Operation & Maintenance Manual: PET Compressor Type Vh15H3N

OPERATION & MAINTENANCE
MANUAL
PET
COMPRESSOR TYPE VH15H3N
Doc. Ref: VH15H3N

Important
This Instruction Manual covers Installation & Commissioning, Operation and Maintenance of
the Gardner Denver Belliss & Morcom ‘PET’ range of compressors.
It is ESSENTIAL that this document is read and understood by everyone who will work with
this equipment, as failure to do so may result in death, injury or damage to the compressor or
its associated equipment.
Disclaimer
While every care was taken in the preparation of these instructions, it cannot be guaranteed
that every aspect has been covered. Gardner Denver Belliss & Morcom cannot, therefore,
accept liability for direct or consequential damage that may arise resulting from non-
conformity with this Manual, from repairs carried out improperly, from using other than
original spare parts, and from non-observance of good operating and maintenance
engineering practices. Should there be any doubt whatsoever, or should any further
information or explanation be required, Gardner Denver Belliss & Morcom must be
contacted.
This information is given in good faith, no warranty or representation is given concerning such
information, which must not be taken as establishing any contractual or other commitment
binding upon Gardner Denver Belliss & Morcom.
Gardner Denver Belliss & Morcom reserve the right to make changes to any information
contained within this manual without prior notice.
Warranty Statement
The compressor(s) and ancillary equipment supplied by Gardner Denver Belliss & Morcom
are covered under Warranty for the period agreed in the Supply Contract.
The equipment provided is well designed to afford many years of trouble free service.
However, should the need arise to implement a warranty claim then this can be done using
Warranty Claim Form Document No.CM4F2 obtainable from Gardner Denver Belliss &
Morcom Service Department. A copy of this form is provided in Appendices located at the
end of this manual.
It should be noted that consumable parts that require replacement during normal compressor
operations are not normally covered under Warranty. Similarly, the Warranty does not cover
running adjustments.
Point of Contact
Gardner Denver Belliss & Morcom Ltd
Chequers Bridge,
Gloucester,
GL1 4LL,
England
Tel: +44 (0) 1452 338198 Email: service@belliss.co.uk
Fax: +44 (0) 1452 338317 Web: www.belliss.com
This document contains confidential information of GARDNER DENVER Belliss & Morcom Ltd (The Company). The
copyright, design right and/or other intellectual property rights in the document belongs to (The Company). All rights
conferred by law and by virtue of International Copyright and other conventions are reserved to The Company. This
document and the information contained therein or any part thereof must not be reproduced, disclosed or used for any
other than those for which the prior written consent of The Company has been given.
 Gardner Denver Belliss & Morcom Ltd
Foreword
Gardner Denver Belliss & Morcom are well known in the market place for the design,
manufacture and supply of high-quality air compressor equipment. This Instruction Manual is
produced for the ‘PET' range of compressors. These compressors are constructed from the
highest quality materials and are designed and built according to the latest manufacturing
techniques. The compressor design will give good service providing that it is operated and
maintained in accordance with the information contained within this Manual.
The information and notes presented in the 'Ancillary Devices’ Instruction Manuals will provide
operational and maintenance information for the control and instrumentation system,
motor/drive unit and where appropriate, intake filter and discharge receiver and any other
device associated with the compressor package.
Targeted Personnel
This document is designed to provide competent operatives, who are fully conversant with
compressor operating and maintenance techniques, with an understanding of the compressor
elements and their operation and subsequent maintenance. It should be noted that the term
'competent' implies that the operative is a compressor engineer suitably trained in the
installation, operation and maintenance of the Gardner Denver Belliss & Morcom product.
This Instruction manual is not intended to supercede or take the place of the Gardner Denver
Belliss & Morcom product-training course. For further information regarding training courses
or to book a place, please contact Gardner Denver Belliss & Morcom Service Department.
The address, telephone/facsimile number is provided at the start of this documentation.
How to Use this Instruction Manual
The Instruction Manual is designed to enable speedy location of relevant information. To this
end the document is divided into six chapters, each of which covers an individual topic. Cross-
references between topics and illustrations are identified within the text using bold characters
i.e. (Refer to Chap 2 Section 4.1) or see Fig 3.
At appropriate locations within this document you will see 'Information Boxes'. It is VERY
IMPORTANT that the information contained within these boxes is adhered to, as failure to do
so may result in death, injury or damage to the compressor or its associated equipment. The
following outlines the philosophy applied to each of the three levels of boxed notation.
WARNING!
This pictogram with the remark "WARNING!" identifies a potential dangerous
hazard. Non-compliance will put the operator or a third party at risk of death or
injury.
CAUTION!
This pictogram with the remark “CAUTION!” identifies the possibility that if non-
compliant the compressor and/or its associated equipment can be damaged.
This pictogram marks important Notes, which identifies supplementary information

for the competent and economic use/operation of this compressor package.
www.belliss.com
Forward (Cont)
Documentation Storage
Always store this Instruction Manual near the compressor so that it is available for reference
at all times. If the instruction manual is lost, Gardner Denver Belliss & Morcom can supply
a new copy for a small fee. When requesting new or additional copies, of this document,
please include your compressor details with your order to the address given at the front of
this document.
Comments and Suggestions
We would welcome comments and suggestions for improvements to this Instruction Manual.
If you decide to comment, make a copy of the page or pages concerned and add your
comments. Then send your response to Gardner Denver Belliss & Morcom. Please do not
forget to include your name and the name of your company, your company address and your
telephone and facsimile numbers.
www.belliss.com
OPERATION & MAINTENANCE MANUAL Issue: 1
COMPRESSOR TYPE VH15H3N Date: July 2002
CONTENTS Page: 5 of 135
1 TECHNICAL DATA & COMPRESSOR DESCRIPTION.....................................9

1.1 Technical Data..................................................................................................... 9
1.1.1 Operating Data....................................................................................................9
1.1.2 Compressor Data ..............................................................................................10
1.1.3 Tightening Torques (Dry Threads) .....................................................................13
1.1.4 Materials of Construction ...................................................................................14
1.2 Technical Description of the Compressor .......................................................... 15
1.2.1 Purpose of the Equipment .................................................................................15
1.2.2 Compressor Identification ..................................................................................16
1.2.3 Compressor Operation ......................................................................................16
1.2.4 Crankcase and Lower Motion Work ...................................................................16
1.2.5 Cylinders, Pistons and Piston Rod Packings......................................................18
1.2.6 Valves ...............................................................................................................19
1.2.7 Motor and Couplings .........................................................................................20
1.2.8 Control Panel and Controls................................................................................20
1.2.9 Safety Equipment and Systems .........................................................................20
2. SAFETY INFORMATION..................................................................................22
2.1 Safety Policy...................................................................................................... 22
2.1.1 Commonplace Hazards .....................................................................................22
2.1.2 Proper Use ........................................................................................................22
2.1.3 Organisational Measures...................................................................................23
2.1.4 General Safety Precautions for Compressors ....................................................23
2.1.5 Installation, Commissioning and Operation ........................................................24
2.1.6 Maintenance......................................................................................................24
3 INSTALLATION & COMMISSIONING .............................................................27
3.1 Safety Precautions............................................................................................. 27
3.2 Installation Requirements .................................................................................. 27
3.2.1 Location ............................................................................................................27
3.2.2 Ventilation .........................................................................................................27
3.2.3 Foundations ......................................................................................................28
3.2.4 Pipework Installation..........................................................................................28
3.2.5 Cooling Water ...................................................................................................30
3.2.6 Electric Cabling .................................................................................................31
3.3 Handling and Unpacking.................................................................................... 31
3.3.1 Stability .............................................................................................................31
3.3.2 Slinging Instructions ..........................................................................................32
3.3.3 Lifting Instructions .............................................................................................33
3.3.4 Unpacking .........................................................................................................33
3.4 Installation Procedure ........................................................................................ 34
3.4.1 Safety Precautions ............................................................................................34
3.4.2 Mounting Arrangements - Anti-Vibration Mounts ................................................34
3.4.3 Levelling and Alignment - Flange Mounted Motors.............................................35
3.5 Preparation for Commissioning.......................................................................... 35
3.5.1 Cleaning the Compressor ..................................................................................35
3.5.2 Preparing the Compressor.................................................................................35
3.5.3 Preparing the Motor...........................................................................................37
3.5.4 Motor Rotation Check........................................................................................37
3.6 Commissioning the Compressor ........................................................................ 37
3.6.1 Trial Run ...........................................................................................................37
3.6.2 Completion of Commissioning ...........................................................................38
 GARDNER DENVER Belliss & Morcom www.belliss.com DOC REF: VH15H3N - ISSUE 1, JULY 02
4 OPERATING INSTRUCTIONS.........................................................................40
4.1 Safety Precautions............................................................................................. 40
4.2 Operating Criteria .............................................................................................. 40
4.2.1 Customer's Responsibility..................................................................................40
4.3 Controls and Indicators...................................................................................... 41
4.3.1 Starter System...................................................................................................41
4.3.2 Load Control System Functions .........................................................................42
4.4 Preparation for Starting...................................................................................... 43
4.4.1 Pre-Start Checks (Before Operating the Machine) .............................................43
4.5 Starting the Compressor .................................................................................... 43
4.5.1 Under Normal Conditions ..................................................................................43
4.5.2 After An Emergency Stop ..................................................................................44
4.6 Running ............................................................................................................. 44
4.6.1 Running Checks ................................................................................................44
4.6.2 Automatic Operation..........................................................................................45
4.6.3 Faults/Hazards ..................................................................................................45
4.7 Stopping the Compressor .................................................................................. 45
4.7.1 Normal Stopping................................................................................................45
4.7.2 Emergency Stopping .........................................................................................45
4.8 Fault Indications ................................................................................................ 46
4.8.1 Fault Finding .....................................................................................................47
5 COMPRESSOR MAINTENANCE.....................................................................52
5.1 Preventive Maintenance .................................................................................... 52
5.1.1 Maintenance Schedule ......................................................................................53
5.2 Maintenance Instructions ................................................................................... 58
JOB No. 001 CRANKCASE OIL CHANGE.....................................................................59
JOB No. 002 FIT PISTON ROD CLAMPS......................................................................61
JOB No. 003 CYLINDER & TOP COVER - REMOVE & REFIT.....................................62
JOB No. 004 PISTON RINGS - REMOVE & REFIT .......................................................65
JOB No. 005 PISTON/CYLINDER END CLEARANCES - INSPECTION........................71
JOB No. 006 PACKING GLAND ASSEMBLY - REMOVE & REFIT................................74
JOB No. 007 PISTON ROD OIL SCRAPER GLAND - REMOVE & REFIT .....................76
JOB No. 008 SUCTION & DELIVERY VALVES - REMOVE & REFIT.............................78
JOB No. 009 SUCTION & DELIVERY VALVES - OVERHAUL.......................................80
JOB No. 010 SUCTION VALVE UNLOADER ACTUATORS - REMOVE & REFIT..........82
JOB No. 011 PISTON RODS - REMOVE & REFIT ........................................................84
JOB No. 012 OIL FILTER - REMOVE & REFIT..............................................................86
JOB No. 013 OIL PRESSURE RELIEF VALVE - INSPECTION .....................................87
JOB No. 014 LUBRICATING OIL PUMP AND DRIVE - INSPECT & OVERHAUL ..........87
JOB No. 015 INTERCOOLER - INSPECT & OVERHAUL ..............................................88
5.3 Lists of Tools ..................................................................................................... 90
5.3.1 Commercially Available Tools List......................................................................90
5.3.2 Specialist Service Tools List ..............................................................................90
5.4 Waste Products ................................................................................................. 91
5.4.1 Oil - After Oil Changes.......................................................................................91
5.4.2 Coolant .............................................................................................................91
6 SPARE PARTS ................................................................................................93

6.1 Ordering Spares and Spares to be Held in Stock............................................... 93
6.2 Spares List......................................................................................................... 94
6.3 Illustrated Parts List - Main Component Location View ...................................... 96
Fig 1 Crankcase Assembly (2-03-302) .......................................................................97
Fig 2 Crankshaft Assembly (2-06-373) .......................................................................98
Fig 3 Flywheel End Cover (2-25-109).........................................................................99
Fig 4 Bearing End Cover Assembly (2-25-118).........................................................100
Fig 5 Oil Pump Assembly (2-34-422)........................................................................101
Fig 6 Oil Cooler Assembly (2-34-498) ......................................................................102
Fig 7 Connecting Rod Assembly (2-76-425) .............................................................103
Fig 8 Main Guide Assembly (2-07-280) ....................................................................104
Fig 9 Distance Piece Assembly (2-07-485)...............................................................105
Fig 10 Crosshead Assembly (2-31-066) .....................................................................106
Fig 11 Scraper Housing Arrangement (2-63-047) .......................................................107
st
Fig 12 1 Stage Cylinder Assembly (2-01-575) ..........................................................109
nd
Fig 13 2 Stage Cylinder Assembly (2-01-842)..........................................................111
rd
Fig 14 3 Stage Cylinder Assembly (2-01-888) ..........................................................112
Fig 15 Piston Rod Assembly (2-30-320).....................................................................113
st
Fig 16 Piston Assembly - 1 Stage (2-28-787) ...........................................................113
nd rd
Fig 17 Piston Assembly - 2 & 3 Stage (2-28-833) ..................................................114
Fig 18 Top Cover Assembly (2-04-307)......................................................................115
st
Fig 19 1 Stage Cylinder Suction Valve Assembly (2-70-534) ....................................116
st
Fig 20 1 Stage Cylinder Delivery Valve Assembly (2-70-535) ...................................117
st
Fig 21 1 Stage Top Cover Suction Valve Assembly (2-70-536).................................118
st
Fig 22 1 Stage Top Cover Delivery Valve Assembly (2-70-537)................................119
nd
Fig 23 2 Stage Suction Valve Assembly (2-70-553) .................................................120
nd
Fig 24 2 Stage Delivery Valve Assembly (2-70-554) ................................................121
rd
Fig 25 3 Stage Suction Valve Assembly (2-70-555)..................................................122
rd
Fig 26 3 Stage Delivery Valve Assembly (2-70-556).................................................123
st nd
Fig 27 1 & 2 Stage Drain Trap Assembly (2-84-003) ..............................................124
rd
Fig 28 3 Stage Drain Trap Assembly (2-84-005).......................................................124
st
Fig 29 1 Stage Pipework (2-71-815) .........................................................................125
nd
Fig 30 2 Stage Pipework (2-71-801) ........................................................................126
Fig 31 Aftercooler Assembly (2-72-690) .....................................................................128
Fig 32 Pressure Gauge Arrangement (2-46-1254)......................................................130
Fig 33 External Pipework & Fittings (2-45-2519).........................................................134
APPENDICES
Appendix 1 Safe Working Limits
Appendix 2 Warranty Authorisation Claim Form
Appendix 3 Compressor Log Sheet
CHAPTER 1
TECHNICAL DATA &
COMPRESSOR DESCRIPTION
CHAPTER 1 - TECHNICAL DATA & Page: 9 of 135
1 TECHNICAL DATA & COMPRESSOR DESCRIPTION

The information contained in this section is intended for the use of the engineer
responsible for the operation and maintenance of the plant. It is essential that any
necessary adjustments, servicing or overhaul work should be carried out by
competent persons who are familiar with the installation, operation and maintenance
of this product and who have the appropriate authorisation.
When communicating with the Gardner Denver Belliss & Morcom on matters
relating to the compressor always quote the compressor type and serial number
(e.g.VH15H3N Serial No. 9320).
This manual is written using SI Units of measurement. The three basic units used
herein are: the metre, the kilogram and the second. All measurements in this manual
are expressed using these units unless otherwise stated.
Standards and Legislation
The compressor is manufactured in accordance with the European Economic

Community Directive: BS EN 1012-1: 1997, and is tested in accordance with British
Standard: BS 1571 Parts 1 and 2.
1.1 Technical Data

1.1.1 Operating Data
Normal Operating Conditions
Instrument Pressure Gauge Range Pressure Range

(Normal Operation)
st
Air Delivery - 1 stage 0 - 7 Bar G 2.0 – 2.4 Bar G
nd
Air Delivery - 2 stage 0 - 28 Bar G 10 - 11 Bar G
rd
Air Delivery - 3 stage 0 - 70 Bar G 45 Bar G
Oil Pressure ** 0 - 10 Bar G 3 - 4.8 Bar G
**Oil pressure will fluctuate with ambient conditions, compressor loading and with the
type and viscosity of the oil being used. Also; oil pressure peaks during start-up
before settling back as the oil achieves its operating temperature.
This machine is fitted with over-temperature monitoring safety switches for final air
from both the third stage cylinder and the aftercooler. Details of the settings for these
devices are given in Section 1.1.2 Compressor Data.
Flows and Capacities

Cooling Water
3
Flow** 15.5 m /h (nominal) ** The cooling water flows are design estimates and
10 m3/h (min) may need to be adjusted at site to meet the exact
cooling requirements.
Pressure 7 Bar G (max)
4 Bar G (min) It is recommended that the compressor is monitored
during its initial running period and that a record is
Temperat 35 ºC. (max) kept of the flows and temperatures for future
ure Inlet 16 ºC. (min) reference.
Compressed Air Data Crankcase Data
Gas being compressed AIR Oil Sump Capacity 45 litres
Delivery Pressure 45.5 Bar G

3
Air Capacity 1260 m /h
Inlet Temperature 0-45 ºC
Relative Humidity 0 - 100%
1.1.2 Compressor Data

Installation Data
Instrument Air: Component Weights
Normal Operating 7 Bar G minimum Compressor 4500 kg.

Range Weight (without motor).
Maximum Pressure 10 Bar G Service/ 1000 kg
Maintenance Lift
Vibration:
Vibration on the compressor may exceed 2.5 mm/s2, but there is no bodily contact
with the operator.
Mechanical Data
Cylinder Data Bumping Clearance (On All Cylinders)
st st
1 Stage Cylinder Bore 316 mm 1 Stage Piston Top to 2.2 - 3.0 mm
Top Cover
nd st
2 Stage Cylinder Bore 282 mm 1 Stage Piston Bottom to 1.2 - 1.8 mm
Cylinder
rd nd
3 Stage Cylinder Bore 142 mm 2 Stage Piston Bottom 1.2 - 1.8 mm
to Cylinder
rd
Piston Stroke 165.10 mm 3 Stage Piston Top to 2.2 - 3.0 mm
Cylinder
Piston/Piston Ring Data:

Figures quoted below for new parts. The upper and lower limits arise due to
accumulated effect of manufacturing tolerances. All butt gaps are measured with the
piston ring in the cylinder.
Diametrical Clearance of Piston Body
in Cylinder Bore:
st
1 Stage 3.16 – 3.46mm
nd
2 Stage 4.65 - 4.80mm
rd
3 Stage 4.00 - 4.14mm
First Stage Piston Rings First Stage Bearer Ring

Radial Thickness 19.99 - 20.09 mm Diametrical Clearance in 0.74- 1.10mm
Cylinder
Axial Clearance in 0.19 - 0.36mm Radial Thickness 9.04 – 9.15mm
Groove
Axial Clearance in Groove 0.42 - 0.57mm
Gap at Butt Joint 9.80 - 10.31mm
Standout from Piston Body 1.06 – 1.33mm
Gap at Joint 7.25 – 7.75mm
Second Stage Piston Rings Second Stage Bearer Ring

Radial Thickness 14.84 - 15.01 mm Diametrical Clearance in 2.94 - 3.29mm
Axial Clearance in 0.23 - 0.40mm Cylinder
Groove Radial Thickness 8.88 - 8.98mm
Gap at Butt Joint 9.00 - 10.00mm Axial Clearance in Groove 0.43 - 0.63mm
Standout from Piston Body 0.91 - 0.71
Third Stage Piston Rings Third Stage Bearer Ring

Radial Thickness 9.85 - 10.00mm Diametrical Clearance in 0.54 - 0.82mm
Cylinder
Axial Clearance in 0.16 - 0.318mm
Groove Radial Thickness 6.14 - 6.23mm
Gap at Butt Joint 4.00- 4.04mm Axial Clearance in Groove 0.79 - 0.95mm
(Each Gap)
Standout from Piston Body 1.61 - 1.78mm
Crankcase Components Clearances

The clearances for new components given are between the limits indicated - the
upper and lower limits arise due to accumulated effect of manufacturing tolerances.
The corresponding maximum figure is the point where renewal of the component is
required. No maximum figure is given against parts which, are not expected to wear
to any significant extent in service.
Part New Max
Connecting Rod Bottom End Bearing 0.10 - 0.18mm 0.23mm
Connecting Rod Top End Bearing 0.121 - 0.076mm 0.17mm
Crosshead to Main Guide Slide 0.22 - 0.30mm 0.42mm
Compressor Performance Data

Speed 735 rpm
Direction of Rotation Clockwise: looking on flywheel
Compressor Absorbed Power 155 kW
Drive Type Direct drive shaftless motor
Heat radiated (at full load) 15 kW (approx)
Cylinder Type Double acting / Single acting tandem - non lubricated
Load Control System 2 Step (Full-load or No-load).
Safety Device Data
Pressure Relief Valve Data:

Safety relief valve settings:
1st Stage 4.5 Bar G
nd
2 Stage 16.5 Bar G
rd
3 Stage 48.5 Bar G
Lubricating oil pump relief valve setting 3.5 Bar G
Setting of Protection Switches/Devices

High air temperature (AST) 177 ºC (rising)
High air temperature (Separator) 65 ºC (rising)**
Low lubricating oil pressure 1.8 Bar G (falling)
Low cooling water flow 65% of normal flow (falling)
** Switch is factory set to 65 ºC. for temperate (UK type) climates. The switch may be
adjusted up to a maximum of 75 ºC. to suit tropical climates during or after
installation. However, adjustments MUST only be performed by a competent,
authorised person.
Normal Settings for the Load Control System (40 Bar G Delivery)
Pressure Switch 1 (PS1) *40.0 Bar G. (unload trip)
*38.0 Bar G. (reload trip)
Pressure Switch 2 (PS2) *39.0 Bar G. (unload trip)
*37.0 Bar G. (reload trip)
Differential Pressure (between unload and reload trips): = *1.0 Bar G (minimum)
The settings quoted above are typical and may be adjusted to suit site requirements
during or after installation. However, the switch setting must not exceed the specified
design operating pressure.
Adjustments MUST only be performed by competent, authorised persons.
Noise Data
With compressor running at 735 rpm the following design figures are available:
Sound Pressure Level 90 dBA at 1m
2
Sound Power Level 110 dBA (ref 2 x 10 Pa)
1.1.3 Tightening Torques (Dry Threads)
CAUTION!
Over-tightening (over-torquing) of the fasteners can lead to damage to the
fasteners and/or the components.
Component Thread Torque Nm

Size (Newton metres)
CRANKCASE COMPONENTS:
Bearing End Cover M20 128 - 140
Flywheel End Cover M16 98 - 108
Oil Pump to End Cover M8 15 - 20
Crankcase Access Covers M10 25 - 30
Scraper Gland Fasteners M10 25 - 30
Flywheel Retaining M42 375 - 400
Distance Piece Components:
Distance Piece to Crankcase M24 200 - 220
Cylinder to Distance Piece M24 200 - 220
Distance Piece Access Cover M6 10 - 15
1ST STAGE CYLINDER COMPONENTS:
Cylinder/Top Cover M20 190 - 210
Valve Covers M12 29 - 32
st
1 Stage Suction/ Delivery Valve Nut M16 90 - 110
Inlet Flange M20 190 - 210
Outlet Flange M16 98 - 108
Packing Gland Fasteners M20 128 - 140
CHAPTER 1 - TECHNICAL DESCRIPTION Page: 14 of 135
Tightening Torques (Cont)
COMPONENT Thread Torque Nm
Size (Newton metres)
2ND STAGE CYLINDER COMPONENTS:
Cylinder to Cylinder M24 200 - 220
nd
2 Stage Suction/ Delivery Valve Nut M16 90 - 110
Inlet/Outlet Flange M24 200 - 210
Packing Gland Fasteners M20 128 - 140
3RD STAGE CYLINDER COMPONENTS:
rd
3 Stage Suction / Delivery Valve Nut M16 90 - 110
Inlet/Outlet Flange M20 190 - 210
MOTION WORK COMPONENTS:
1
Crosshead Nut to Crosshead 1 /2” BSF 555 - 610
Piston Nut to Piston 1.375” BSF 510 - 560
nd rd
Piston Assembly (2 to 3 Stage) M16 152
1.1.4 Materials of Construction

Crankcase & bearing end cover, main guides (for Cast Iron - Gr 250, BS1452
crossheads),distance pieces, cylinders & cylinder
top covers
st nd rd
Valve cages, covers 1 , 2 & 3 stage Cast Iron - Gr 250, BS1452
Crankshaft S.G. Iron - Gr 420/12, BS2789
Crankshaft Main Bearings Steel (spherical roller)
Connecting Rods & Crossheads S.G. Iron - Gr 600/3, BS2789
Connecting Rod End Bearing Top Lead-Bronze
Bottom Lead-Copper on Steel Shells
Crosshead Gudgeon Pin Case Hardened Steel
st nd rd
Piston Rod 1 , 2 & 3 stage Carbon Steel - 605M36T, BS970
Oil Scraper Gland Rings/Springs Stainless Steel
Packing Gland Rings/Springs PTFE/Stainless Steel
Packing Boxes Stainless Steel
Pistons Aluminium - LM16TF, BS1490
Piston Rings: PTFE
Valve Seats and Guards, Valve Plate, Damper Carbon Steel
Plates, Lift Washers, Springs and Bolts
Fixed tubeplates Intercoolers & aftercoolers Carbon Steel with copper tubes +
bonded inserts
1.2 Technical Description of the Compressor

1.2.1 Purpose of the Equipment
The compressor provides a constant supply of compressed air, at a regulated

pressure and of a known volume. The compressed air can then be used as part of an
industrial process.
External View of VH15H3N PET Compressor
1.2.2 Compressor Identification

All Gardner Denver Belliss & Morcom compressors have a rating plate located on
the crankcase. The information stamped onto this plate identifies the compressor
type, capacity and serial number. The compressor designation indicates the following:
V - Denotes cylinder configuration
H - Denotes multi-stage compression
15 - Denotes normal capacity
H3 - Denotes high pressure three stage
N - Denotes oil free cylinder operation
1.2.3 Compressor Operation
The compressor operates by drawing air from atmosphere into the 1st stage cylinder
where it is compressed to approximately 2.2 Bar G. The heat generated by
compressing the air is dissipated in the water-cooled intercooler, positioned after the
1st stage cylinder. The cooled air then flows through the 2nd stage suction separator,
which removes any moisture condensed during cooling. The air then passes to the
2nd stage cylinder where the air is further compressed to approximately 15 Bar G. The
heat generated by compressing the air is dissipated in a water-cooled intercooler,
positioned after the 2nd stage cylinder. The cooled air then flows through the 3rd stage
suction separator, which removes any moisture condensed during cooling. The air
then passes to the 3rd stage cylinder where the air is further compressed to its final
delivery pressure of 45 Bar G (max). The heat from compression is dissipated in the
water-cooled aftercooler positioned after the 3rd stage cylinder. The cooled air then
flows through the final delivery separator, which removes any moisture condensed
during cooling. The compressed cool dry air is then discharged into the delivery
pipework.
1.2.4 Crankcase and Lower Motion Work
Crankcase
The crankcase is a heavily-ribbed iron casting with integral mounting feet and cylinder
mounting flanges. Also integral within the crankcase are housings for the two
crankshaft drive-end bearings. There are machined faces for the flange mounted
motor, bearing end cover, crankcase and main guide doors. The bolt-on bearing end
cover incorporates the housing for the third crankshaft bearing.
The crankcase forms the lubricating oil sump, and is complete with tapped holes for
the oil level window nut, the oil pump suction feed pipe, the crankcase drain plug and
the oil cooler. Oil retention in the crankcase is made possible by a lip seal fitted at the
drive-end of the crankshaft and by scraper rings fitted around the piston rods.
Immediately beneath the drive-end crankshaft seal housing is an integral oil return
passage.
Crankshaft
The single throw, cast high-tensile iron, crankshaft has integral design counter-
balanced weights. The standard throw is 82.55 mm, giving a piston stroke of 165.10
mm. The crankshaft is supported by three self-aligning, double-race spherical roller
bearings, two at the driving end and one at the oil-pump end. Endwise location is by
clamping the outer drive-end main bearing (in the oil seal holding cover) against a
machined shoulder in the crankcase. The driving end has a tapered shaft, which is
keyed to accommodate the rotor of a direct mounted motor. The oil pump end of the
crankshaft has internal oil passages to the crankpin.
Cutaway View of Compressor Cylinder (2nd / 3rd Stage)

Oil Pump
The gear type oil pump is mounted on the crankshaft bearing end cover and is driven
via a coupling off the non-drive end of the crankshaft. Oil is drawn by the pump from
the crankcase sump through a wire mesh strainer and external pipe. The oil is
delivered through a full-flow fine-mesh cartridge filter to the oil ways in the crankshaft.
Any excess oil output is by-passed back to the sump by a spring-loaded pressure
relief valve mounted on the crankcase main bearing housing.
All the bearing surfaces in the crankcase are lubricated by the oil passing through the
bore of the crankshaft and connecting rods. The main roller bearings are splash lubed
by the oil from the crosshead, and also by the general oil mist in the crankcase.
Connecting Rods
The connecting rods have detachable bottom end caps to facilitate removal of the
rods and rods have split-shell bottom end bearings and bush type top end bearings.
The bottom end bearing shells are steel backed copper-lead, lead-tin plated. The
pressed-in top end bushes are lead bronze.
An oil passage connects the top and bottom bearings allowing oil under pressure
(from the oil pump via passages in the crankshaft) to lubricate both. Oil is sprayed,
from an annular groove around the top end bush and through two small holes, onto
both slides of the crosshead guide.
Crossheads
The crossheads run in the main guides which are bolted to the cylinder mounting
flange of the crankcase. The crossheads are attached to the top of the connecting
rods by gudgeon pins (which are retained themselves by circlips). The top face of the
crosshead is drilled and tapped for reception of the piston rod. The piston rod is
retained by a securing pin which passes through the side of the crosshead into the
slot in the end of the piston rod. The piston rod is then clamped by a nut, which is
tightened down against the top of the crosshead. The securing pin is prevented from
coming loose by a retaining plate.
1.2.5 Cylinders, Pistons and Piston Rod Packings
Cylinders
The double-jacketed cylinders are cast complete with mounting base, valve chambers
and a housing for the piston rod packing assembly. They have machined faces for the
top cover, lower mating flange, valve covers, distance rings and valves and the air
and water inlets and outlets. The inner jacket of the cylinder is for the cooling water,
the outer jacket is divided into air valve chambers.
The first and second stage cylinders are cast with integral valve chambers, cooling
water passages and air chambers. The third stage cylinder and top cover is a
combined casting. The cylinders all have machined faces for the cylinder joint, valve
covers, distance rings and valves.
The cylinders are non-lubricated, the piston rings being made of low friction material,
and are spaced off the crankcase by distance pieces. This is to help prevent oil from
the crankcase sump getting into the cylinders. Cooling is provided by passing water
first through the compressor intercoolers, and then, via a series of flexible pipes,
around the cylinder water jackets and cylinder top covers..
Pistons & Rings
The pistons are of a two-piece hollow construction, with machined piston-ring

grooves. The centre body is drilled and recessed to take the piston rod. The pistons
are made from aluminium and the piston rings are made from composite PTFE
material. Both sets of rings are jointed to assist with replacement during servicing.
Piston Rods & Packing
The steel piston rods are threaded at both ends. The piston rod bottom end has a
cruciform slot to accommodate a securing pin (to prevent rotation of the rod in the
crosshead) and is held in the crosshead by a locknut. The top end of the rod is
shouldered and waisted inside the piston. A self-locking nut secures the piston to the
rod. The piston/cylinder end clearances at the top and bottom are governed by the
distance the piston rod is screwed into or out of the crosshead.
The oil-free cylinder compressor has separate packing and scraper gland assemblies.
The packing comprises four pairs of glass and carbon loaded PTFE rings, each pair
of rings being housed in a container and held against the piston rod by a garter
spring. The four containers are assembled to a base by three long studs and nuts,
and the assembly held in its housing in the base of the cylinder by two studs and
nuts. A soft iron ring is recessed into the top surface of the upper container to prevent
air leakage around the packing.
The separate scraper assembly is mounted in a 'top hat' housing above the
crosshead-guide and comprises two sets of segmented rings in a split casing, each
ring is held in contact with the piston rod by a garter spring.
An oil shedder is fitted to the piston rod between the packing and the scraper
assemblies to prevent any oil-creep along the rod.
1.2.6 Valves
Suction and delivery valves are similar in construction but differ in detail. Care must
always be taken when servicing the compressor to ensure that the correct valve is
fitted into the correct valve chamber.
All suction valves are controlled by plate depressors (or unloaders), their location
being identified by the presence of actuators on the valve covers. The actuators have
small bore instrument air pipes connected to them.
To unload a working compressor. the suction valves are rendered inoperative by the
valve plates being pressed off their seats. This is accomplished by plate depressors
(unloaders) being operated by load control actuators.
A plate depressor is basically an inverted cup-shaped body with fingers protruding

from its rim, assembled with a spring-loaded central guide surmounted by a cylindrical
cap. The fingers operate through slots in the suction valve seat directly onto the valve
plate.
In action the plate is depressed, against its spring, by the pneumatically operated
actuator. Compressed air fed to the load control actuator, by the load control solenoid
valve, acts on a multi-layer diaphragm, which is sandwiched between the two halves
of the actuator body. The diaphragm is in contact with the head of the spring loaded
plunger immediately under the disk. The plunger, guided in the lower half of the
actuator body, has its stem end in contact with the cap of the plate depressors. When
the control air is exhausted by the solenoid valve, springs return the plunger away
from the valve plate.
1.2.7 Motor and Couplings
The compressor can be supplied with a flange-mounted motor, or as a bare-shaft

machine.
The standard motor is a brushless cage rotor type, with a power output suited to the
delivery requirements of the compressor.
The motor's rotor is keyed directly onto the crankshaft and the stator casing is bolted
to the crankcase.
1.2.8 Control Panel and Controls
The compressor can be supplied with or without a starter system. The standard
starter system is housed in a two compartment dust and damp proof wall or floor
mounted sheet steel cubicle. The control panel is an integral part of the front of the
cubicle and the controls and gauges are divided between the upper and lower
compartments. (For full details of the controls their operation and functions refer to
the supplementary information provided with your compressor).
1.2.9 Safety Equipment and Systems
There are several safety features fitted to Gardner Denver Belliss & Morcom
compressors as standard, with additional features available as options. The following
are standard fitments:
a. low lubricating oil pressure indicator and alarm
b. high delivery air temperature indicator and alarm
c. low cooling water flow indicator and alarm
d. pressure relief valves after each of the cylinders
e. pressure relief valve after the oil pump
Faults 'a' to 'c' (if supplied with a standard control panel) are indicated on the
annunciator panel, which is integral with the main control panel. The fault results in
the simultaneous alarm signal on the panel and shutdown of the compressor. The
fault protection equipment is interlocked with the starter. Fault 'd' results in the release
of pressurised air to atmosphere by the relief valve immediately after the over
pressured cylinder. During normal operation 'e' bypasses excess oil back to the
crankcase sump.
For full details of the system and its operation refer to the supplementary information
supplied with your compressor.
CHAPTER 2
SAFETY INFORMATION
CHAPTER 2 - SAFETY INFORMATION Page: 22 of 135
2. SAFETY INFORMATION
2.1 Safety Policy

The compressor and its associated equipment are to be operated in accordance with
current Statutory Health & Safety Policies (and any such regulation applicable in the
country of installation). It is the responsibility of the operative to familiarise him/her
self with these Policies/regulations.
Any work practices that may pose a potential health and safety hazard or any
faulty/suspect equipment associated with the safe operation or maintenance of the
compressor package must be bought to the immediate attention of the supervisor or
supervising authority.
Always wear appropriate safety equipment when operating or maintaining this
equipment. Personnel safety equipment to include but not limited to:-
• Ear Defenders
• Safety Glasses.
• Industrial Boots.
• Appropriate Hand Protection (gloves and/or barrier cream).
• Any other safety item identified under Risk or COSHH Assessments.
Loose fitting or frayed/ripped clothing MUST NOT be worn while operating or
maintaining this equipment.
2.1.1 Commonplace Hazards
If a hazard is identified that is not identified within the Operating Authority 'Standing
Safety Instructions' a separate Risk Assessment must be made. Similarly If a hazard
in the form of a Control Of Substances Hazardous to Health (COSHH) is identified,
steps must be taken to assess the risk of injury to staff.
The compressor and its associated equipment are to be operated in accordance with
current statutory Health & Safety at Work Policies. It is the responsibility of the
operative to familiarise him/her self with these Policies. Any work practices that may
pose a potential health and safety hazard or any faulty/suspect equipment associated
with the safe operation and maintenance of the compressor must be brought to the
attention of the supervisor or supervising authority.
2.1.2 Proper Use
The compressor is built to stringent manufacturing guidelines to guarantee safe

operation. However, using compressed air can be linked to dangerous occurrences if
compressed air is not properly handled. Proper use also includes the following:
• Follow the guideline laid down within this instruction manual, observing all
pertinent regulations and notes for the compressor.
• Maintaining the equipment at the mandatory inspection and maintenance
intervals.
• Correct repair of the compressor equipment.
• The compressor MUST NOT be operated in any other manner than that for
which it was originally designed.
• Operating in accordance with the relevant environmental and operating
regulations.
2.1.3 Organisational Measures
It is the customer’s responsibility to ensure that the operating manual is adequately

supplemented with internal regulations regarding supervision and notification duties,
work organisation, and personnel qualification etc.
No modifications may be carried out on the compressor or its peripheral devices
without the written consent of Gardner Denver Belliss & Morcom. Unauthorised
Modification of the equipment will invalidate the WARRANTY.
When renewing compressor components use only original spare parts and
accessories supplied by Gardner Denver Belliss & Morcom.
2.1.4 General Safety Precautions for Compressors
Electrical System - Before performing work on the electrical system the compressor
and the peripheral devices must be isolated form the mains and secured against
switching on accidentally. Work on the electrical system must only be carried out by
qualified staff who are aware of the risk involved with the task.
Pressure Relief Valves - These MUST be Full Compressor Capacity relief valves
connected directly to the flow pipework to relieve any excess pressure that may build-
up between the cylinder discharge flange and in line equipment (e.g., stop valve, non-
return valve, cooler, etc).
WARNING!
It is forbidden to operate the compressor unless all relief valves are
correctly fitted, in fully operational condition and are set at the
correct relief pressure for the compressor duty.
There must be no restriction of any kind between the relief valve position and the
preceding cylinder. Relief valves must be directly mounted with no isolating valves
interposed between the relief valve and the pressure sensing point. The exhaust from
the relief valves must only discharge into designated safe areas. The setting of relief
valves must be checked regularly as required by statutory codes and regulations.
Pressure vessels must be fitted with a full capacity pressure relief valve. Vessels
must not be operated above their stated operation rating and must be checked
regularly as required by codes and regulations.
Protection Equipment - All protection, control switches and circuits must be
regularly checked for correct operation.
Switches can be tested by checking in calibration rigs, or by carefully controlled
simulation of fault conditions at the actual machine. Circuits can be checked by
mechanically operating the switches.
Frost Protection - Where, due to its location, the compressor could be exposed to
frost, then adequate precautions must be taken to prevent freezing of the water
system.
Guards - All guards and covers must be in position and secure before start-up.
Operating Records - It is IMPORTANT that a regular log sheet be kept for the
compressor recording operating pressures, temperatures and oil pressure (a copy of
a Log Sheet is provided within the Appendices located at the end of this manual).
Variances from normal running performance should be brought to the immediate
attention of the Supervisor responsible for consideration and action.
Lifting Equipment - Before using any lifting equipment, it is IMPORTANT that the
crane, gantry, hoist or chain block and any slings employed must be certified capable
of lifting the weight of the compressor (or motor/compressor assembly). Any such
lifting equipment MUST have a current CITB Test Certificate (or an equivalent
certificate applicable to the country of installation).
2.1.5 Installation, Commissioning and Operation

In all matters of safety regarding the Installation, Commissioning and Operation of the
compressor or package, the reader's attention is directed to the full implementation of
the requirements of the Health & Safety at Work Act (and any such regulation
applicable in the country of installation). Gardner Denver Belliss & Morcom may be
consulted should any doubt exist regarding matters of safety related to their product.
2.1.6 Maintenance
In addition to the General Safety Precautions, the following safety precautions MUST
be observed when maintaining your machine.
1. Before commencing any maintenance work on the compressor or its driving unit
or any ancillary, the driving unit must be rendered incapable of being started
whilst maintenance and adjustment work is in progress.
In the case of an electric motor for example, the machine must be isolated from
the main electricity supply, the isolator locked off and/or the fuses withdrawn.
This is particularly important with auto start/stop machines where the machine
could be started automatically.
2. Affix "NOT TO BE USED" boards to the compressor and control cabinet.
3. Isolate the compressor from the discharge main and the instrument air.
4. Before opening up the machine, all pressurised compartments MUST be
depressurised down to atmospheric pressure in a safe and controlled
manner.
5. Isolate the compressor from the cooling water supply and drain all relevant water
containing compartments.
6. If the compressor motion work or rotational parts are to be worked on then piston
rod clamps MUST be fitted to prevent accidental movement. Also chocking the
crankshaft should be considered where necessary.
7. ALL lifting equipment MUST be correctly rated for the loads being applied and
MUST be certified as being in good working condition. Always ensure that when
lifting equipment is used, only specified lifting or slinging points are used.
8. Always refer to the applicable procedure when undertaking maintenance and
overhaul procedures.
9. Bolts and nuts must not be under or over tightened, see appropriate torque
values in Chapter 1 Section 1.1.3.
10. Ensure that ALL tools and spare parts are accounted for after reassembly, since
any items left on or within the compressor may cause serious damage upon
restarting.
11. DO NOT place the electrical isolating switch to the 'ON' position until your
supervisor has inspected and approved the work carried out.
12. Before starting the compressor, bar over the machine by hand where possible to
ensure free rotation and that no metallic 'knocking' noise is evident.
CAUTION!
Particular care must be taken with compressor valves to ensure that suction
valves and associated securing and actuating components are not fitted in
delivery valve pockets or vice-versa. Failure to do so could result in severe
damage to the compressor.
CHAPTER 3
INSTALLATION
&
COMMISSIONING
CHAPTER 3 - INSTALLATION & Page: 27 of 135
COMMISSIONING
3 INSTALLATION & COMMISSIONING
3.1 Safety Precautions

Before carrying out any work related to this Section, it is a requirement that you read
and work in accordance with, the Safety Precautions given in Chapter 2 of this
manual. For your own protection, be sure to read and obey the WARNING and
CAUTION notices you find in this Section and any associated literature.
WARNING!
1) If the compressor is to be supported on anti-vibration mountings,
air, water and electrical services are to be made with non-rigid
(flexible) connections.
2) Due to possible electrical insulation effects of pipe gasket
material and anti-vibration mountings, the machine must be
provided with a permanent earth continuity connection of a non-
rigid (flexible) type, which should comply with local regulations
and safety requirements.
3.2 Installation Requirements

The installation of the compressor, and its associated pipework, should be the subject
of careful consideration before undertaking the actual task. This section of the manual
provides the necessary information for the installation engineer to locate and to install
the compressor to the best advantage.
3.2.1 Location
The compressor should be located in a clean, well-lit, well-ventilated area with ample
space all around it to facilitate inspection and maintenance. Sufficient room must be
allowed for the removal of pistons and cylinders, crankshaft and motor, and as the
compressor and many of its components are heavy, there must be headroom
sufficient to permit the operation of a crane or hoist, which must be certified capable
of lifting safely the weight.
Statutory regulations and local by-laws governing the operation of heavy machinery
must be complied with, this may have some influence on the choice of location.
3.2.2 Ventilation
Approximately 10% of the energy consumed by a compressor is lost as heat. This is
the heat generated by the motor, the mechanical losses of the compressor and
straight-forward heat radiation from the air manifolds.
For instance, a 155kW water-cooled compressor would require some 207m3/min of
ambient air circulation to limit the compressor room temperature rise to 6ºC. Natural
convection is normally adequate with the outlet vents at a high level to prevent the
temperature building down from the roof.
COMMISSIONING
3.2.3 Foundations
For vibration isolator mounted compressors, all that is required is a floor of sufficient
strength to carry the weight of the compressor, motor and ancillaries. For solidly
mounted compressors the foundation dimensions must be determined for each
installation, consideration being given to the nature of the subsoil and local
surroundings.
WARNING!
The floor must be level and flat.
Foundation depth must be such that the subsoil reached is, in the opinion of an
expert, capable of taking the load of the working compressor and preventing the
transmission of vibration. Unless the foundation rests on bed-rock or hard-pan, a sub-
footing should be made of such a size and design as to provide a solid bottom. In
extreme cases of poor subsoil, piling may be required, and in such circumstances a
competent foundation engineer should be consulted.
If the compressor is to be mounted on a metal floor, it can be either bolted direct to
the floor, or beam or skid mounted. The beams or skids may be bolted or welded to
the floor, with due consideration being given to structural vibrations and floor strength.
A foundation plan (for good subsoil conditions) is furnished in advance of the
shipment of the compressor, and the foundation used must not be less than given in
the plan.
When installing a solidly mounted compressor, it must be ensured that the crankcase
feet are ALL flat down and fully supported BEFORE tightening the "Holding-Down"
fasteners. A detailed foundation drawing is available (on request) from Gardner
Denver Belliss & Morcom.
3.2.4 Pipework Installation
These paragraphs give recommendations with regard to both suction and delivery
pipework and will help the plant engineer plan the best possible installation.
Pipes must not be fixed inflexibly such that heavy thrust can act back onto the
compressor otherwise serious damage could result, examine carefully the anchoring
point locations and pipework support arrangements.
WARNING!
All inlet and outlet connections to compressors mounted on vibration
isolates MUST use suitable flexible pipes. All flexible pipes MUST be
installed in accordance with the manufacturer's instructions.
Inlet System
An efficient air intake filtration system is essential to ensure that debris is removed
from the air flow to the compressor thereby prolonging the life of the machine.
Standard Gardner Denver Belliss & Morcom practice is to fit a machine mounted,
combined filter/silencer, however, in hot or dirty locations, or in the presence of
difficult combinations (e.g. fumes, alumina or cement dust), filtration may be improved
by mounted the intake remotely and ducting the air to the compressor. Special
filter/silencer arrangements are available for this type of installation.
Only dry type filters must be used with oil-free compressors.
Noise regulations should be taken into account when deciding silencer requirements
and locations.
COMMISSIONING
Delivery System
The delivery pipe connects the aftercooler to the receiver (where fitted). It must be of
the correct specification for the pressure and temperature and nature of the medium
being compressed, and not smaller than the size specified on the drawing supplied
with the compressor.
At the junction with the receiver, or pipe main, a shut-off valve should be fitted to
isolate the compressor as required. On automatic and multi-machine installations,
non-return valves should also be fitted to isolate standby units from system pressure.
A safety valve must be fitted, close to the compressor, in the delivery pipe. The valve
must be fitted before any shut-off valve, non-return valve or aftercooler to prevent
damage in the event of the compressor being run with the shut-off valve closed. The
valve should be a spring-loaded type and of sufficient size to pass safely the
maximum compressor output.
A small blow-down valve should be fitted between the compressor and shut-off valve
to relieve residual pressure when required for maintenance purposes.
Air Receiver
An air receiver of ample capacity is required for use with this equipment. The receiver
should have a capacity equal to a one minute supply of compressed air (neglecting
temperature rise).
The air receivers should, ideally, be located in the coldest place possible, to ensure
that as much condensate as possible is precipitated from the air in the receiver. This
means that the receiver must be drained frequently, either by fitting an adequate
drain or an automatic drain trap.
To facilitate servicing of the drain trap whilst the receiver is in commission, a by-pass
should also be incorporated.
Distribution Piping (air systems)
Water collectors of an automatic discharge type should be fitted at suitable points in

the pipe system. They should be fitted with three-way cocks (either in connection with
the traps or separately) so that pipes may be blown through to disperse
condensation.
Delivery pipework must be arranged to prevent condensation running back from the
aftercooler or receiver into the compressor cylinders.
The pipe system for air distribution should be carefully considered if optimum results
are to be obtained. Moisture-laden air can cause rusting in low-lying parts of the pipe
system so, ideally, all distribution pipework should be internally galvanized and
angled slightly towards the drain points.
An effective way of eliminating possible water damage is to install a refrigerative air
dryer or, for dryer air, an adsorption dryer.
COMMISSIONING
Load Control Piping

Connect (with similar size piping) the load control system on the compressor to the
control air take-off points on the compressor panel, the connections on the
compressor will indicate the size.
Connect (with similar size piping) the compressor panel control air inlet point to the
compressed air/instrument air main - any isolating valve fitted here must be of the
lockable-open type.
Drain Valves & Drain Valve Piping
It is important that the drain pipes from the water separator drain traps are run
individually to open ends (e.g., over OPEN drains). They must NOT be piped together
as there would then be a risk of "blow-back" along adjacent pipes in the event of a
trap malfunctioning.
Drain valves are fitted to the separators of each compression stage. These valves
exhaust the collected moisture at high pressure and must be piped away to a safe
area using solid pipework.
MOST IMPORTANT - if the exhausts of any vent valves are piped away, it is
essential that these have direct outlets to atmosphere, they must NOT be connected
into any other pipe. It is also strongly recommended that a silencer is fitted to the
exhaust in order to reduce noise levels.
3.2.5 Cooling Water

An adequate source of clean, cool water for the compressor cylinders, intercoolers
and aftercooler should be provided.
Cooling water must be as free as possible from scale forming salts, with (if the water
is not clean) an efficient filter(s) placed in the intake pipeline. A Duplex type
arrangement is recommended as this will allow one filter to be cleaned whilst the
other is in service.
The temperature of the cooling water supply to the compressor (NOT aftercooler)
should not be less than the ambient temperature. The methods of achieving this
depend on the cooling system employed:
The temperature of the cooling water supply should be in the range of 20ºC to 35ºC.
In situations where the ambient temperature is in excess of 35ºC., advice should be
sought from Gardner Denver Belliss & Morcom.
The pressure in the cooling water pipeline at the compressor must be sufficient to
promote the flow required by the size and duty of the machine. This should take into
consideration all the friction losses in the overall pipework and valves and across the
heat exchanger units (as may be installed) as well as across the compressor.
Except for compressors made to special customer requirements, water pressure in
the jackets should not exceed 7 Bar G.
It is recommended that thermometer pockets are fitted to the water inlet and outlet
pipes to the compressor and, the aftercooler. Temperature differentials between
these points will give a good indication of sufficient water flow, 10 to 15ºC being
usual.
COMMISSIONING
CAUTION!
Failure of water flow is a cause of major damage and must be avoided.
Ensure that cooling water pipes to and from the compressor are
constructed to avoid the formation of air locks
For compressors operating in cold environments, drain points are present on the
cylinders to empty the water jackets of the machine (when out of service) to prevent
damage in the case of frost. Open air vent cocks at the tops of the cylinders at the
time of water drainage. Certain water pipe connections should afterwards be
disconnected to completely drain the system.
CAUTION!
Exposure to frost conditions will damage your machine unless the proper
frost precautions are taken. If advice is required, please contact Gardner
Denver Belliss & Morcom .
3.2.6 Electric Cabling
The electric cabling to the motor must be run such that small amounts of movement
at the motor terminals can be safely absorbed within inherent flexibility of the type of
cabling used.
Check that the motor nameplate details agree with those of the electricity supply on
which the motor is to be used.
Connect motor in accordance with the instruction supplied. Use cables of adequate
size to carry the full load current and also large enough to carry the starting current
without excessive voltage drop.
Ensure that the motor frame is properly earthed.
3.3 Handling and Unpacking

3.3.1 Stability
Due consideration must be given to maintaining the compressor's stability during all
and any lifting procedures. The compressor is only in a stable condition when
standing on a suitable, level floor surface with all four crankcase feet firmly down. The
Centre of Gravity diagram will help when assessing slinging/lifting requirements. The
Centre of Gravity (C of G) migrates depending on whether the compressor is 'bare-
shaft' or fitted with a 'drive unit'.
COMMISSIONING
Compressor Slinging Diagram (Typical)
WARNING!
The crane, gantry, hoist or chain block or any slings employed must
be certified capable of lifting the weight of the compressor (or
Motor/Compressor assembly.
3.3.2 Slinging Instructions
On all compressors two cradle slings are positioned, one under each of the two outer
cylinder crankcase flanges. A third sling is used to balance the compressor. Care
MUST be taken to ensure that no small bore pipes or other components become
trapped by the slings while lifting.
a. In the case of a compressor fitted with a flange mounted motor, a cradle
sling is passed under the motor, taking care to keep it clear of the fan
housing.
b. In the case of a bare shaft compressor, a sling is passed round the
intercooler pipework.
c. If the compressor is fitted with a flywheel, a balancing sling is passed
around the shaft.
WARNING!
Under no circumstances use the motor lifting point as a compressor
slinging or balancing point (this lifting point is for manoeuvring the
motor only.
Care MUST be taken to ensure that no small bore pipes or other small components
are trapped by slings
COMMISSIONING
3.3.3 Lifting Instructions

Because the type of lifting equipment in each customer's factory is unknown to
Gardner Denver Belliss & Morcom, these instructions are written with the intent of
being a general guide rather than specific instructions.
For compressor maintenance purposes a one tonne block is usually suitable to give
good control of the lifting of components.
1. Whatever your equipment or conditions, good safety procedures must be
practiced, i.e.:
a) Establish the actual weight of the load.
b) Check whether the lift will be a straight lift, or will an angle rig be needed.
These factors will affect the lifting capacity required.
c) The slings must be free of kinks, knots, broken strands or loose
connections etc, and meet the regulation requirements.
d) Check the clearance available to make sure the lift can be attempted
safely.
e) To prevent damage to the machine's finish or the edges of the machine
from cutting into the slings, use proper blocking and padding.
CAUTION!
Never pass the slings through the distance pieces as this could damage the
piston rods.
2. Know your equipment, and anticipate potential hazards.

3. When involved in the lifting of heavy loads, we suggest you protect yourself by
wearing approved protective gear such as: safety helmets, steel toe cap safety
shoes, gloves, eye protection, etc.
4. Prepare the installation area before moving the machine.
5. Refer to the machine installation drawings and note the location of the machine
support points. Review all machine installation requirements carefully before
positioning the machine.
3.3.4 Unpacking
No special unpacking instructions can be given here as the compressors may be

transported fully boxed, crated, or on open bases, depending on destination and
mode of transportation. Boxed compressors have directions for lifting and opening on
or with the boxes. Some of the cylinder valves will have been replaced with silica-gel
bags. The displaced valves and the accessories are packed in a separate container,
which should be located and safeguarded until after the installation of the
compressor.
COMMISSIONING
3.4 Installation Procedure

3.4.1 Safety Precautions
The following additional safety precautions should be observed before installing the
compressor onto its foundation.
Personnel must be a safe distance from the compressor during positioning, guide
ropes may be used to assist, but not 'hands-on'. The compressor must be lowered
slowly, in small stages with no sudden jerks whilst observing for any indications of
potential problems. Once in position the compressor must be properly secured with
suitable foundation bolts or anti-vibration mounts (AVM's).
If the floor is to be drilled for foundation bolts, the compressor must be moved away
whilst work proceeds.
Each time the compressor is moved check for stability and correct sling placement.
DO NOT apply load tension to the slings if the compressor is held to the floor.
3.4.2 Mounting Arrangements - Anti-Vibration Mounts
A flat and level floor of sufficient strength to support the combined weight of the
motor, compressor and ancillaries should be prepared in advance of the compressor
delivery. The procedure should then be as follows:
1. Ensure that the underfaces of the compressor feet are clean.
2. Bolt the anti-vibration mountings on to the compressor feet.
3. Move the compressor into position and mark on the floor the position of the
holding down bolt holes in the anti-vibration mounting plate.
4. Remove the compressor and attached mounts and drill the floor for appropriate
size holes for the Raw-bolt shells.
5. Insert shells, reposition compressor and bolt onto floor by means of the
mounting holding down bolts.
OR:
The anti-vibration mountings may be held down by bolts or anchors of a similar
diameter to the holes in the mounting plate. Use of these will eliminate the need
to move the compressor to drill the floor holes. The appropriate instructions
supplied with the bolts should be followed precisely.
6. Finally, check the bolts holding the compressor onto the anti-vibration
mountings and use these bolts to finish levelling the compressor (See Levelling
and Alignment).
COMMISSIONING
3.4.3 Levelling and Alignment - Flange Mounted Motors

Compressors with flange mounted motors are completely assembled and lined-up
before shipping, it is therefore only necessary to set the machine on the foundations
and level it in both directions as follows:
1. Adjust the pressure within the pneumatic AVM's around the machine until the
desired level is achieved. Do not inflate AVM's unless the static weight of the
compressor is placed on them.
2. Ensure that the final levelled height of each mount is within the makers limits
and that each mount is levelled until it carries its correct proportion of the overall
machine weight.
3. If any mount is compressed solid, levelling must be carried out on the free
mounts to redistribute the load.
4. Using a spirit level on any horizontal surface, check that the compressor is level
in both planes (i.e.. parallel to and at right angles to the crankshaft).
5. If NOT, then adjust again until satisfied.
3.5 Preparation for Commissioning

3.5.1 Cleaning the Compressor
The compressor must be thoroughly cleaned before preparing for commissioning.
Care should be taken when making connections to see that no grit or impurities of
any kind are allowed to enter while the compressor is being piped up and prepared
for work.
3.5.2 Preparing the Compressor

After works testing, the compressor is prepared for shipment. Before use therefore,
the compressor will require to be prepared for use as follows:
1. Remove the 'mouldable' wrapping from around the piston rods and clean the
rod surfaces.
2. Remove control piping from cylinder valve covers marked with adhesive labels
and remove the covers.
3. Extract the silica gel bags from the valve chambers; ensuring that where more
than one bag is present, ALL bags are removed.
4. Using a plastic or soft metal scraper, remove rust resistant paint from the
seating in the valve chambers.
5. Remove the valve assemblies from their wrappings.
6. Fit components in their correct order, ensuring that suction and delivery valves
are fitted in the correct valve chambers. Where plate lifters are fitted to suction
valves, care must be taken to ensure correct assembly.
COMMISSIONING
7. Tighten the valve covers and refit the control air pipes
8. Remove and store the adhesive labels and warning plates with the silica gel
bags.
9. Check that all gauges and small-bore pipework are undamaged, and are
properly connected.
10. Ensure that all external nuts and bolts on the compressor and its ancillary
equipment are tight, including all holding down bolts and bolts of all pipework
flanges and supports.
11. Remove the crankcase access covers (and wooden blocks where fitted), and
crosshead access aperture covers, and check to ensure that the interior of the
crankcase is clean and free of foreign matter.
12. Ensure free movement of compressor motion by turning the crankshaft round a
number of times in the correct direction of rotation.
13. Fill the oil sump (in the bottom of the crankcase) with the recommended grade
of lubricant to level indicated by the window nut on the front of the crankcase.
Initially fill to near the top of the window, the level will fall towards the bottom of
the window when the compressor is started, rising to about half-way when the
oil has reached its sustained running temperature.
14. Wearing suitable (oil resistant) protective gloves, liberally coat clean oil onto all
the main guide slides - turning the crank to different positions to achieve full
face coverage (keep hands out of the crankcase when the shaft is being
turned).
15. As the compressor may have been in transit/storage for some time, prime the
suction side of the lubricating oil pump by disconnecting the suction pipe top
fitting. Then using the recommended grade of lubricant pump oil 'in' to 'wet' the
gears and fill partially the suction side of the pump body. This promotes a quick
pick up of oil pressure on start up of the compressor.
16. Refit the crankcase and crosshead access covers.
17. Ensure that the compressor pressure instrument isolating cocks are open.
18 Ensure that the pipes of the rubber filling plugs are removed to vent the gauge
cases and allow correct gauge indication.
19. Ensure that the pressure signal pipelines of the load control system are open
(i.e., make certain that any isolating valves are fixed open).
20. Fill slowly and carefully (to avoid trapping air) in the cooling water spaces of the
compressor - do not rush this operation. Open the air vent cocks, at the tops of
the cylinder covers to rid the system of trapped air. The operation is carried out
in association with any other water cooled ancillary items in the overall cooling
water system of the installation.
COMMISSIONING
3.5.3 Preparing the Motor

Check the driving motor insulation resistance (IR) using a 500 volt megohmeter taking
note that the insulation resistance in mega-ohms, measured between any terminal
and the frame with the machine cool, is infinity.
If the windings have become damp and the insulation resistance is low, then the
windings must be thoroughly dried out and re-tested for satisfactory condition before
commissioning.
CAUTION!
Before using the insulation tester disconnect the supply leads at the motor
terminals so that only the motor windings are tested. This will avoid the
possibility of the test instrument potential destroying any electronic
equipment that may be in ancillary circuits.
3.5.4 Motor Rotation Check

The compressor is designed to rotate in a clockwise direction when viewed from the
drive end.
CAUTION!
Running the compressor with incorrect rotation will result in serious
damage.
After checking it is safe to do so, switch on the electricity supply to the compressor
control panel. Prepare the compressor for an 'unloaded' start and press the START
button, as soon as the compressor starts press the STOP button. Check motor is
rotating in the correct direction (indicated on motor end). In the event of wrong
direction of rotation, isolate the machine immediately. A qualified electrician must
rectify the problem before rechecking.
3.6 Commissioning the Compressor

Before commissioning the compressor, read and fully understand Part 3 "Operation"
and any associated literature regarding the control panel and any other ancillary
equipment.
3.6.1 Trial Run
When commissioning, the trial run must include certain vital checks, and these should
be carried out as follows:
1. Ensure that the factory delivery mains and air using equipment are safe to
pressurise - and all delivery isolating valves in the system are open.
2. Ensure that the load control sensing pipework is open to the compressed air
main.
3. Ensure that the isolating cocks of all pressure gauges are open.
4. Ensure that the by-pass valves situated at the drain traps are closed.
5. Start compressor in the unloaded condition and allow to run up to full speed,
observe oil pressure is quickly established (this will be high with a cold machine)
and observe compressor running generally.
COMMISSIONING
6. After a 3 minute run, stop and electrically isolate the compressor. Remove the
crankcase main doors and check the temperatures of the motion work bearings
and guides. This should be done using a thermometer fitted with a suitable
surface probe.
WARNING!
Take care during examination, as some of the parts will have become
heated.
All should be cool except the bottom end bearings, which can be a little warmer than
other bearings - also one side (the 'working face' side) of main guides may be slightly
warmer than the opposite side.
7. Refit the crankcase main doors and reconnect the compressor.
8. Run the compressor for a further 10 minutes and repeat checks as in step 6.
9. When satisfied that all is in order, restart the compressor. When the compressor
has settled on speed place the load control to the load condition whereupon the
compressor will commence compressing.
10. Observe compressor operation and the build up of pressure.
The load control must be set for no higher pressure than that for which the
compressor is supplied. (See Section 1.1.1 Technical Data).
During the first commissioning run on load, make careful observation of the general
operation of the compressor.
Observe the compressor gauges, until the desired unloading set-point (as set on the
load control pressure switches) is reached, at this point the compressor will unload
automatically as described in Load Control System.
Check that the loading/unloading sequence is in accordance with requirements -
adjust the control as necessary.
3.6.2 Completion of Commissioning
1. Run the compressor until it attains operational temperature and check that the
oil pressure settles at a satisfactory level, approx. 3.5 Bar G or above; this will
depend upon ambient temperature, oil viscosity at running temperature, and on-
load/off-load running pattern.
2. After a settled period of running (approx. 24 hours) check the tightness of all
external bolts and nuts - particularly cylinder and valve cover fasteners, also
compressor and compressor driver fixings - to complete the commissioning of
the machine.
3. During this run (on water cooled machines) adjust the cooling water flow control
valve to achieve the required temperature rise. When on sustained full load, the
optimum temperature rise is about 10oC to 15oC.
CHAPTER 4
OPERATING INSTRUCTIONS
CHAPTER 4 - OPERATING INSTRUCTIONS Page: 40 of 135
4 OPERATING INSTRUCTIONS
4.1 Safety Precautions

Before operating this equipment, it is a requirement that you read and work in
accordance with, the Safety Precautions given in Chapter 2 of this manual. For your
own protection, be sure to read and obey the WARNING and CAUTION notices
located in this Section and any associated literature.
These instructions are designed to providing experienced operatives, who are fully
conversant with compressor operating techniques, with operational informational for
the Gardner Denver Belliss & Morcom 'PET' range compressors.
4.2 Operating Criteria

Note: The following operating information assumes that the compressor is
fitted with a standard Gardner Denver Belliss & Morcom control system.
However, if the control equipment is of different manufacture, the
compressor MUST be operated in accordance with the supplementary
Operating Information supplied with the control system.
The compressor is designed and built for continuous running and will provide long
term reliable operation if regular periodic checks and servicing are carried out in
accordance with the information provided within Chapter 5 of this Instruction Manual.
CAUTION!
Prolonged unloaded running of the machine should be avoided not only
because of power wastage, but unnecessary component wear can result.
4.2.1 Customer's Responsibility
It is the customer's responsibility to:
1) Maintain the inlet filter system and air blast cooler in a clean condition as dictated
by site conditions.
2) Ensure that the specified, clean lubricant is added to ensure the correct
crankcase oil level is maintained
3) Report promptly to Gardner Denver Belliss & Morcom Service Department any
operating abnormalities, faults defects or malfunctions of the compressor and/or
associated ancillary equipment. Such reports must be forwarded in writing by
facsimile transmission. Oral reporting shall be deemed to be acceptable if
confirmed in writing in the following 48 hours.
4.3 Controls and Indicators

4.3.1 Starter System
If supplied with your compressor, the standard Gardner Denver Belliss & Morcom
starter control equipment consists of a two compartment panel enclosed in a dust and
damp proof wall or floor mounted sheet steel cubicle, and suitable for use on various
electrical supplies. The panel incorporates the following features:
1) Automatic Star/Delta starter.
2) Pushbutton operated Start and Stop, adjustable timer with overload protection.
3) 'Unload/Manual/Auto' selector switch for operation mode selection.
4) Transformer providing 110 volts a.c. and 24 volts d.c. for control and fault
protection equipment.
5) Three fault protection units giving alarm and shutdown on:
• Low lubricating oil pressure
• High discharge air temperature
• Low cooling water flow
6) 'Test' pushbutton to check panel lamps.
7) 'Accept' pushbutton to cancel the audible alarm.
8) 'Reset' pushbutton to clear the alarm annunciators and make the compressor
available for restarting. This ensures the compressor cannot be restarted except
as a deliberate operator action.
9) A pressure switch and solenoid valve give on/off load control with automatic
unloaded starting and stopping.
10) A panel mounted mains isolator, interlocked with the start circuit.
11) Ammeter for motor drive current.
12) 'Hours Run' meter.
13) Automatic stop/start to give shutdown after 15 to 30 (adjustable) minutes
unloaded running and restart on pressure demand.
Faults are indicated on annunciators with a single fault resulting in simultaneous
alarm and shutdown. The fault protection equipment is interlocked with the starter to
give automatic override of the oil pressure/low cooling water flow fault conditions
during start sequence. The fault circuit is enabled after a short delay in the start cycle.
For additional features, see the Operating Philosophy Document provided (where
necessary).
Assuming that the pressure in the delivery line now begins to fall, (as insufficient air is
being supplied into it to meet the demand), and the lower limit of PS1 is reached, then
PS1 will energise solenoid valve (SV1). This will then isolated the pneumatic signal to
the lower suction valve unloader actuators and vent valves. The vent valves will close
and the bottom suction valves will reseat thereby allowing compression to take place
on the undersides of the pistons.
If a plc panel is supplied - please refer to separate instructions.
4.3.2 Load Control System Functions
All of the suction valves in the compressor have actuators which cause the valve
plate to be held off its seat whenever a pneumatic signal is applied. When the plate is
held off its seat no compression can take place and that mean the compressor is
'OFF LOAD'. On removal of the pneumatic signal the plate returns to its seat and
compression can then recommence. The unloader is pushed back by the valve plate
springs and the unloader return spring. The compressor is now back 'ON LOAD'.
Two-Step Load Control means that the compressor is either on:-
a) ON LOAD (compression taking place) - all suction valves being in service,

or:
b) OFF-LOAD (no compression taking place) - all suction valves being held open
A complete On-Load to Off-Load & return to On-Load sequence occurs as follows:-
The compressor is on ON-LOAD
Assuming the compressor is running On-Load and pressure in the delivery main is
rising (too much air is being supplied by the compressor for the reducing
requirements of the end using equipment).
When the pressure rises to the upper limit of the pressure switch (PS1), PS1 will de-
energise solenoid valve (SV1). This will then allow pneumatic signal to pass into the
small bore pipework interconnecting all the compressor unloader actuators. This
causes ALL of the suction valves to be held open and the vent valve to vent to
atmosphere (blow down), thereby reducing the pressure within the compressor to
atmospheric levels.
The compressor is now OFF-LOAD
Assuming that the pressure in the main now begins to fall, (as insufficient air is being
supplied into it to meet the demand), and the lower limit of PS1 is reached, then PS1
will energise solenoid valve (SV1). This will then isolate the pneumatic signal to the
suction valve unloader actuators and the vent to the atmosphere. All suction valves
will re-seat, the vent valve closes, and the compressor returns to On-Load operation.
The compressor is back ON-LOAD
If at any point of the sequence the demand increases or decreases randomly, then
the pressure switch reacts to maintain the compressor load function at the required
level to meet the change demand.
The Set Points of the pressure switch are given in Chapter 1 - Technical Data.
4.4 Preparation for Starting

Note: The following operating information assumes that the compressor is
fitted with a standard Gardner Denver Belliss & Morcom control system.
However, if the control equipment is of different manufacture, the
compressor MUST be operated in accordance with the supplementary
Operating Information supplied with the control system.
4.4.1 Pre-Start Checks (Before Operating the Machine)
1) Establish that it is safe to discharge high-pressure air into the delivery lines.
2) Ensure that all machine guards are correctly fitted to the machine and auxiliary
equipment. It is IMPORTANT that any loose, missing or damaged guards are
correctly fitted before attempting to operating the compressor.
3) Check that access ways around the machine are clear and free from tripping or
slipping hazards. Remove any obstacles and neutralise any fluid spillage such
as oils or greases, using an absorbent material. Allow spillage to be absorbed
for a short time before thoroughly cleaning the spillage area.
4) Ensure that all of the fault warning, annunciators are extinguished and that the
compressor is safe to start.
5) Check oil level in sump. Correct level is halfway up window nut in front face of
crankcase.
6) If the machine has been standing idle for some time it may be necessary to
prime the oil pump.
7) Ensure that the cooling water supply valve is open promoting water circulation
through the compressor jackets, intercoolers, aftercooler and oil cooler.
8) Ensure that the air pressure sensing pipeline from the air main to the pressure
switches and solenoid valves in the control panel is locked open.
9) Ensure that the main air isolating valve is OPEN.
4.5 Starting the Compressor

4.5.1 Under Normal Conditions
Step Supplementary Information

1) Turn the main isolator to the 'ON' The 'SUPPLY ON' lamp will illuminate.
position
2) Turn the 'Control Off/On' selector to If the emergency stop pushbuttons are not
the 'ON' position latched, the 'CONTROL SUPPLY ON' indicating
lamp will illuminate.
3) Press the 'EMERGENCY STOP The hazard lamps will illuminate and the audible
RESET/HEALTHY' illuminated push- alarm will sound to indicate they are all
button to reset the Safety Relay operational.
4) Press the 'ACCEPT' push-button to This will energise relay 'A', and removes the
silence the alarm supply to the alarm.
5) Press the 'RESET' push-button to This removes the supply from the hazard lights
energise the fault monitoring relays whilst retaining their respective relays
FR1 to FR4
With relays FR1 to FR4 energised, relay SR2 (faults healthy) is now energised.
Ensure that the 'TRIPPED' indicator is extinguished, if illuminated reset thermal
overload (OL1) and/or thermistor relay (THR1).
6) Select 'MANUAL' on the 'UNLOAD/
MANUAL/AUTO' selector switch
7) Press the 'START' push-button. The Hours Run Meter will be energised as
soon as the 'START' push-button is pressed.
After a short delay the 'RUNNING' indicator
lamp will be illuminated. The motor is now
running at full speed and the compressor is
ready for use.
When the 'START' pushbutton is pressed, the motor starter will energise by pulling in
the Star (SC) contactor and the Main (MC) contactor. After a small delay, set by the
timing relay (MCT1), (usually between 15 and 20 seconds) the Star contactor will de-
energise and the Delta (DC) contactor will energise. When the delta contactor is
energised the 'RUNNING' indicator lamp will be illuminated indicating that the motor is
now running at full speed and the compressor is ready for use.
A normally open contact on the main contactor of the motor starter will energise the
Commissioning Timer (CTD) for a period of approximately 30 seconds. After a small
delay the time contacts change state and allow the fault circuit to check for low
cooling water flow (LCWF) and low lubrication oil pressure (LLOP). If either of these
items have failed to reach their working levels during the start-up period, the
compressor motor will trip and a fault will be indicated.
4.5.2 After An Emergency Stop
Rectify fault condition and proceed from Step 3 of 4.5.1 Starting Compressor Under
Normal Conditions.
4.6 Running
4.6.1 Running Checks
1. Allow the compressor to run up to full speed and then close the small drain
cocks.
2. Check the oil pressure. This will fall initially as the oil temperature rises, but
should steady at above 1.75 to 4.0 Bar G even in a hot environment.
3. Check the cooling water is flowing at the visible outlet or flow indicator. On
multi-compressor installations balance the flows in the parallel systems of the
compressors (including intercooler) to give equal water temperature rise across
both - ideally 11 ºC.
4. Check all automatic drain traps for unusual discharge.
5. Check all temperatures and pressures periodically.
6. Check for undue noise, vibration or heat. If present, report immediately. It is
good practice to carry out these checks regularly and log the results.
4.6.2 Automatic Operation

Before Automatic Operation is selected, the compressor must be prepared for starting
as described in 4.4.1 Pre-Start Checks.
Once the compressor is running, 'AUTO' may be selected using the
'UNLOAD/MANUAL/AUTO' selector switch. This will allow the compressor to
automatically stop and start on the dictates of the Light Run Timer (LRT) which is
usually set at between 15 and 30 minutes. If the compressor has not been on load
during the preset period, the compressor will automatically shutdown. During the
shutdown period an indicating lamp is illuminated to show that the compressor is on
'AUTO STANDBY'. When air is again required, the compressor will automatically
start.
4.6.3 Faults/Hazards
Should a fault develop, this will be detected by the appropriate sensing switch and
this in turn will de-energise the appropriate fault relay (FR1 to FR4) and illuminate the
appropriate fault indicator. At the same time SR2 will also be de-energised, which will
automatically stop the motor via the motor starter and sound the audible alarm. The
compressor will be automatically unloaded via the CTD timer, which will be de-
energised by the motor starter.
4.7 Stopping the Compressor

4.7.1 Normal Stopping
Step Supplementary Information

1) Select the 'UNLOAD' position on the This ensures that the compressor is fully
'UNLOAD/MANUAL/AUTO' selector unloaded for 10 minutes before stopping. This
switch. The 'NO LOAD' indicator lamp will allow moisture to be purged from the
will illuminate. cylinders.
2) Press the 'STOP' push-button. The compressor will stop automatically in a
controlled manner.
3) Close the main isolating shut-off valve.
4) Open the blow-down valve.
5) Close the cooling water supply valve.
The compressor can also be stopped with the 'UNLOAD/MANUAL /AUTO' selector in
the 'AUTO or MANUAL' position. However, this leaves the compressor in a
pressurised state and is not recommended. DO NOT attempt to restart the
compressor until it has automatically de-pressurised via the automatic blow-down
valves.
4.7.2 Emergency Stopping

Pressing the 'EMERGENCY STOP' mushroom button stops the machine instantly in
whatever mode of operation it is operating.
CAUTION!
This is not recommended for routine stopping and should only be used
in the case of an emergency where normal stopping is not possible or is
impractical.
4.8 Fault Indications

The following is a list of indications of possible faults which could arise in service;
periodic surveillance of pressures and temperatures, etc, will establish the normally
experienced levels applicable to the site and load conditions.
Variation from these due to a fault arising may be slow to impinge - the early effect of
a fault (with the robust reciprocating type machine) being, usually very gradual. It is
IMPORTANT therefore, to retain a simple daily record sheet of pressures and
temperatures. Comparison with previous readings will then warn if there is an
untoward trend arising - when reference to the following fault indication's list will
indicate the probable cause and remedial action to take. A copy of a typical log sheet
is provided in the Appendices located at the end of this manual.
The running performance of the compressor can also indicate when it is necessary to
renew a particular part: Generally, wear or malfunction of valves or piston rings will be
indicated by variations (other than those due to suction or delivery conditions) in the
interstage or final delivery pressure and temperature.
Progressive crankcase bearing wear will slowly give rise to a gradual lowering of the
lube oil pressure; if low oil pressure does occur and cannot be traced to any other
cause listed, then connecting rod bottom end bearings should be inspected.
4.8.1 Fault Finding
Minor variations in pressure and temperature readings may occur, due to possible small
changes in the suction or delivery conditions. These factors should be considered when
checking and assessing instrument readings.
Fault Possible Cause Remedial Action
Low first stage delivery 1) Leaking or broken suction valve Replace valve plate &
pressure (normal or low plate in first stage. examine seat for damage.
first stage air delivery st
temperature. 2) One or more 1 stage suction Remove, clean & refit
valve depressor(s) sticking in "off- depressor(s) & examine valve
load" position. for damage
Low first stage delivery 1) Fouling of inlet filter. Renew filter elements.
pressure (high first stage
air delivery temperature 2) Leaking or broken delivery valve Replace valve plate &
plate in first stage. examine seat for damage.
3) Worn, broken or malfunctioning Renew rings & clean grooves.
piston rings in first stage.
High first stage delivery 1) Leaking or broken suction valve Replace valve plate &
pressure (normal or high plate in second stage. examine seat for damage
first stage delivery 2) Second stage suction valve Examine, clean, & refit valve
temperature. depressor sticking in "off-load" plate depressor, also
position. examine valve for damage
3) Worn, broken or malfunctioning Renew rings & clean grooves.
piston rings in third or second
stage cylinders.
High first stage air delivery 1) Cooling water flow through first Examine & clean intercooler
temperature after cooler. stage intercooler restricted or tubes (both on air & water
caused by blockage sides).
First stage delivery 1) Leaking or broken delivery valve Replace valve plate &
pressure relief valve plate in second stage. examine seat for damage.
blowing. 2) Worn, broken or malfunctioning Renew rings - clean grooves.
piston rings in third stage.
3) First stage intercooler tubes Examine & clean air-side of
blocked on air-side. intercooler tubes.
4) Relief valve defective. Repair or fit new valve.
Low second stage delivery 1) Leaking or broken suction valve Replace valve plate &
pressure (normal or low plate in second stage. examine seat for damage.
second stage delivery
temperature). 2) Second stage suction valve Remove, clean & refit
depressor sticking in "off-load" depressor, also examine
position. valve for damage.
Low second stage delivery 1) Leaking or broken delivery plate Replace valve plate &
pressure (high second in second stage. examine seat for damage.
valve stage delivery
temperature). 2) Worn, broken or malfunctioning Renew rings & clean grooves.
piston rings in second stage.
High second stage 1) Leaking or broken suction valve Replace valve plate &
delivery air pressure & plate in third stage. examine seat for damage.
temperature.
High second stage air 1) Cooling water flow through Examine & clean intercooler
delivery temperature after second stage intercooler cooler tubes (both on air & by
intercooler restricted or ceased blockage. water sides)
Second stage delivery 1) Leaking or broken suction valve or Replace valve plate &
pressure relief valve delivery valve plate in third stage. examine seat for damage
blowing. 2) Third stage suction valve Remove, clean & refit
position. valve for damage.
3) Second stage intercooler tubes Examine & clean air-side of
blocked on air-side. intercooler tubes.
4) Relief valve defective. Repair or replace valve.
Low third stage delivery 1) Demand of end using equipment If none of the previous faults
pressure. has overtaken capacity of are present, i.e. compressor
compressor. running normally, no remedial
action possible.
When demand reduces, the
pressure will rise to normal
level (as set by the load
controller).
2) Low setting of load controller. Adjust to required pressure.
3) Malfunction of load controller. Repair/replace pressure
controller.
High third stage delivery 1) Leaking or broken delivery valve Replace valve plate &
temperature. plate in third stage. examine seat for damage.
2) Leaking or broken suction valve Replace valve plate &
plate in third stage. examine seat for damage.
3) Third stage suction valve Remove, clean & refit
position valve for damage.
4) Worn, broken or malfunctioning Renew rings & clean piston
piston rings in third stage. ring grooves.
High third stage delivery 1) Isolating valve, between Open valve.
pressure (relief valve compressor & delivery main
blowing). closed or partially closed.
2) Incorrect setting or malfunction of Adjust to required pressure or
load controller. repair/replace pressure
controller.
3) Restriction or blockage of control Remove restriction.
signal to compressor unloader
system.
4) Aftercooler tubes blocked or Examine and clean air side of
restricted on air side. aftercooler tubes.
5) Seized closed, or partially closed Repair valve.
non-return valve in delivery main
(if fitted).
Aftercooler tubes blocked 1) Examine & clean air side of or Clean aftercooler tubes.
restricted on air-side.
2) Seized closed, or partially closed Repair valve.
non-return valve in delivery main
(if fitted).
High final air temperature 1) Cooling water flow through Check & adjust hand valve
from aftercooler. aftercooler is restricted or ceased openings.
by maladjustment of h& valves.
2) Aftercooler tubes partially blocked Examine & clean air / water
on air-side, or water side of tubes side of tubes.
is fouled.
Low lubricating oil 1) Crankcase oil level is low. Check oil level, add oil as
pressure. required.
2) Air leakage into suction side of Check oil level & connecting
pumping system. unions on suction pipe to
pump.
3) Partially blocked oil pump suction Remove, clean & refit.
strainer in crankcase.
4) Oil relief valve set too low or Remove, check & reset.
valve sticking open.
5) Failure or wear of big end or small Renew bearing(s). Check
end bearings. crankshaft for damage.
6) Partially blocked oil pump delivery Replace element.
filter element.
Loss of oil pressure. 1) Compressor rotation incorrect Change compressor rotation
(first trial run, or after a rebuild). & recheck
2) Crankcase oil level very low. Check oil level, add oil as
required.
3) Serious air leakage into oil pump Check suction pipe & unions
section pipe. to pump.
4) Blockage of oil pump suction Check & clean oil sump.
strainer. Remove, clean & refit
strainer.
Change oil as necessary.
Oil pump drive failure. 1) Examine drive coupling, ascertain Ascertain cause of failure &
cause of failure & rectify. rectify.
2) Oil pump seizure. Replace pump. Check drive

coupling.
No condensate from drain 1) Drain trap blocked. Dismantle, clean & refit.
trap of interstage moisture
separator or aftercooler 2) Separator drain pipe to trap Dismantle, clean & refit.
moisture separator. blocked.
st
3) Dry atmospheric conditions. Applies to 1 stage only.
Large quantity of 1) This suggests that there is an Trace the fault & rectify as
condensate emitted from internal leakage from the cooling necessary.
drain trap. water spaces into the air spaces
of the compressor (low pressure
stage).
Note: Water emitted from the traps is usually in the form of a trickle
(intermittent or steady) - depending on the humidity of the air taken in by
the compressor - or nil in the case of very dry atmospheric conditions.
CHAPTER 5
COMPRESSOR MAINTENANCE
CHAPTER 5 - COMPRESSOR Page: 52 of 135
MAINTENANCE
5 COMPRESSOR MAINTENANCE
WARNING!
Before opening up the machine, all pressurised components MUST be
depressurised down to atmospheric pressure in a safe and controlled
manner.
5.1 Preventive Maintenance

This schedule of maintenance, in general terms, is a preventive maintenance
programme and running service necessary for our range of reciprocating
compressors. However, it does not cover for any eventualities, which could occur
from neglect or incorrect operation by the customer.
Before carrying out any preventive maintenance work related to this equipment it is a
requirement that you read and work in accordance with the Safety Precautions given
in Chapter 2 of this Instruction Manual. Also, for your own protection, be sure to read
and obey WARNING and CAUTION notices and observe any special notes you find
in this Chapter and any associated literature.
When working on the compressors rotational parts you MUST fit piston rod clamps to
prevent possible uncontrolled movement of the crankshaft and motion work. Refer to
Maintenance Procedure Job No. 002 Fitting Piston Rod Clamps.
When working on the third stage of this compressor the following additional checks
must be made to ensure the compressor is safe to work on.
1) Isolate the non-return valve to prevent possible blow-back pressure.
2) When the compressor is depressurised it should be completely disconnected
from all drain systems.
3) Isolate the compressor from the receiver at the stop valve.
4) Vent down the third stage of the anti-surge vessel immediately after the
cylinder.
5) Carefully open the vent valves on the third stage cylinder to check de-
pressurising has been completed successfully
6) When removing the valve cover, very carefully slacken the fasteners initially.
WARNING!
Caution should be exercised at all times during the inspection and/or
work on the compressor plant.
MAINTENANCE
On plants with two or more compressors the opportunity should be taken during the
early weeks of running, following commissioning, to vary the service hours of the
compressors so that no two machines reach their maintenance interval at the same
time. A gap of about 200 hours between machine running times is recommended.
When 'running-in' a new compressor the crankcase oil MUST be renewed after the
first 500 hours of operation and thereafter change in accordance with the intervals
laid down in the following maintenance schedule.
5.1.1 Maintenance Schedule
The following schedule, lists recommended maintenance tasks which are designed to
both prevent unplanned machine breakdowns and to help the maintenance teams to
plan maintenance activities. Where a maintenance activity requires greater
explanation than that given in the schedule a reference to the relevant associated
maintenance instruction is given.
All materials used for scheduled maintenance and repair MUST COMPLY with
Gardner Denver Belliss & Morcom standards and the standards laid down by
associated equipment manufacturers. Only approved spares may be used.
When a system component associated with a mechanical or electrical device is
changed or renewed, the system must undergo a functional test before the equipment
is returned to service.
Gardner Denver Belliss & Morcom are not responsible for premature failures of
parts which are caused by neglect, inappropriate servicing, use of none Gardner
Denver Belliss & Morcom parts, or any other similar conditions over which we have
no control.
MAINTENANCE
EACH DAY
A shutdown of the compressor is not normally required for a Shift inspection.
Tasks Supplementary Information
Check all temperature and pressure gauge Report immediately any abnormality.
readings are normal.
Note: Observe operation of moisture trap drains.
Check for undue noise, oil leakage, vibration or Report immediately any abnormality.
heat.
Note: Ensure that load control equipment is operating correctly.
Test protection circuits annunciator lamps. All The 'Test' push-button is normally located on the
lamps MUST illuminate compressor control panel. If a lamp fails, renew
the bulb. If the new bulb does not illuminate
report failure to the Supervisor.
Check the crankcase oil level. Oil level should Use the breather aperture in the top of the
be halfway up the window nut. crankcase to top-up the oil. Refer to the table of
lubricants for oil type.
Any aspect of the Shift inspection requiring further attention MUST be reported for action as
required.
MAINTENANCE
MONTHLY - INSPECTION
A shutdown of the compressor is not normally required for a monthly inspection.
Carry out a running examination to ensure Record all temperatures, pressures and hours
satisfactory operation of all compressor and run on compressor log sheet.
ancillary equipment.
Note: Check air inlet filter element cleanliness - renew if necessary.
Check the cleanliness and ensure correct Clean drains and renew worn or damaged parts,
operation of drain traps on compressor and as required.
ancillary equipment where applicable.
Check all external bolts and nuts on the Re-tighten or renew any missing nuts and bolts.
compressor including the holding down nuts for Tighten nuts to appropriate torque.
tightness.
Check air pressure supplied to compressor Pressure should be 7 bar minimum at unloader.
unloaders and note pressure drop.
Any aspect of the Monthly inspection requiring further attention MUST be reported for action
as required.
MAINTENANCE
SIX MONTHLY - SERVICE

The compressor is required to be shutdown for two days to perform this service schedule.
Carry out a running examination to ensure Record all temperatures, pressures and hours run
satisfactory operation of all compressor and on compressor log sheet. A copy of this form is
ancillary equipment. provided in Appendices located at the end of this
manual. Check cooling water flow rate (If flow
recorder is fitted).
Check the cleanliness and ensure correct Clean drains and renew worn or damaged parts,
operation of drain traps on compressor and as required.
ancillary equipment where applicable.
Check all external bolts and nuts on the Re-tighten or renew any missing nuts and bolts.
compressor including the holding down nuts for Tighten nuts to appropriate torque.
tightness.
Visually examine (through the valve pockets) Replace worn or damaged parts, as required
the general surface condition of cylinder bores
for evidence of ring wear or scoring.
Check valve unloaders & interconnecting small Clean and service as necessary. Replace worn or
bore pipework for defects. damaged parts as required.
Examine piston rods along gland travel to Clean and service as necessary. Renew worn or
ensure no scoring is present. damaged parts as required.
Check that inlet filter is clean Clean and service as necessary.
Check that inter and aftercooler moisture Clean and service as necessary
drains are operational and that the diffusers on
the blowdown valves are clear and clean..
Check one suction and one delivery valve from Clean and service as necessary. Renew worn or
each stage for cleanliness or fouling. damaged parts as required.
Renew third stage piston rod packing, piston Renew worn or damaged parts as required.
rings and rider rings.
Check integrity of all flexible air and water Record condition. Renew worn or damaged parts
pipes. as required.
CRANKCASE INSPECTION
Examine crossheads and main guide slipper Clean and service as necessary. Renew worn or
paths, condition and clearances. damaged parts as required.
Check connecting rod bottom end bolts are Rectify as required.

pinned.
Check that lubrication oil suction strainer is Clean and service as necessary. Tighten unions
clean and all pipework to main pump is in good and renew worn or damaged parts as required.
order and that unions are tight.
MAINTENANCE
SIX MONTHLY - SERVICE (Cont)

Check that crankcase oil is clean and no If dirty renew crankcase oil and delivery filter
foreign particles are present. Ensure that oil element. If necessary investigate source of any
delivery filter is clean and that oil pressure is foreign particles. Refer to table of lubricants for oil
satisfactory. type and quantity.
The crankcase oil and the delivery filter are
renewed as a matter of course during the Annual
Service.
Any aspect of the Six Monthly service requiring further attention MUST be reported for action
as required. On completion of the service, re-commission the compressor and recording all
operating pressures and temperatures. Ensure that the working area is left in a clean and
tidy condition.
ANNUALLY - SERVICE - (or as stipulated by local regulations)

The compressor is required to be shutdown for five days to perform this service schedule. All
Six Monthly tasks are to be undertaken as part of this schedule.
Remove all air valves and replace with factory

refurbished units.
Renew crankcase oil and delivery filter Refer to table of lubricants for oil type and
element. quantity.
Inspect connecting rod bottom end shells, Clean and service as necessary. Renew worn or
crankpin, top end bearing and gudgeon pin. damaged parts as required.
Check motion work clearances.
Withdraw pistons and piston rods and examine Renew piston rings, piston rod packings, and
wear. Gauge cylinder bores and piston rods for piston rod scrapers.
wear and record readings.
Check condition of water jacket spacers for Report condition.

fouling from lime deposits.
Check cleanliness of motor ventilation fan and Clean and service as necessary. Renew worn or
that air flow paths are clean. Carry out an damaged parts as required.
insulation resistance check on motor windings
and record readings.
Check all system protection devices and Use a calibrated test rig to test the protection
circuits for correct operation. devices. Alternatively the devices can be tested
by simulation of fault conditions at the machine.
Any aspect of the Annual service requiring further attention MUST be reported for action as
required. On completion of the service close compressor using new gasket and 'O' rings. Re-
commission the compressor and recording all operating pressures and temperatures. Ensure
that the working area is left in a clean and tidy condition.
MAINTENANCE
TABLE OF LUBRICANTS
Lubricant Supplementary Information
Crankcase Oil Recommended Lubricant SAE 30 oil (ISO VG 100)
(Ambient temperature 0oC to 45oC)
Oil Capacity
45 Litres Approved Brands:-
BP Vanellus M30 Esso Essolube HDX 30
Mobil Delvac 1330 Shell Rimula X30
Alternatively:- The oil MUST be a good quality mineral oil having a flash
o
point (open test) of not less than 210 C and within a viscosity range
o o
(Centistokes) of 110 at 40 C to 12.5 at 100 C, the oil should also
contain rust and oxidation inhibitors and anti-foam additives.
o
If the site is particularly hot (over 45 C) then use an SAE 40 oil (ISO VG
150)
5.2 Maintenance Instructions

The following procedures are intended for the use of the technician responsible for
the maintenance of the compressor. It is essential that any necessary adjustments,
servicing or overhaul work should only be carried out by competent persons who are
familiar with the compressor installation and who have the appropriate authority
(Permit to Work). To avoid possible warranty invalidation the following instructions
should be read before attempting to maintain the machine.
WARNING!
When working on compressor rotational parts you MUST fit piston
rod clamps to prevent possible uncontrolled movement of the
crankshaft and motion work. THIS COULD RESULT IN INJURY OR
LOSS OF LIFE.
MAINTENANCE
JOB No. 001

CRANKCASE OIL CHANGE
LIST OF SPECIAL TOOLS

Description Qty
Thin Spanner (approx. 10 mm thick) 1
LIST OF CONSUMABLES
Crankcase Oil SAE 30 oil (ISO VG 100) (Normal Operating Conditions) As
required
Industrial cleaning fluid (White Spirit) & lint free cloth As
required
WARNING!
To avoid scalding by hot oil, allow the compressor to cool down before beginning
work.
1) Isolate mains power and display appropriate warning signs.
2) Remove the crankcase doors whilst taking care not to damage the oil seals.
MAINTENANCE
JOB No. 001 CRANKCASE OIL CHANGE (Cont)

3) Wipe any excess oil off the doors using an industrial cleaning fluid and a lint free
cloth. Place the cover in a clean location to avoid oil contamination when refitting.
4) Empty the oil sump via the oil drain plug using suitable equipment and clean out the
crankcase sump (using a lint-free cloth, to avoid fouling of the oil strainer).
To avoid oil spillage, never remove the oil suction strainer while oil remains in the
crankcase
5) To remove the oil strainer use a thin spanner, on the strainer body hexagon to
unscrew the strainer whilst holding the external hexagon fitting to prevent turning.
This fitting is not screwed into the crankcase - it passes through a clear hole.
OIL
PUMP
Crankcase Oil Change

6) Refit the oil strainer and check that all tools and cleaning cloths have been removed
from the crankcase sump.
7) Refill the crankcase sump with the required quantity of clean, new oil.
8) Refit the crankcase doors after checking the condition of the door seals.
9) Test run the compressor and check for oil leaks around the strainer seal and
crankcase doors. If all is satisfactory, return the machine to service.
MAINTENANCE
JOB No. 002

FIT PISTON ROD CLAMPS

Description Qty
Piston Rod Clamp (Drg No. DD579 - available on request) 1 Set
LIST OF CONSUMABLES
required
1) Isolate mains power and display appropriate warning signs.
2) Remove the distance piece access covers from the line of motion works NOT being
worked on. Wipe any excess oil off the covers using an industrial cleaning fluid and a
lint free cloth. Place the cover in a clean location to avoid oil contamination when
refitting.
3) Mark the position of the oil shedder on the piston rod and remove shedder.
4) Loosely assemble the piston rod clamps onto the piston rod.
5) Manually 'bar-over' the compressor to the desired position and hold steady.
6) Whilst one person holds the crankshaft bar in position, the other must tighten the one
piston rod clamp firmly against the packing gland box and the other firmly against the
scraper gland box.
7) Only when both clamps are tight in place can the crankshaft bar be carefully released
and safe work or inspection takes place.
When working on the third stage of this compressor the following additional checks
MUST be made to ensure that the compressor is safe to work on.
8) Isolate the non-return valve to prevent possible blow-back pressure.

9) Isolate the compressor from the receiver at the stop valve.
10) Vent down the third stage at the delivery pipe immediately after the cylinder.
11) Carefully open the vent valves on the third stage cylinder to check de-pressurising
has been completed successfully.
12) When removing the valve cover very carefully slacken the fasteners initially in case
there is any residual pressure present.
WARNING!
When maintenance work has been completed the piston rod clamp MUST be
removed.
MAINTENANCE
JOB No. 003

CYLINDER & TOP COVER - REMOVE & REFIT

Description Qty
Lifting Eye-Bolts 1 Set
Slings, Lifting Equipment As
required
LIST OF CONSUMABLES
required
1st Stage Top Cover
To Remove
1) Ensure that the compressor is fully de-pressurised, electrically isolated and isolated
from the air supply.
2) Post signs instructing personnel that the machine MUST NOT be used.
3) Isolate and drain the cooling water from the compressor cylinders.
4) Remove cooling water pipes from the top cover and fit blanking plugs to prevent dirt
ingress.
5) Check that there are no supply pipes or hoses fastened to the top cover.
6) Release and remove the top cover securing nuts from the cylinder fixing studs.
7) Fit lifting eye-bolts into the relevant lifting holes
8) Attach a suitable sling to the eye-bolts, and using suitable lifting equipment, take up
the slack in the sling.
9) Slowly lift and guide the top cover from the cylinder studs taking care not to damage
the gasket on lifting.
10) Clean the top cover using an industrial cleaning fluid and a lint free cloth.
11) Lower the top cover onto a suitable, clean work-surface taking care not to damage
the machined face.
To Refit
If any maintenance has been carried out on the motion work which may affect the piston to
cylinder (bumping) clearances, check the clearances are correct before refitting the top
cover. Refer to Job No. 005.
1) Ensure that the cylinder top cover and cylinder top mating faces are clean.
2) Check the condition of the cylinder top cover gasket. Renew if necessary.
3) Fit the gasket over the cylinder studs and onto the cylinder mating face.
4) Attach a suitable sling to the eye-bolts, and using suitable overhead lifting equipment,
raise and position the top cover over the cylinder.
MAINTENANCE
JOB No. 003 - CYLINDER & TOP COVER - REMOVE & REFIT (Cont)
5) Slowly lower and guide the top cover onto the cylinder, ensuring the correct
positioning of the cooling water and gas pockets.
6) When in position, remove the sling and lightly secure the top cover to the cylinder
with the fixing nuts.
7) Tighten the cylinder cover nuts down evenly and progressively. Nuts to be torque
tightened to the appropriate torque figure. Refer to Chapter 1 Section 1.1.3.
8) Remove the eye-bolts from the top cover and refit the cooling water pipe
9) Secure the supply lines to the cylinder top cover with their fasteners.
10) Re-establish water and electrical supplies to the compressor.
11) Bleed off any trapped air in the cooling system using the plugs in the cylinder water
jacket.
12) Test run the compressor on clean, dry air or nitrogen and check for correct operation
and freedom from leaks around any of the disturbed gaskets.
Integral 3rd Stage Cylinder / 2nd Stage Top Cover
To Remove
1) Ensure that the compressor is fully de-pressurised, electrically isolated and isolated
from the air supply.
2) Post signs instructing personnel that the machine MUST NOT be used.
3) Isolate and drain the cooling water from the compressor cylinders.
4) Remove cooling water pipes from the top cover and fit blanking plugs to prevent dirt
ingress.
5) Check that there are no supply pipes or hoses fastened to the top cover.
6) Disconnect and remove as necessary the 3rd stage aftercooler and the 2nd stage
intercooler using suitable lifting equipment.
7) Release and remove the cylinder-to-cylinder securing screws from the base of the 3rd
stage cylinder.
8) Attach a suitable sling to the eyebolts and using suitable lifting equipment take up the
slack in the sling.
CAUTION!
Take care when removing this cylinder/top cover casting that you don't damaging
the 3rd stage piston rings as they are exposed.
9) Slowly lift and guide the 3rd stage cylinder casting from the 2nd stage cylinder and 3rd
stage piston.
10) Collect the 3rd stage piston rings as they are exposed and place them on to a clean
work-surface.
11) Lower the 3rd stage cylinder casting onto a clean work surface taking care not to
damage the machined face.
MAINTENANCE
JOB No. 003 - CYLINDER & TOP COVER - REMOVE & REFIT (Cont)
To Refit
If any maintenance has been carried out on the motion work which may affect the piston to
cylinder (bumping) clearances, check the clearances are correct before refitting the top
cover. Refer to Job No. 005.
1) Ensure that the combined 3rd stage cylinder/cylinder top cover and 2nd stage cylinder
top mating faces are clean.
2) Check the condition of the cylinder-to-cylinder gasket. Renew if necessary.
3) Fit the gasket to the 2nd stage cylinder mating face.
4) Fit piston rings to the 3rd stage piston.
5) Attach a suitable sling to the eye-bolts in the 3rd stage cylinder and using suitable
lifting equipment, raise and position over the 2nd stage cylinder.
6) Slowly lower and guide the 3rd stage cylinder onto the 2nd stage cylinder, ensuring the
3rd stage piston rings are not damaged as the 3rd stage cylinder is lowered into
position. Also ensure that the cooling water and gas pockets are correctly positioned.
7) When in position, remove the sling and lightly secure the 3rd stage cylinder to the 2nd
stage cylinder with the fixing screws.
8) Tighten the cylinder screws down evenly and progressively. Screws to be torque
tightened to the appropriate torque figure. Refer to Chapter 1 Section 1.1.3.
9) Remove the eye-bolts from the top of the 3rd stage cylinder and refit the cooling water
pipe
10) Secure the supply lines to the cylinder top with their fasteners.
11) Re-establish water and electrical supplies to the compressor. Bleed off any trapped
air in the cooling system using the plugs in the cylinder water jacket.
12) Test run the compressor on clean, dry air or nitrogen and check for correct operation
and freedom from leaks around any of the disturbed gaskets.
MAINTENANCE
JOB No. 004

PISTON RINGS - REMOVE & REFIT
Description Qty
Piston rod bullet 1
LIST OF CONSUMABLES
Description Qty
required
To Remove
1st Stage Piston
1) Remove the cylinder top cover as described in Job No. 003.
2) Remove the main guide access cover and gasket.
3) Manually 'bar-over' the compressor to ensure that the piston is at its BDC position.
Measure and record the TDC and BDC "Bumping Clearances". Refer to Chapter 1 -
Technical Data.
1st Stage Piston Assembly
MAINTENANCE
JOB No. 004 - PISTON RINGS - REMOVE & REFIT (Cont)
4) Bend back the tab on the locking plate retaining the piston rod/crosshead, securing
pin and remove the pin.
Ensure that the securing pin is removed before slackening the piston nut. Otherwise,
if the piston rod turns in the crosshead while the securing pin is in position, the pin will
distort making it extremely difficult to remove.
5) Slacken the piston nut, by no more than one turn.
WARNING!
It is possible that pressure can have accumulated within the interior of the
piston. There is a pressure release hole drilled in the piston top half, which
is (on assembly) covered by the underside of the piston nut/washer. It is
essential, where the hole is covered by a washer, to ensure that the washer
is not stuck in place before the nut is unscrewed by more than one turn.
This is to make certain that the pressure relief hole is fully open to
atmosphere.
6) Remove the piston nut. Remove the piston and washer by lifting the piston (which is
in halves) very carefully off the rod.
If the piston is tight on the rod and cannot be easily lifted, proceed as follows:
7) Manually 'bar-over' the compressor to turn the piston to TDC and insert diametrically
opposite IMPORTANT two equal length pieces of hard wood (165mm long) via valve
pockets to block the piston. Place the wood chocks about 25mm clear of the piston
rod sides NOT at the piston periphery.
8) Manually 'bar-over' the crankshaft to withdraw the rod to BDC and insert a 3mm thick
steel plate (125mm x 90mm) centrally across the top of the rod to press against the
piston bottom
9) Carefully 'bar-over' the compressor back to TDC taking the piston upwards.
An observer MUST be stationed to control the piston emerging from the cylinder. The
two halves being lifted separately from the rod top with care being taken to remove
the piston rings safely during the operation.
10) Remove the wood blocks when the piston has been lifted out.
If the piston halves are stuck together, lift the piston off as an assembly and part the
halves carefully on a work-bench taking care not to damage the piston body.
3rd Stage Piston
1) Remove the third stage cylinder/top cover casting as described in Job No. 003.
2) Remove the main guide access covers,
3) Ensure that the piston is at its Top-Dead-Centre (TDC) position.
4) Remove the locking plate and securing setpin from the crosshead to prevent
accidental damage to the pin should the piston rod turn in the crosshead during piston
nut removal.
MAINTENANCE
2nd & 3rd Stage Piston Assembly
MAINTENANCE
5) Bend down the tabs retaining the set pins fixing the third stage piston to the second
stage piston and slacken the set pins by no more than one turn.
WARNING!
In hollow pistons it is possible that pressure can have accumulated within
the interior of the piston. There are pressure relieving holes drilled in the
piston walls at the base and just below the pressure rings. Ensure that these
are fully open to atmosphere before removing the set pins.
6) Whilst supporting the third stage piston, slacken and remove the set pins
7) Carefully withdraw the third stage piston. Care must be taken to avoid damaging
either of the piston mating faces during disassembly.
8) Remove the piston to a suitable, clean work surface for examination and cleaning.
2nd Stage Piston
1) Remove the third stage piston as described above and then proceed as follows:
2) Slacken and remove the second stage piston nut.
3) Fit suitable lifting eyes into two diametrically opposed holes in the second stage
piston.
4) Attach suitable slings and lifting gear to the lifting eyes and carefully lift the second
stage piston out of the cylinder. Care MUST be taken to avoid damaging either the
piston or cylinder bore during lifting.
5) Remove the piston to a suitable, clean work-surface for examination and cleaning.
Examination
Piston Pressure Rings - For piston pressure ring dimensions refer to Chapter 1 - Technical
Data. The pressure rings MUST be replaced with new ones when the radial thickness at any
point has worn to 65% or less of the original thickness.
Piston Bearer Rings - For piston bearer ring dimensions refer to Chapter 1 - Technical
Data. The bearer rings MUST be replaced by new ones, when the standout at any point has
worn to 0.5mm or less.
Piston Rings - Renew

1) Remove and discard the old piston rings.
2) Clean piston ring grooves carefully.
3) Remove the PTFE film from the cylinder bore by either flexihoning or by using a
grade 180 emery paper.
4) Insert the new piston ring squarely into the cylinder bore and check that the butt gap
is correct. Refer to Chapter 1 - Technical Data.
5) Fit the new piston rings by carefully springing them over the piston body.
6) Ensure that the rings are correctly seated in the piston groove.
MAINTENANCE

To Refit
1st Stage Piston
1) Manually 'bar-over' the compressor to turn the piston to TDC and, after checking that
the bottom reinforcing washer is in order and correctly in place, lower the bottom half
piston body onto the washer and rod and settle it into place. If the bearer ring is of a
split type, ensure that the ring butts are at the 12 o'clock position.
2) Refit the top half piston rings, setting the butt gaps to opposite sides, (i.e., stagger the
ring gaps equally around the piston circumference) and carefully lower into place.
3) Refit the top half of the piston to the bottom half of the piston.
4) Check that the pressure relieving hole is clear and fit the steel reinforcing disc onto
the piston top half.
5) Fit and very lightly tighten the piston nut.
6) Check the piston bumping clearances against the figures earlier recorded to ensure
that the piston is properly down. If adjustment is required, refer to Job No. 005.
MAINTENANCE

7) Fully-tighten to the piston nut to the correct torque. Refer to Chapter 1 - Technical
Data.
8) Check that the piston rod has not turned in the crosshead and that the crosshead nut
has not been disturbed during these operations.
9) Refit main guide covers and the cylinder top cover.
10) Test run compressor to ensure correct operation and freedom from leaks before
returning to service.
2nd Stage Piston
1) Manually 'bar-over' the compressor to turn the piston to TDC
2) Fit and check that the bottom reinforcing washer is serviceable and correctly in
place.
3) Fit the piston rings onto the piston body and stagger their butt gaps around the
piston circumference (i.e.. at about 120º to each other).
4) Carefully lower the bottom half of the piston into the cylinder and onto the reinforcing
washer and settle it into place.
5) Fit and VERY LIGHTLY tighten the piston nut.
7) Fully tighten to the piston nut to the correct torque. Refer to Chapter 1 - Technical
Data.
3rd Stage Piston
Note: The 2nd stage piston must be fitted prior to fitting of the 3rd stage
piston.
1) Check that the piston vent holes in the side of the piston are clear and that the mating
faces are in good condition.
2) Fit the third stage piston onto the second stage piston and secure with the set pins
removed earlier. New tab washers MUST be used with the set pins.
3) Tighten the set pins to the correct torque and bend over the washer tabs.
4) Set the butt gaps of the pressure rings to around the piston (i.e., stagger the ring gaps
equally around the piston circumference).
6) Check that the piston rod has not turned in the crosshead and that the crosshead nut
has not been disturbed during these operations.
7) Refit main guide covers and the cylinder top cover.
8) Test run to ensure correct operation and freedom from leaks before returning
compressor to service.
MAINTENANCE
JOB No. 005

PISTON/CYLINDER END CLEARANCES - INSPECTION
LIST OF CONSUMABLES
Description Qty
Sealing Gasket (between 0.8mm - 1.0mm thick) As
required
required
There are two ways of measuring the piston Top-Dead-Centre (TDC) clearance: Method 1 is
by removing the cylinder top cover and Method 2 is by removing the valves and checking the
clearance through the valve pockets. The Bottom-Dead-Centre (BDC) clearance is checked
using Method 2.
Method 1 (Applies to 1st Stage Only)
1) Remove the cylinder top cover refer to Job No. 003.
2) Place a sealing gasket of between 0.8mm - 1.0mm on to the cylinder mating face.
3) Place the machined straight-edge across the top of the gasket on the cylinder.
4) Bar over the compressor to place the piston exactly at TDC.
5) Measure the clearance between the straight edge and the piston crown. Ensure that
the straight edge is held firmly against the gasket when measuring clearance. record
the with a feeler (thickness) gauge. The required clearances are detailed in Chapter
1 Technical Data. If the clearances are out side of the tolerance band the clearance
MUST be adjusted (see later in this procedure).
Method 2
1) Remove either a suction or delivery valve from a top cylinder pocket (if measuring
TDC clearance) or a bottom cylinder pocket (if measuring BDC clearance).
2) With the piston exactly at TDC or BDC, insert a feeler gauge through the valve pocket
and measure the clearance. Record the end ("bumping") clearances with the piston at
the top (Top-Dead-Centre) and bottom (Bottom-Dead-Centre) of its stroke. The
clearances are detailed in Chapter 1 Technical Data. If the clearances are outside of
the tolerance band the clearance MUST be adjusted (see later in this procedure).
CAUTION
Feeler gauges MUST NOT be inserted into the valve pocket whilst turning the
machine over because if trapped, the machine components could be strained or
damage.
MAINTENANCE
JOB No.005 - PISTON/CYLINDER END CLEARANCES - INSPECTION (Cont)

Piston/Cylinder End Clearances - Adjustment
The end ("bumping") clearance is adjusted by screwing the piston rod into, or out of, the
crosshead. To adjust the piston to cylinder end clearances proceed as follows:
1) Remove the crosshead access cover and gasket from the crankcase.
2) Bar over the crankshaft to reveal the crosshead locknut and the piston rod securing
pin.
3) Bend back the locking plate tab retaining the securing pin and remove the pin.
Ensure that the securing pin is removed before slackening the crosshead nut.
Otherwise, if the piston rod turns in the crosshead while the securing pin is in
position, the pin will distort making it extremely difficult to remove
4) Slacken the crosshead locknut.
The piston rod has a slotted end at the crosshead (through which the securing pin
fits) it can only be turned in 90o steps, one step represents a linear movement of
0.8mm, (the screwed end of the rod having 8 threads per inch).
5) To adjust the top end clearance, screw the piston rod into or out of the crosshead.
Ensure that the top and bottom clearances are as close to equal as is possible. If
equal clearances are not obtainable then always, on final setting, make the TOP
clearance the larger of the two (by an amount equal to no more than one quarter turn
only of the piston rod in the crosshead i.e., by no more than 0.8mm).
MAINTENANCE
JOB No.005 - PISTON/CYLINDER END CLEARANCES - INSPECTION (Cont)

6) Fully tighten the crosshead locknut.
7) Recheck that the piston rod slots are correctly aligned for clearance of the piston rod
securing pin.
8) Fit a new locking plate to the securing pin before fitting and fully tighten the pin. Refer
to Chapter 1 Section 1.1.3.
9) Bend over the locking plate tab to prevent the securing pin from rotating.
10) Inspect the crosshead access cover gasket. Renew if necessary.
11) Refit the access cover.
MAINTENANCE
JOB No. 006

PACKING GLAND ASSEMBLY - REMOVE & REFIT
LIST OF CONSUMABLES
Description Qty
required
Due to their construction, these packing glands can only be satisfactorily examined and
repaired when they are removed from the compressor and disassembled on a suitable
workbench.
To Remove First & Second Stage Packing Assemblies
1) Fit piston rod clamps to prevent possible uncontrolled movement of the crankshaft
and motion works. Refer to Job No. 002.
2) Mark the position of the oil shedder on the rod surface and remove shedder with its
two clamping screws.
Gland Packing Assembly
MAINTENANCE
JOB No. 006 - PACKING GLAND ASSEMBLY - REMOVE & REFIT (Cont)
3) Remove the nuts from the small diameter gland assembly tie studs.
4) Remove the securing nuts from the gland cover and lower the cover down the piston
rod until it is resting on the oil scraper gland assembly.
5) Slide each container assembly down the piston rod until it is clear of the gland.
6) Slide the container a little way back up the piston rod to expose the packing rings and
in turn, unhook the garter springs and remove the packing ring segments.
7) Reassemble and carefully store each ring of segments and garter spring, immediately
on removal. Repeat Step 7 until all of the packing rings have been removed.
Observe that each ring is marked with matching numbers and letters for use in
reassemble. Also the lowermost ring has a peg which locates into a hole in the
uppermost ring to form a container pair. The rings can be reused depending upon
condition after inspection.
CAUTION!
The rings and glands refitted completely without oil (the compressor being an oil-
free cylinder machine) - on NO ACCOUNT introduce oil or grease into the gland.
If refitting "used" rings first ensure that there is no dirt or grit embedded - examine
also the piston rod surface
If the piston rod is out of the compressor, the gland can be assembled on the work-
bench, then fitted into place as a finished unit. If the rod is in place, the rings and their
springs are assembled around the rod by working through the distance piece
apertures.
1) Assemble each ring onto the piston rod with its garter spring.
2) Fit the rings as pairs into their respective containers (ensure peg is pointing upwards).
3) Slide each container assembly up the piston rod in turn, finally clamping the
completed gland assembly with the tie rod nuts.
4) Refit and tighten the packing nuts and secure the gland assembly to the cylinder
bottom. Refer to Chapter 1 Section 1.1.3.
5) Refit the oil shedder to the piston rod in the position marked during removal and
secure with its clamping screws.
6) Remove piston rod clamps.
7) Inspect the crosshead access cover gasket. Renew if necessary.
8) Refit the access cover.
MAINTENANCE
JOB No. 007

PISTON ROD OIL SCRAPER GLAND - REMOVE & REFIT
Description Qty
Wear Check Tool (Drg No. DD600 - available on request) 1
LIST OF CONSUMABLES
Description Qty
required
The support housings of the scraper glands fit directly on to the top of the guide for the
crossheads
To Remove
1) Fit piston rod clamps to prevent possible uncontrolled movement of the crankshaft and
motion works. Refer to Job No.002.
2) Remove access covers from the cylinder distance piece.
3) Unscrew the nuts holding the top container to the top of the gland support housing.
4) Lift the plate and slide the upper pair of scrapers up the rod.
Scraper Housing Assembly

SCRAPER
JOB No. 007 PISTON ROD OIL SCRAPER GLAND - REMOVE
BOX & REFIT (Cont)
1) Unhook the garter springs and remove the scraper ring segments. Re-assemble and
carefully store each ring of segments immediately upon removal.
Note:. The segments are marked relative to each other, the lower ring pair having
a peg and locating hole arrangement for correct re-assembly. The rings can be re-
used depending upon condition.
2) Lift the container and slide the lower pair of scrapers up the rod.
3) Re-assemble and carefully store each ring of segments immediately upon removal.
To Inspect
1) The oil scraper rings are checked for wear by reassembly, with garter spring, squarely
around the piston rod, or on the wear check tool and examining the butt clearances in
the case of ring 'Wl'. The segments of the mating ring (ring 'W2') has angle cut
contact faces, there are no butts.
2) When parts are new the butts of 'W1' are each 1.0mm wide.
3) Discard the ring, also its mating ring, when the butts reduce to 0.2mm (a total of
0.6mm) or less, and replace by a new pair.
MAINTENANCE
JOB No. 007 PISTON ROD OIL SCRAPER GLAND - REMOVE & REFIT (Cont)
5) Unhook the garter springs and remove the scraper ring segments. Re-assemble and
carefully store each ring of segments immediately upon removal.
Note:. The segments are marked relative to each other, the lower ring pair having
a peg and locating hole arrangement for correct re-assembly. The rings can be re-
used depending upon condition.
6) Lift the container and slide the lower pair of scrapers up the rod.
7) Re-assemble and carefully store each ring of segments immediately upon removal.
To Inspect
1) The oil scraper rings are checked for wear by reassembly, with garter spring, squarely
around the piston rod, or on the wear check tool and examining the butt clearances in
the case of ring 'Wl'. The segments of the mating ring (ring 'W2') has angle cut contact
faces, there are no butts.
2) When parts are new the butts of 'W1' are each 1.0mm wide.
3) Discard the ring, also its mating ring, when the butts reduce to 0.2mm (a total of
0.6mm) or less, and replace by a new pair.
4) In the case of ring 'W2', when parts are new the outside diameter of the ring is 67mm.
As this ring wears the point is reached where the garter spring loses its grip and there
is then no significant inward springing load. Discard the ring, also it mating ring, when
the outside diameter - the largest diametrical measurement remaining across the worn
parts - has reduced to 60mm or less.
To Refit
1) Ensure that the correct relationship is maintained between the rings. There are oil drain
slots cast in the bottom of the housing. Should the housing need to be removed it must
be refitted with these slots positioned lower-most. Also the deflector must be refitted to
the housing.
2) Bar over the compressor a couple of turns to check for correct operation.
3) Refit the access covers to the cylinder distance piece.
MAINTENANCE
JOB No. 008

SUCTION & DELIVERY VALVES - REMOVE & REFIT
LIST OF CONSUMABLES
Description Qty
required
Grinding Paste As
required
Each valve is installed in an individual pocket. They are fitted with metal-to-metal contact
(i.e.. no gasket material) to the seat face in the cylinders.
To Remove
CAUTION!
Serious damage could result from suction valves and their associated
components, being fitted in delivery valve pockets or vice-versa. Therefore,
ensure valves are correctly identified with their pockets.
1) Remove the securing bolts from the valve cover.
2) Remove the valve cover/cage complete with 'O' ring.
3) Remove the valve from its pocket (using a valve extraction tool where necessary).
To Refit
1) Ensure that there are no bruises or burrs on the valve seat or pocket seat. A light
grinding-in operation may be needed, it is important to ensure that no grinding paste
enters the cylinder and that all is clean after completion.
The diametric clearance between the valve seat and the seating in the cylinder is
small, therefore the valve has to be fitted very carefully to ensure that it fits squarely
on to its seat. It is essential that the valve is squarely fitted on its seat and metal to
metal contact established.
2) Check that 'O' rings are in good condition and that their associate grooves are clean
before final assembly of valve cover/cage. Renew if necessary.
3) Refit the valve cage and the valve cover.
4) Refit the cover securing bolts and tighten evenly and squarely to the correct torque.
CAUTION!
It is important after fitting valves (or after work of any kind which has been done
inside the cylinders) to ensure that all is clear in the cylinders by barring over the
crankshaft a few revolutions.
MAINTENANCE
JOB No. 008 SUCTION & DELIVERY VALVES - REMOVE & REFIT (Cont)
Delivery Valve (Typical)
Suction Valve (Typical)
MAINTENANCE
JOB No. 009

SUCTION & DELIVERY VALVES - OVERHAUL
Description Qty
Valve Holding Tool (Drg No. DD816 - available on request) 1
LIST OF CONSUMABLES
Description Qty
required
To Remove
1) Remove the suction delivery valve in accordance with Job No.008.
To Inspect
CAUTION!
The correct holding tool must be used when dismantling and assembling valves.
The valves themselves must never be gripped in a vice.
2) Inspect the 'O' ring for each valve cover/cage. Renew if necessary.
3) Disassemble the valves.
There are locating pegs in all valve seats; these ensure correct relationship between
various components, except the valve coil springs.
4) Thoroughly clean all parts and examine for signs of fatigue or wear.
5) Check for distortion or damage to the sealing faces of valve seats, examine also the
guards.
6) Check for distortion, wear, cracks or breakage of valve plates.
7) Compare the height of displaced springs, with new spares, to determine any
deterioration in spring loading.
8) Replace any part, which is found to be defective.
To Overhaul
CAUTION!
Care must be taken when reassembling overhauled valve components. The
components must be assembled correctly. An incorrectly assembled valve will
quickly deteriorate in service and consequently may damage other parts or affect
the compressor performance. Particular care must be taken when assembling
valves to ensure that the springs remain correctly in their locations.
MAINTENANCE
JOB No. 009 - SUCTION & DELIVERY VALVES - OVERHAUL (Cont)
1) The valves have locating pins, which ensure that the various components are
correctly related radially. The pins are of differing diameters which ensures that the
valve seat, valve plate, valve damper plates, and valve guard are correctly fitted, one
to the other.
If new locating pins are fitted to an old seat it is essential that they are of the correct
sizes and positioned exactly as on original valve seats, with correct standout height
above the valve seat top surface.
2) Lift Washers - when not of identical thickness - should be fitted with the thinner one
next to the valve seat (this thinner one is referred to as the lower lift washer).
3) Conical type springs are fitted with the large diameter end located in the holes in the
valve guard.
4) Torque the centre bolt nut to the correct value to complete the assembly. Refer to
Chapter 1 Section 1.1.3.
MAINTENANCE
JOB No. 010

SUCTION VALVE UNLOADER ACTUATORS - REMOVE & REFIT
LIST OF CONSUMABLES
Description Qty
required
To Remove
1) Disconnect the control air pipe from the actuator and cap open ends.
2) Remove the end fittings from the actuators and store carefully.
3) Slacken locknut and screw actuator out of top cover. Place the actuator onto a clean
work surface.
To Inspect
4) Remove the diaphragm chamber cover and disassemble the unit for examination of
the condition of the diaphragm, spring, bush, spindle and seal ring.
5) Check that the small vent hole in the side of the lower half case is clear (if this
becomes blocked then the diaphragm cannot deflect properly due to pressure build-
up).
6) If there is deterioration of any part, it is recommended that the complete actuator is

replaced. Under normal circumstances actuators given long and trouble free service.
To Refit
1) Ensure that the suction valve is fitted correctly and that its securing cover is fully
tightened down squarely.
It is essential that the correct gap is present between the actuator and the valve,
otherwise the suction valve may not open or close fully.
2) Carefully screw the actuator (with its locknut screwed back) until the spindle just
contacts the valve unloader.
The unloader is spring loaded so take care to just contact it and NOT depress it.
3) Screw back the actuator about 1.5mm and pinch tighten the locknut.
4) Insert a hard wood dowel/rod through the control air connection hole in the top of the
actuator casing until it just touches the top of the diaphragm.
5) With the dowel/rod in position, mark it accurately in line with the actuator cover plate
top.
MAINTENANCE
JOB No. 010 - SUCTION VALVE UNLOADER ACTUATORS - REMOVE & REFIT
(Cont)
6) Using the dowel/rod depress the actuator (against the action of the spindle return
spring) until it just contacts the unloader, but do not depress it.
7) While holding the dowel/rod in position, mark it accurately again in line with the
actuator cover plate top. Then release the dowel/rod (it will rise under the action of
the actuator spindle return spring).
8) Remove the dowel/rod and measure the distance between the marks. If it is NOT
between 1.4mm and 1.6mm then adjust the actuator position, by screwing it in or, out
of the cover plate, as required.
9) When the gap is set correctly, tighten the locknut to the correct torque. Refer to
Chapter 1 Section 1.1.3.
10) When all the actuators on the compressor are correctly set, fit the end fittings to the
actuators; reconnect the control air pipework to the actuators and to the associated
vent vale and test the compressor for correct operation.
MAINTENANCE
JOB No. 011

PISTON RODS - REMOVE & REFIT
Description Qty
Piston rod thread guard cap (Drg No. DD578 - available on request) 1
LIST OF CONSUMABLES
Description Qty
required
To Remove
1) Remove the cylinder top cover as described in Job No.003.
CAUTION!
It may be necessary to bar over the compressor to present the crosshead nut at
the main guide opening. If this is necessary, then caution should be exercised
because the crankshaft and motion work will be placed in an unbalanced state.
Piston rod clamps MUST be fitted. Refer to Job No.002.
2) Remove the piston as described in Job No.004 or if the piston rod is to be removed
with the piston attached skip this step.
Before slackening the crosshead locknut mark on the crosshead two fine centre-
punch dots (about 70 to 75mm apart). One on the piston rods taper portion and the
other on the crosshead. Then, set a pair of dividers to the length between the dots
and record this figure.
3) Remove the locking plate and securing pin from the crosshead and slacken the
crosshead nut.
4) Unscrew the piston rod from the crosshead - the loosened locknut should be held by
a spanner to be unscrewed off the rod end simultaneously, and removed as the rod is
withdrawn. Take care as the threaded portion of the rod is lifted through the gland
rings. Bind the threads of the piston rod end to prevent damage.
5) Using suitable lifting equipment, carefully withdraw the piston and rod assembly from
the cylinder
If the packing gland is to be reused, great care must be taken as the threaded portion
of the rod is lifted through the gland rings to prevent damage.
To Refit
Prior to refitting the piston rod, examine the rod with a gauge and if found to be worn
(evenly or tapered) or scored then renew as necessary.
1) Fit the piston rod, using a piston rod thread guard cap, to pass through the packing
gland and scraper gland until it just enters the main guide.
2) Remove the cap and fit the crosshead locknut at the crosshead as the rod enters the
guide.
MAINTENANCE
JOB No. 011 PISTON RODS - REMOVE & REFIT (Cont)

Note: When refitting the rod, ensure that the centre-punch dots coincide at the
correct distance apart and check the alignment of the cruciform slot at the bottom
of the rod to the securing pin hole in the crosshead, before tightening the locknut
on the crosshead.
3) Ensure that the securing pin can pass through the piston rod foot (slot in line). Fit new
locking plate and tighten the locknut to the crosshead.
4) Refit the piston as described in Job No.004 (if necessary).
5) Check the piston bumping clearances as described in Job No.005.
6) Turn the compressor over a couple of times to ensure satisfactory operation.
MAINTENANCE
JOB No. 012

OIL FILTER - REMOVE & REFIT
LIST OF CONSUMABLES
Description Qty
required
To Remove
1) To open the filter body undo the bottom bolt (using a clean bucket to catch spilled oil),
the filter body and element draw off vertically downwards.
2) Discard the old element and clean out the body.
3) When replacing the assembly (with a new filter pack) care should be taken that the
seal ring gasket at the top and the washer at the bottom are in their correct positions.
A new seal ring gasket is supplied as part of the filter element spare.
There is a spring fitted internally onto the bolt - this is installed to hold the filter
element up against the top cover and so form the seal; it also provides the automatic
safety filter bypass (for use should the element become heavily fouled).
4) Before assembly of the filter body to its cover, fill the body with clean compressor
lubricating oil.
OIL
PUMP
Crankcase Arrangement
MAINTENANCE
JOB No. 013

OIL PRESSURE RELIEF VALVE - INSPECTION
LIST OF CONSUMABLES
Description Qty
required
The oil pressure relief valve is screwed into a boss connecting to the internal oil way of the oil
pump end main bearing end cover. Adjustment is best carried out with the relief valve
removed from the end cover and set using a shop air line and a calibrated pressure gauge.
To adjust the relief valve
1 Remove the blank end cap
2 Loosen the locknut and adjust using the hexagon on the relief valve. Screw the
hexagon 'IN' to increase pressure and 'OUT' to decrease the pressure.
3 Tighten the locknut after adjustment and replace the blank end cap.
Note:. Adjustment is not normally necessary. However, if a fault should occur and
adjustment has no noticeable effect, the trouble could be a particle of foreign
matter trapped under the valve. Dismantling, cleaning and reassembly is then
required (The valve cap setting should be noted before attempting to dismantle
the valve).
JOB No. 014

LUBRICATING OIL PUMP AND DRIVE - INSPECT & OVERHAUL
LIST OF CONSUMABLES
Description Qty
required
To Overhaul
1) Disconnect all pipes connected to the oil pump.
2) Remove the cap screws securing the oil pump to bearing housing and carefully
withdraw the pump, together with the filter body attached, its drive coupling can then
be inspected.
Wear on the coupling is expected to be negligible but if excessive wear is present
investigate the cause, remove, and fit a new drive coupling.
3) When refitting the oil pump renew the gasket if the old one has deteriorated.
4) Prime the suction side of the pump with oil.
5) Refit the pipework to the oil pump.
MAINTENANCE
JOB No. 015

INTERCOOLER - INSPECT & OVERHAUL
LIST OF CONSUMABLES
Description Qty
required
To Inspect
1) The cooler MUST be removed completely in order for a complete examination to be

performed. Internal and external inspection, to check for fouling or damage, is annual.
This period will, however, vary depending on site conditions (being extended with
good clean water circulating).
MAINTENANCE
JOB No. 015 INTERCOOLER - INSPECT & OVERHAUL (Cont)
To Overhaul
1) It is not expected that the inside (i.e., tube internals) will foul. Any untoward
accumulation of soft deposits at the tube entrance may be removed by blowing
backwards with compressed air, the cooler being off the compressor for this purpose.
2) If hard carbonaceous deposits have accumulated, specialist attention may be
required.
3) Should the cooling water side become fouled then use a proprietary procedure as
recommended by local water treatment specialists - this to be compatible with the
materials of construction (see Chapter 1 - Technical Data).
4) When refitting (after cleaning) all joints must be in good condition.
MAINTENANCE
5.3 Lists of Tools

5.3.1 Commercially Available Tools List
The following is the recommended list of tools required to perform maintenance tasks
on this compressor:
Tool Supplementary Information
Standard tool box tools including:- Various job locations

A range of open-jaw, ring, and socket
type spanners
A set of hexagonal section Allen keys
(Metric)
Torque wrench Tightening range 0 to 650 Nm
Circlip pliers For removal and refitting crosshead gudgeon
pin retaining circlips.
Eyebolts M20 x 2.5 (male)
M16 x 2.0 (male & female)
M12 x 1.75 (male).
Fitters tools Feeler (thickness) gauges, standard sizes
Long-nosed pliers Thin ended, for removal of circlip from suction
valve unloader
5.3.2 Specialist Service Tools List
Specialist service tools (which can be manufactured locally) or purchased direct from
Gardner Denver Belliss & Morcom, can be used to aid compressor maintenance
work. Illustrations of these are available on request.
Tool Drg No Supplementary Information
Valve extractor DD594 (2nd stage)

Valve extractor DD622 (1st stage)
Valve holding clamp DD816 -
Valve supporting details - Use of clamp DD816
Piston rod gland wear checking tool DD600
Tool for assembling piston rod packing DD938
gland
Piston rod clamp DD579
Piston rod thread guard cap DD578
MAINTENANCE
5.4 Waste Products

There are very few waste products associated with air compressors: old lubricating oil
and oil filter elements and condensate mainly. On closed loop systems, coolant may
also be considered.
5.4.1 Oil - After Oil Changes
When handling and disposing of sump oil after an oil change several important points
need to be followed:
a. Avoid contact with the skin and wash off any contamination immediately.
b. Dispose of old oil and filter elements in accordance with local regulations.
For further details contact your local oil company representative, or local government
department dealing with factory wastes. .
5.4.2 Coolant
Coolant from closed loop systems i.e.. water with anti-freeze added, should be
disposed of in a safe manner. For further advice contact the local Water Authority.
CHAPTER 6
SPARE PARTS
CHAPTER 6 - SPARE PARTS Page: 93 of 135
6 SPARE PARTS
This document provides information regarding the recommended spare parts policy
for this equipment. Information regarding recommended consumables and special
tool requirements are provided at the end of Chapter 5.
Items not identified as a spare can be found within the Illustrated parts list for the
compressor. These items, under normal operating conditions, will last for the
designed lifetime of the equipment.
Fasteners used on this equipment, such as screws, nuts, washers, bolts and clips etc;
have not been included within the Spare Lists. For details regarding the fastener refer
to the Illustrated Parts List for this equipment.
WARNING!
Always use the specified fastener. On no account should a lower
specification fastener be used.
6.1 Ordering Spares and Spares to be Held in Stock

IMPORTANT - When ordering spare parts please quote the following details:
Compressor Serial Number
Compressor Type
Description of Part required.
Part Number (if available)
Quantity required
We recommend that users of our compressors should hold in stock a complete set of
spares. The spares stock should be maintained at the original level, replacements
being ordered in good time to ensure availability when required. Parts must be kept in
good order with appropriate preservation precautions to meet the climatic conditions.
The quantities given within the lists are the recommended minimum holding.
For spare parts associated with the control console, drive system etc; reference
should be made to the spares information and recommendations provided with these
items.
6.2 Spares List

COMPRESSOR SPARE PARTS
Item Description Qty Part No.
1 1st Stage Top Cover Gasket 1 2-01-575-02
2 2nd Stage Top Cover Gasket 1 2-01-842-02
3 Scraper Box Gasket 2 2-63-069-02
4 Crankcase Door Gasket 2 PSB008-005
5 Main Guide Door Gasket 2 PSB008-006
6 1st Stage Valve Cage 'O' Ring 8 PSB008-018
7 2nd/3rd Stage Valve Cover 'O' Ring 3 MB133-49
8 2nd/3rd Stage Valve Cover 'O' Ring 3 MB133-48
9 Actuator Diaphragm 7 PSB028-003
10 1st Stage Piston Rod Pkg Wrg Parts 1 Set PSB032-007
11 2nd Stage Piston Rod Pkg Wrg Parts 1 Set PSB032-007
12 Piston Rod Scraper Wearing Parts 2 Sets PSB032-004
13 1st Stage Piston Rings 2 2-28-764-03
14 1st Stage Rider Ring 1 2-28-764-04
15 2nd Stage Piston Rings 3 2-28-833-03
16 2nd Stage Rider Ring 1 2-28-833-05
17 3rd Stage Piston Rings 6 2-28-833-06
18 3rd Stage Rider Ring 1 2-28-833-07
19 Piston Rod Nut 2 PSB002-004
20 Piston Rod Locking Plate 2 PSB004-003
21 Bottom End Bearing 2 Pairs PSB014-002
22 Bottom End Split Pin 4 NSBP-220-025
23 Oil Suction Strainer 1 PSB025-001
24 Oil Delivery Filter C/W 'O' Ring 1 PSB025-010
24A Oil Filter Element 'O' Ring 1 PSB025-006
25 Air Inlet Filter Element 1 ASB512-001
VALVE SPARE PARTS

26 1st/2nd Stage Valve Plate 12 PSB027-014
27 2nd Stage Suction Valve Plate 4 QAP13-70-8767A
28 3rd Stage Valve Plate 2 2-70-717-01
29 1st/2nd Stage Valve Cushion Plate 6 PSB027-015
30 2nd Stage Suction Valve Cushion Plate 2 QAP13-70-8767B
31 3rd Stage Valve Cushion Plate 1 2-70-717-03
32 1st Stage Suction Valve Spring 64 PSB027-018
33 1st Stage Delivery Valve Spring 64 PSB029-007
34 2nd Stage Delivery Valve Spring 64 PSB027-156
35 2nd Stage Suction Valve Spring 32 PSB029-006
36 3rd Stage Suction Valve Spring 8 PSB027-010
VALVE ASSEMBLIES
39 1st Stage Suction Valve Complete 4 PSB027-001
40 1st Stage Delivery Valve Complete 4 PSB029-064
41 2nd Stage Suction Valve Complete 2 2-70-553-01
42 2nd Stage Delivery Valve Complete 2 PSB029-104
43 3rd Stage Suction Valve Complete 1 2-70-649-02
44 3rd Stage Delivery Valve Complete 1 2-70-650-02
6.3 Illustrated Parts List - Main Component Location View
Main Component Location View Key

Fig 1 Crankcase Ass'y Fig 18 Top Cover Ass'y
st
Fig 2 Crankshaft Ass'y Fig 19 1 Stage Cylinder Suction Valve Ass'y
st
Fig 3 Flywheel End Cover Fig 20 1 Stage Cylinder Delivery Valve Ass'y
st
Fig 4 Bearing End Cover Ass'y Fig 21 1 Stage Top Cover Suction Valve Ass'y
st
Fig 5 Oil Pump Ass'y Fig 22 1 Stage Top Cover Delivery Valve Ass'y
nd
Fig 6 Oil Cooler Ass'y Fig 23 2 Stage Suction Valve Ass'y
nd
Fig 7 Connecting Rod Ass'y Fig 24 2 Stage Delivery Valve Ass'y
rd
Fig 8 Main Guide Ass'y Fig 25 3 Stage Suction Valve Ass'y
rd
Fig 9 Distance Piece Ass'y Fig 26 3 Stage Delivery Valve Ass'y
st nd
Fig 10 Crosshead Ass'y Fig 27 1 & 2 Stage Drain Trap Ass'y
rd
Fig 11 Scraper Housing Arrg't Fig 28 3 Stage Drain Trap Ass'y
st
Fig 12 1st Stage Cylinder Ass'y Fig 29 1 Stage Pipework
nd
Fig 13
nd
2 Stage Cylinder Ass'y Fig 30 2 Stage Pipework
Fig 14
rd
3 Stage Cylinder Ass'y Fig 31 Aftercooler Ass'y
Fig 15 Piston Rod Ass'y Fig 32 Pressure Gauge Arrg't
st Fig 33 External Pipework/Fittings
Fig 16 Piston Ass'y - 1 Stage
nd rd
Fig 17 Piston Ass'y - 2 & 3 Stage
Fig 1 Crankcase Assembly (2-03-302)

Item Part No. Description Qty
1 2-03-302-01 Crankcase 1
2 MB006-03 Setscrew, M10x16 long 36
3 MB006-10 Bolt, M10x35 long 6
4 MB007-11 Bolt M12x50 long 12
7 MB013-27 Bolt, M24x150 long 2
8 MB033-06 Washer, M12 12
9 MB118-08 Plug, 1/2" BSP 1
10 PSB004-010 Locking plate 1
11 PSB008-005 Crankcase door gasket 2
12 PSB008-006 Crankcase guide gasket 2
13 PSB008-119 Bearing housing gasket 1
14 PSB009-001 Crankcase door 2
15 PSB009-002 Main guide door 2
16 PSB024-001 Crankcase breather 1
17 MB130-01 Window nut, 1. 1/2" BSP 1
Fig 2 Crankshaft Assembly (2-06-373)

1 2-06-373-01 Crankshaft 1
2 2-06-299-02 Motor key 1
3 PSB002-003 Clamping nut 2
4 PSB004-002 Locking washer 2
5 PSB003-005 Distance piece 1
6 PSB014-001 Roller bearing 3
7 2-25-109-02 Clamping ring 1
8 2-06-310-02 Driving dog 1
Fig 3 Flywheel End Cover (2-25-109)

1 2-25-109-01 Flywheel End cover 1
2 PSB007-005 Oil seal 1
3 PSB008-013 Flywheel end cover gasket 1
4 MB031-06 Washer, M10 6
Fig 4 Bearing End Cover Assembly (2-25-118)

1 2-25-118-01 Bearing housing 1
2 MB046-18 Capscrew M8x50 long 8
3 MB121-04 Plug, 1/2" BSP 1
4 PSB008-023 Oil pump gasket 1
5 PSB013-013 Oil relief valve 1
Fig 5 Oil Pump Assembly (2-34-422)

1 PSB017-003 Lub oil pump 1
2 PSB025-001 Oil suction strainer 1
1
3 MB125-05 Barrel nipple /2" 1
4 MB041-23 Copper washer 3
1
5 PSB026-100 Socket /2" 1
6 PSB026-351 Suction hose c/w nipples 1
7 PSB025-009 Oil filter 1
8 PSB008-009 Oil filter gasket 1
9 MB006-30 Bolt, M10x90 long 2
1
10 MB121-01 Plug /8" BSP 2
1
11 PSB026-263-03 Backnut 1 /2" BSP 1
Fig 6 Oil Cooler Assembly (2-34-498)

1 2-34-459-05 Oil cooler 1
2 3-34-459-01 Oil manifold block 1
3 2-34-498-01 Flex hose 1
4 2-34-498-02 Flex hose 1
5 2-34-459-03 Oil cooler bracket 1
6 MB004-03 Bolts 4
7 2-34-459-02 Studs 2
8 MB021-06 Nuts 2
9 PSB008-009 Gasket 1
10 MB006-03 Bracket bolts 2
11 2-45-1562-04 Cone adapter 3/4" 4
Fig 7 Connecting Rod Assembly (2-76-425)

1 2-05-102-01 Connecting Rod (Supplied as 2-05-104) 1
2 2-05-104-02 Bottom end bolt (Supplied with 2-05-104) 2
3 2-05-104-03 Bottom end bolt nut (Supplied with 2-05-104) 2
4 PSB005-003 Snug (Supplied with 2-05-104) 2
5 NSBP-220-019 Split pin 2
6 PSB014-002 Bottom end bearing 1 Set
7 PSB014-005 Top end bearing (Supplied with 2-05-104) 1
Fig 8 Main Guide Assembly (2-07-280)

1 2-07-280-01 Main Guide 1
2 PSB006-001 'O' ring 1
Fig 9 Distance Piece Assembly (2-07-485)

1 2-07-281-01 Distance piece 1
2 MB004-01 Setscrew M6x8 long 8
3 MB013-17 Bolt M24x100 long 12
4 MB031-13 Washer, M24 12
5 PSB009-006 Aperture cover 2
6 MB118-04 Plug 1/4" BSP 1
Fig 10 Crosshead Assembly (2-31-066)

1 2-31-066-01 Crosshead 1
2 2-31-045-02 Gudgeon pin 1
3 MB137-09 Circlip 2
4 PSB001-002 Securing pin 1
5 PSB004-001 Locking plate 1
Fig 11 Scraper Housing Arrangement (2-63-047)

1 PSB032-001 Packing box complete 1
2 PSB032-002 Oil shedder 1
3 PSB032-003 Support plate 1
4 MB007-03 Setpins for box M12 4
5 MB006-05 Setpins for plate 6
6 PSB008-015 Plate gasket 1
7 PSB008-016 Box gasket 1
Fig 12 1st Stage Cylinder Assembly
Fig 12 1st Stage Cylinder Assembly (2-01-575)

1 2-01-575-01 Cylinder 1
2 2-01-575-02 Top cover gasket 1
3 2-01-575-03 Air inlet gasket 1
4 2-01-575-04 Air outlet gasket 1
7 MB021-09 Hex nut M16 8
8 MB021-11 Hex nut M20 18
9 MB023-09 Dome nut 2
10 MB029-09 Philidas nut 2
11 MB084-05 Stud M16x57 long 8
12 MB086-08 Stud M20x85 long 2
13 MB086-19 Stud M20x170 long 20
14 MB118-07 Plug ½” BSP 2
15 PSB026-279-07 Plug 2” BSP 6
Fig 13 2nd Stage Cylinder Assembly
Fig 13 2nd Stage Cylinder Assembly (2-01-842)

1 2-01-842-01 Cylinder 1
2 2-01-842-02 Cylinder gasket 1
3 2-01-842-03 Inlet gasket 1
4 2-01-842-04 Delivery gasket 1
7 MB021-13 Nut M24 16
9 MB029-09 Philidas nut M20 4
10 MB035-11 Plain washer M24 12
11 MB086-11 Stud M20x100 long 4
12 MB118-03 Steel plug 1/4" BSP 4
13 PSB026-279-04 Plug 1" BSP 6
14 PSB026-279-07 Plug 2" BSP 8
15 PSB026-280-06 Plug 1. 1/4" 2
16 MB088-05 Stud M24 x 79 long 13
17 MB088-08 Stud M24 x 94 long 3
Fig 14 3rd Stage Cylinder Assembly (2-01-888)

1 2-01-888-01 Cylinder 1
2 2-01-843-02 Inlet/delivery gasket 2
3 MB086-07 Stud, M20x80 long 16
1
5 MB118-03 /4" bsp steel plug 1
1
6 PSB026-269-29 Reducing bush 2" x 1. /4" BSP 1
7 PSB026-279-07 Plug 2" BSP 6
1
8 PSB026-279-05 Plug 1. /4" BSP 1
9 MB021-11 Nut M20 16
Fig 15 Piston Rod Assembly (2-30-320)

1 2-30-320-01 Piston rod 1
2 PSB002-004 Piston rod nut 1
3 PSB002-009 Nut crosshead 1
Fig 16 Piston Assembly - 1st Stage (2-28-787)

1 2-28-787-01 Piston, top half 1
2 2-28-787-02 Piston, bottom half 1
3 2-28-539-03 Piston ring 2
4 2-28-539-04 Bearer ring 1
5 PSB003-001 Bottom washer 1
Fig 17 Piston Assembly - 2nd & 3rd Stage (2-28-833)

nd / rd
1 2-28-833-01 2 3 stage piston 1
2 Y30236 'O' ring 1
3 2-28-833-02 3rd stage piston cap 1
4 2-28-833-03 2nd stage piston bottom 1
5 2-28-833-04 2nd stage piston ring 3
6 2-28-833-05 2nd stage bearing ring 1
7 2-28-833-06 3rd stage piston ring 1
8 2-28-833-07 3rd stage bearing ring 1
10 MB030-03 Locking Washer M8 4
12 MB030-08 Locking Washer M16 4
13 PSB003-003 Top washer 1
14 PSB003-001 Reinforcing washer 1
Fig 18 Top Cover Assembly (2-04-307)

1 2-04-307-01 Top cover 1
3 PSB026-279-07 Plug 2” BSP 1
Fig 19 1st Stage Cylinder Suction Valve Assembly (2-70-534)

1 2-70-206-01 Suction valve spacer 1
2 2-70-211-04 Valve cover 1
3 PSB028-008 Actuator 1
4 PSB006-018 'O' ring 1
5 PSB044-001 Disc spring 1
6 PSB027-001 Suction valve 1
7 2-70-503-01 Locating peg 1
Fig 20 1st Stage Cylinder Delivery Valve Assembly (2-70-535)

1 2-70-207-01 Delivery valve spacer 1
2 2-70-210-04 Valve cover 1
3 PSB006-018 ‘O’ ring 1
5 PSB029-064 Delivery valve 1
6 2-70-224-10 Valve cover centre bolt 1
Fig 21 1st Stage Top Cover Suction Valve Assembly (2-70-536)

1 2-70-206-01 Suction valve spacer 1
2 2-70-211-02 Valve cover 1
4 PSB006-018 'O' ring 1
6 PSB027-001 Suction valve 1
7 2-70-503-01 Locating peg 1
Fig 22 1st Stage Top Cover Delivery Valve Assembly (2-70-537)

1 2-70-207-01 Delivery valve spacer 1
2 2-70-210-02 Valve cover 1
3 PSB006-018 ‘O’ring 1
6 2-70-224-10 Valve cover centre bolt 1
Fig 23 2nd Stage Suction Valve Assembly (2-70-553)

1 2-70-525-01 Valve cage 1
2 2-70-553-02 Valve cover 1
3 MB133-48 'O' ring 1
4 MB133-49 'O' ring 1
5 2-70-553-01 Suction valve 1
Fig 24 2nd Stage Delivery Valve Assembly (2-70-554)

2 2-70-554-01 Valve cage 1
3 2-70-554-02 Valve cover 1
4 MB133-48 'O' ring 1
5 MB133-49 'O' ring 1
Fig 25 3rd Stage Suction Valve Assembly (2-70-555)

1 2-70-649-02 Suction valve 1
2 2-70-555-02 Valve cage/cover 1
3 MB133-48 'O' ring 1
Fig 26 3rd Stage Delivery Valve Assembly (2-70-556)

1 2-70-650-02 Delivery valve 1
2 2-70-555-03 Valve cage/cover 1
3 MB133-48 'O' ring 1
Fig 27 1st & 2nd Stage Drain Trap Assembly (2-84-003)

1 2-84-003-01 Drain Trap Assembly 1
Fig 28 3rd Stage Drain Trap Assembly (2-84-005)

1 2-84-005-01 Drain Trap Assembly 1
Fig 29 1st Stage Pipework (2-71-815)

1 2-71-815-01 Delivery pipe 1
2 2-71-766-02 Intercooler 1
3 2-71-766-03 Inlet pipe 1
4 MB013-13 Bolt, M24 x 80 long 16
5 MB021-13 Nut, M24 16
6 2-01-842-03 Gasket 2
7 2-136-01 Temperature gauge and Thermowell 2
8 PSB013-073 Relief valve 1
Fig 30 2nd Stage Pipework (2-71-801)

2 2-71-801-02 Intercooler 1
3 2-71-801-03 Separator 1
4 2-71-801-04 Inlet pipe 1
5 2-71-801-05 Gasket 3
6 MB009-21 Nut, M20 36
7 MB011-22 Bolt, M20 x 100 long 33
9 2-136-01 Temperature gauge 2
10 MB011-24 Bolt, M20 x 110 long 3
11 2-71-801-06 Support bracket 1
Fig 31 Aftercooler Assembly
Fig 31 Aftercooler Assembly (2-72-690)

2 2-72-688-02 Cooler 1
3 2-72-690-02 Aftercooler pipework 1
4 MCB16/110Z Bolt, M16 x 110 long 26
5 MB021-09 Nut, M16 34
7 MB120-01 Vent valve 1
8 MB118-08 Plug 1/2" BSP 2
9 MB118-04 Plug 1/4" BSP 1
10 2-72-690-03 Aftercooler bracket 1
11 MB021-13 Nut, M24 2
12 MB013-23 Bolt, M24 x 130 2
13 2-72-688-06 Gasket 2
14 MB084-24 Stud M16x120 long 2
15 PSB012-015 HAT switch 1
16 2-136-001 Temperature gauge and thermowell 2
17 MCB16/120Z Bolt M16x120 long 4
Fig 32 Pressure Gauge Arrangement
Fig 32 Pressure Gauge Arrangement (2-46-1254)

1 2-46-1253-01 Pressure gauge board 1
2 PSB026-106 Pressure gauge adaptor 4mm 1
3 PSB026-107 Pressure gauge adaptor 6mm 3
4 PSB026-110 Leather gasket 4
5 PSB012-064 Diffuser 2
6 MB108-05 Male stud elbow 1/8" X 6mm 2
7 PSB012-063 Suction blow down valve 2
8 PSB026-350-05 Reducing bush 1/2" x 1/4" BSP 2
9 PSB026-347-02 Hexagon nipple 1/4" BSP 4
10 PSB026-349-02 Union 1/4" BSP M/F 2
11 PSB026-328 Barrel nipple 1/4" BSP 1
12 MB110-04 Male stud tee 1/4" x 6mm BSP 7
13 MB108-06 Male stud elbow 1/4" x 6mm BSP 3
14 MB111-03 Equal tee 6mm 3
15 MB101-03 Copper pipe 6mm 13 M
16 MB106-05 Stud coupling 1/4" x 6mm BSP 2
17 MB120-01 Ball valve 1/4" BSP 2
18 MB111-01 Equal tee 4mm 1
19 MB108-01 Male stud elbow 1/8" x 4mm BSP 2
20 PSB012-011 Hat/lop switch 1/2" BSP 1
21 MB040-15 Copper washer 1
22 MB101-01 Copper pipe 4mm 3M
23 MB128-03 Treble pipe clip 6mm 10
24 MB128-02 Double pipe clip 6mm 10
25 MB129-03 Screws for pipe clips 20
26 MB142-01 Drain valve 1/4" 1
27 2-46-1253-02 Gauge 0-7 Bar 2
28 2-46-1253-03 Gauge 0-28 Bar 1
29 2-46-1253-04 0-70 BAR gauge 1
30 Y27793 A/V foam pads 4
31 Y24566/16 Setscrews M8 x 16 4
32 MPW8Z Washer M8 4
33 Y37865 Label oil pressure 1
34 Y35730 Label 1st stage pressure 1
35 Y35731 Label 2nd stage pressure 1
36 Y35732 Label 3rd stage pressure 1
Fig 33A External Pipework & Fittings
Fig 33B External Pipework & Fittings
Fig 33C External Pipework & Fittings
Fig 33 External Pipework & Fittings (2-45-2519)

1 2-45-1626-01 Flange 2
2 PSB026-277-08 Nipple 2" BSP 7
3
3 PSB026-287-19 Tee 2" x 2" x /4" 2
3
4 2-45-1562-04 Hose adapter /4" 4
1
5 PSB026-287-121 Tee 2" x 2" x 1. /4" 1
1
6 PSB026-277-06 Nipple 1. /4" BSP 6
1 1
7 PSB026-288-06 Tee 2" x 1. /4" x 1. /4" BSP 2
1
8 PSB026-142 Hose adaptor 1. /4" 14
9 2-45-2515-04 Flowmeter 1. 1/2" BSP 3
1
10 2-45-1678-06 Globe valve 1. /4" BSP 3
1
11 PSB026-299-04 Elbow union, M/F 1. /4" BSP 1
12 2-89-002 2" Flanged from meter switch 1
3
13 PSB026-223 Ball valve /4" BSP 1
14 PSB026-277-04 Nipple 3/4" BSP 1
1 1 1
15 PSB026-289-05 Tee 1. /4" x 1. /4" x /2" BSP 3
1
16 MB120-03 Cock /2" BSP 3
1
17 PSB026-269-29 Bush 2" - 1. /4" BSP 2
1
18 PSB026-297-06 Union 1 /4" BSP 1
19 14464/27 Pipe 1 1/4" n/b mild steel 12"
1
20 2-45-2519-02 Flexible hose 1 /4" N/B 1
1
21 2-45-2463-01 Flexible hose 1 /4" N/B 1
1
22 2-45-2463-02 Flexible hose 1 /4" N/B 1
1
23 2-45-2462-04 Flexible hose 1 /4" N/B 1
1
24 2-45-2519-06 Flexible hose 1 /4" N/B 1
1
25 2-45-2462-06 Flexible hose 1 /4" N/B 1
26 2-45-2462-07 Flexible hose 1 1/4" N/B 1
3
27 2-45-2519-04 Flexible hose /4" N/B 1
3
28 2-45-2519-05 Flexible hose /4" N/B 1
29 MB168-01 U Bolt 2
1
30 PSB026-287-22 Tee 2" x 2" x 1 /2" BSP 1
31 PSB026-297-02 Union 1 1/2" BSP, M&F 1
1
32 PSB026-277-07 Nipple 1 /2" BSP 1
Fig 33 External Pipework & Fittings (2-45-2520) (Cont.)
33 PSB026-269-25 Bush 11/2" x 1 1/2" 1

1 1
34 PSB026-278-13 Nipple 1 /2" x 1 /2" 4
35 43445 Gasket 1
36 MB009-11 Bolt M16 x 60 long 4
37 MB021-09 Nut, M16 4
38 MB021-06 Nut, M10 4
39 MB038-07 Spring washer 4
1
40 PB026-264-06 Bend 1 /4 " F/F 1
APPENDICES
SAFE WORKING LIMITS
Chequers Bridge, Gloucester, GL1 4LL, England
SAFE WORKING LIMITS
EQUIPMENT MODEL No…………………………………………………..…… VH15H3N
MAXIMUM COMPRESSOR SPEED:………………………….………..……… 750 RPM
1st STAGE MAXIMUM WORKING PRESSURE:……………………..……..… 4.5 BAR G
2nd STAGE MAXIMUM WORKING PRESSURE:……………………...……… 16.5 BAR G
3rd STAGE MAXIMUM WORKING PRESSURE:………………………………. 48.5 BAR G
MAXIMUM TEMPERATURES: 3rd Stage Delivery Pipe………….… 175 °C

3rd Stage Separator Pipe………..… 65 °C
MAXIMUM AMBIENT TEMPERATURE:……….…………………………….… 45°C
COOLING WATER PRESSURE: Maximum…………….…………….. 7.0 BAR G

Minimum…………………………… 3.0 BAR G
COOLING WATER TEMPERATURE: Maximum…………...……………… 36 °C

Minimum………..…………………. 16°C
COOLING WATER MINIMUM: 1ST STAGE COOLER/CYLINDERS 3.7 m3/hr

FLOWS 2ND STAGE COOLER……………. 5.2 m3/hr
AFTERCOOLER………………….. 3.0 m3/hr
OIL PRESSURE: Start-up Maximum………………… 8.0 BAR G

Normal Operation Maximum…….. 4.8 BAR G
Shut Down Minimum……………… 1.8 BAR G
WARRANTY REQUEST CLAIM
FORM
QUALITY MANUAL CLAIM DATE:

SECTION 1 - Request For Authorisation To Y Number and Category Number
Proceed With Work
Y __ __ __ __ __ / __
Customer: Agent:
Site: Site Address:
Contact:
Fax / Tel No:
Serial No:
Machine Type: Date Despatched:
Date of Commissioning: Warranty End Date:
Hours Run: Customer Order No:
Problem / Defect:
This form is to be completed and faxed to Belliss & Morcom Service Department PRIOR to
commencement of work. Fax No: +44 (0) 1452 338317. All parts are to be returned to Belliss &
Morcom by the most economical means of transport unless otherwise requested. Should failed
parts not be returned within 60 days of the date of this claim, Belliss & Morcom shall reserve the
right to charge for parts replaced.
Authorisation to Proceed: Yes No Signed: Date:
SECTION 2 - Warranty Claim Details
Action Required / Taken: Detail Below Completion Date:
Date of Issue This Sheet - JUNE 2001 Document No. CM4F2 Rev. 6 Page 1 of 2
WARRANTY REQUEST CLAIM
FORM
QUALITY MANUAL VOLUME 4 Continuation

Parts Used
Part Description: Part No. (If Known)
Continue on a separate sheet if necessary.

Details of Labour (sub contract or direct)
For Gardner Denver Belliss & Morcom Internal Use Only

Warranty Claim Categories Estimated Value of Warranty Claim
A- Warranty claim for a failure of GDB&M product where reasons for Value of Parts £_________
failure cannot be allocated to others.
B- Warranty claim charged to external suppliers. Value of Labour £_________
C- Warranty claim charged to manufacturing, i.e. rework caused by
Total £_________
original manufacturing defect or failure.
D- Goodwill expenditure particularly after warranty expiry date.
E- Warranty claim due to design defect or problem.
F- Warranty claim due to incorrect or failure of service work. Signed ____________________
G- Warranty claim due to incorrect contract specification or failure to

include a feature or requirement specified by the customer. Authorised _________________
H- Special reason please state.

Dated _____________________
X- Warranty claim that cannot be attributed or deferred to any of the

above, therefore remains "uncategorised".
Date of Issue This Sheet - JUNE 2001 Document No. CM4F2 Rev. 6 Page 2 of 2
COMPRESSOR LOG SHEET

Operation & Maintenance Manual: PET Compressor Type Vh15H3N

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Operation & Maintenance Manual: PET Compressor Type Vh15H3N

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OPERATION & MAINTENANCE

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How to Use this Instruction Manual

This pictogram marks important Notes, which identifies supplementary information

Comments and Suggestions

1 TECHNICAL DATA & COMPRESSOR DESCRIPTION.....................................9

6 SPARE PARTS ................................................................................................93

1 TECHNICAL DATA & COMPRESSOR DESCRIPTION

The compressor is manufactured in accordance with the European Economic

1.1 Technical Data

Instrument Pressure Gauge Range Pressure Range

Oil Pressure ** 0 - 10 Bar G 3 - 4.8 Bar G

Flows and Capacities

Compressed Air Data Crankcase Data

Gas being compressed AIR Oil Sump Capacity 45 litres

Delivery Pressure 45.5 Bar G

Inlet Temperature 0-45 ºC

Relative Humidity 0 - 100%

1.1.2 Compressor Data

Normal Operating 7 Bar G minimum Compressor 4500 kg.

Piston/Piston Ring Data:

First Stage Piston Rings First Stage Bearer Ring

Second Stage Piston Rings Second Stage Bearer Ring

Third Stage Piston Rings Third Stage Bearer Ring

Crankcase Components Clearances

Compressor Performance Data

Safety Device Data

Pressure Relief Valve Data:

Setting of Protection Switches/Devices

1.1.3 Tightening Torques (Dry Threads)

Component Thread Torque Nm

1.1.4 Materials of Construction

1.2 Technical Description of the Compressor

The compressor provides a constant supply of compressed air, at a regulated

External View of VH15H3N PET Compressor

1.2.2 Compressor Identification

Cutaway View of Compressor Cylinder (2nd / 3rd Stage)

Pistons & Rings

The pistons are of a two-piece hollow construction, with machined piston-ring

Piston Rods & Packing

A plate depressor is basically an inverted cup-shaped body with fingers protruding

1.2.7 Motor and Couplings

The compressor can be supplied with a flange-mounted motor, or as a bare-shaft

1.2.8 Control Panel and Controls

1.2.9 Safety Equipment and Systems

2.1 Safety Policy

2.1.2 Proper Use

The compressor is built to stringent manufacturing guidelines to guarantee safe

2.1.3 Organisational Measures

It is the customer’s responsibility to ensure that the operating manual is adequately

2.1.5 Installation, Commissioning and Operation

3 INSTALLATION & COMMISSIONING

3.1 Safety Precautions

3.2 Installation Requirements

Distribution Piping (air systems)

Water collectors of an automatic discharge type should be fitted at suitable points in

Load Control Piping

3.2.5 Cooling Water

3.3 Handling and Unpacking

Compressor Slinging Diagram (Typical)

3.3.3 Lifting Instructions

2. Know your equipment, and anticipate potential hazards.

No special unpacking instructions can be given here as the compressors may be