Instruction manual air compressor HLF2/77

CCG DOC NO. 346055
INSTRUCTION MANUAL
AIR COMPRESSOR
HLF2/77
SPERRE
GB
CCG DOC NO. 346055
Instruction manual for compressor type HLF2/77
PREFACE
Sperre has produced this instruction manual in order to provide users of its compressor equipment
with information about the compressor’s construction and operation, as well as basic information about
inspection and maintenance.
It is important that the operator should familiarise himself with the contents of this instruction manual,
so as to ensure that installation, use and maintenance work is carried out in a correct and safe manner
from the outset.
The maintenance intervals and individual technical data are average values based on experience, and
may vary, depending on the compressor’s operational parameters.
The supplier accepts no responsibility for damage resulting from careless operation or inadequate
maintenance. Keep the compressor in good mechanical condition, and remember that preventive
maintenance of the equipment reduces the danger of damage and unnecessary operational
interruptions.
Sperre reserves the right to modify details without prior warning.
Ellingsøy, January 2010
Sperre Industri AS
CONTENT
Content
Page
Personal safety ............................................................................................................................ 2
General description ..................................................................................................................... 2
Sketch .......................................................................................................................................... 3
Installation.................................................................................................................................... 4
Starting up ................................................................................................................................... 5
Operation ..................................................................................................................................... 5
Stopping....................................................................................................................................... 5
Maintenance – Overhaul – Repairs ............................................................................................. 5
Valves ....................................................................................................................................... 5
Piston and connecting rod ........................................................................................................ 6
Bearings - Dismantling and Assembly ..................................................................................... 7
Coolers ..................................................................................................................................... 8
Gaskets .................................................................................................................................... 8
Recommended lubricating oil brands .......................................................................................... 9
Table of normal pressures and temperatures ............................................................................. 9
Maintenance routines .................................................................................................................. 10-11
Fault tracing chart ........................................................................................................................ 12
Tolerances – wear limits .............................................................................................................. 13
Ordering spare parts.................................................................................................................... 14
Spare parts list ............................................................................................................................. 15
Available spare part kits .............................................................................................................. 16
Illustration for spare parts list....................................................................................................... 17-21
Page 1
CCG DOC NO. 346055
Instruction manual for compressor type HLF2/77
PERSONAL SAFETY
The installation, operation and maintenance of the compressor should be carried out by trained
personnel who are familiar with the contents of this instruction manual.
The compressor must only be used to compress air.
Unauthorised remodelling or modification of the compressor may result in a safety hazard, and are not
permitted.
Before any form of work is commenced on the compressor the electrical power must be turned off at
the starter panel and at the main switchboard, and the switch on the main switchboard must be
marked with a notice indicating that repair work is in progress. The discharge valve of the compressor
must be closed, and the pressure must be released in all pressurised parts of the compressor.
The safety valves for LP and HP air and any other safety equipment must be inspected regularly.
Damaged components should be replaced with new, original parts. Adjustment of the safety valves
shall only be carried out by authorised personnel. The compressor must never be used if the safety
equipment is defective.
GENERAL DESCRIPTION
This is a two cylinder, two stage compressor. The cylinders are fitted in a V-shape at 90° angle to
each other. Cylinders and compressed air coolers are air-cooled by a built in fan. Supply pressure is
determined by adjusting the safety valve.
The compressor and motor are normally supplied fitted together as a single unit. The compressor and
motor are connected by means of a heavy duty flexible coupling.
All the materials used are of first class quality, thoroughly tested and in accordance with the
requirements of the classification societies.
Instrumentation is supplied in accordance with classification society requirements and if desired the
compressor can be fitted with equipment for fully automatic operation.
Bearings and cylinder walls are splash lubricated. The oil level in the sump can be checked through a
sight glass. An automatic low oil level alarm can be supplied as an optional extra.
The compressor is normally supplied without a relief mechanism for the LP cylinder suction valve.
However, a relief mechanism can be ordered from SPERRE if required.
The compressor unit can be supplied either for bolting directly to the foundation, or for flexible
installation by means of resilient mountings fitted under the bedplate.
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CCG DOC NO. 346055
Instruction manual for compressor type HLF2/77
Page 3
CCG DOC NO. 346055
Instruction manual for compressor type HLF2/77
INSTALLATION
The compressor and el. motor are normally connected by a flanged connection piece, and not by the
means of a separate baseplate. In this assembly it is not necessary to take any special measures to
align the motor and compressor.
If the compressor is delivered as an assembly with compressor and engine mounted on a common
baseplate, it is very important to ensure that the alignment of the compressor and motor shafts are
within the required limits.
Alignment should be carried out as follows:
1. Use vernier callipers to check that the distance between the coupling halves is equal around the
whole circumference. The distance between the coupling halves should be 33 ± 1 mm. The exact
distance is not important, but it must be the same all around the coupling.
2. When angular alignment has been checked as described above, check for parallel displacement,
using a dial gauge mounted on a magnetic base. Measure the parallel displacement around the
circumference. Displacement must not exceed ± 0,05 mm.
In order to ensure trouble-free operation it is important that the foundation is well stiffened and free
from vibrations from other installed machinery. This applies to rigid mounting and flexible mounting
alike.
A well-dimensioned fresh air duct must be provided to the location where the compressor is installed.
The mouth of the duct should be as close as practically possible to the suction side of the cooling fan.
The ambient temperature should not exceed 45°C.
In principle the pipe from the compressor to the air reservoir should be arranged as shown in the
installation diagram supplied with the compressor. A non-return valve of strong construction and little
air resistance should be installed between oil and water separator and air receiver.
If the compressor unit is installed with resilient mountings, a flexible hose must be installed in the
compressed air pipe. An oil and water separator should be fitted at some distance from the
compressor, and arranged so that the line slopes downwards from the compressor to the separator. It
is recommended to provide the oil and water separator with both manual and automatic draining.
Equipment for automatic draining is available as an optional extra.
If the pipe from compressor to reservoir is longer than about 10 meters, the dimensions shown in the
installation diagram supplied with compressor should be somewhat increased to ensure the lowest
possible air resistance.
Arrange the piping so that condensate cannot collect in pockets.
All piping must be well clamped and free from vibration.
Page 4
CCG DOC NO. 346055
Instruction manual for compressor type HLF2/77
STARTING UP
Before initial starting up and after long periods out of use, carry out the following operations in the
sequence given:
1. Check the oil level (sight glass).
2. If the compressor has been out of service for more than 6 months, remove valves and lubricate
cylinder walls.
3. Open valves on compressed air line, and start the unit.
4. Check that all components are running normally. Inspect instruments, check for air leaks.
OPERATION
During operation, pressures and temperatures must be within the recommended limits. Any deviation
is abnormal and it’s cause should be ascertained by means of the fault tracing chart. In the case of
pressure or temperature deviations, it is recommended first to check the values with new
thermometers and pressure gauges in order to ensure that the fault is not to be found in the
instruments.
STOPPING
If the compressor is to remain unused for a long period, lubricate valves and cylinder walls with oil.
The compressor should be turned over from time to time.
MAINTENANCE – OVERHAUL – REPAIRS
Only Sperre original spare parts should be used for overhauls and repairs. Before ordering spare parts,
please read the instructions given in chapter: “Ordering spare parts”.
Valves
LP valve
To dismantle the valve, proceed as follows:
1.
2.
3.
Loosen pipe connections.
Loosen and remove cylinder head.
Loosen the bolts holding the valve in place on the cylinder head.
Carefully separate the upper and lower sections of the valve body to remove the valve insert with valve plates.
Important: There are milled slots in the upper and lower sections of the valve body. When the valve is
correctly assembled these slots correspond.
It is important that the valve is be correctly fitted under the cylinder head. The valves suction side should
be turned towards the suction air filter and the pressure side must face towards the fan/electric motor.
Press the valve (3036) against the cylinder head (1283) by means of a hydraulic press or vice. Force
approx. 2T. Tighten the screws (4401) to a torque of 24 Nm.
The screws 4401 must be locked so that they cannot come loose. The edge of each screw head has a
notch. After tightening the screws, lock them by putting a punch mark in the valve at each notch.
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CCG DOC NO. 346055
Instruction manual for compressor type HLF2/77
HP valve
To dismantle the valve, proceed as follows:
1. Loosen pipe connections at cylinder head.
2. Loosen cylinder head nuts and lift off cylinder head.
3. The valve is now free and can be removed.
Valve assembly sequence is the opposite of the above.
Worn and damaged parts should be replaced. Always replace valve gaskets.
Valve overhaul: Release the lock at the top of the valve, loosen the nuts and carefully open the valve.
Note the location of the parts, so that they can be correctly refitted.
Clean the valve parts, carbon deposits can best be removed by means of a good solvent, carbon
remover or similar, then flush with hot water.
Important: The valves are an essential part of the compressor and it is important for
operational safety that all parts have the correct material specifications and machining
tolerances. Even the smallest defect in a valve component may lead to overheating and
consequent damage. The supplier accepts no responsibility for damage to the compressor
resulting from the use of non-original parts.
Only original Sperre copper gaskets can be used as valve seating gaskets. Exact dimensions
and correct hardness are of great importance for trouble free operation.
Cylinder head nuts should be tightened a little at a time, in sequence, to prevent unsymmetrical load
on the valve.
Piston and connection Rod
The procedure for dismantling and assembling the piston and connecting rod is as follows:
1. Dismantle the electric motor, coupling, and intermediate piece from the compressor.
2. Remove the LP cylinder head.
3. Remove the crankcase cover and remove the counterbalance at the end of the crankpin.
4. Loosen the bearing housing and pull it axially together with the crankshaft, far enough to bring the
connecting rods clear of the crankpin.
5. Pull the LP piston with the connecting rod out of the top of the cylinder.
6. Pull down the HP piston with connecting rod out through the crankcase.
Assembly sequence is the opposite order.
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CCG DOC NO. 346055
Instruction manual for compressor type HLF2/77
Bearings - Dismantling and Assembly
Important: Work on bearings requires great care and scrupulous cleanliness.
Worn or damaged crankshaft bearings should be replaced complete. Replacement of parts of
the bearings is not satisfactory. Bearings dismantled from shaft and/or connecting rod should
always be replaced with new bearings.
Crankshaft bearings
Dismantle as follows:
1. Remove the outer ring from the connecting rod, using a hydraulic press.
2. Remove the inner ring from the crankpin by heating it rapidly with a welding torch, then push it off
the pin by means of a screwdriver or the like. If necessary, grind a notch in it to reduce its tension.
3. Fit a new outer ring to the connecting rod by using a hydraulic press.
4. To fit the inner ring, heat it in an oil bath or on an electric hotplate to 80 – 100 °C before sliding it
onto the pin.
Gudgeon pin bearings
Dismantle as follows:
1. Remove seeger rings.
2. Press out the gudgeon pin. If necessary, heat the piston slightly.
3. Use a hydraulic press to remove and re-install the gudgeon pin bearing in the connecting rod.
Important: Check that there is axial play between connecting rod and piston after installation.
Main bearings
Dismantle as follows:
1. Remove the crankcase cover and detach the counterbalance at the end of the crankpin.
2. Dismantle the electric motor, coupling piece, coolers and flywheel.
3. Dismantle cylinder heads, pistons and connecting rods as described under ”Piston and connection
Rod”.
4. Pull the bearing housing and crankshaft clear of the crankcase.
5. Remove seeger ring and pull the crankshaft out of the bearing housing. Carefully tap the bearings
off the shaft and bearing housing respectively.
Before fitting the bearings, heat them in an oil bath to about 100°C. Ensure that the seeger rings are
correctly placed in their respective slots.
Assembly is done in the opposite order.
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CCG DOC NO. 346055
Instruction manual for compressor type HLF2/77
Coolers
To ensure trouble-free operation it is of the greatest importance to ensure that the coolers are kept
clean and free of foreign matter at all times. If the coolers are not kept properly clean, high air
temperatures will result, with a consequent reduction of working life of valves and cylinders.
The coolers can be externally cleaned by spraying on a good grease solvent and then blowing them
clean with compressed air.
In the case of heavy deposits of dirt the coolers should be dismantled for external and internal
cleaning.
Any carbon deposits in the tubes can be removed by placing them in a bath of carbon remover or
similar solvent overnight, and then flushing with hot fresh water.
Important: Make sure that the cleaning products are suitable for use on copper pipes.
Gaskets
In order to achieve satisfactory operation it is recommended to replace gaskets at every overhaul.
Worn or damaged gaskets will reduce compressor capacity and cause faulty operation.
Use only original SPERRE gaskets.
Page 8
CCG DOC NO. 346055
Instruction manual for compressor type HLF2/77
LUBRICATING OIL
The lubrication oil volume in the crank case is 1,8 litres.
The following lubricating oil brands are recommended:
Synthetic oil
Mineral oil
ANDEROL 555
BP ENERSYN RX 100
CASTROL AIRCOL SN 100
COSMO RECIPRO SX 100
DAPHNE MARINE COMPR. 100
ESSO / EXXON ZERICE S 100
ESSO / EXXON SYNNESTIC 68
FAMM CETUS DE 100
MOBIL RARUS 827
NIPPON OIL CO. FAIRCOL SA 100
SHELL CORENA AP 68
STATOIL FRIDGEWAY S 100
TOTAL LUBMARINE BARELF AL 100
STATOIL COMPWAY SX68
BP ENERGOL RC 68
CASTROL AIRCOL PD 100
CALTEX RPM COMPR. OIL 68
ESSO / EXXON EXXCOLUB 77
COSMO RECIPRO 100
FAMM COMPRESSOR OIL EP VDL 100
GENERAL COMPOL A 100
MITSUBISHI COMPR. OIL 100
MOBIL RARUS 427
PHILLIPS COMPR. OIL 68
SHELL CORENA P 68
STATOIL COMPWAY 68
TOTAL DACNIS P
Ask SPERRE for advice before using lubricating oil of any other type.
TABLE OF NORMAL PRESSURES AND TEMPERATURES
Temperatures in service, with shaft speed 1450 rpm. The values are valid for ambient temperature
40°C and delivery pressure 30 bar.
Pressure after LP cylinder:
Temperature after LP cylinder:
Temperature after LP cooler:
Temperature after HP cylinder:
Temperature after HP cooler:
2 - 3 bar
125°C
115°C
210°C
80°C
At lower or higher ambient temperatures, the compressed air temperatures at the points indicated
above will be approximately an equal number of degrees lower or higher.
Temperatures will be lower at lower shaft speeds.
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CCG DOC NO. 346055
Instruction manual for compressor type HLF2/77
MAINTENANCE ROUTINES
The following is a guideline for a normal maintenance schedule. However, the compressors operating
conditions vary widely from installation to installation and it is therefore important to adapt the
maintenance schedule to the experience of the individual operator.
The following schedule applies to automatically monitored and manually operated installations alike.
After the first 200 hour operation:
Change lubricating oil. Drain the sump while the oil is warm. Clean the sump thoroughly before filling
with fresh oil.
Daily inspection:
Make a quick general inspection of the whole compressor (in normal operation) and specially check
the following:
1. Lubricating oil level.
2. Compressed air temperature and pressure.
3. Automatic equipment.
Overhaul routine A (1.000 running hours or every 2 years):
Make sure that overhaul kit no. 3036MK2 and 3037MK2 are in stock before starting overhaul of
compressor according to Routine A - 1.000 hour service. Please follow installation instructions
included in the kit.
1. Replace lubricating oil.
2. Remove the valves from both cylinders. Check for carbon deposits. Dismantle the valve for
cleaning and repair if necessary. Use spare part kit no. 3036MK2 and 3037MK2 to overhaul
valves. All valve gaskets should be replaced with new parts at assembly.
3. Inspect the flexible coupling between compressor and motor.
4. Check all bolts and nuts for proper tightness. Also check vibration dampers and hose connections
if the unit is flexibly mounted. Check that no oil has come in contact with the rubber elements in
the vibration dampers.
5. Function-test the safety valve. Start the compressor, and slowly close the stop valve on the
compressed air line. The air pressure should not exceed max. working pressure + 10%. The
safety valves are sealed and the setting should not be adjusted. If the valves are malfunctioning or
open at wrong pressure, the safety valves should be replaced.
6. Check all pipe connections (compressor running).
7. Check that all automatic equipment is functioning correctly.
8. Change suction air filter, insert (Part no. 8451).
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CCG DOC NO. 346055
Instruction manual for compressor type HLF2/77
Overhaul routine B (5.000 running hours):
Make sure that overhaul kit no. 7933 are in stock before starting overhaul of compressor
according to Routine B - 5.000 hour service. Please follow installation instructions included in
the kit.
1. Change lubricating oil.
2. Remove the valves from both cylinders. Check for carbon deposits. Overhaul valves. Use spare
part kit no. 3036MK2 and 3037MK2 to overhaul valves. All valve gaskets should be replaced
with new parts at assembly.
3. Replace the flexible coupling between compressor and motor.
4. Check all bolts and nuts for proper tightness. Also check vibration dampers and hose connections
if the unit is flexibly mounted. Check that no oil has come in contact with the rubber elements in
the vibration dampers.
5. Function-test the safety valve. Start the compressor, and slowly close the stop valve on the
compressed air line. The air pressure should not exceed max. working pressure + 10%. The
safety valves are sealed and the setting should not be adjusted. If the valves are malfunctioning or
open at wrong pressure, the safety valves should be replaced.
6. Check all pipe connections (compressor running).
7. Check that all automatic equipment is functioning correctly.
8. Change suction air filter, insert (Part no. 8451).
9. Remove the compressors cooler tubes and clean the outside and inside. Spray the outside with a
good grease solvent, and wash clean with warm water. The inside is cleaned by letting the cooler
tube soak in a bath of carbon remover, and then flushing the tube with warm water. Make sure
that cleaning products suitable for copper tubes are used.
10. Remove cylinders, pistons and connecting rods. Inspect cylinder walls and piston. Replace the
piston rings (use a piston ring expander tool to fit the rings on the piston). Clean all parts. Replace
gudgeon pins with bearings and crank bearings. Rotate the shaft by hand, and check that the
main bearings are rotating smoothly and without any signs of excessive wear. Use overhaul kit
no. 7933.
Overhaul routine C (10.000 running hours):
Make sure that overhaul kit no. 7963 are in stock before starting overhaul of compressor
according to Routine C - 10.000 hour service. Please follow installation instructions included in
the kit.
1. Change lubricating oil.
2. Replace the LP and HP valves. Use spare part kit no. 3036MK and 3037MK. All valve gaskets
should be replaced with new parts at assembly.
3. Replace the flexible coupling between compressor and motor.
4. Check all bolts and nuts for proper tightness. Also check vibration dampers and hose connections
if the unit is flexibly mounted. Check that no oil has come in contact with the rubber elements in
the vibration dampers.
5. Function-test the safety valve. Start the compressor, and slowly close the stop valve on the
compressed air line. The air pressure should not exceed max. working pressure + 10%. The
safety valves are sealed and the setting should not be adjusted. If the valves are malfunctioning or
open at wrong pressure, the safety valves should be replaced.
6. Check all pipe connections (compressor running).
7. Check that all automatic equipment is functioning correctly.
8. Change suction air filter, insert (Part no. 8451). Replace crank case breather valve.
9. Remove the compressors cooler tubes and clean the outside and inside. Spray the outside with a
good grease solvent, and wash clean with warm water. The inside is cleaned by letting the cooler
tube soak in a bath of carbon remover, and then flushing the tube with warm water. Make sure
that cleaning products suitable for copper tubes are used.
10. Remove cylinders, pistons and connecting rods. Inspect cylinder walls and piston. Replace the
piston rings (use a piston ring expander tool to fit the rings on the piston). Clean all parts. Replace
gudgeon pins with bearings, crank bearings and main bearings. Use overhaul kit no. 7963.
Page 11
CCG DOC NO. 346055
Instruction manual for compressor type HLF2/77
FAULT TRACING CHART
1. Compressor capacity is low, or the compressor is not delivering full pressure
Possible causes
Remedy
Clean and check all valve plates, springs and
Dirty, damaged or worn valves.
gaskets. Replace defective parts.
Piston rings are worn. Replace.
Carbon deposits on valves.
Unsuitable lubricating oil. Change oil brand.
Loosen and remove piston rings.
Piston rings are stuck.
Clean piston ring grooves and rings.
Air filter clogged.
Clean filter.
Air leaking to surroundings or leaking inside the
Check for external leakages with soapy water.
compressor through valve gaskets and valve
Check valve gaskets and valves.
plates.
Faulty automatic control equipment.
Inspect components and circuits.
2. Safety valve blows
Possible causes
Closed air line valve.
Carbon deposits in non-return valve.
Faulty adjustment of automatic system.
Compressor does not stop when air reservoir is
full.
Safety valve damaged or defective (causing it to
open at lower pressure).
3. Valves require maintenance too frequently
Possible causes
Overheating.
Dirt or foreign matter in intake air.
Cooler tubes dirty.
Remedy
Open the valve.
Clean the valve.
Check pressure switch and automatic circuitry.
Replace safety valve.
Remedy
High ambient temperature. Improve fresh air
supply. Carbon deposits in coolers. Clean
coolers.
Air filter damaged. Improve suction air quality.
Clean.
4. Bearings and bearing housings running hot. Lub. oil overheating. Noise from bearings
Possible causes
Remedy
Damaged or worn bearings.
Replace bearings.
Uneven wear on crankshaft bearings.
Check crankshaft for straightness.
Low oil level.
Refill lub. oil.
5. Piston running hot
Possible causes
Worn bearing on flywheel end.
Piston and/or rings binding in cylinder.
Remedy
Check little end bearing, piston rings and piston
clearance.
Ensure cool fresh air supply to cooling fan and
suction air filter. If the piston has completely
seized, wait a while before turning over the
compressor. Clean cylinder and piston, fit new
piston if necessary.
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CCG DOC NO. 346055
Instruction manual for compressor type HLF2/77
TOLERANCES - WEAR LIMITS
1. End tolerances for piston rings
Push a piston without piston rings halfway into the cylinder, and place the piston ring in the cylinder so
that it presses against the top of the piston. Withdraw the piston and using a feeler gauge, measure
the clearance between the piston ring ends.
Piston
diameter
50 mm
77 mm
Clearance for new
rings in new cylinder
0,2 - 0,35 mm
0,3 - 0,45 mm
Maximum
Permissible clearance
0,7 mm
0,8 mm
2. Height clearance in piston ring grooves
Clean piston rings and ring grooves. Fit ring in groove and measure the height clearance of the ring in
the groove using a feeler gauge.
Top ring
All other rings
Clearance for new
rings in new piston
0,015 - 0,04 mm
0,00 - 0,025 mm
Maximum
Permissible clearance
0,06 mm
0,04 mm
These values apply to both piston diameters.
3. Clearance between piston and cylinder
Measure the clearance by means of a dial gauge, measuring the cylinder and piston separately.
Alternatively the piston can be placed in the cylinder and the clearance measured with thickness
gauges. The piston clearance should be measured in the area above the upper ring groove.
The clearance listed in the table below is the difference in diameter for the two parts.
Piston
diameter
50 mm
77 mm
Clearance for new piston
in new cylinder
0,20 mm
0,25 mm
Maximum
Permissible clearance
0,60 mm
0,65 mm
4. Clearance between piston top and cylinder head/valve.
The clearance between the piston crown and the cylinder head (valve) should be not less than 0,75 mm.
The normal gasket thickness is approx. 1,0 mm, and the piston crown may project a maximum of 0,25
mm above the cylinder at top dead centre.
Page 13
CCG DOC NO. 346055
Instruction manual for compressor type HLF2/77
ORDERING SPARE PARTS
The following information must be given when ordering spares:
(A)
(B)
(C)
Compressor type
Compressor number
Quantity, parts number and description of the spare parts required
(A) and (B) are stamped on the compressor rating plate, which is fixed to the side of the crankcase
and (C) will be found in the spare parts list in this instruction book.
SPERRE INDUSTRI AS reserves the right to amend technical specifications without prior notice and
disclaims all legal liability in connection with such amendments.
Address for ordering parts:
Original parts can also be ordered from:
SPERRE INDUSTRI AS
6057 ELLINGSØY
NORWAY
Sperre Rotterdam BV
Glasblazerstraat 12B
NL-2984 BL Ridderkerk
NETHERLANDS
Tel.
: +31 180 463 299
Fax
: +31 180 463 264
E-mail
: rotterdam@sperre.com
Phone:
Fax:
E-mail:
+ 47 70 16 11 00
+ 47 70 16 11 10
industri@sperre.com
www.sperre.com
Sperre Asia Pte. Ltd.
63 Hillview Avenue # 09-13
Lam Soon Industrial Building
SINGAPORE 669569
Tel.
: +65 763 6300
Fax
: +65 763 1811
E-mail
: asia@sperre.com
Sperre China
Room 16E, No.257 Siping Road
Hongkuo District
200081 Shanghai, China
Tel.
: +86 216 5070436
Fax
: +86 216 5070402
E-mail
: china@sperre.com
Page 14
CCG DOC NO. 346055
Instruction manual for compressor type HLF2/77
SPARE PART LIST
Qty
Description
Part no.
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
2
1
1
1
1
1
1
1
1
2
2
1
1
2
1
1
1
1
1
1
1
1
1
4
1
1
2
2
Crankcase ...................................... 1022
Crankcase cover ............................ 1070
Cylinder head H.P. ......................... 1281
Cylinder head L.P. .......................... 1283
Drive coupling................................. 1371
Piston rod ....................................... 1428
Crankshaft ...................................... 1436
Flywheel ......................................... 1444
Bearing housing ............................. 1446
Counterbalance .............................. 1520
Spacer ............................................ 1991
Bracket ........................................... 2046
Valve, L.P. ...................................... 3036
Valve, H.P. ..................................... 3037
Valve plate, L.P. ............................. 3122
Valve plate, H.P.............................. 3123
Valve plate, H.P.............................. 3124
Washer ........................................... 3131
Valve nut ........................................ 3236
Valve spring H.P............................. 3279
Valve spring H.P............................. 3280
Guide ring ....................................... 3298
Plain nipple ..................................... 3345
Oil scoop ........................................ 3347
Tubular pin ..................................... 3350
Piston, H.P. .................................... 3352
Piston, L.P. ..................................... 3354
Valve part, upper ............................ 3430
Valve part, lower............................. 3431
Catch plate, lower H.P. .................. 3432
Catch plate, upper H.P. .................. 3433
Gudgeon pin, H.P. .......................... 3451
Gudgeon pin, L.P. .......................... 3452
Compression ring, stepped, H.P. ... 3487
Compression ring, stepped, L.P. .... 3488
Compression ring, plain, H.P. ........ 3501
Oil ring, H.P. ................................... 3528
Oil ring, L.P..................................... 3529
Inspection glass.............................. 3634
Intercooler, complete ...................... 3657
After cooler, complete .................... 3658
Key ................................................. 3682
Air relief valve ................................. 3700
Air filter ........................................... 3711
Pressure gauge, H.P. ..................... 3773
Nipple ............................................. 3783
Seeger ring ..................................... 3806
Seeger ring ..................................... 3813
Seeger ring ..................................... 3815
Ball bearing .................................... 3872
Needle bearing ............................... 3877
Needle bearing ............................... 3878
Qty
Description
1
1
2
1
1
2
8
1
1
5
1
1
1
1
1
2
1
4
4
4
12
2
1
1
2
1
1
3
3
3
1
1
1
3
1
1
1
1
Ball bearing .....................................3881
Valve sealing ring ...........................3918
Valve sealing ring ...........................3919
Copper gasket ................................3925
Copper gasket ................................3926
Copper gasket ................................3929
Copper gasket ................................3930
Spring washer .................................3937
Serrated washer .............................3939
Bolt ..................................................3946
Gasket ............................................3998
Gasket ............................................4075
Gasket ............................................4095
Gasket ............................................4096
Set of gaskets .................................4127
Lock nut ..........................................4133
Stud bolt ..........................................4189
Stud bolt ..........................................4193
Stud bolt ..........................................4194
Stud bolt ..........................................4199
Nuts.................................................4238
Set screw ........................................4268
Nipple muff ......................................4283
Threaded plug.................................4297
Bolt ..................................................4401
Safety valve, H.P. ...........................4420
Safety valve, L.P.. ...........................4421
Unbraco screws ..............................4445
Double male end union ...................4457
Double male end union ...................4460
Elbow ..............................................4466
Tee piece ........................................4472
Tee piece ........................................4473
Connecting bolt ...............................4484
Flexible coupling insert ...................4519
Male/female nipple..........................4590
Bolt ..................................................4618
Air filter, insert .................................8451
Page 15
Part no.
CCG DOC NO. 346055
Instruction manual for compressor type HLF2/77
SPARE-PART & MAINTENANCE KITS
SPERRE’s kits of genuine spare-parts include the wear parts you must change when you overhaul the
compressor. For example, if you replace a valve, it is strongly recommended to replace the valve
gaskets at the same time. With a spare-part kit available, all necessary parts are at hand together with
clear installation instructions.
For model HLF2/77 following kits are available:
Description
Part no.
Content of kit
Gasket kit
4127
Crankshaft
1436MK
Valve LP
3036MK
All flat gaskets, O-rings, sealing rings, and valve gaskets.
Crankshaft with all bearings, flywheel key and nut, Seegerrings, endplate and screw.
Valve and necessary copper rings and/or gaskets.
Valve HP
3037MK
Valve and necessary copper rings and/or gaskets.
Overhaul kit - LP valve
3036MK2
Valve springs, plates and gaskets.
Overhaul kit - HP valve
Piston LP
3037MK2
3354MK
Valve springs, plates and gaskets.
Piston, gudgeon pin with Seeger-rings and piston rings.
Piston HP
3352MK
Connecting rod
1428MK
Flexible coupling
4519MK
Piston, gudgeon pin with Seeger-rings and piston rings.
Connecting rod with small- and big-end bearings, oil scoop
with set screw.
Rubber coupling with bolts.
Overhaul kit Routine B
7933
All parts needed for 5 000-hours’ maintenance: Overhaul
kits for valves complete with gaskets and guide rings, piston
rings, connecting rod bearings, gudgeon pins, Seeger-rings,
gaskets and ventilator.
Overhaul kit Routine C
7963
All parts needed for 10 000-hours’ maintenance: Same as
kit B, plus complete valves, crankshaft bearings and seal
ring.
Maintenance kits:
•
•
All necessary parts at hand when you need them
With clear installation instructions enclosed
Genuine Sperre parts give you peace of mind at sea !
Page 16
CCG DOC NO. 346055
CCG DOC NO. 346055
CCG DOC NO. 346055
CCG DOC NO. 346055
CCG DOC NO. 346055
CCG DOC NO. 346055
Sole suppliers of genuine spare parts:
Sperre Industri AS
N-6057 Ellingsøy
Norway
Tel +47 70 16 11 00
Fax + 47 70 16 11 10
industri@sperre.com
Sperre Asia PTE Ltd
63 Hillview Avenue #09-13
Lam Soon Industrial Building
Singapore 669569
Tel +65 6763 6300
Fax + 65 6763 1811
asia@sperre.com
Sperre Rotterdam BV
Glasblazerstraat 12B
NL-2984 BL Ridderkerk
The Netherlands
Tel +31 180 463 299
Fax + 31 180 463 264
rotterdam@sperre.com
www.sperre.com
Sperre China
Room 16E, No.257 Siping Road
Hongkuo District
200081 Shanghai, China
Tel +86 216 5070436
Fax +86 216 5070402
china@sperre.com
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