pipe and joints (322) and (333).
8. Remove the nuts (224) and (228) and spring washers (229) securing the cooler return
6. Remove the nuts (1871 and spring washers I88) seqsing the outlet cover (193) to the cooler diaolvagm we cover (222);
remove code, return cove, and joint (225) and 1226).
1195)/cooler tubeplate asser.bly (178) and wittraw the outlet cover, taking care not to darroge the
n’et diaphragm (195). 9. Remove the nuts (214) securing the delivery cove (210) to the ttibeplateand remove the
delivery
‘p cover a.-id joint (211).
7. Renove the nuts (201) and spring ivashers (202) remining me dapivagm sling ring (198).
10, Remove the nuts 218) and spring washers (219) securing the diaphragm sealing ring (215)
to the
8. Carefully remove diaphragm (195) and both joints (194). cyfinder block. Remove the sealin9 ring, diaphragm (212) and joint 1211). king care not
to damage
the thin metal diaphragm.
9. Remove the bolts (183) and setscrews 190) and nuts (184) securing the cooler inlet cover (179) to
the cylinder block and withdraw the inlet cover and joint (185). 11. Wthdraw the cooler assembly (209) from the non-drive end of the co,nprsar.
p
10. Withdraw the code, assembly (178) from the non-drive end of the compressor. The co&er assembly can now be inspected and cleaned as detailed in the iragraph headed Air Coolers
Genal at the bottom of page 5/7. Defective or dangod con,Qonenn mwt be renewed. The cylinder
The cooler sembly can nw be inspected. dned and defective damaged compornts renewed as required. block in the region of the cooler must also be inspected and cleaned of any flIt or dris.
The cylinder block in the region of the cooler should also be inspected and clned of any sale or dr,s.
Re-.matfy of Second Sag. Cool.,. To re-fit the second sage coder tt.be aanbly in the cylinder block
R.-wa....bly of First Stag. Cooler. To re-fit the first stage cooler tube aembly in tt cylinder block procd yP
proceed as follots:
as follows:
1. Position the cooler assembly (209) in the cylinder block from the non-drive end of the machine.
1. Position the cooler tube assembly (178) in the cylinder block from the non-drive end of the machine. -

2. Fit the coaler return cover tubeplate joint (225), cover joint (226) and cover (222) to the machine
2. Fit inletcover joint (185) tubeplatejoint (180) and cover (179) and securewithspring washers (188).
and secure with nu (224) and (228) and spring washen (229).
nuts (187). bolts (183) and setsae’ws (190). tip
3, Fit tubeplate joint (211), sealing ring joint (216). diaphragm (212) and saling ring (2151 and secse
3. Pla ttk,ecbte joint (199), sealing ring joint (194), diaphragm (195) into position arC secixewith with nuts (218) and spring washers (219).
sealing ring (198), spring washers (202) and nu (201).
4.
4. Fit joint (181) and outlet cover (193) on tubeplate sttCsand sacurewith retaining nuts (197).
4a Pition the delivery cove- saint (211) and delivery co’ (210) on the studs and fit retaining nuts (214).

n 5. Pttion the main air delvery line joint and re-connect the main air delivery
5. Re-connect the cooler drain pipe (828) to the drain block (815). pi to the outlet cover,

6. Pition the cylinder head joint (333) and cooler delivery cover joint (332). Fit the air pipe (331) and
6. Reconnect the LP. gauge pipe (911) to the outlet cover connection. secure with nut (336) and setsaews (334).

7. Fit drain plug (241) and washer (242).

.4a
7. Connect the second stage gauge air pipe (912) to the outlet cover, and the cooler drain pipe (833) to

8. Re-fit air deUvery poe (331 and joints (332 and 1333) between the delivery cove, and cylinder he.
4a the cooler drain block (815).
Secure with setsaews (334) arC nuts (336) 8. Refit the draTh plug 1241) arC washer (242).

Sm
5/9
 n
to
0
C n
z Item No. Daaption Qtv. It.i Na Dci flon Oty.
C

S
I
n 178 1st Stage Tube Nest Assembly 213 —
Studs: Cover Tubepiate 6
0 179 Coo’er Inlet Cover 1st Stage 214 Nut : 213
S. fl 6
C, 180 —
Joint Cover Tubeplate 215 Diaphragm Sealing Ring
a 181 —
Studs Cover Tubeplate
E 2 216 Joint
C, n
‘I 162 —
Studs Cover Tubepiace 2 —
Diaphragm Cylinder Block
83 —
Bolt. Cover Tjbeplate -
2 m Cooler Return Cover 2nd Stage
n 184 Nt 4 225 —
Joint : Cov& Tubep!ate
185 —
Joint Cover Cyinder Bock 226 —
Joint : Cover Cyinder Block
185 —
Stu Cover Cyinder Block —
8 221 Stud : Cave Cylirder 8lack 8
187 Nuts: 186 8 228 Nut: 225
n 8
188 Spring Washer : 187 8 229 Spring Washer : 227 8
1 89 Joint : Cooler Cover — 231 Fusible Plug
n L.P. Cylinder Head 1 232 Washer
190 Setscrew Cooler — 235 .
Relief Valve 2nd Stage
n LP. Cylinder Head 2 236 Joint Washer
193 Cooler Outlet Cover: 1st Stage 1 329 F!ange: 1st & 2nd Stage Air Pipe 2
n 194 Joint: cover— 332 —
Joint : Flange Cooler Covers 2
—
—
Diaphragm Tubevlate 2 334 Setscrew: Flange Cooler Covers 4

(N
I fl
195
96
197
198
Daphragm: 1st Stage Cooler
Stud: Cover —Tuoepa1e
Nut: 196.
Diaphragm Sealing Ring
B
5
1
806
807
809
Drain Valve: 1st Stage Cooler
Adapter Dr&n Jalve
Joint Washer 806
Drain Vaive : 2nd Stage Cooler
199 Joint: 811w Adapter
—
Diaphragm Cylinder Btock 1 812 Joint Washer :811
n 205 Relief Valv€: 1st Stage 1 915 Stud Coupling: L.P. & H.P.
206 Joint Waw :206 1 Ceder Covers 3
n 209 2nd Stag. Tube Nt Assembw 1 916 JontWa,er :915 3
210 Cooler Delivery Cover : 2nd Stage 1 Fl Coaler Tubeplate:lst Stage 2
211 Joint: F2 Cooler Tube, 15
—
Diaphragm Tubeplate 2 GI Cooler Tubeptate 2nd Sage 2
212 Diaphragm 2nd Stage Cooler 02 Cooler Tubes 33

n
n
n

n
n

4s
5110 5/11
 41

Compitior Not in US.

‘4w Coniprenor Dinn.rntrnç Procedure
The runnng and standby compressor shou’d be IIernated weekly If rly compressor snot being regularly
operated ii should be rotated wkly by barring’ the tlvwheel round by at least one revolution. The following procedure must be adopt when completely dismantling the compror.

OVERHAUL OR REPAIR OF COMPRESSOR Removal of Second Stage Cylinder Heed

WARNING 1. DO NOT ATTEMPT TO CARRY OUT REPAIR OR OVERHAUL OF COWRESSOR WARNING: OBSERVE THE SAFETY PRECAUTION WARNINGS AT THE BEGINNING OF THIS
UNTIL ThIS MANUAL HAS BEEN STUDIED. SUBSECTION: BEFORE COMMENCING ON THE DISMANTLING OPERATIONS.

2. BEFORE COMMENCING ANV OVERHAUL OR REPAIR WORK A PRELIMINARY S 1. Drain the ccrrpresso of ccoling water by en’ovr drain plu (247) and 241) and wasner 242)
CHECK OF AVAILABLE SPARES SHOULD BE CARRIED OUT, E.G. REPLACEMENT situated on the siaes of tie winder clock.
SET OF JOINTS OR JOINTING MATERIAL
2. If fitted. ‘emove thwnorn.e:er (gee), therrometer pocket (969) and tee plece 973).
3. ENSURE THAT THE PRIME MOVER HAS BEEN ISOLATED AND CANNOT BE
STARTED INADVERTENTLY. 3 if fitted. cisconnect temperature switch (841) and remove it from the comp-eor.

4. THE COMPRESSOR AIR DELIVERY LINE SHOULD BE ISOLATED AND ALL AIR
n
4. if fined, dsconnect and remove the two air pics (802) and (796) from the conpessor unloader
PASSAGES VENTED. (781) to thesecond stage cylinder head.

5. COOLING WATER INLET AND RETURN LINES SHOULD BE ISOLATED AND THE fl 5. Dsconnect the cooling water ouflet pine (767) from the cylinder had.
COF.WRESSOR WATER SPACES DRAINED.
fl 6. Remove the nuts (336) and setscrews (334) securing the air pioe (331) from the first stage cooler
6. WHEN USING LIFTING EQUIPMENT TO DISMANTLE THE COMPRESSOR1 ENSURE delivery cover to the second stage cylinder head and remove pipe and joints (332) and (333).
THAT IT IS ADEQUATE FOR THE LOADS INCURRED. THE CORRECT LIFTING fl
POSITIONS AS INDICATED IN THIS HAN0600K (SECTION 3) SHOULD BE T Remove the nuts (336) arid setscrews (334) securing the air pipe (331) from the snd stage cylinder
ADHERED TO AT ALL TIMES. fl head to the second stage inlet/delivery cover and remove pipe and 0mm (332) and (333).
General
8. Disconrtct the first stage and second stage air plessure gauge pipes (911) and (912) and the oil pressure
The comprezor ,ouio be ru’ariy overhauiad in accorcance wilt me ‘mintenance scitedule which will be
gauge pipe (913) and water gauge pice (914), take out setscrews (925) or (932) and remove gauge support
found at the beginning of this Section.
bracket (924) or gauge board 929) complete with all gauges.

The following sit sentlies or components can be removed from the comprsor without completely fl 9. Remove the cylir,der hd securing nuts (305) and withdraw the cylinder hed (302) from the studs by
disrrn1iinq the rrine.
ifting vvly.
1. AulorreticV&veAssernblies
2. Ar Coojer Assemblies io. Remove water hoJe joint wasJ’ers (303) and joint ring (158).
3. Water Pump Asseritly (f fitted) fl
4. Oil Pump Assembly Removal of First Stegi Cylind.. Heed
5. Unloader Asseritly (it flnec) fl
6. Silencer/Filter Asseritly 1. Remove c,’ankoasedoo,s (115) and joints (116): bar thecompossor until the sLod stage ‘rank isat
7. Oil F;iter Ascthly fl the bottom of its stroke.
8. Oil Relief Valve Assembly
2. Air Relief Assentlies fl 2. Remove the fasteners securing the flywheel guard to the baseplate and remove the guard.
10. Water Jacket Relief Valve Assembly
II. Auxiliary Indication and Protection Devices fl 3. Disconnect the actuating air supply line to the compsor unloader at thestud coupling (794)
12 Bg End Bearings (it fUedL
The dismantling and reassembly produres far all the above assemblies are detailed later in this section und n
the heading AndIIary Equipment. 4. Remove the nuts (287) and spring washers (288) securing the silencer elbow (285) to the cylinder
head. Withdraw theelbow completewith silencer and unloader (if fitted).
When rrying out repair, overhaul or inspection of the following items of equipment, twill be necary to
proceed as detailed in the compressor dismantling procedure until the required components have bn removed: fl 5. Remove the nuts 154) acid (187), bolts (183) and setw’ews (190) and spring washers (188) securing
1. CyHnder Heads and Joints the first stage inlet cooler cover (179) and withdraw cooler cover and joints (185) and (189).
2. Cylinder Blocks and Liners
3. Piston and Connecting Rod Assemblies 6. Remove the nuts (256) securing the first stage (L.P.) cylinder head (253) to the cylinder block. The
4. Crankshaft and Flywheel Assembly fl cylinder head can now be lifted vertically from the second stage piston and first stage cylinder black.
5. Crankcase Assembty
6. Comprsor Main Bearings NOTE: irmusebe ensured that rh/s I/ft/s vertical and the head conctIy ba/axed, otherwise the
second rnge piston may be seriously damaged.
Once inspection or overhaul of the components has beer, completed, the re-assembly procedure indicated later
in this section should be commenced at the appropriate stage. 7. Remove Cylinder head loint 25O

6/12
a 5/13
Remova of Patom .nd Connecting Rods
‘is 5. Remove the nuts (148) from nside the a’ankcase and liftoff the cylinder block (145).

Second Stage Piston Assembly 6. Remove cylinder block oint (151) and two locating buttons (1w).

1. Remove seccnd stage conrectirig roO botmm end bolt split pins (167k Flywhed/Cnnkthaft Anembly

NOTE the series of identification mat*s a’ the connecting ,ocf boithead. cannwtir,g rod To withdraw the flywhe and aankthafi asse.r.bl i it is necy to remow the machine from the p’in*
connxnng rod cgp .d Waned nut Thne components must be replxai in The identical ri-ova. This can be carhed out before co’nn*ncement ot the dismantling edure of at this stage.
positions as found on removal.
1. Withara-w :ne tlywheei key 138).
2. Re’ncve ‘he sctted ruts (C3) ana bearing caD (Cl) whch is located by a p n (CB on tie rriatirg
surfac of the connecting rod assembly. 2. Withdraw flywhee’ 134) and remove drive end bearing cover (94) and joint (95) from shaft taking
care not to damage the oil seal.
3. Remove the remaining bearing half lEner (C?).
3. Remove nuts (818) and withdraw the drain block (815) complete with automatic drain tram (819)
Screw an eye bolt into the tapped hole n the top of the piston (El) - e * and fittings.
4.

5. Carefuily withdraw the piston assembly (175) from the.cylinder bore. 4. Disconnect thewater pump inlet and outletcompanionflanges (765) and (766) (if pump fitted)
I
and remove pump outlet pipe (767) and pints (762).
CAUTION: IT MUST BE ENSURED THAT THE CONNECTING ROD DOES NOT FOUL
THE CYLINDER BORE ON REMOVAL 5. Remove securing nuts (107) and sprng washers (108) and withdrawauxiliary drive cover (103)
fl complete with water pump (750) (it fitted) and joint (104).
-

6. For dismantling procedure of the piston assembly, refer to the section on ancillary equipment and
sub-assemblies, 6. Remove oil pump drive chain (24).

Fint Stag. Piston Assembly fl 7. Disconnect the oil system supply pip (81), (82), (83) and (84) from the banjo couplings (70) and
(71) on the main bearing caps (A2) and (A3).
1. For removal of the first stage piston assembly, an identical procedure to the removal of the second
stage piston should be followed (Procedures 1 to 6 inclusive). NOTE: Identification marks on each mEn bearing cap *1/tat. ,e-aseirnbly.
—y

First Stag. Cvlind., “Wet” Line, 8. Unscrew bring cap nuts (A6) and withdraw the bering caps.
V.
The first stage cylinder ‘‘wet” type liner is located by one ‘0-ring 160) at the upper end and two ‘0-rings 9. Lift out crankshaft (7) from crankcase (1).
(161) at the ower end. It can be removed by pulling from the first stage cylinder block. This is most easily V *
achieved by the use of suitableextraction equipment. 10. Remove main bearing half liners (4) from each bearing cap and crankcase housing and store in pairs
fl noting relative position of the bearing. This wiI facilitate corrt assembly of main bearings if ro-us.
Second Stag. Buff. “Wet” Line
fl 11. Rernovetfirtt half whers (5) from the centre bearing.
me second stage Duff. cyhnder ‘wet’ type liner is located by one 0-ring (162) at the upp end and two
‘0-rings (163) on the lower end. It can be removed by pJlling from the first stage cylinder block. This s fl Dismantling of thecompresso’ is now comete,
most eily achiesed by the te of suitable extraction equipment,
Cleaning and lmç.ctioa
Second Sag. Cylind. “Wet” Line
-
fl Once the compressor is compietely asrnantled, all components should be thoroughly clned, and impected.
The second stage cylinder “wet’ type liner is located by one ‘O’-ilng (164) at its lower end and by a cooper Wnrn parts must be replaced. All oints and 0-ring seals should be checked for serviceability and renewed if
washer (158) under ii,. upper spigot lotion It can be removed by pulling from the second stage cylinder 0 nesary, 411 ‘O’.irig seals must DO carefully identified to ensure correct replacement after inspection. The
block. This is most easily achieved by the use of suitacle extraction equipnwlt. oil pump chain drive and sprockets should also be checked for signsof wear or damage.

—
First Stag. Cylind. Block Dirrensional checks on all rotating parts must be carried out, and comred with figures supplied (ta Section
Recomr’ended Renewal Clearances) and parts be replaced as nery.
1. Rentve the drain pipe (626) and (8) from cooler covers.
CAUTION: IF THERE IS ANY DOUBT AS TO ThE CONDITION OF A COWONENT,
2. Disconnect cooiing water inlet pipe (167) and the ‘rain air daivery IN PARTICULAR THE SHELL BEARINGS, IT MUST BE REPLACED.

3. Remove oil drain plug (110) and washer (111) and drain crankse sunlp of oil, Assembly of Comp.nsor

4. Remove nuts (97) and spring washers 98) and withdraw drive end bearing ccv. (94) and loint (95) CAuTION: IT IS ESSENTIAL THAT AtL COMPONENTS ARE CLEAN BEFORE
along the crankshaft clear of the cylinder block. Care iouId be taken not to damage the oil seal (99). COMMENCEMENT OF ASSEMBLY.

5/14 5/15
io asserTtJle the compror from individual components and SubassentIj ‘oceed as follows: 5. Fit and tighten oil drain plug (110) and washer (111).

Installation of Crankshaft and Flywheel Asiembly 7. Attach the water pump outlet pipe 1767) to the cylinder block and secure it to the pump with joint
V (762). plain washers 764) alt setscrews (763). Cormect the fir air delivery pipeand joint.
1. LighTly lubricate each nan half cearr snell {4).
S 8. Re-ft drain pipe (833) to cooler (second stage) ard tighten connections.
Z Locate and fit each haf bearing sti& to it respectve oankcase .nousng or bearirg cap, f used
bearinqs are employed they must be replac in mesan,e relative posilion as removed. W W Aen’cly of first stage cylinder biock is now complete.

3. Fit thrust haif washers 5) to ceqtre bear;rn. W V Pint Stag. Cylinder Wet’ Liner

4. Lightly lubricate the crankshaft brinq surtaces with oil. W V The first stage cyl nd€r liner (153) cn now be refitted to the first stage cylinder block by lightly greasing
upper (160) and both lower (161) ‘0-rings and lightly pressinq into position.
5. Position crankshaft (7) in crankcase (1. W V -

Second Stage Buffer ‘Wet’ Liner

6. Locate the bearing caps in their respective crankcase housings and secure with bearing cap nuts (A6).
These must be tightened uniformly to the torque setting recommended in the Data Section. The second stage buffer cylinder liner (154) can now be re-fitted to the first stage cylinder block. Lghtty
- S V grease upper (162) and both lower (163) O-nngs and lightly press into position.
7. Re-connect the oil system supply pipes (81), (82) and (84) and banjo connections (70), (71) and
joint washers (72) to the main bearing caps. Second Stage Cylinder ‘Wet’ Liner

8. Lightly lubricate thedriveend bearing cover (94) and joint (95) with grease, and locate on studs The second stagecylinder liner (155) can flaw be re-fitted. Fit copper washer (158) to the lower end of
taking care not to damage theoil seal 99). Do not secureat this stage. liner upper flange and lightly grease lower ‘0-ring (164). Press into position in thesecond stage cylinder
0 block.
NOTE: Ensure that the oil walls not damaged when inserting over the wrn,kshaft keyway.
0 NOTE: Liner will pro vi,de from the lower fre of the and stagecylindm block. it/s used for spigot
9. Re-fit oil pump drive chain (24). locatIon of the second stage cyl inde, block to the fint smg.cylirzder block.
0
10. Locate auxiliary drive end cover (103) and joint (104) (completewith water pump, if fined) on Fitting Pistons and Connecting Rod Asiamblies
studs. Secure with spring washers 108) and nut (107). 0
First Stag. Piston Assembly. To install a first stage piston and connecting rod:
11. Connect the water pump inlet flange to the supply pipe and secure with joint (762), plain washers
(76.4) and setscrews (763). Do not fit thewater pump to cylinder block at thisstage. 1. Ensure that the piston rings are free in their grooves and lightly lubricate the piston and rings with
0 oil. Position the rings so that the gaps on adjacent rings are 180° spat.
12. Locateand fit drain block sub-aembly 1815) and securewith nuts (818).
0 2. Locateand fit bg end bearing shell half lins (Cl) in the connecting rod and bearing cap (Cl) with
13. The flvwhod (134) and ankshaft keywaysshould becarefudly d,burred and the flywhe me lug on the lines fitting in the notch ri the rod and cap.
on to the cranktaft. Befe fitting fl flywhe ensue that the keyway alignneit is correct. The 0
flywhed w be drawn on to the theft with the aid of the tapped hde in the crankshaft. NOTE: If a tsbenw fined. a’wsre that the half mien nlocataj in the sa’ne
0 ,a’atlve position — bairn their ,wnovt The pkton, if ,..seo n?wt *0 be fitted in the
14. Drive in a new taper key and cutoff flu, to the flywheel. SM the crankshaft (136) by at east W79 ra’atvepait,on — baton ,e,,avt
reydution to isLye that the assembly i5 free to turn- Flywheel and crankshaft essently is now mete.
The nline can be re-located to the prime mover, if desired, or this can be carried out on completion 3. Lightly lubricate the bearing half liners with oi[
of the asserrtly procedure.
-
NOTE: To facilitate the cor,ttliftlng of the piston and connecting rod membly, a pp’ hole
Am.nbly of Firn Sag. Cylinder Block to Cranka.. is provided in the &‘p ci the piston for fitting., eye bolt

1. Lidy grse crankse joint (151) and locate on aanke (1). Ensure that the locating buttons 0 4. Lower the first steconnecting rod through thebore in the cylinder blocg, eking extreme care
(150) are in Position, not to foul the cylinder wall or damage the p.ston rings.
0
2. Carefully lower cylinder block (145) into pition on the locating buttons and aankse, 5. Locate comecting rod beating on ctankthift, and locate and fit bmrirq cap to the connectIng rod.
Erure that all identification ,raks are correct.
3. Ensure that the machined face of the cylinder block at the drive end is lined up with that of the
crankcase. 5. Fit connecting rod bolts (02) and slotted nuts (C3) and tighten to the torque setting as detailed in
Section 1, Data.
4. Fit joint (95) and drive end cover (94) on studs and secure with spring washers (98) and nuts (97).
7. Fit new split pins (161L
5. Fit and tighten cylinder block retaining nuts (148) inside the crankcase to the recommended torque
setting, Section 1— Data. -

- n
5/16 5/17
 NO TE: if a new connecting tvd bolt is zo be used, pre-torque the bearing assembly 6. Locate air pipe (331) and joints (332) and (333) from the first stage cooler delivery cover to the
L the figure
given in Data Section before i/tm ent. Stamp connecting rod nut and bolt head with second stage cylinder head and secure with nuts (336) and setscrews (334).
identification marks for future use.
7. Re-connect the cooling water outlet pipe and joint from the cylinder hd.
8. Ensure assembly is free to turn on crankshaft
8. Re-connect the two air pipes (796) and (802) from the compressor unloader (787) to the second stage
Second Stage Piston Assembly. For fitment of the second stage piston assembjy
a procedure identical to
cylinder head.
that emproyed for fitment of the first stage piston assembly should be followed
Procedures 1 to 8 inchisive)
9. If fitted, locate and secure air temperature switch (841) and re-connect cabling.
Assembly of First Stage Cylinder Head ‘F

10, If fitted, locate and secure oil pressure switch (850) and re-connect cabling.
Proceed as follows
11. If fitted, Locate thermometer (965) or (968) and associated pocket (966) or (969) and tighten
1. Lightly grease LP. cylinder head joint (250) and locate on stage cvi nder block fittin.
(145).
2. Turn the crankshaft until the second stage piston is at the bottom dead centre ‘s 12. O,eck alignment of compressor as detailed in Installation Pocedure.
position.
3. Lift the first stage cylinder head and ad?ust lift so thatthe second stage cylinder ye 13, Fit crankcase doors (115) and joint (116) and securewith spring washers (119) and nuts (118).
bore is vertical and
lightly oil piston assembly Posihon he piston rings so that the gaps on adjacent
rings are 1800 apart.
14. Carry out commissioning checks as detaüed in Operation Procedure — Initial Start Up.
4. Carefully lower first stage cylinder head onto piston assembly and locating studs. Ensure
ye
that the
piston rings are correctly entered into the second stage cylinder when hd is being 15. Fit flywheel guard.
lowered. ye
CAUTION: IF CARE IS NOT TAKEN AT THIS STAGE DAMAGE TO THE PISTON Assently of the compressor is comp1ete.
ASSEMBLY MAY OCCUR.
‘1w
SJy
5. Ad1ust the machined face of cylinder head at drive end so that the firt stage cooler inlet
cover (179)
En be fitted. ,re

6. Locate and fit the first stage cooler inlet cover and joint (189) and secure with nuts
(184) and spring iis
washers (188) and nuts (187). bolts (183) and setscrews (190).
TW
7. Fit and tighten the cylinder head retaining nuts (256) uniformly to the correct torque
setting, Data
Section 1. The retaining nuts should be tightened diametrically, starting from the centre of
the machine.
Sub-Assemblies and Ancillary Equipment
8. Connect the actuating air supply to unloader (it fitted),
G.nfl -

9. Fit first stage cool drain pipe (828) and tighten connections.
The following ancillary equipment can be removed from the compressor, inspected, overhauled and be refitted
10. Rotate compressor to ensure that piston assembly is free to turn. individually without carrying out the complete dismantling and re-assembly procedure. Also included are the
procedures to be adopted for the maintenance of the big end bearing shells without completely dismantling
Assembly of cylinder head is complete. the compressor. Maintenance procedures for the first and second stage piston assemblies are also induded.

Assembly of Second Stage Cylinder Head WARNING: 1. MAINTENANCE MUST NOT BE CARRIED OUT ON THE COMPRESSOR WHILST IT IS
IN MOTION.
1. Fit water hole joint washers (303) and joint ring (158).
2. BEFORE CARRYING OUT ANY MAINTENANCE ON THE MACHINE, THE COMPRESSOR
2. Lift second stage cylinder head (302) and lower it on to retaining studs fit nuts (305) and tighten to MUST BE STOPPED AND ISOLATED MECHANICALLY AND ELECTRICALLY, AND
the recommended torque setting, Section 1 Data.
VISIBLE WARNING NOTICES DISPLAYED.
at
3. Re-fit gauge support bracket angle (923) or (924). or gauge board (929) or (g30), and secure with
3. WHEN WORK IS TO BE CARRIED OUT ON WATER AND/OR AIR PASSAGES THE
screws (925) or (932).
COMPRESSOR MUST BE VENTED OF ALL PRESSURISED AIR AND DRAINED OF
COOLING WATER.
4. Re-connect first and second stage air’pressuregauge pipes (911) and (912). the oil pressure gauge
pipe (913) and, if fitted, water gauge pipe (914).
Lubricating Oil Pump
5.
fl
Locate air pipe (331) and joints (332) and (333) from the second stage cylinder hd to the second
The compressor oil pump shou’d not require any attention or adjustment between malor overhaul periods, at
stage cooler inlet/delivery cover and secure with nuts (336) and setscrews (334). n which time it should be inspected for signs of wear. When examination is necessary the following procedure
should be adopted:

5119
5/18
 -w

C. Lightly coat all companen with oil before assembly.

Removal end Dismanding of Pump — D5527 and 65110206
Assembly end Insullatian of Pump —05247 and 66110206
I Disconnect all pipes to the drain black (615) if fitted) and remove drain block retaining nuts (8181
Withdraw the drain block complete with automatic drain traps and fittings.
1. Position rivin9 and driven irDeIaS (3) and (4) in body.
2. i fitl1. disconnect me water puma net pipe ana outlel p:pe (767L take oil screws (760) aro sirg
wasnecs 761) and remove waler curio (75O and joint (75g). 2. Position joint (5) ama cov& (1) on bocv (2) and fit crews (9).

1Q3)
a. 3. Press socket (16) on to thedriving impeller shaft (3) and secure with a men grooved pin (17). Ensure
3 Remove ntis 107) and spring wast,ers 108) suring ,,e auxiliary drive end cover aria Wilhrjraw
cover and Oiflt {104) that the sprocket setting dimension shown on drawing 66110206 is maintained.
ES
4. Re-position me oil pump n the cran<e. Fit and secure retainirq setsaews (19).
4. Remove the nuts (118) aria sprig wasj,ecs (‘19) rela:n.ng the right-harm cranKcase coo’ (ii Si nok nq a.
fron, the non-drive end). Remove crankcase coor and joint 116).
5. Re-connect the iniet strainer and cipe (31) and ddivey pipe (80) to the pump.
5. Disconnect the oil pump inlet srainw :31 arm &ivery pioe (80) from the oil sump (13L
6. Ft pump drive chain (24).
as
6. Remove oil pump drive chain (24).
7. Re-fit crankcase joint (116) and door (115) and securewith spring washers (119) and nut, (118).
7. Unscrew setscrews (19) which secure the oil pump assembly to the crankcase and withdraw ol pump.
as
8. Position auxiliary drive end cover joint (104) and cover (103) on studsand secure with spring washers (108)
8. Remove the grooved pin (17) which secures the sprocket (16) to the pump driving gr shaft
as and nuts (107)

9. withdraw sprocket from shaft.

as 9. If a watm pump is fitted, position joint (759) and water pump (750) on the auxiliary drive end cover and
secure with setscrews (760). Connect the water inlet pipe and outlet pipe (767).
NOTE: Thewrocketis apress fit ons’,aft.
a’
10. Re-fit drain block (815) and secure with retaining nut, (818).
10 Remove cap screws (9) securing cover (1) and body (2) and withdrawcover, joint(S), driving impeller (3)
11. Connect the cooler drain pipe (828) and (833) to the drain block.
and driven mpler (4). n
Oil Pressure Rdiqf Valve
The pump components should be cleaned in kerosene and inspected. If gears are damaged or worn Or pump bearings fl
are worn they mtst be dianged.
Once set, the oil prsure system reBel valve should not require re-adjustment, However, during the initial running
fl in eriod or after a major ov&aul, adjustment, if required, can be rith out as follows:
NOTE: Oä pump bn,irqx re a fit bta
n 1. Remove nut, (107) and springwa* (108) and takeotfthoright-hand aanksedooc 115) and joint (116)
(looking from the non-drive id of compra).
n
2. Relee the relief valve locknut (58).
0
3. Screw the reBel valve adjustma,t setscrew (57) nwards to incro system prire or outv,rds to ruce
0 system pressise.
SCoew An,gem.,t oa Punp
Drawing No. 66110206 Issi. 3, 0 NO TE: One p.,,,, of atjustrnent xrew is equweleat to pmximatdy a 5 bar ure ,riedoa
0 4. Tighten the rie’f valve locknut (58).
0 5. Re-fit crankcasedoor (115) and joint (116) and secure with spri%shefl (119) and nuts 118L
0 Water Pump (it fined)

P1550 RASI 70 Item No. Description

n The cDolir water pump is of the flexible rotor type and should not, normally, require adjustment between riejor
agTS overhaul periods, -

Oil Pump Cover

0
2 Oil Pump Body It is important howewr, that the pump should not be run dry for a longer period than necesry for self priming,
3 Driving Impeller
0 as the impeller is dependent upon the liquid being pumped for both lubrition and heat dissipation purposes.
4 Driven Impeller
5 Joint: 1—2
0 Occasional maintenance of the mechanical seal faces may be required. If this is being carried out the impeller,
6 Bust, : 3 & 4 4 impeller wear plate and bearing, should also be inspected for evidence at cracking, wear or other form of darmge.
a Dowel: 1—2 2 0
9 Capsoews 1—2 4
0
0 5/21
5/20
 tie
Removal and Dismantling of Pump
‘-Jr 10
1. Disconnect thewater inlet pipeand outlet pipe (767) from the pump flanges.
fl
2. Remove setscrews (760) and spring washers {761 ) retaining the pump to the auxiliary drive end cover
wje
and withdraw the pump assembly. Z4y

3. Remove the cover screws (5) and withdraw cover (7), joint(S) and spline seal (6).
‘1•
4. Withdraw pump mpeller (4) from pump shaft 15). If difficulty is experienced in removing the impeller,
turn the pump shaft in the oppositedirtion to the normal rotation whilst firmly hoiding the impeller.
This should release the shaft.

5. Remove the cam screw (2) and cam (3). ,ja

6. Withdraw wear plate (10) and seal assembly (18) taking care not to damage seal faces. ‘-I
7, Remove setscrews (24) and spring washers (25) securing body (9) to the bearing housing (23). Remove ‘1—
water thrower (11),

8. Remove the coupling disc (752) and press on the impeller end of the shaft to remove the shaft (15) I
and the ball bearings (13).

9. Support each bearing inner race and press the shaft through the bearing. n
10. Visually inspect the bearing seal for wear or damage. If it is serviceable do not disturb assembly. If seal
requires replacement care must be taken not to damage housing bore:

11. Ensure water drain positions in pumpibearing housing are clear.

n
a
All components should be carefully inspected and all worn or damaged or corroded components replaced.

Ammbly .nd Installation of Pump

1. Lubricate the bearing seal (12) with grease and press into the bearing seal bore (with the open face
a
towards bearing bore). a
2. Supporting the inner race of the bearing, press the shaft (15) into each bearing (13). a
3. Insert the shaft through the bearing housing (23) and press in the bearings. a Lçø1Z
4. Fit water thrower (11) on shaft (15). a Self-priming Water Pump Drawing No. E10458
5. Assemble bearing housing (23) and pump body (9) with setscrews (24) and spring washers (25). a
Item No. Description Qty. Item No. Description Oty.
6. Fit wear plate (10) to the body, locating it on dowel pin (1). a
7. Remove the jointing compound from the thread of cam screw (2). top side and back of cam (3) 1 Dowel Pin 1 10 Wear Plate 1
and re-coat with non-setting jointing compound.
a 2 CamScrew 1 11 Thrower 1
3 Cam 1 12 Seal—13 1
B. Secure the cam to the pump body with cam screw (2).
a 4 Impeller 1 13 Bearing 2
5 Screw—i 5 15 Shaft 1
9. Lightly grease the seal seat cup rubber and press seal seat assembly (17) into the pump body with
a 6 Spline Seal 1 16 Seal Assembly 1
7 End Cover 1 23 Bearing I-lousing 1
the seal face towards the impeller bore. Extreme care should be taken not to damage the seal face a 8 Joint 1 24 Bolt 4
9 Body 1 25 Spring Washer 4
10. Lightly grease the pump shaft between the end of splines and seal seatand slideseal sub-assembly (18) a
into position.
0
11. Lightly grease impeller (4) and casing bore and press impeller onto shaft.
a
5/22 5/23
 .1-is Delivery Line Non-R.wm Valve E9402
12. Fit spline seal (6) and locate oint 8) and cover 7) in position. Secure cover with retaining screws
(5)
tie R.mo,4 and ln.p.ciion of Daiwy Vain. To remove a delivey valve from the non-feturn vatv housjn9
13. Fit the cDupiing dsc (752) ptoceed as follows:

14. Locate Dump assembly an Girt 7591 on auxiiary arve end Cover. Secure w:h setscrews {760) and WARNING: 1. MAINTENANCE MUST NOT BE CARRIED OUT ON ThIS VALVE WHILST
Spr:ng washers (761). V_c THERE IS PRESSURE IN THE COMPRESSOR OR RECEIVER.

15. Connect warer inlet pipe and outlet pipe (767) and joints 762) to Dump flanges. 2.
41T THE COêWRE$SOR MUST BE STOPPED AND ISOLATED MECHANICALLY
AND THE SYSTEM DRAINED OF ALL PRESSURISED AIR AND VISIBLE
Fint Stag. Air Cooler. Fcr reroval, disrnantirg and assemby p.ocecture. refer to Roucne Maintenance at
•1- WAHNING NOTICES SHOULD BE DISPI.AYED.
the beginning of This Section.
We 1. Carefully unscrew plugs (10) and joints (II) from the valve housing to drain off moisture. Ensure that
Second St.ge Air Cooler. For removal, dismantling, assembly and insta)lation procedures, refer to Routine there is no remaining air under pressure internal to this section of pipework, before completely removing
Maintenance at the begLnnirig of this Section. 4* plugs and joints.

Automatic VaIvn For removal, dismantling, assembly and installation procedures, refer to Routine We 2. Remove p screws(S) securing the valve cage (2) to the non-return valve housing (1).
Maintenance at the beginning of this Section.
V. 3. Remove valve cage taking Care not to damage 0-ring seal (4).
Water Jacket Relief Valve D5247
tt 4. Using a valve extractor tool, withdraw the delivery valve (3).
This should not require any maintenance. Qcsionally it must be Lifted to ensure that it is not sticking.
The valve can now be dismantled and inspected as detailed for automatic valves (delivery) in Routine
VT
Maintenance at the beginning of this Section.
During a rr.ajo. overhaul the four retaining ru’.s (282) thould be removed and me 0-ring (89) and seat (B5)
iroected for damage. TIC
A,wnb(y and InstWtafion of Delivery Vii..
Automatic Drain Trap. 05427 ala.
1. Assemble automatic delivery valve as desaibed in this Section under Routine Maintenance.
The automatic drain trap has only one novng an and therefore requires the minimum of naintance.
2. Should it be aoparenz that eakaqe occurs at the n,etal-zo-metal mating surta betwea, the delivery
valve (3) and its seating n the housing (I. the mating surfas nim be littly 7ound in with
The cap should be removed ocionally and the dsc cleaned. The strainer sceen should also be cleened VT
carborundum ste and dearwd thoroughly.
ocsiona lv.
et 3. Position valve cage (2) taking care not to damage O’-ring seal (4) and tighten retaining cap screws (5)
Before re-assembly it Is important to lubricate threads with an anti-selie compound.
to the recommended torque setting, Section 1, Data.
4t
After maintenance the shims (820) fitted between the cap and body should be adjusted so that frequency
of operation is approximately five times per minute. 4. Refit plum (10) and joints (Ii) and tighten.
VT
Sr
6
pp

pp

Autmnatic Diii.. Trap ap

no Item No. Dacflpta Ow. a(a

1 Body aa
2 Disc
3 Cap pp
4 Plug
5 Strainer Screen
6 Joint Washer
820 Shims (05247) (As Req’d)

p 5/25
5/24
4s
 All unloader mponents should be thoroughly cleaned and inspected for signs of damage or wear. All O-rin
and joints should be checked for serviceability.

If the valve seats are damaged, the valves must be lapped to their respective seats using a fine carborundum
paste. Sewdriva slots are o.ded in the valves for this purpose. Parts should be washed thoroughly to
remove all trac of rborundum paste.
5
2 n Before re-assembiy check that the clearance between valves s as shown in drawing E9523 and adjust as
necessary by filing the top off the second stage valve stern.
4
3 20
Si.
Non-neon, VaIn, Drawing No. E9402 282927 8
V. 22
Item No. Description Ow. V.
1 Housing 1
V.
2 Valve Cage 1
3 Delivery Valve 1
4 0-ring Seal
V-I.
1
5 Capscrew 4
V. 2
6 Plug
7 Joint II
1
10 Plug 1
11 Joint 1 28

Automatic Delivery Lint Unload., — Plunger Op.rat.d

The autonIic unloader (if fitted) is situated on the first stage cylinder head and must be removed for 0
servicing. The following produre should be adopted:
0
R.n,onl .id DUII..Uinq Proc.dur, — D5247 .nd E9523 Auton.lic DWivecy tin. UMoedet, Dnwing No. E9523
0
1. Disconnect me unloader air pipes 796) and (2) and the ntrol air pipe and connections and remove. Item No. D.,cflptian Oty. item No. D... .,tk,n Oty.
0
2. Disconnect the unloader retaining nuts (790) and spring washers (791 and remove ambly (787).
—
1 Chamber discharge 1 20 —
Spring valve
0 2 —
Chamber first stage 1 21 Grooved pin
3. Remove the nuts (28) and spring washers (29) loting second stage diamber (3) to first stage chamber
3 — 1
Chamber second stage 22 0’-ring —2
(2) and remove. Care should be taken during this oQeration. not to damage tF,e 0-ring (23). 0 4 Plung.guidecover 1 23 0-ring—3
S Plunge. guide 1 24 0-ring—li
4. The seccnd stage valve (9) and spring (20) should now be removed. 0 . 27 Stud
8 Valve—firitstage 1 8
9 Valve—secondstage 1 28 Nut B
5. Remove the nuts (28) and spring washers (29) looting the first stage chamber (2) to the discharge 0 10 Seat—B 1 29 Spring washer B
chamber (1) and remove. 11 Joint—4
Seat—9 1
—

6. Take mit setsa-ews (31) and withdraw plunger guide (5) cover (4) and joint (30).
n 19 0-ring valve plunger 1 31 Setscrew 4

0
7. Rotate the first stage valve until the grooved pin (21) which holds the plunger to the valve is in line
Assembly and linilation of Unloader
with the access holes n the flange of the discharge chamber. Hold valve in the fully open position and 0
tap out the grooved pin with the aid of a two mm. diameter rod. Unscrew plunger 12) from first stage
valve (8) and remove valve. 1. Fit 0-ring seal (23) in the second stage valve seat (11) and press seat into the first stage chamber (2)
0 from second stage chamber end.
8. Pret the first stage valve seat (10) out of the discharge chamber.
2. Press the first stage valve seat (10) into the discharye chamber (1).
9. Screw a 3/Sin. B.S.P. plug into the internal thread of the second stage valve seat (11). Pass a six mm.
diameter rod through the bore to locate onto the plug and press the valve seat from the first stage 3. Fit first stage valve (8) rI seat (10) and the spring (20) in the discharge chamber recess.
chamber (from discharge chamber end).
4 Screw the plunger (12) on to the valve stem (8) until ha hole lines up with the hole in the valve stem.
Fit a new grooved Jrn (21).
10. Removeplug.

5/28 5/27
I-
 4—
WV
B. Fit ‘0-ring
(19) on plunger groove and fit plunger guide (5). joint (30) and cover {41 to discharge Dismantling of Pig00 Anwnbly
ctamber and secure with setscrews (3?). I.. I Remove gudgeun pin retaining circlips D3).
6. Position the 0-ring (22) in first stage chamber (2) and locate them on discharge chamber 1.
Secure with spring washers (29) and nuts (28). 2. Withdraw gudgeon pin (02) and the connecting rod will be separated from the piston assembly.

7. Fit second stage valve (9) in seat. 3. To remove connecting rod small end bush C4). press out.
4
8. Position ‘0-ring (23) and spring (20) in second stage chamber and locate this chamber on to the 4. Work piston rings (D4) and (D5) loose in their qrcoves. Carefully spring them open and remove
first stage chamber. Secure with spring washers (29) and nuts (28). from the piston noting the order and which way up they were fitted.
4.
9. Check unit for ease of movement by pressing on plunger with a piece of wood. “-.4. All components should be thoroughly cleaned and washed in kerosene and be dimensionally checked or wear.

10. Re-fit the unloader assembly to the first stage cylinder head and secure with spring washers (791) The piston rings must be inserted into the cylinder bore and loceted in the running section of the cylinder. The
n
and retaining nuts (790). ring gap can Then be checked by use of gauges and checked against recommendations in Section 1, Data.
Ensure that the mating ends ot the piston rings are square before re-assembly.
ii. Connect all air pip and secure.
If new rings are required they should be inserted into the cylinders and the gap checked. The ring gap must
Inspection or Hen.w of 84g End Shell Bearing. be adius:ed to the recommended dearance by filing the end of the rings.
a
The big end bearings can be remover] witflnut completely dsmantlng the “lachine as follows If rings are distorted they mtst be danged.
a
Removal of First Stage Coan.cUn Rod Big End Owing Shells Assembly of Pitt0.. Compoo.ms
a
1- Remove nuts (118) and spring wastiers (119) securing crankcase coo, (115). Withdraw ci’ankse door Once all components have been checked the following senibly procedure diould be adopted.
and joint (116). a
1. Fit the piston rings to the pistons.
2. Remove first stage nnecting rod big end bolt solit pins (167). a
NOTE: If old rings an d they must be re-fitted the arne its’ cw &id in their odginsi o,*r.
N0rE: The series of idenaifica Won marks on the connecting rod bait head. connec Wng ‘od, If new piston dn an used Me ring s musebe checked prior to wernbly.
a
connecting rod c, and slotted nuL These components must be replaced and Piston ring gaps should be ananged 1800 apart on adjacent ring.
ti, retied to the ide,, rice) position as found on removal. a
2. Light[y oil piston assembly and components. Press new small end bush (C4) into the connecting rod.
3. Remove the nuts (C3) and bearing cap, which is located by a pin on the mating surface of the a
nnecting rod assembly. 3. Place the connecting rod in position and press in the gudgeon pin (D2).
a
4. Remove the remaining bearing halt-line, (C7). The shell bearing can now be inspected, If they are 4. Fit retaining cirelips (D3).
scored or worn they must be replaced. These bearings MUST NOT be scraped or tiled. a
5. Position the piston rings with the gaps on adjant rings 1800 apart.
ln:taII.tion and Assembly of First Stag. Connecting Rod Big End Boring.
6. Enter the piston into the bottom of the cylinder bore and compress and enter each piston ring
I. Fit top and bottom half-liners (C7 and locate the bearing cap to connecting rod (Cl). carefully to avoid breakage.
a
2. Fit connecting rod bolts (C2) in the correct relative position and tighten to the correct torque 7. Fit the wnnecting rod as detailed previously in the paragraph Installation and Assembly of First Stage.
ci.
setting, Section 1, Data. or Second Stage, Connecting Rod Big End Bearings’.

3. Fit new split pitt (167). Second Stage fl.t., Assembly

a.
4. Refit crankcase door (115) and joint (116) and securewith sping washers (119) and nuts (118). To dismantle. inwece and rtuild the piston assembly procsed in an identical nw,iw as employed for the
a. first ste piston assently.
Insp.cnon ci Rn...) of Second Stage CoanCng Rod Big End Owing Shut
as
Proed as detailed tor removal and installation of first stage big end bearing shells.
R.mo,ing .d Dismamling Air Goeen.or
a.
First Stagi Pistos, Assembly
The air gorr should not nornlly require attention but during comr overhauls t should be cleaned
as and inspected for darrge.
To dismantle inspect and ruild the first stage oiston assembly, remove complete with connecting rod,
as previously detailed earlier in this Section, and then proceed as follows: at WARNING: BEFORE COMMENCING WORK ON ThE AIR GOVERNOR ThE AIR RECEIVER MUST
BE EXHAUSTED OR ThE GOVERNOR MUST BE ISOLATED FROM THE AIR RECEIVER.
Cs

5/28 5/29
 6
4.
10 S. Thoroughly clean all components and examine them for corrosion, cracks or any other damage, paying
II 3 13 14 2 12 I
n particular attention to the valve and the upper and lower seats, If necessary, the valve must be apped
in lightly with carborundum paste, to provide an air tight seal wiih the two seats, and be cleaned
fl thoroughly. The upper and lower valve seals must be fitted, in turn, to the body to locate the valve
when lapping in the seats.

Assembling and Installing Air Governor

n 1. Screw the lower valve seat 4) into the body (1
.1w 2. Position valve 2) in body and fit shims (10) on to upper valve seal (3) and screw seat in to body.

3. Drop ball (12) in to position in valve and fit spindle (5). Fit soltinq collar (8) on upper valve seat
and spring (11) on the spindle. Ft the adjuster (6) o the valve seat.

sJr 4. Fit the filter (9) in the rower valve seat and retain with plug (7).

5. If fitted, position joint washer (16) on the lower valve seat and screw on the adapter (15).

n 6. Refit the air governor and joint washer to the air receiver and fit and secure the pipe to the
automatic delivery line unloader.
Drawing No. A11414 lisue 1 and A11415 Air Governor
WIT
WARNING: IF ADJUSTMENT OF THE CUT-IN AND CUT-OUT PRESSURE IS REQUIRED,
Item No. Description Ow. Inc THE AIR GOVERNOR MUST BE ISOLATED FROM THE AIR RECEIVER, OR
THE RECEIVER MUST BE EXHAUSTED, BEFORE ThE ADJUSTER IS
Body REMOVED.
2 Valve
3 tipper Seat 7. If the valve has been lapped in, it may be neccy to adjust the cut-in and cut-out pressures.
4 Lower Seat Removal of a shim 110) will raise the cut-cut pressure, and removal of one of the setting collars
5 Spindle -

4w (8) will raise both the cut-in and cut-cut pressure.

6 Adjuster for Cut-out Pressure
7 Filter Plug
V.
8 Setting Collar for Cut-out Prsure As Req’d.
Removing and Dismantling Water Sliut.off Valve E10756
9 Filter
V.
10 Shims for Cut-in Pressure As Req’d.
The water shut-off valve requires very little maintenance but it is advible to inspect it during compressor
11 Spring
vie overhauls. The only parts that may require replacing are the diaphragm (7) and backing disc assembly (5),
12 Ball
the ‘0-ring (4), mpression spring (11) and valve assembly (15). To dismantle the valve:
13 Compression Fitting
14 Joint Washer
n 1. Remove the air supply pipe (780). and disconnect the water supply pipe from the globe valve.
15 Adapter: Al 1415 only
16 Joint Washer: All4l5only
0
2. Remove the assembly from the compressor water jacket.
a
3. Linsoew the valve cover (16) and remove compression spring (11) and, if fined, spring guide (12).
a
P 4. It is now possible to withdraw the valve assembly (15).
1. Disconnect the air pipe from the compressor unloader.
a
5. Remove bolts (9) and spring washers (10) and top cove (8).
2. Remove the air governor from the air receiver.
a
6. Withdraw the diaphragm (7) and the backing disc (5) together with the push rod (3); remove ‘O’-rin (4).
3. If fitted, unscrew and remove adapter (15) and joint washer (16).
a
7. If it is nery to remove the globe valve body (1) from adapter flange assembly (2), remove locknut (17)
4. Unscrew the adjuster (6). spring (11) and setting collar (5) (8) taking note of how many are fined for and unsaen the body from the adapter flange assembly.
reassembly.
a
a 8. To remove the backing disc from the push rod, drive out spring pin (6).
5. Withdraw spindle (5) and tip out ball (12),
a Anambfln and linIling Water Shut-off Vii..
6. Unscrew the upper seat (3) and remove shims (10) taking note of how many are fitted for reassembly.
Remove valve (2) and lower seat (4). 1. Secure backing disc (5) to push rod (3) with spring pin (6).
a
7. Take out filter plug (7) and remove filter (9). 2. Fit ‘O’qin (4) to push rod.
a
5/30
n 5/31
.-t.
 Air Pressure Safety Valve

The air pressure safety valves are fitted to the first and second stage coolers at the drive end of the machine. Ac the
intervals indicated in the maintenance schedifle the valves should be removed, examined. cteaned, and tested to
enSure :1ev sDen at :0% asove :ne zarticjlar stage presstse apDlicable

ce
C
a ‘I
I
U
.
S
S
A. Cap
Ca B. Adjuster
Drawing No. E10756 bw. 1. Secdoa.I Aq.en......,.t Wit.’ Sh4Lt-otf Vain CS C. Body
D. Spring
lt.rnMo. E. Plunger
Dncnpton Ot’. a * F. Seat
Globe Valve Body as
2 Adapter Flange Aernbly Air Prewn Safttr Valve
3 Pushf ad as
4 0 ‘ring: 3 2 Ord.flnq Spat. Parts
5 Backing Disc Assembly ‘I as
6 Spring Pin : 3—5 The following ,nforrnation is required by l4arnwonhy Engineering Limited to fully identify the unit and ensure that the
7 Diaphragm C. correct scare pans are suppled.
S Top Cover
9 Bolts 2—B So, 12 C. Type of Machine: ) Obtained from machine nameplate
10 Spring Washers : 9 Sor 12 Serial Number of Machine: ) attached to right-hand crankcase door.
11 Comprsion Spring C. [tern Number of Part Required: ) Obtained from Sectional Arrangement
12 Full Description at Pan Required: ) Drawings included in this Secnon.
Spring Guide :11 (50 mm. Valve Only)
List at Parts eferlnce Number of this Manufacturer
15 Valve Assembly C. Drawing Number and Issue Number Obtained from this Publication.
16 Valve Cover
17 Locknut : 1 Cs Spare Parts can be ordered direct frorn the following address:

Cs Pumno & Compressor Division.

3. Screw globe valve body (1) in to adapier flange assen,bly (2) and fit locknut (17). Spares Department.
I .amwonfly Engineering Umited.
Feets Corner.
4. Position pud-’ rod and backing disc assembly (3) and (5). diaphram,1 (7) and top cover (8) on adapter
Poole. Dorset
flange assembly and fit spring washers (101 and bolts (9). but do not tighten the bolts. Press the push 6)417 7LA
rod in to the adapter flange assembly as far as it will go to stretch the diaphragm and fully tighten the England.
bolts 10). Release preure on push rod.
Teier 41348 Teleonone No: Poole 5123 (SIt Cooe 020—13)
5. Fit valve aembly (15) in globe valve tiody followed by mprsion spring (11) and, if fitted, spring From March 1982. (0202) 675123
guide (12) and fit valve cover (16).
or from any Hamworthy Office or Agency throughout the world.
6. Fit water shut-ott valve to co’npresso, water jacket tapping.
n all cases t s essenual that the above information be supplied with the order.
7 Cojineci the water ,(ilt supply pine to globe valve body and refit the air supply pipe (780) to the
cooler cover and air flow control valve.

t.
t.
5/32 5,33
C S
 Item No. Description lien, No. Description
Sectional Arrangement Drawing No. D5241 Issue 0. Oty.
167 Sont Pin Connecing cd Bolt 241 Plug: Cylinder Blcck Drain
169 Piston Assembly : 1st Stage 242 Joint Washer
List of Part Reference No. 1
175 Piston Assembly : 2nd Stage 244 Gaivion Anode 16
178 1st Stage Tube Nest Assembly 245 Support Plug : Galvion Anode
Item No. Description Qty. Item No. Description 5
Qt. 179 Cooier rnlet Cover: lst Stage 247 Plug: Cylinder Block 2
180 —
Jornt Cover Tubeplate
Crank ase 250 Joint : Cylinder Head L.P.
1
4 Half Bearirg Shell Nlan Beerng 6
82
83
Ppe: 70—70
Poe 70—75
H
V.
181 —
Studs : Cover Tuteelate 2 Cvlinaer Block 1
—
182 Studs : Ccver Tuoeoiate 2 253 Cyiinder Head —LP.
S Thrust Half Washer 2 84 Pipe 75—71 1
—
183 Bolt Cover Tubepate 2 254 Stud: LP. Cylincer -eao —
1 Crankbaft 85 Pipe 14—65 184 Nut 4 Cylinder Block 10
13 Oil Pump Assemb’y 86 Pipe : Relief Va Ive—Fi Iter 185 —
Joint Cover Cylinder Block 255 Stud: L.P. Cylinder Head —
16 Sprocket: 13 87 Pipe : 75—75 .u1# 186 —
Studs Cover Cylinder Block 8 Cylinder Block
17 Grooved Pin: 16—13 94 Bearing Cover Drive End 187 Nuts: 186 8. 256 Nuts: 254—255 11
19 Setscrew : 13—1 4 95 Joint 94 188 Spring Washer 1 87 8 258 Plug: L.P. Cylinder Head 1
21 —
Sprocket Oil Pump Driving ‘It’
96 Stud 12 Ag Joint Cooler Cover —
259 Plug 5
22 Cap Head Scraw 2 97 Nut 12 LP. CyInder -7ead 1 261 Valve Cage: 1st Stage Suction
24 Chain 98 Spring Washer 12 190 Setscrew: Cooler —

Stud Coupltng 262 Suction Vaive; 1st Stage See nage 5/5 1
28 99 Oil Seal 1* LP. Cylinder Head 2 263 Cap Head Sue.’. 4
Oil Pump Suction (Ste. Rotation) 100 Dowel 2 193 Coder Outlet Cover: 1st Stage 264 0-ring: Valve Cage
29 Elbow Oil Pump Suction 103 Cover: Aux. Dnve End 194 Joint: Cover —

(Non-Std. Rotation) 266 Valve Cage: 1st Stage Delivery 1

104 Joint: 103 —
Didphragm Tubeplate 2 267 Delivery Valve : 1st Stage See page 5(5 1
30 Joint Washer (28 or 29) 105 Stud 11 195 Diaphragm : 1st Stage Cooler 268 V&ve Cover :1st Stage Delivery 1
31 Inlet Strainer: 13 106 Stud 196 —
Stud : Cover Tubeptate
Ta 6 269 0-ring : Valve Cover 1
33 Elbow: Lub. Oil Press. Switch Bracket 2 197 Nut: 196 6 270 Valve Screw
Ol Pump Outlet (Std. Rotaton I07 Nut 13 198 Diachra9mSe&ing Ring
34 Stud Coupling Oil Pump Outlet 0 lstStageDdweryV&ve 1
108 Spn9 Washer 13 199 Joint: 271 CapNut:270 1
(Non-Std. Rotation) 109 Dowel 2 —
Dapnragm Cylinder Block
35 Joint Washer: (33 or 34) 0 272 Joint Washer: 271 1
110 Plug: Crankcase Drain 200 Studs: Slirç Ring —

Oil Filter 1 273 Cap Road Screw:

111 Joint Washer Cylinder Block 8
Elbow: 38 0 ValvecoverlstStage 4
115 -
Crankcase Door 2 201 Nuts 200 8
40 Inlet Connection: 38 275 Water Jacket Relief Valve 1
116 Joint: 116 2 202 Spring Washer: 201 8 278 Studs: Water Jacket Relief Valve —
41 Pipe Ferrule: Inlet Connection 117 Stud 20 205 Air Pressure Safety Valve: 1st Stage
42 Union Nut Inlet Connection Cylinder Heed 2
118 Nut 20 206 Joint Washer: 206
43 —
Jdnt Washer: Cono. Filter I 280 Studs : Water Jacket Relief Valve
i Spring Washer 20 209 2nd Stage Tube Nest Aembly
46 Cl,,pRing:38 Cylinder Head 2
121 Instruction Plate 210 Cooler Detivery Cover; 2nd Stage
47 Bracket 38—1 282 Nuts 4
122 Drive Screw 4 211 Joint
48 Setscrew: 46 285 Elbow: itt Stage Inlet Slencer
124 Nameplate Cover: Diahran Tubeplete — 2 286 —
Studs: Elbow Cylinder Heed 4
49 Nut:46 125 Drive Screw 4 212 Diaphragm: 2nd Stage Cooler 1 287 Nuts: 286 4
SO Setscrew 38—1 127 Dipstick 213 —
Studs: Cover Tubeplate 6 285 Spring Washer: 287 4
54 Relief Valve Body : Lub. Oil 128 Joint Washer 0 214 Nut: 213 6 289 Suction Filter & Silencer 1
55 Spring 130 Breather 215 Diaphragm Sealing Ring
Ball 291 Blanking Plate: Elbow
56 131 Joint Washer 216 Joint: 292 —
Joint : Blanking Plate Elbow
57 Setscrew: 134 Flywheel: Direct Coupled M/C. I —
Oiaohragrn Cylinder Block 293 —
Studs: Blanking Plate Elbow 3
Relict Valve Adjusting Key : Gib Head 0 217 Stua:
58 Locknut : 57 294 Nut,:293 3
145 Cylinder Block —
Siing Ring Cylinder Block 8
59 Tee—Equal 0 295 Spring Washer: 294 3
147 Sttxt: 145—I 8 218 Nut:217 8
tub. Oil Re4i€t Valve I 296 Plug:lst&2rtStage
148 Nun: 147 B 219 Spring Wasj,er: 218 8
60 Joint Washer: (54—59) Air Pipe Elbows 2
150 Locating Button: 145—1 2
62 Reducing Bush 222 Cooler Return Cover : 2nd Stags 297 Joint: 296 2
151 Joint: 145—1
223 Studs : Return Cover Tubeplate— 6 302 Cylinder Heed : 2nd Stage
63 Stud Coupling 152 Eye Bolt 4
65 Stud Coupling 224 Nuts: 223 6 303 Joint Washer: Water Hole
153 Cylinder Liner: 1st Stage
225 —
Joint : Cover Tubeplate 1 st-2nd Stage Cylinder Head 2
66 Joint Washer 154 Cylinder Liner: Buffer
226 —
Joint: Cover Cylinder Black 304 Studs: 1st to 2nd Stage Heads 4
70 Banjo Coupling inc. 72: Double 2 156 Cylinder Liner: 2nd Stage
227 —
Stud : Cover Cyincer Black 305 Nuts:304 4
71 Banjo Coupling inc. 72 158 Joint fling: 155 2 0
72 Joint Washer:70 & 71 228 Nut : 227 B 307 Valve Cage: 2nd Stage Suction
6 160 0-ring: l53Top
74 Tee Coupling 229 Scring Washer 227 8 308 Si.ction Valve: 2nd Stage
I 161 O-rtng: 153 Boffocu I
75 Tee Coupling 231 Fusible Plug 309 Cap Head Suew:
162 O’-ring: 154 Top
76 Stud Coupling 232 Washer 2nd Stage Suction Cage 4
163 0-ring: 154 Bottom
80 Pipe: 28 or 29—74 235 Air Pressure Safety Valve:2nd Stage 310 O’-ring : Valve Cage
164 0-ring : 1 55
81 Pipe: 74—70 236 Joint Washer 320 Valve Cage: 2nd Stage Delivery
186 Connecting Rod Assembly
See page 5/5

5/34 5/35
Item No. Dacriptico Qty. Iteni No. Description Item No. Description Qty. Item No. Description Oty.
321 Del iverv Valve: 2nd Stage See pe 5/5 1 797 Stud Coupling: 857 -Rucing Nippie 920 Siuo Coupling Oil Gauge
—
Switch 3-way Cock
322 Valve Cover: 2nd Stage Delivery —
1st Stage Air Elbow Unloader 1 921 Stud Coupling
—
323 -
0-ring Valve Cover 798 Joint Washer 797 1 858 Stua Coupirg Oil Gauge Pipe CranKcaw
799 Banjoinc800&801: 3-way Cock Tee — 922 ,c’nT Ivasnec 921
324 Valve Screw:
2nd Stage Delivery Valve 1st Stage Unload Inlet fl 859 Joint Washer : 858 923 Gouge Stwcort Angle 3 GausJ
325 Cap Nut; 324 1 800 Joint Washer 799 1 860 Pipe : 855 1° 858 924 Gauge Supuort Ang!e 4 Gaugt,,
326 Joint Joint Washer : 799 1 862 Thannostatic ‘Ialve 925 Screw
327 Cap Head Screw: 802 Pipe:lst Stage Air 1 B63 3-way Vaive T ‘or,ed Suprt Angle to Cy-inder -‘ead 2
4 804 Drain Valve : 1st Stage Cooler 1 86 F s : ‘len!Cock Tapoinç 926 Locknut Oil Gauge
2nd Stage Delivery Valve Co
329 Flange- Is! & 2nd Siage Air Pipe 2 806 Adapter : Drain Valve 1 865 929 Gauge Bears 3 Gauges)
330 Elbow: Air Pipes to Cylinder Heads 2 807 Joint Washer ; 806 869 Pipe 862 to 863 930 Gauge Board (4 Gauges
331 Pipe: Cooler Covers to 809 Drain Valve : 2nd Stage Cooler 870 Pipe : Water Pump 10836 931 Support Angle 929 & 930
2 811 Adapter 871 Vent Cock: 932 Screws
Cylinder Heads
812 Joint Washer : 811 2nd Stage Cyinder Head Support Angle’— Cylinder Head 2
332 —
Joint : Flange Cooler Covers 2
815 Drain Block : Auto Drains 872 Joint Washer: 864 or 871 933 Screws:
333 Joint Elbow to Cylinder Heads 2 H 873 —
Gauge Board Support Angle
334 —
Setscrew: Flange Cooler Covers 4 816 —
Spacer : Drain Block Aux. Cover Instruction Plate : 863 2
817 —
Stud : Drain Block Aux. Cover 874 Pipe Clip :873—876 934 Nuts : 933 2
335 —
Studs : E’bow Cylinder Head 8
875 Screws No. 6 S&f Tapping - 935 Washer Plain : 934
8 818 Nut 817 2
336 Nut,; 335
n 873 to 814 2 937 —
Screws : Gauges Board 12
750 Water Pump Jabsco 11790 1 819 Auto Drain Trap
877 Plug: Gauge Tappings 4 938 —
Screws Name Plates Board 8
752 Coupling Disc 1 820 Adjusting Shims: 819 As reqd.
878 Joint Washer : 877 4 939 Gauge Cock : L.P. & H.P. Gauges 2
753 —
Dowel : Disc Pump 1 821 Adapter
880 Gauge 50 mm. (2 in.) Dial 940 Tail Pipe: Oil & Water Gauges 1
2 —
Auto Drain Trap Drain Block 2
754 Dowel Crankshaft Low Pressure Air 941 Union Nut : Oil & Water Gauges
4 1
755 Companion Flange: 822 Joint Washer : 821
881 Gauge 50 mm. (2 in.) Dial 942 Joint Washer
Water Pump Suction 824 Adapter: Silencer 2
High Pressure Air 1 Oil, Water. LP. & H.P. Gauges 4
755 Companion Flange: 826 Silencer: Auto Drain Exhaust 2
883 Gauge 50 mm. (2 in.) Dial 943- Nameplate: 1st Stage Air Prsure
Water Pump Delivery 1 826 Joint Washer:
944
Oil Pressure I Nameplate : 2nd Stage Air Pressure
169 —
Joint: Pump Crankise Cover 1 Adapter—DrainTrap 2 885 Gauge 50mm. (2 in.) Dial: 945 Nameplate: Oil Pressure
760 —
Screw,: Pump Crankcase Cover 6 828 Pipe: lstStageCoolerCover—
Water Pressure 1 946 Nameplate: Water Pressure
761 Spring Washers: 760 6 Drain Block -I 901 947 Plug : Thermometer Tapping.
Gauge 100 mm, (4 in.) Dial 4
762 Joint: Companion Flanges Pump — 2 829 Banjo inc. 831 : 1st Stage Cooler
cm Low Pressure Air 1 948 Joint Washer : Plug & Thermometer
763 Screw: —
Cover Drain Block 2 902 Gauge 100 mm. (4 in.) Dial Pocket 4
Suction & Delivery Companion 830 Male Stud Coupling: High Pressure Air 965 Thermometer Dial Type
1 3
Flanges 8 Drain Valve Outlet 905 Gauge 100 mm. (4 in.) Dial 966 Thermometer Pocket 3
764 Plain Washer; 763 8 831 Joint Washer: 829 4 c. Oil Preswe 967 Thermometer : Water, Stem Type 2
765 Elbow 1 833 Pe:2nd5togeCooler- 907 Gauge 1C mm. (4 in.) Dial: 968 Thermometer : Air, Stem Type
766 Joint Washer: 765 1 Drain Block 1 cm Water Pret,e 1 970 flange
767 Pipe:WaterPump— 834 Banjo Inc. 8 & 836: 911 Pipe: L.P. Gauge 1 971 Joint
Cylinder Block 1 2nd Stage Cooler Cover 1 cm 912 Pipe:H.P.Gauge 1 972 Joint .•Q,er- Thermometer Pocket 3
770 Water Shist.ofl Valve 1 835 Joint Washer; 834 2 913 Pipe: Crankceso to Oil Gauge 1 973 Tee : Water Thermometer 2
772 Adapter: Valve Outlet 1 836 Joint Wesh.:834 914 Pipe: C/Block to Water Gauge 1 974 Tee: Air Thermometer
773 Joint Wash.: 772 1 837 StudCouplirc:2ndStageCocler 975 ,
Nipple Water Tees 2
915 StudCoupling:
776 Flow Regulator: —
Covet Drain Block LP & H.P. Cooler Covers 3 976 Nipple: Air Tee
Air to Shut-oft Valve 1 838 Stud Coupling: 916 JointWasher:915 3 977 —
Joint Washer : Nipple Air Tee 2
777 Adapt.,: Regulator Valve — 1 —
Drain Valve Outlet 917 Washer : Gauge to Support Angle 8 en Son 970—985 4
778 Banjo inc. 779 — Joint Wash. 837 918 Coct: LP.&H.P.&WaterGaug 3 981 ‘Jut 4
1st Stage Cooler Cover 1 841 H* Air Temp. Switch I 919 Joint Washer: Oil Gauge 920 — 2
179 Joint : 776—777 2 843 Joint CRANKSHAFT SUB ASSEMBLY PREFIX A — ITEM 1
780 —
Pipe : 8anjo Regulator 1 845 Tee Piecs: Temp. Switch cm
781 Stud Coupling : 780—776 1 846 Air Pipe Item Na Dafltion OW.
187 Unloader 1 847 Air Pipe 1
788 —
Joint; Unloader Silen Elbow 850 Low Lub. Oil Prs. Switch Al CmnkQse
789 Studs: Unloader Elbow — 3 861 Mounting Plate: Switch 42 Main Bearing Cap : End 2
790 Nuts: 789 3 852 Setnew Switch to Mounting Plate 43 Main Bearinq Cap Centre
791 Spring Washer 3 853 Nut: 852 44 Bolt Main Bearing 6
794 Stud Coupling 2nd Stage 864 Spring Wash.: 863 AS Grooved Pin
—
Air Elbow Unloader In & Out 3 855 Male Stud Tee: Main Bearinq Boll 6
795 Joint Washer: 794 3 Crankc,e—Gauge—3-way Cock A6 Nuts Main Bearing Bolt 6
796 Pipe; 2nd Stage Air 856 3-way Cock: Switch A? Dowel Main Bearing Cap 6

5/37
5/36
 -
.___zz.... :: t2ii v—— sccr t r
Itam No. Description Qty. ZTM6 MK AIR CORE5SOR
E t
WATER JACKET RELIEF VALVE ASSEMBLY — PREFIX B ITEM 275 -— r — —
D. 5 2 4 7
— I —
— I — fl • T*
—
. lT5 I 01 b oi • •
—: —— at swtn
I
81 Body 1 €1. S0TtS S—flW*T

54 Spindle
85 Backing Disc
C
B9 Sealing Ring 1 2
wjy C
BlO Spring 1 r

1st & 2nd STAGE CONNECTING ROD ASSEMBLY — PREFIX C ITEM 166
=

Cl a
Connecting Rod 2
C2 Connecting Rod SoIt 4
vii,
CS Nut: Connecting Rod Bolt 4
rIy
C4 Small End Bearing 2
C5 Dowel 4
C6 Spht Pin 4 n
C7 Big End Half Bearing 4
n 0 —

1st STAGE PISTON — PREFIX D ITEM 169

2 :

Dl Piston 1 n
D2 Gudgeon Pin
D3 Crclip 2
n
D4 Piston Ring
Comp. internally stepped 2
05 Piston Ring: Scraper conformable 1
n
2nd STAGE PISTON — PREFIX E ITEM 115

El Piston 1 0
62 Gudgeon Pin 1
63 Circlip 2
E4 Piston Ring: Camp. taper faced 3

lit STAGE TUBE NEST — PREFIX F ITEM 178

Fl Cooler Tube Plate 2 n

F2 Cooler Tubes 75

—
2nd STAGE TUBE NEST PREFIX 0 ITEM 209 n
G1 Cooler Tube Plate 2
G2 Cooler Tubes 33

—
STEM TYPE THERMOMETERS AIR PREFIX H ITEM 968

HI Casing & Insert 1

n
H2 Thermometer Pocket 1
n
fl
— a
n ;!
0 2 S
0

5/38 5/39
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 C

Ordering Spare Parts

The following information is required by flamworthy Pumps & Compressors Limited
to fully identifiy the unit and ensure that the correct spare parts are
supplied. C
Type of Machine: Obtained from machine nameplate
Serial Number of Machine: Obtained from machine nameplate
Item Number of Part Required: ) (Obtained from Sectional Arrangement
Full Description of Part Required:)— —(Drawings included in this
Drawing Number and Issue Number: ) (Publication
Spare Patti can be ordered direct from the following address: C
Hamworthy Pumps and Compressor Ltd, Spates Dept., Fleet, Corner,
Poole, Dorset Bull 7LA, England. C
Telex: 41348 (HAMPAC G) Telephone No. 0202—665566 Facsimile: 0202—665444.
Or from any Ilamvorthy Office or Agency throughout the world. C
In all cases it is essential that the above information be supplied with the
order.
Technical Service and Advice
Technical service and advice can be obtained during normal working hours from
the above address 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 0202—665566.
Overseas Offices and Associated Coapanies
Australia: Hamworthy Engineering Australia Pt7., Unit C, P.O. Box 475,
Baulkham Hills, N.S.W. 2153.
Brazil: Tridente Indu.tria e Comercio de Equipmentos Ltda., Ày. Rio
Branco, No. 4. 407/8/9 Rio de Janeiro, 20090 Centro, Brazil.
Canada: Hamworthy Canada Ltd.. 113—115 Cushman Road, St. Catharines,
Ontario.
Holland: Hamworthy Benelux By, Bristolstraat 1, 3047 A.B., Rotterdam.
Japan: Japan Hamworthy Company Limited, Park Omogata La, 15—1, 1—Chome,
Shigino—nishi, Jyoto—Ku, Osaka 536.
Norway: Hamworthy Engineering Ltd., Oslo Office, Stroinsveien 312, N—108l,
Oslo 10.
Singapore: Hamvorthy Engineering (FE) Pte, 9 Pioneer Road North, Hex 01—59,
Singapore 2262.
South Africa: Uamworthy Engineering Africa (Pty) Ltd., Corner tangwa and Susan
Road, Strydompark, Olivedale 2058, Johannesburg.
U.S.A. Hamworthy U.S.A. Inc., 5690 Southfield Court, Suite 100, Forest
Park, Atlanta, GA 30050.
D.C. Offices
London: Ground Floor East, 22 Bevi. Marks, London EC3A 1JB.
Scotland: 27 Buruside Place, Troon, Ayrshire KAIO 6LZ.
AND AGENTS THROUGHOUT THE WORLD.

CAUTION:

NOTICE TO ALL USERS OF KANVORTUT PUMPS AND COMPRESSORS:

SPARE PARTS
EQUIPMENT FAILURES HAVE BEEN IXPERIENCED AS A DIRECT RESUtT OP OUR
CUSTOMERS USING LOW QUALITY SPARE PARTS SUPPLIED BY COMPANIES OTHER
THAN RAMWORTHY (ot THEIR APPOINTED AGENTS).

PLEASE NOTE THAT WARRANTY CLAIMS MAY BE INVALIDATED AS A DIRECT

RESULT OP USING SON—ORIGINAL SPARES.

STATUTORY RIGHTS ARE Not AFfECTED.