SPERRE Compressor HL290A

INSTRUCTIO
CTION MANUAL
ANUAL
GB
AIIR COMPRESSOR
A
HL2/90
SPERRE
Instruction manual for compressor type HL2/90
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....................................................................................................................................
Installation........................................................................... ......................................................... 4
Starting up ...........................................................................................................
...................................................................................................................................
........................ 5
Operation .....................................................................................................................................
..................................................................................................................................... 5
Stopping.........................................................................
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 te mperatures .............................................................................
............................................................................. 9
Maintenance routines ...................................................................................................
..................................................................................................................
............... 10-11
Fault tracing chart ...................................................................................
........................................................................................................................
..................................... 12
Tolerances – wear limits ............................................................................
..............................................................................................................
.................................. 13
Ordering spare parts ..............................................................................
....................................................................................................................
...................................... 14
Spare parts list .............................................................................
.............................................................................................................................
................................................ 15-16
Available spare part kits ............................................................................................................
..............................................................................................................
.. 17
Illustration for spare parts list............................................................................
list.......................................................................................................
........................... 18-23
Page 1
PERSONAL
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.
Cooling air is supplied by a well-dimensioned fan fitted in flywheel.
The compressor and motor are normally supplied fitted together on a strong bedplate. 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.
Page 2
Page 3
INSTALLATION
When the compressor is being installed, it is of the greatest importance to ensure that there are no
distortion of the bedplate. The compressor and motor are normally supplied ready-fitted to the
bedplate. In cases where the motor is installed separately, alignment must be carried out with great
care.
Al ig nm
nment
ent shou
sh ould
ld be carr
c arr ied ou
outt as foll
fo ll ows:
ow s:
1. Use vernier callipers

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
ambient temperature sho uld n ot exceed 45°C.
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
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
compressor has been
been out of service for more than 6 months, remove valves and lubricate
lubricate
cylinder walls.
3. Turn the compressor by hand.
4. Open valves on compressed air line, and start the unit.
5. 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
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. 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 to remove the valve insert with valve p lates.
Important: There are milled slots in the upper and lower sections of the valve body. When
When the valve is
correctly assembled these slots correspond.
It is impor tant that the valve is be correctly fitt ed under the cylinder head. The valve
valvess suction side should
be turned towards the sucti on air fil ter and the pressure side must face towards the fan/electric
fan/electric motor.
Press the valve (3036
(3036)) against the cylin der head (1283
(1283)) by means of a hydraulic p ress or vic e. Force
approx . 2T. Tighten the scr ews (4401)
(4401) to a torqu e of 24 Nm.
The screws 4401 must b e locked so that th ey cannot co me loose. The edge of each screw head has a
notch. After tightening the screws, lock them by putt ing a punch mark in the valve at each each notch.
Page 5
HP valve
To dismantle the valve, proceed as follows:
1. Loosen pipe connections at cylinder head.
2. Loosen cylinder head nuts and lift
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 fr om the use of non-original parts.
parts.
Only orig inal Sperre copper gaskets can be used as valve seating gaskets. Exact dimensions
and correct hardness are of great importance for t rouble free operation.
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. Loosen and remove the cylinder head.
2. Remove the crankcase front cover, and remove the locking plate at the end of the crankpin.
3. Remove the cylinder from the crankcase.
4. Turn the crankshaft until the piston is at TDC.
TDC.
5. Slide the connecting rod off the crank pin.
Assembly sequence is the opposite order.
Page 6
Bearings
Bearings - Dismantling
Dismantling and Assembly
Important: Work o n bearings requires gr eat

eat care and scrup ulous cleanliness.
cleanliness.
Worn or dama
damaged
ged crankshaft bearings shoul d be replaced complete. Repla
Replaceme
cement
nt of parts of
the bearings
bearings is not s atisfactory. Bearings
Bearings dis mantled from shaft and/or
and/or connecting rod s hould
always be replaced with new bearings.
Crankshaft
Crankshaft bea
bearings
rings
Dismantle as follows:
1. Remove the outer ring from the connecting rod, using 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
Gudgeon pin bea
bearings
rings
1. Remove seeger rings.
2. Press out the gudgeon pin. If necessary, heat the piston
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

between connecting rod and pist on after installation.
Main bearings
1. Remove the grille from the front of the fan, loosen the air deflector from base and manifold and
pull the deflector backwards over the electric motor.
2. Remove fan and flywheel.
3. Loosen the cooler pipe from the manifold, cylinder head and lower clamps.
4. Dismantle cylinders,
cylinders, pistons and connecting rods as described under "Piston and connecting rod".
5. Loosen bearing housing nuts. Pull the bearing housing and crankshaft clear of the crankcase.
6. Remove the internal seeger rings in the bearing housing and pull the crankshaft complete with
with
bearings out of the bearing housing.
7. Pull the bearings off the shaft.
8. Check that the oil sealing ring in the bearing housing is not damaged.
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.
Page 7
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
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
LUBRICATING OIL
The lubrication oil volume in the crank case is 4,0 litres.
The followi ng lubri cating oil br ands are recommended:

recommended:
Synthetic
Synthetic oil Mineral
Mineral oil
ANDEROL 555 BP ENERGOL RC 68
BP ENERSYN RX 100 CASTROL AIRCOL PD 100
CASTROL AIRCOL SN 100 CALTEX RPM COMPR. OIL 68
COSMO RECIPRO SX 100 ESSO / EXXON EXXCOLUB 77
DAPHNE MARINE COMPR. 100 COSMO RECIPRO 100
ESSO / EXXON ZERICE S 100 FAMM COMPRESSOR OIL EP VDL 100
ESSO / EXXON SYNNESTIC 68 GENERAL COMPOL A 100
FAMM CETUS DE 100 MITSUBISHI COMPR. OIL 100
MOBIL RARUS 827 MOBIL RARUS 427
NIPPON OIL CO. FAIRCOL SA 100 PHILLIPS COMPR. OIL 68
SHELL CORENA AP 68 SHELL CORENA P 68
STATOIL FRIDGEWAY S 100 STATOIL COMPWAY 68
TOTAL LUBMARINE BARELF AL 100 TOTAL DACNIS P
STATOIL COMPWAY SX68
Ask SPERRE for advice before using lubricating oil of any other type.
TABLE
TAB LE OF NORMAL
NORMAL PRESSURES
PRESSURES AND TEMPERATURES
TEMPERATURES
Temperatures in service, with shaft speed 1750 rpm. The values are valid for ambient temperature
40°C and delivery pressure 30 bar.
Pressure after LP cylinder: 3 - 4 bar

Temperature after LP cylinder: 145 - 165°C
Temperature after LP cooler: 55 - 65°C
Temperature after HP cylinder: 175 - 190°C
Temperature after HP cooler: 45 - 55°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.
Page 9
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.
Af t er t he f ir st 200 hour

ho ur op erat io n:
Change lubricating oil. Drain the sump while the oil is warm, clean the sump thoroughly before filling
with fresh oil.
Daily
Daily in spection:
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 rout ine A (1.00

(1.000
0 runnin g hour s or every 2 years):
years):
Make sure that o verhaul ki t no. 3036M

3036MK2
K2 and 3037
3037MK2
MK2 are
are in st ock b efore starti ng overh aul of
compressor according to Routine A - 1.000 1.000 hour service. Please
Please follow inst allation
allation i nstruct ions
included in the kit.
1. Replace lubricating oil.
2. Remove the valves from both cylinders. Check for carbon deposits. Dismantle
Dismantle the valve for
cleaning and repair if necessary. Use spare part k it no. 3036M
3036MK2 K2 and 3037MK2
3037MK2 to o verhaul
valves. All
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,
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)
Page 10
Overhaul routi ne B (5.

(5.00
000
0 runnin g hour s):
Make
Make sure that overhaul kit no. 7935 7935 are
are in st ock before starting overhaul of c ompressor
according to Routine B - 5.0 5.000
00 hour service. Please
Please follow ins tallation instruc tions included in
the kit.
1. Change lubricating oil.
2. Remove the valves from both cylinders. Check for carbon deposits. Overhaul valves.Use valves.Use spare
part k it no. 3036M
3036MK2 K2 and 3037M
3037MK2 K2 to overhaul valves. All valve gaskets should be replaced
with new parts at assembly.
3. Replace the flexible coupling
coupling between compressor and motor.
8. Change suction air filter, insert.
insert. (Part no. 8451).
9. Remove the compressors cooler tubes and clean 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 wear. Use overhaul
overhaul kit
no. 7935.
Overhaul rout ine C (10.

(10.00
000
0 runni ng ho urs ):
Make
Make sure that overhaul kit no. 7965 7965 are
are in st ock before starting overhaul of c ompressor
according t o Routine C - 10.0 10.000
00 hour service. Plea
Please
se follow installation in structi ons in cluded 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
coupling between compressor and motor.
8. Change suction air filter, insert. (Part no. 8451). Replace crank case breather valve.
9. Remove the compressors cooler tubes and clean 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 k it no. 7965 7965 .
Page 11
FAULT TRACING CHART
1. Compressor capacity
capacity is low, or the compressor is not delivering
delivering full pressure
Possi ble causes Remedy
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. Safe
Safety
ty valve blow s
Remedy
Closed air line valve. Open the valve.
Carbon deposits in non-return valve. Clean the valve.
Faulty adjustment of automatic system.
Compressor does not stop when air reservoir is Check pressure switch and automatic circuitry.
full.
Safety valve damaged or defective (causing it to
Replace safety valve.
open at lower pressure).
3. Valves requir e maintenance too frequent ly

Remedy
High ambient temperature. Improve fresh air
Overheating. supply. Carbon deposits in coolers. Clean
coolers.
Dirt or foreign matter in intake air. Air filter damaged. Improve suction air quality.
Cooler tubes dirty. Clean.
4. Bea
Bearings
rings and bearing
bearing housings running hot. Lub. oil overhea
overheating.
ting. Noise from bearings
bearings
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

Remedy
Check little end bearing, piston rings and piston
Worn bearing on flywheel end.
clearance.
Ensure cool fresh air supply to cooling fan and
suction air filter. If the piston has completely
Piston and/or rings binding in cylinder. seized, wait a while before turning over the
compressor. Clean cylinder and piston, fit new
piston if necessary.
Page 12
TOLERANCES - WEAR LIMITS
1. End
End tolerances for pist on 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 Clearance
Clearance for new Maximum
diameter rings in new cylinder Permissible clearance
50 mm 0,2 - 0,35 mm 0,7 mm
90 mm 0,35 - 0,55 mm 0,9 mm
2. Height
Height clearance
clearance in piston ring groov es
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.
Clearance
Clearance for new Maximum
rings in new piston Permissible clearance
Top ring 0,015 - 0,04 mm 0,06 mm
All other rings 0,00 - 0,025 mm 0,04 mm
These values apply to both piston diameters.
3. Clearance
Clearance between pist on and
and cylin der
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 Clearance for new piston Maximum

diameter in new cylinder Permissible clearance
50 mm 0,20 mm 0,60 mm
90 mm 0,30 mm 0,70 mm
4. Clearance
Clearance between
between pisto n top and cyl inder 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
ORDERING SPARE PARTS
The followi ng infor mation must be given when ordering spares:
(A) Compressor type

(B) Compressor number
(C) Quantity, parts number and description of the spare parts required
(A) and
(A) and (B) are
(B) are stamped on the compressor rating plate, which is fixed to the side of the crankcase
and (C) will
(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.
Addr
Ad dr ess fo r o rderi
rd eri ng parts
par ts : Original parts can also be ordered from:
SPERRE INDUSTRI AS Sperre Rotterdam BV

Glasblazerstraat 12B
6057 ELLINGSØY
NL-2984 BL Ridderkerk
NORWAY NETHERLANDS
Tel. : +31 180 463 299
Phon e: + 47 70 16 11 00 Fax : +31 180 463 264
Fax: + 47 70 16 11 10 E-mail : [email protected]
E-mail: [email protected]
Sperre Asia Pte. Ltd.
www.sperre.com
63 Hillview Avenue # 09-13
Lam Soon Industrial Building
SINGAPORE
SINGAPORE 669569
Tel. : +65 763 6300
Fax : +65 763 1811
E-mail : [email protected]
Sperre China
Room 16E, No.257 Siping Road
Hongkuo District
200081 Shanghai, China
Tel. : +86 216 5070436
Fax : +86 216 5070402
E-mail : [email protected]
Page 14
SPARE PART LIST

Qty. Descript ion Part no. Qty. Descript ion Part no.
1 Crankcase .................................. 1018 1 Guard...................................... ... 3794

1 Bearing housing ......................... 1052 1 Seeger ring ................................. 3802
1 Crankcase cover ........................ 1070 1 Seeger ring ................................. 3804
1 Flywheel ..................................... 1080 4 Seeger ring ................................. 3813
1 Cylinder, HP............................... 1133 1 Sealing ring ................................ 3857
1 Cylinder, LP ............................... 1137 1 Ball bearing ................................ 3871
1 Cylinder head, HP...................... 1281 1 Ball bearing ................................ 3872
1 Cylinder head, LP ...................... 1283 2 Needle bearing ........................... 3877
1 Manifold ..................................... 1346 2 Needle bearing ........................... 3878
1 Drive coupling ............................ 1374 1 Bolt ............................................. 3883
1 Crankshaft .................................. 1403 1 Valve sealing ring ....................... 3918
2 Connecting rods......................... 1424 2 Valve sealing ring ....................... 3919
1 Coupling, .................................... 1981 1 Copper gasket ............................ 3925
1 Coupling housing ....................... 1985 1 Copper gasket ............................ 3927
1 Fan ............................................. 1995 3 Copper gasket ............................ 3929
1 Cranked bracket ........................ 2040 2 Copper gasket ............................ 3930
1 Right-angle bracket .................... 2042 2 Copper gasket ............................ 3932
1 Valve, LP.................................... 3036 2 Serrated washer ......................... 3939
1 Valve, HP ................................... 3037 15 Bolt ............................................. 3945
1 Valve plate, LP........................... 3122 4 Bolt ............................................. 3946
1 Valve plate, HP .......................... 3123 2 Bolt ............................................. 3947
1 Valve plate, HP .......................... 3124 1 Gasket ........................................ 4075
1 Washer....................................... 3131 1 Gasket ........................................ 4076
1 Valve nut .................................... 3236 2 Gasket ........................................ 4077
1 Crankshaft end disc ................... 3247 1 Gasket ........................................ 4095
1 Flywheel end disc ...................... 3248 1 Gasket ........................................ 4096
2 Valve spring ............................... 3279 1 Set of gaskets............................. 4120
2 Valve spring ............................... 3280 2 Lock nut ...................................... 4133
1 Guide ring .................................. 3298 2 Clamp (pair)................................ 4150
1 Filter elbow................................. 3343 1 Stud bolt ..................................... 4189
1 Plain nipple ................................ 3345 7 Stud bolt ..................................... 4192
1 Oil scoop .................................... 3348 1 Stud bolt ..................................... 4193
1 Tubular, pin ................................ 3350 4 Stud bolt ..................................... 4194
1 Piston, HP .................................. 3352 4 Stud bolt ..................................... 4199
1 Piston, LP................................... 3356 1 Stud bolt ..................................... 4200
1 Valve part, upper ....................... 3430 8 Stud bolt ..................................... 4205
1 Valve part, lower ........................ 3431 16 Nuts ............................................ 4238
1 Catch plate, lower ...................... 3432 8 Nuts ............................................ 4239
1 Catch plate, upper ..................... 3433 6 Lock nut ...................................... 4251
1 Gudgeon pin, HP ....................... 3451 5 Lock nut ...................................... 4253
1 Gudgeon pin, LP ........................ 3453 2 Set screw.................................... 4268
2 Compression ring, stepped ........ 3487 1 Nipple muff ................................. 4283
2 Compression ring, stepped ........ 3489 1 Threaded plug ............................ 4296
1 Compression ring, plain ............. 3501 2 Threaded plug ............................ 4297
1 Oil ring, HP................................. 3528 1 Threaded plug ............................ 4298
2 Oil ring, LP ................................. 3531 2 Bolt ............................................. 4401
1 Inspection glass ......................... 3634 6 Bolt ............................................. 4405
1 Intercooler, complete ................. 3659 2 Elbow .......................................... 4410
1 After cooler, complete ................ 3660 2 Nipple ......................................... 4412
1 Key ............................................. 3675 16 Washer ....................................... 4414
1 Air relief valve ............................ 3700 4 Washer ....................................... 4416
1 Air filter ....................................... 3711 1 Safety valve, HP......................... 4420
1 Pressure gauge, HP .................. 3773 1 Safety valve, LP ......................... 4421
1 Grille ........................................... 3788 1 Plain union..................................
union.................................. 4481
Page 15
Qty. Descript ion Part no.
1 Plain union ................................. 4482

1 Flexible coupling insert .............. 4515
6 Bolt ............................................. 4603
6 Washer....................................... 4650
4 Cone .......................................... 7880
4 Nut ............................................. 7882
4 Support tube for cone ................ 7884
1 Air filter, insert ............................ 8451
Page 16
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
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 HL2/90 following kits are available:
Descript
Descript ion Part
Part no. Content
Content of kit
Gasket kit 4120 All flat gaskets, O-rings, sealing rings, and valve gaskets.
Crankshaft with all bearings, flywheel key and nut, Seeger-
Crankshaft 1403MK
rings, endplate and screw.
Valve LP 3036MK 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 3037MK2 Valve springs, plates and gaskets.
Piston LP 3356MK Piston, gudgeon pin with Seeger-rings and piston rings.
Piston HP 3352MK Piston, gudgeon pin with Seeger-rings and piston rings.
Connecting rod with small- and big-end bearings, oil scoop
Connecting rod 1424MK
with set screw.
Cylinder LP 1137MK Cylinder with gaskets, stud bolts/nuts and fittings.
Cylinder HP 1133MK Cylinder with gaskets, stud bolts/nuts and fittings.
All parts needed for 5 000-hours’ maintenance: Overhaul

kits for valves complete with gaskets and guide rings, piston
Overhaul kit Routine B 7935
rings, connecting rod bearings, gudgeon pins, Seeger-rings,
gaskets and ventilator.
All parts needed for 10 000-hours’ maintenance: Same as

Overhaul kit Routine C 7965 kit B, plus complete valves, crankshaft bearings and seal
ring.
Maintenance
Maintenance kit s:
• All necessary
necessary parts at hand when you needneed them
• With clear
clear installation
installation instruc tions enclosed
Genui
Genuine
ne Sperre
Sperre parts gi ve you peace
peace of mi nd at sea !
Page 17
NOTE:
Sole suppliers of genuine spare parts:
Sperre
Sperre Industri AS Sperre Asia PTE Ltd Sperre Rotterdam BV Sperre China
N-6057 Ellingsøy 63 Hillview Avenue #09-13 Glasblazerstraat 12B Room 16E, No.257 Siping Road
Norway Lam Soon Industrial Building NL-2984 BL Ridderkerk Hongkuo District
Singapore 669569 The Netherlands 200081 Shanghai, China
Tel +47 70 16 11 00
Tel +65 6763 6300 Tel +31 180 463 299 Tel +86 216 5070436
Fax + 47 70 16 11 10
Fax + 65 6763 1811 Fax + 31 180 463 264 Fax +86 216 5070402
[email protected] [email protected] [email protected] [email protected]
www.sperre.com

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What is the purpose of the instruction manual?

What is the purpose of the instruction manual?

What are maintenance kits and what do they contain?

What are maintenance kits and what do they contain?

INSTRUCTIO

Sperre reserves the right to modify details without prior warning.

Ellingsøy, January 2010

Personal safety ..................................................................................................

The compressor must only be used to compress air.

Cooling air is supplied by a well-dimensioned fan fitted in flywheel.

1. Use vernier callipers

Arrange the piping so that condensate cannot collect in pockets.

All piping must be well clamped and free from vibration.

1. Check the oil level (sight glass).

Valve assembly sequence is the opposite of the above.

Piston and connection Rod

Assembly sequence is the opposite order.

Important: Work o n bearings requires gr eat

Important: Check that there is axial play between

Assembly is done in the opposite order.

In order to achieve satisfactory operation it is recommended to replace gaskets at every overhaul.

Use only original SPERRE gaskets.

The followi ng lubri cating oil br ands are recommended:

Pressure after LP cylinder: 3 - 4 bar

Temperatures will be lower at lower shaft speeds.

Af t er t he f ir st 200 hour

1. Lubricating oil level.

Overhaul rout ine A (1.00

Make sure that o verhaul ki t no. 3036M

Overhaul routi ne B (5.

Overhaul rout ine C (10.

FAULT TRACING CHART

3. Valves requir e maintenance too frequent ly

5. Piston running hot

TOLERANCES - WEAR LIMITS

These values apply to both piston diameters.

Piston Clearance for new piston Maximum

ORDERING SPARE PARTS

The followi ng infor mation must be given when ordering spares:

(A) Compressor type

SPERRE INDUSTRI AS Sperre Rotterdam BV

SPARE PART LIST

1 Crankcase .................................. 1018 1 Guard...................................... ... 3794

Qty. Descript ion Part no.

1 Plain union ................................. 4482

SPARE-PART & MAINTENANCE KITS

For model HL2/90 following kits are available:

All parts needed for 5 000-hours’ maintenance: Overhaul

All parts needed for 10 000-hours’ maintenance: Same as

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