Hf2-77eb

INSTRUCTION MANUAL

AIR COMPRESSORHLF2/77

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Air-Cooled Air Compressor Type : HLF2/77 Page - 1 -

GBINSTRUCTION MANUAL

FOR AIR-COOLED AIR COMPRESSOR HLF2/77

IMPORTANT

The following information must be given when ordering spares:

(A) Compressor type, HLF2/77(B) Compressor number, e.g. 70007(C) Quantity, description and parts number of the spares required

(A) and (B) are stamped on the compressor rating plate which is fixed to the side ofthe crankcase and (C) will be found in the spare parts list at the back of thisinstruction book.

SPERRE INDUSTRI A/S reserves the right to amend technical specifications withoutprior notice and disclaims all legal liability in connection such amendments.

PERSONAL SAFETY

Whenever work is to be carried out on the compressor, the electric current must beswitched off, and the compressed air delivery pipe valve must be closed.

SPERRE INDUSTRI A/S6057 ELLINGSØY - NORWAYPhone : + 47 70 16 11 00Fax : + 47 70 16 11 10Telex : 42 509 SPAIR NE-mail: [email protected]: www.sperre.com

CONTENTS PageGeneral Description ------------------------------------------------------------------ 2Installation------------------------------------------------------------------------------- 2Starting up------------------------------------------------------------------------------- 2Operation -------------------------------------------------------------------------------- 3Stopping --------------------------------------------------------------------------------- 3Maintenance, Overhaul, Repairs -------------------------------------------------- 3Valves ------------------------------------------------------------------------------------ 3Piston and Connecting Rod--------------------------------------------------------- 4Bearings - Dismantling and Assembly ------------------------------------------- 4Multi-finned tube coolers ------------------------------------------------------------ 5Gaskets ---------------------------------------------------------------------------------- 5Lubricating Oil -------------------------------------------------------------------------- 5Table of Normal Pressures and Temperatures in Service ------------------ 6Maintenance Schedule--------------------------------------------------------------- 6-7Fault Tracing Chart-------------------------------------------------------------------- 8Tolerances - Wearing Limits-------------------------------------------------------- 9Automatic Relief Mechanism ------------------------------------------------------- 9Replacements Parts List------------------------------------------------------------- 10Illustrations for replacement parts list ------------------------------------------- 11

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GENERAL DESCRIPTIONThis is a two-stage 90o vee compressor. Cylinders and compressed air coolers are air-cooled. Supply pressure isdetermined by adjusting the safety valve.

The compressor and motor are supplied as a single unit. The compressor and motor are connected by means of a flywheel.

All the materials used are of first class quality, thoroughly tested and in accordance with the requirements of theclassification societies.

Instrumentation is supplied in accordance with classification society requirements and if desired the compressor can befitted with equipment for fully automatic operation.

Bearings and cylinder walls are splash lubricated. The oily level in the sump can be checked through a sight glass.An automatic low oil level alarm can be supplied as an optional extra.

The compressors is normally supplied without a relief mechanism for the L.P. cylinder suction valve. However, a reliefmechanism can be ordered from SPERRE if required.

The compressor set can be supplied either for bolting direct to the foundation or for flexible installation by means of resilientmountings fitted under the bedplate.

INSTALLATIONThe compressor and motor are normally supplied ready-fitted to a bedplate. In cases where the motor is installedseparately, alignment must be carried out with great care.

In order to ensure trouble-free operation it is important that the foundation should be well stiffened and free from vibrationsfrom other installed machinery. This applies to rigid mounting and flexible mounting alike.

A well-dimensioned fresh air duct must be provided to the location where the compressor is to be installed. The mouth ofthe duct should be as close as practically possible to the suction side of the cooling fan. The ambient temperature shouldnot exceed 45oC.

In principle the pipe from the compressor to the air reservoir should be arranged as shown in the installation diagramsupplied with the compressor. A non-return valve of strong construction and offering little air resistance should be installedafter the compressor.

If the compressor set is installed with resilient mountings, a flexible connection (hose) must be installed in the compressorair supply line after the compressor. A water/oil separator should be fitted at some distance from the compressor, and soarranged that the line slopes downwards from the compressor to the separator. This will prevent condensate fromdamaging valves and cylinders.

It is recommended to provide the water separator with manual and automatic draining. Equipment for automatic draining isavailable as an optional extra.

If the pipe from compressor to reservoir is longer than about 10 metres the dimensions shown in the installation diagramsupplied with compressor should be somewhat increased to ensure the lowest possible air resistance.

Care should be taken to arrange the piping so that condensate cannot collect in pockets.

All piping must be well clamped and free from vibration.

STARTING UPBefore initial starting up and after long periods out of use, carry out the following operations in the sequence given:

1. Check out the oil level (sight glass).2. If the unit has been unused for more than 6 months, remove valves and lubricate cylinder walls.3. Open air line cocks and start the unit.4. Check that all components are running normally. Inspect instruments, check and repair any leaks.

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OPERATIONDuring operation, pressures and temperatures must be within the given limits. Any deviation is abnormal and its causeshould be ascertained by means of the fault tracing chart. In the case of pressure or temperature deviations it isrecommended first to check the values with new thermometers and pressure gauges in order to ensure that the fault is notto be found in the instruments.

STOPPINGNo special adjustment or the like are required before stopping the compressor.If the compressor is to remain unused for a long period, lubricate valves and cylinder walls with oil. The compressor shouldbe turned over from time to time

MAINTENANCE - OVERHAUL - REPAIRSOnly ORIGINAL SPERRE REPLACEMENT PARTS must be used in connection with overhauls and repairs. Before orderingspare parts, please read the instructions given on page 1.

VALVESL.P. ValveTo dismantle the valve, proceed as follows:

1. Loosen pipe connections.2. Loosen and remove cylinder head.3. Loosen the bolts holding the valve in place on the cylinder head.

Carefully separate the upper and lower sections of the valve body.

IMPORTANT! THERE ARE MILLED SLOTS IN THE UPPER AND LOWER SECTIONS OF THE VALVE BODY. WHENCORRECTLY FITTED THESE SLOTS CORRESPOND.

Clean the valves, carbon deposits can best be removed by means of a good solvent, carbon remover or the like, then flushwith fresh water.

IMPORTANT! SEALING SURFACES MUST NOT BE SCRAPED WITH SHARP TOOLS: USE A WAIRE BRUSH IFNECESSARY.

Worn and damaged parts and gaskets should be replace. Valve assembly sequence is the opposite of the above.

IMPORTANT! THE VALVE MUST BE CORRECTLY FITTED UNDER THE CYLINDER HEAD. THE SUCTION SIDE MUSTFACE FORWARDS (TOWARDS THE FILTER) AND THE PRESSURE SIDE MUST FACE BACKWARDS (TOWARDSELECTRIC MOTOR).

H.P. ValveTo dismantle he valve, proceed as follows:

1. Loosen pipe connections.2. Loosen cylinder head nuts and remove cylinder head.3. The valve can now be lifted out of the cylinder.

Clean the valve in the same way as the L.P. valve.

Assembly sequence is the opposite of the above.

IMPORTANT! ONLY ORIGINAL SPERRE COPPER RINGS MUST BE USED AS VALVE SEATING GASKES. EXACTDIMENSIONS AND CORRECT HARDNESS ARE OF DECISSIVE IMPORTANCE FOR GOOD OPERATING RESULTS.

Cylinder head nuts should be tightened a little at a time, in sequence, to avoid torsional strain on the valve.

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PISTON AND CONNECTION RODThe 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. Loosen and remove the L.P. cylinder head.3. Remove the crankcase cover from the crankcase and detach the counterbalance at the end of the crankpin.4. Loosen the bearing end shield and pull it axially together with the crankshaft, far enough to bring the connecting rods

clear of the crankpin.5. Pull the L.P. piston with the rod out of the top of the cylinder.6. Pull down the H.P. piston with rod out through the crankcase.

Assembly sequence is the opposite of the above.

BEARINGS - DISMANTLING AND ASSEMBLYWork on bearings requires great care and scrupulous cleanliness.

Crankshaft bearingsThese are needle bearings.

IMPORTANT! WORN OR DAMAGED CRANKSHAFT BEARINGS MUST BE REPLACED COMPLETE. REPLACEMENTOF PARTS OF THE BEARINGS IS NOT SATISFACTORY. BEARINGS DISMANTELED FROM SHAFT AND/ORCONNECTINGS ROD MUST ALWAYS BE REPLACED BY NEW BEARINGS.

1. Remove the outer ring from the connecting rod, using pressing tools.2. Remove the inner ring from the crankpin by heating it rapidly with a welding torch, then push it off the pin by means of a

screw driver or the like. If necessary, rapidly cool the ring so that it cracks, or grind a notch in it to reduce its tension.3. Fit a new outer ring to the connecting rod by means of a pressure tools.4. To fit the inner ring, heat it in an oil bath or on an electric hotplate to 80 - 100oC before pressing it onto the pin.

IMPORTANT! DO NOT USE AN OPEN FLAME TO HEAT THE NEW RING.

Gudgeon pin bearingsThe gudgeon pin bearings are needle bearings.

Dismantle as follows:

1. Remove seeger rings.2. Press out the gudgeon pin. If necessary, heat the piston slightly and rapidly.3. Use pressing tools to remove and re-install the connecting rod bearing outer ring.

IMPORTANT! CHECK THAT THERE IS SLIGHT AXIAL PLAY BETWEEN CONNECTING ROD AND PISTON AFTERINSTALLATION.

Crankshaft bearings

Dismantling and replacement procedure is as follows:

1. Remove the crankcase cover from the crankcase 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 CONNECTING ROD".4. Pull the bearing housing and crankshaft clear of the crankcase.5. Pull the crankshaft clear of the bearing housing, remove seeger ring and carefully tap the bearings off the shaft and

bearing housing respectively.

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

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MULTI-FINNED TUBE COOLERSTo ensure trouble-free operation it is of the greatest importance to ensure that the coolers are kept clean and free of foreignmatter at all times. If the coolers are not kept properly clean, high air temperatures will result, with a consequent reductionof 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 compressedair.

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.

GASKETSIn order to achieve satisfactory operation it is recommended to replace gaskets at every overhaul. Worn or damagedgaskets will reduce compressor capacity and cause faulty operation.

Use only original SPERRE gaskets.

LUBRICATING OILThe crankcase lub. oil volume is 1,8 litres.The following lubricating oils are recommended:

MOBIL RARUS 427MOBIL RARUS 827BP ENERSYN RX 100BP ENERGOL RC 68CALTEX RPM COMPR. OIL 68CASTROL AIRCOL SN 100CASTROL AIRCOL PD 100CHEVRON HD COMPR. OIL 100ELF PRIMERIA SG 100ESSO/EXXON ZERICE S 100

ESSO/EXXON SYNTESSTIC 68FINA EOLAN ACMITSUBISHI COMPR. OIL 100NIPPON OIL CO. FAIRCOL SA100NYNÄS COMPR. OIL 68PHILLIPS COMPR. OIL 68SHELL CORENA P 68STATOIL COMPWAY S 100TEXACO SYN STAR DE 100DAPHNE MARINE COMPRESSOR 100

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

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TABLE OF NORMAL PRESSURES AND TEMPERATURES IN SERVICE

Temperatures in service, with shaft speed 1450 rpm.The given values are for intake temperature (ambient temperature) 35oC and supply pressure 30 bars.

Pressure after L.P. cylinder: 2-3 barsTemperature after L.P. cylinder: 125oCTemperature after L.P. cooler: 115oCTemperature after H.P. cylinder: 210oCTemperature after H.P. cooler: 80oC

At lower or higher intake temperatures the temperatures at the points indicated above will be approximately an equalnumber of degrees lower or higher.

Temperatures will be lower at lower shaft speeds.

MAINTENANCE SCHEDULEThe following is a guideline for a normal maintenance schedule. However, compressor operating conditions vary widelyfrom installation to installation and it is therefore important to adapt the maintenance schedule to the experience of theindividual operator.

The following schedule applies to automatically monitored and manually operated installations alike.

Daily inspection:

Make a quick general inspection of the whole compressor (in normal operation) and specially check the following:

1. Lubricating oil level.2. Compressed air temperature and pressure.

After the first 200 hours' operation:

Change lubricating oil. Drain the sump while the oil is hot, clean the sump thoroughly before filling with fresh oil.

Further maintenance can suitably be effected in accordance with the following plan(The scope of each maintenance routine is given in the notes).

Total running time from Maintenanceinstallation of the new unit routine

1000 hours Routine A2000 hours Routine A3000 hours Routine A4000 hours Routine A5000 hours Routine B6000 hours Routine A7000 hours Routine A8000 hours Routine A9000 hours Routine A

10 000 hours Routine C

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

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ROUTINE A1. Change lubricating oil.2. Remove the valves from both cylinders. Check for carbon deposits. Use a stick or similar object to check whether

springs, plates or the like have been broken. Dismantle the valve for cleaning and/or repair if necessary.3. Inspect the flexible coupling between compressor and motor.4. Check bed bolts. Also check vibration dampers and hose connections if the unit is flexibly mounted. Check that no oil

has come into contact with the rubber elements in the vibration dampers.5. Function-test the safety valve. Close the stop valve on the pipe to the receiver. The safety valve should blow at

maximum working pressure + 10%. If necessary, dismantle safety valve, clean and readjust.6. Check all pipe connections (compressor running).7. Check that all automatic equipment is functioning correctly.8. Clean air filter.9. Check all bolts and nuts for proper tightness.

ROUTINE B1. Change lubricating oil.2. Remove the valves from both cylinders. It is recommended to dismantle the valves for full inspection and cleaning or

replacement as necessary.3. Carry out Routine A, items 3,4,5,6,7 and 8.4. Dismantle compressor cooler tubes and clean internally as described on page 5.

ROUTINE C1. Change lubricating oil.2. Remove the valves from both cylinders. It is recommended to dismantle the valves for full inspection and cleaning or

replacement if necessary.3. Dismantle cylinders, pistons and connecting rods. Inspect cylinder walls, pistons and piston rings. Clean and replace

any damaged or worn parts. Inspect big end and little end bearings.4. Dismantle compressor cooler tubes and clean internally as described on page 5.5. After dismantling cylinders, pistons, cooler tubes etc., check wear on crankshaft frame bearings by testing crankshaft

lateral play. The life of ball and roller bearings may vary considerably.6 Carry out Routine A, items 3,4,5,6,7 and 8.

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FAULT TRACING CHART

1. Compressor capacity is low, or compressor not supplyingfull pressure.

Possible causes Remedy

Dirty, damaged or Clean and check allworn valves valve plates, springs

and gaskets. Replacedefective parts.

Carbon deposits on Piston compressionvalves rings worn. Replace.

Unsuitable lubricatingoil. Change.

Piston rings have Loosen andstuck remove rings.

Clean grooves andrings. (after longperiods out of use thecylinder will be dry and itmay therefor easily bescored when thecompressor is startedup. This is indicated by asharp increase ofblow-off through thecrankcase cover reliefvalve).

Air filter blocked Clean filter.

Faulty automatic Inspect componentscontrol equipment and circuits.

2. Safety valve blows off

Possible causes Remedy

Supply line stop Open valve.valve closed

Carbon deposits in Clean valve.non-return valve

Faulty adjustment of Check automaticautomatic system: circuitry.Compressor does notstop when air reservoir is full.

Safety valve damaged Overhaul safety valve.or defective (causingit to blow at lowerpressure).

3. Valves require maintenance too frequently

Possible causes Remedy

Overheating High ambienttemperature. Improvefresh air supply. Carbondeposits in coolers.Clean coolers.

Dirt or foreign Air filter damaged.matter in intake air Clean or replace.

Cooler tubes dirty Clean.

4. Bearings and bearing housings running hot. Lubricatingoil overheating. Noise from bearings.

Possible causes Remedy

Damaged or worn Replace bearings.bearingsUneven wear on Check crankshaft forcrankshaft bearings straightness.

Low oil level Replenish sump.

5. Piston running hot

Possible causes Remedy

Worn little end Check little endbearing bearing, piston rings

and piston clearance.

Piston and/or rings Check fresh air supplybinding in cylinder to cooling fan. If the

piston has completelyseized, wait a whilebefore turning over thecompressor. Cleancylinder thoroughly andclean off piston, fit newpiston if necessary.

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TOLERANCES - WEARING LIMITS

1. End tolerances for piston rings

Push a piston without rings halfway into the cylinder frombelow, and place the piston ring in the cylinder bore so thatit presses against the top of the piston. Withdraw the pistonand using a feeler gauge measure the clearance betweenthe ends of the piston ring.

Piston Clearance for new MaximumDiameter rings in cylinder permissible

without wear clearance(approx.)

50 mm 0.2-0.35 mm 0.7 mm77 mm 0.3-0.45 mm 0.8 mm

2. Height clearance in piston ring grooves

Clean piston rings and ring grooves. Fit ring in groove andusing a feeler gauge measure the height clearance of thering in the groove.

Clearance for new Maximumrings in piston permissiblewithout wear clearance

(approx.)

Top ring 0.015-0.04 mm 0.06 mmAll other rings 0.00-0.025 mm 0.04 mm

These values apply to both piston diameters.

3. Clearance between pistons and cylinders

Measure the clearance by means of a dial gauge, taking thecylinder and piston separately. Alternatively the piston canbe placed in the cylinder and the clearance measured withthickness gauges. If the latter method is chosen, twogauges should be used, one inserted at either side of thepiston, opposite each other. The piston clearance should bemeasured in the area above the upper ring groove.

The sums of clearance on both sides should be as follows:

Piston Clearance for new Maximumdiameter piston in new permissiblecylinder clearance (approx.)

50 mm 0.20 mm 0.6 mm77 mm 0.25 mm 0.65 mm

4. Clearance between piston crown and cylinder head.

The clearance between the piston crown and the cylinderhead should be not less than 0,75 mm.The normal gasketthickness is ca. 1,0 mm, and thus the piston crown mayproject a maximum of 0,25 mm above the cylinder at topdead centre

AUTOMATIC RELIEF MECHANISM

To order complete pressure relief equipment, quote Part No. 3428. In addition, the Part No. and voltage of the solenoid coilmust be quoted.

Note! The solenoid valve (4688) should be located away from the compressor.

The control air pressure for the solenoid valve must be maintained within the following limits.

Maximum control air pressure: 10 barsMinimum control air pressure: 4 bars

When fitting the gripper (3436) in the cylinder head (1283), it is very important to set correctly the distance between thegripper and the valve. Adjustment is effected by means of the adjustment screw (3438) on the upper face of the cylinderhead.

When the gripper is correctly fitted, its pins should project 3 mm from the plane lower surface of the cylinder head.

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COMPRESSOR TYPE HLF2/77

Qty Description Part No. Qty Description Part No.

1 Crankcase 10221 Crankcase cover 10701 Cylinder head H.P. 12811 Cylinder head L.P. 12831 Drive coupling 13712 Piston rod 14281 Crankshaft 14361 Flywheel 14441 Bearing housing 14461 Counterbalance 15201 Spacer 19911 Bracket 20461 Valve, L.P. 30361 Valve, H.P. 30371 Valve plate, L.P. 31221 Valve plate, H.P. 31231 Valve plate, H.P. 31241 Washer 31311 Valve bolt 32031 Valve nut 32362 Valve spring H.P. 32792 Valve spring H.P. 32801 Guide ring 32981 Plain nipple 33451 Oil scoop 33472 Tubular pin 33501 Piston, H.P. 33521 Piston, L.P. 33541 Catch plate, lower H.P. 34321 Catch plate, upper H.P. 34331 Gudgeon pin, H.P. 34511 Gudgeon pin, L.P. 34522 Compression ring,stepped,H.P. 34872 Compression ring,stepped,L.P. 34881 Compression ring, plain, H.P. 35011 Oil ring, H.P. 35282 Oil ring, L.P. 35292 Safety valve seat 35602 Safety valve spindle 35722 Ball 35761 Spring, H.P. 35801 Spring, L.P. 35812 Regulating nut 35992 Lifting lug 36081 Inspection glass 36341 Intercooler, complete 36571 Aftercooler, complete 36581 Key 36821 Air relief valve 3700

1 Air filter 37111 Pressure gauge, H.P. 37731 Seeger ring 38064 Seeger ring 38131 Seeger ring 38151 Ball bearing 38722 Needle bearing 38772 Needle bearing 38781 Ball bearing 38811 Valve sealing ring 39182 Valve sealing ring 39191 Copper gasket 39251 Copper gasket 39261 Copper gasket 39297 Copper gasket 39301 Spring washer 39371 Serrated washer 39395 Bolt 39461 Gasket 39981 Gasket 40751 Gasket 40951 Gasket 40961 Set of gaskets 41272 Lock nut 41312 Lock nut 41334 Stud bolt 41934 Stud bolt 41944 Stud bolt 419912 Nuts 42382 Set screw 42681 Nipple muff 42831 Threaded plug 42931 Threaded plug 42972 Bolt 44011 Safety valve, L.P.. 44211 Safety valve, H.P. 44223 Unbraco screws 44453 Double male end union 44573 Double male end union 44601 Elbow 44661 Tee piece 44721 Tee piece 44733 Connecting bolt 44841 Clamp 45141 Flexible coupling insert 45191 Male/female nipple 45901 Bolt 46051 Bolt 4618