WH40H3N Manual

OPERATION & MAINTENANCE
MANUAL
PET
COMPRESSOR TYPE WH40H3N
Doc. Ref:WH40H3N
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 nonconformity 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:
Fax:
+44 (0) 1452 338198

+44 (0) 1452 338317
Email:
Web:
service@belliss.co.uk
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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.
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, 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 supersede 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 noncompliant 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.
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Foreword
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.
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.
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OPERATION & MAINTENANCE MANUAL
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CONTENTS
TECHNICAL DATA & COMPRESSOR DESCRIPTION.....................................9

1.1
Technical Data..................................................................................................... 9
1.1.1
1.1.2
1.1.3
1.1.4
1.2
Technical Description of the Compressor .......................................................... 15

1.2.1
1.2.2
1.2.3
1.2.4
1.2.5
1.2.6
1.2.7
1.2.8
1.2.9
2.
Purpose of the Equipment .................................................................................15

Compressor Identification ..................................................................................15
Compressor Operation ......................................................................................16
Crankcase and Lower Motion Work ...................................................................16
Cylinders, Pistons and Piston Rod Packings......................................................18
Valves ...............................................................................................................19
Motor and Couplings .........................................................................................19
Control Panel and Controls................................................................................19
Safety Equipment and Systems .........................................................................20
SAFETY INFORMATION..................................................................................22
2.1
Safety Policy...................................................................................................... 22
2.1.1
2.1.2
2.1.3
2.1.4
2.1.5
2.1.6
Operating Data....................................................................................................9
Compressor Data ..............................................................................................10
Tightening Torques (Dry Threads) .....................................................................13
Materials of Construction ...................................................................................14
Commonplace Hazards .....................................................................................22

Proper Use ........................................................................................................22
Organisational Measures...................................................................................23
General Safety Precautions for Compressors ....................................................23
Installation, Commissioning and Operation ........................................................24
Maintenance......................................................................................................24
INSTALLATION & COMMISSIONING .............................................................27

3.1
3.2
Safety Precautions............................................................................................. 27
Installation Requirements .................................................................................. 27
3.2.1
3.2.2
3.2.3
3.2.4
3.2.5
3.2.6
3.3
Handling and Unpacking.................................................................................... 32

3.3.1
3.3.2
3.3.3
3.3.4
3.4
Safety Precautions ............................................................................................35

Mounting Arrangements - Anti-Vibration Mounts ................................................35
Levelling and Alignment - Flange Mounted Motors.............................................36
Preparation for Commissioning.......................................................................... 36

3.5.1
3.5.2
3.5.3
3.5.4
3.6
Stability .............................................................................................................32
Slinging Instructions ..........................................................................................33
Lifting Instructions .............................................................................................34
Unpacking .........................................................................................................34
Installation Procedure ........................................................................................ 35

3.4.1
3.4.2
3.4.3
3.5
Location ............................................................................................................27
Ventilation .........................................................................................................27
Foundations ......................................................................................................28
Pipework Installation..........................................................................................28
Cooling Water ...................................................................................................31
Electric Cabling .................................................................................................32
Cleaning the Compressor ..................................................................................36

Preparing the Compressor.................................................................................36
Preparing the Motor...........................................................................................38
Motor Rotation Check........................................................................................38
Commissioning the Compressor ........................................................................ 38

3.6.1
3.6.2
Trial Run ...........................................................................................................38

Completion of Commissioning ...........................................................................39
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DOC REF: WH40H3N - ISSUE 1, MAY 02
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CONTENTS
OPERATING INSTRUCTIONS.........................................................................41
4.1
Controls and Indicators...................................................................................... 41

4.1.1
4.1.2
4.2
Preparation for Starting...................................................................................... 43

4.2.1
4.3
Under Normal Conditions ..................................................................................44

After An Emergency Stop ..................................................................................45
Running ............................................................................................................. 45
4.4.1
4.4.2
4.4.3
4.5
Before Operating the Machine (Pre-Start Checks) .............................................44
Starting the Compressor .................................................................................... 44

4.3.1
4.3.2
4.4
Starter System...................................................................................................41
Load Control System Functions .........................................................................42
Running Checks ................................................................................................45

Automatic Operation..........................................................................................45
Faults/Hazards ..................................................................................................45
Stopping the Compressor .................................................................................. 46

4.5.1
4.5.2
Normal Stopping................................................................................................46
Emergency Stopping .........................................................................................46
4.6. Fault Indications ................................................................................................ 46

4.6.1
Fault Finding .....................................................................................................47
COMPRESSOR MAINTENANCE.....................................................................51
5.1
Preventive Maintenance .................................................................................... 51

5.1.1
5.2
Maintenance Schedule ......................................................................................51
Maintenance Instructions ................................................................................... 56

JOB No. 001 CRANKCASE OIL CHANGE.....................................................................57
JOB No. 002 FIT PISTON ROD CLAMPS......................................................................59
JOB No. 003 CYLINDER TOP COVERS - REMOVE & REFIT.......................................60
JOB No. 004 PISTON RINGS - REMOVE & REFIT .......................................................62
JOB No. 005 PISTON/CYLINDER END CLEARANCES - INSPECTION........................68
JOB No. 006 PACKING GLAND ASSEMBLY - REMOVE & REFIT................................70
JOB No. 007 PACKING GLAND ASSEMBLY - OVERHAUL ..........................................74
JOB No. 008 PISTON ROD OIL SHEDDER - REMOVE & REFIT ..................................76
JOB No. 009 OIL SCRAPER GLAND - REMOVE & REFIT............................................78
JOB No. 010 SUCTION & DELIVERY VALVES - REMOVE & REFIT.............................79
JOB No. 011 SUCTION & DELIVERY VALVES - OVERHAUL.......................................81
JOB No. 012 SUCTION VALVE UNLOADER ACTUATORS - REMOVE & REFIT..........83
JOB No. 013 PISTON RODS - REMOVE & REFIT ........................................................85
JOB No. 014 OIL FILTER - REMOVE & REFIT..............................................................86
JOB No. 015 OIL PRESSURE RELIEF VALVE - ADJUSTMENT ...................................86
JOB No. 016 LUBRICATING OIL PUMP AND DRIVE - INSPECT & OVERHAUL ..........87
JOB No. 017 INTERCOOLER - INSPECT & OVERHAUL ..............................................87
5.3
Lists of Tools ..................................................................................................... 88

5.3.1
5.3.2
5.4
Commercially Available Tools List......................................................................88

Specialist Service Tools List ..............................................................................89
Waste Products ................................................................................................. 90

5.4.1
5.4.2
Oil - After Oil Changes.......................................................................................90

Coolant .............................................................................................................90
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CONTENTS
SPARE PARTS ................................................................................................92

6.1
6.2
6.3
Ordering Spares and Spares to be Held in Stock............................................... 92

Spares List......................................................................................................... 93
Illustrated Parts List - Main Component Location View ...................................... 95
Fig 1 Crankcase Assembly (2-03-288)...........................................................................96
Fig 2 Connecting Rod Assembly (2-76-426)...................................................................97
Fig 3 Crankshaft Assembly (2-06-383)...........................................................................98
Fig 4 Main Guide Assembly (2-07-280)..........................................................................99
Fig 5 Bearing End Cover Assembly (2-25-121) ............................................................100
Fig 6 Flywheel End Cover Assembly (2-25-123) ..........................................................101
Fig 7 Second Stage Piston Rod Assembly (2-30-144)..................................................102
Fig 8 Third Stage Piston Rod Assembly (2-30-202)......................................................102
Fig 9 Crosshead Assembly (2-31-066).........................................................................103
Fig 10 Oil Pump and Cooler Assembly (2-34-562) .......................................................105
Fig 11 Piston Rod Scraper Assembly (2-63-047) .........................................................106
Fig 12 Crosshead Assembly (2-31-067).......................................................................107
Fig 13 First Stage Piston Rod Assembly (2-30-252).....................................................108
Fig 14 First Stage Cylinder Assembly (2-01-908) .........................................................110
Fig 15 First Stage Top Cover Assembly (2-04-467)......................................................111
Fig 16 Distance Piece Assembly (2-07-414) ................................................................112
Fig 17 First Stage Piston Assembly (2-28-660) ............................................................113
Fig 18 First Stage Packing Box Assembly (2-64-285)...................................................114
Fig 19 First Stage Suction Valve Assembly (2-70-489).................................................115
Fig 20 First Stage Delivery Valve Assembly (2-70-490)................................................116
Fig 21 Second Stage Cylinder Assembly (2-01-531) ....................................................118
Fig 22 Second Stage Top Cover Assembly (2-04-274).................................................119
Fig 24 Second Stage Piston Assembly (2-28-481) .......................................................121
Fig 25 Second Stage Packing Box Assembly (2-64-286) .............................................122
Fig 26 Second Stage Suction Valve Assembly (2-70-503)............................................123
Fig 27 Second Stage Delivery Valve Assembly (2-70-504)...........................................124
Fig 28 Third Stage Cylinder Assembly (2-01-481)........................................................126
Fig 29 Third Stage Top Cover Assembly (2-04-305) ....................................................127
Fig 31 Third Stage Piston Assembly (2-28-523) ...........................................................129
Fig 32 Third stage Packing Box (PSB032-060) ............................................................130
Fig 33 Third Stage Suction Valve Assembly (2-70-236) ...............................................131
Fig 34 Third Stage Delivery Valve Assembly (2-70-237) ..............................................132
Fig 35 First Stage Interstage Pipework Assembly (2-71-780) .......................................134
Fig 36 Second Stage Intercooler Assembly (2-71-781) ................................................136
Fig 37 Cooling Water Assembly (2-45-2515)................................................................138
Fig 38 Pressure Gauge Assembly (2-46-1250) ............................................................141
Fig 39 Unloader Assembly (2-68-642) .........................................................................144
Fig 40 Ancillaries (2-150-055)......................................................................................145
APPENDICES
Appendix 1
Appendix 2
Appendix 3
Safe Working Limits

Warranty Authorisation Claim Form
Compressor Log Sheet
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CHAPTER 1
TECHNICAL DATA &
COMPRESSOR DESCRIPTION
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CHAPTER 1 - TECHNICAL DATA &

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.WH40H3N Serial No. 8759).
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)
Air Delivery - 1st stage
0 - 7 Bar G
2.3 - 2.9 Bar G
Air Delivery - 2nd stage
0 - 30 Bar G
11.8 - 13.2 Bar G
Air Delivery - 3rd stage
0 - 76 Bar G
45.0 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.
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Flows and Capacities
Cooling Water
Flow**
36 m3/h (nominal)
24 m3/h (min)
Pressure
7 Bar G (max)
4 Bar G (min)
Temperature
Inlet
** The cooling water flows are design

estimates and may need to be adjusted at
site to meet the exact cooling requirements.
It is recommended that the compressor is
monitored during its initial running period and
that a record is kept of the flows and
temperatures for future reference.
38 C. (max)
16 C. (min)
Compressed Air Data
Crankcase Data
Gas being compressed
AIR
Oil Sump Capacity
Delivery Pressure
45.0 Bar G
Air Capacity
2220 m3/h
Inlet Temperature
0-45 C
Relative Humidity
0 - 100%
91 litres
1.1.2 Compressor Data

Installation Data
Instrument Air:
Component Weights
Normal Operating Range
7 bar g
minimum
Compressor Weight
9000 kg.
(without motor).
Maximum Pressure
10 bar g
Service/
Maintenance Lift
1000 kg
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)
1st Stage Cylinder Bore
515.00 mm
Piston Top to Top Cover
2.8 - 3.1 mm
2nd Stage Cylinder Bore
287.75 mm
Piston Bottom to Cylinder
1.2 - 1.8 mm
3rd Stage Cylinder Bore
165.10 mm
Piston Stroke
165.10 mm
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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:
1st Stage
4.65 - 4.81mm
2nd Stage
3rd Stage
3.37 - 3.55mm
3.25 - 3.45mm
First Stage Piston Rings
First Stage Bearer Ring
Radial Thickness
18.67 - 18.92 mm
Radial Thickness
11.53 - 11.67mm
Axial Clearance in
Groove
Gap at Butt Joint
0.27 - 0.32mm
Axial Clearance in
Groove
Gap at Joint
0.50 - 0.55mm
Diametrical Clearance
in Cylinder
Standout from Piston
Body
1.66 - 2.10mm
11.21 - 13.31mm
Second Stage Piston Rings

Radial Thickness
Axial Clearance in
Groove
Gap at Butt Joint
1.31 - 1.55mm
Second Stage Bearer Ring
15.21 - 15.39mm
0.27 - 0.32mm
8.00 - 8.50mm
Third Stage Piston Rings

Radial Thickness
Axial Clearance in
Groove
Gap at Butt Joint
(Each Gap)
15.73 - 18.82mm
Radial Thickness
Axial Clearance in
Groove
Gap at Joint
9.15 - 9.25mm
0.38 - 0.43mm
in Cylinder
Body
0.55 - 0.80mm
8.00 - 8.50mm
1.31 - 1.41mm
Third Stage Bearer Ring
9.47 - 9.58mm
0.21 - 0.36mm
3.86 - 4.88mm
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Radial Thickness
Axial Clearance in
Groove
Gap at Joint
9.27 - 9.37mm
0.71 - 0.91mm
in Cylinder
Body
0.57 - 0.89mm
6.35 - 7.11mm
0.21 - 1.42mm
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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
Crankshaft Bearings (radial clearance)
0.06 - 0.11mm
Connecting Rod Bottom End Bearing
0.10 - 0.15mm
0.20mm
Connecting Rod Top End Bearing
0.10 - 0.07mm
0.15mm
Crosshead to Main Guide Slide
0.22 - 0.30mm
0.38mm
Compressor Performance Data

Speed
Direction of Rotation
Compressor Absorbed Power
Drive Type
Heat radiated (at full load)
Cylinder Type
Load Control System
735 rpm
Clockwise: looking on flywheel
365 kW
Direct drive shaftless motor
365 kW (approx)
Double acting non lubricated
3 Step (Full-load or Half-load or No-load).
Safety Device Data

Pressure Relief Valve Data:
Safety relief valve settings:
1st Stage
nd
2 Stage
rd
3 Stage
Lubricating oil pump relief valve setting
3.5 Bar G
15.0 Bar G
47.8 Bar G
5.5 Bar G
Setting of Protection Switches/Devices

High air temperature (AST)
High air temperature (Separator)
Low lubricating oil pressure
Low cooling water flow
177 C (rising)
65 C (rising)**
1.8 Bar G (falling)
65% of normal flow (falling)
** Switch is factory set to 65 C. for temperate (UK type) climates. The switch may be
adjusted up to a maximum of 75 C. to suit tropical climates during or after installation.
However, adjustments MUST only be performed by a competent, authorised person.
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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)
*39.0 Bar G. (unload trip)
*37.0 Bar G. (reload trip)
Pressure Switch 2 (PS2)
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
Sound Power Level
90 dBA at 1m
2
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
Flywheel End Cover
Oil Pump to End Cover
Crankcase Access Covers
Scraper Gland Fasteners
Flywheel Retaining
M20
M16
M8
M10
M12
M42
190 - 210
65 - 72
15 - 20
25 - 30
45 - 55
375 - 400
M20
M24
M6
190 -210
200 - 220
10 - 15
M24
M20
M20
M24
M24
330 - 364
128 - 140
178 - 215
330 - 364
200 - 220
DISTANCE PIECE COMPONENTS:

Distance Piece to Crankcase
Cylinder to Distance Piece
Distance Piece Access Cover
1ST STAGE CYLINDER COMPONENTS:

Cylinder/Top Cover
Valve Covers
1st Stage Suction/Delivery Valve Nut
Inlet/Outlet Flange
Packing Gland Fasteners
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Component
Thread
Size
Torque Nm
(Newton metres)
M20
M20
M16
M20
190 -210
128 - 140
98 -108
128 - 140
M24
M20
M24
M20
330 - 364
128 - 140
330 - 364
128 - 140
2ND STAGE CYLINDER COMPONENTS:

Cylinder to Top Cover
Valve Covers
Inlet/Outlet Flange
3RD STAGE CYLINDER COMPONENTS:

Cylinder to Top Cover
Valve Covers
Inlet/Outlet Flange
MOTION WORK COMPONENTS:

5
Crosshead Nut to Crosshead

Piston Nut to Piston
1/ /8 BSF
5
1/ /8 BSF
950 - 1050
950 - 1050
1.1.4 Materials of Construction

Crankcase & bearing end cover, main guides (for
crossheads), distance pieces, cylinders & cylinder
top covers valve cages and covers, packing gland
containers
Crankshaft
Crankshaft Main Bearings
Connecting Rods & Crossheads
Connecting Rod End Bearing
Top
Bottom
Crosshead Gudgeon Pin

Piston Rod
Oil Scraper Gland Rings/Springs
Packing Gland Rings/Springs
Packing Boxes
Piston
st
1 stage
2nd stage
rd
3 stage
Piston Rings:
Valve Seats and Guards,
Valve Plate, Damper Plates, Lift Washers, Springs
and Bolts
Fixed tubeplates Intercoolers & aftercoolers
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Cast Iron - Gr 250, BS1452
S.G. Iron - Gr 420/12, BS2789

Steel (spherical roller)
S.G. Iron - Gr 600/3, BS2789
Lead-Bronze
Lead-Copper on Steel Shells
Case Hardened Steel
Carbon Steel - 605M36T, BS970
surface hardness 485 Brinell
Stainless Steel
PTFE/Stainless Steel
Stainless Steel
Aluminium - LM16TF, BS1490
Cast Iron Gr 250, BS1452
Cast Iron Gr 250, BS1452
PTFE
Carbon Steel Zinc Plated
Stainless Steel
Carbon Steel with copper tubes +
bonded inserts
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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.
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:
W
H
40
H3
N
Denotes cylinder configuration

Denotes multi-stage compression
Denotes normal capacity
Denotes high pressure three stage
Denotes oil free cylinder operation
External View of WH40H3N PET Compressor
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1.2.3 Compressor Operation
The compressor operates by drawing air from atmosphere via an efficient air filter and
silencer system into the 1st stage cylinder where it is compressed to approximately 3
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 11 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.
The single throw, cast high-tensile iron, crankshaft has integral design counterbalanced 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.
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.
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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 pressedin 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
flanges 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.
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1.2.5 Cylinders, Pistons and Piston Rod Packings
Cylinders
The double-jacketed cylinders are cast complete with mounting base, lower valve
chambers and housing for piston rod packing assembly. They have machined faces for
the top cover; lower mating flange, valve covers, distance rings and valves, and air and
water inlets and outlets. The inner jacket of the cylinder is for the cooling water, the
outer jacket is divided into suction and delivery air chambers.
The cylinder top covers are cast with integral valve chambers, cooling water passages
and suction and delivery air chambers. They 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 containing oil scraper packings.
These 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 pipes, around the compressor cylinder water jackets and cylinder
top covers.
Pistons and Rings
The 1st & 2nd stage pistons are of a two-piece hollow construction with the 3rd stage
piston being of solid construction. Each piston is machined with piston-ring grooves
with the centre body of each piston drilled and recessed to take the piston rod.
Piston Rods and Packings
The 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 the crosshead.
The oil-free cylinder compressor has separate packing gland assemblies. The packing
comprises multiple pairs of PTFE rings, each pair of rings being housed in a container
and held against the piston rod by a garter spring. The containers are assembled to a
base by long studs and nuts, and the assembly held in its housing in the base of the
cylinder by 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 housed in the crosshead-guide loose plate and
comprises a number 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 also fitted to the piston rod between the packing and the scraper
assemblies to prevent any oil-creep along the rod.
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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 brush-less 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).
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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 - compressor
C.
low cooling water flow indicator and alarm
d.
high outlet air temperature indicator and alarm - aftercooler
e.
pressure relief valves after each of the cylinders
f.
pressure relief valve after the oil pump
Faults 'a' to 'd' (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 'e' results in the release of
pressurised air to atmosphere by the relief valve immediately after the over pressured
cylinder. During normal operation 'f' 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.
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CHAPTER 2
SAFETY INFORMATION
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CHAPTER 2 - SAFETY INFORMATION
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 brought 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 COSH 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/herself 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.
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2.1.3 Organisational Measures
It is the customers 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 buildup between the cylinder discharge flange and in line equipment (e.g., stop valve, nonreturn 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.
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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)
3)
4)
5)
6)
7)
8)
9)
10)
Affix "NOT TO BE USED" boards to the compressor and control cabinet.

Isolate the compressor from the discharge main and the instrument air.
Before opening up the machine, all pressurised compartments MUST be
depressurised down to atmospheric pressure in a safe and controlled
manner.
Isolate the compressor from the cooling water supply and drain all relevant water
containing compartments.
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.
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.
Always refer to the applicable procedure when undertaking maintenance and
overhaul procedures.
Bolts and nuts must not be under or over tightened, see appropriate torque
values in Chapter 1 Section 1.1.3.
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.
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11)
12)
DO NOT place the electrical isolating switch to the 'ON' position until your
supervisor has inspected and approved the work carried out.
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.
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CHAPTER 3
INSTALLATION
&
COMMISSIONING
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CHAPTER 3 - INSTALLATION &

COMMISSIONING
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 nonrigid (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 example, a 365kW water-cooled compressor would require some 486 m3/min of
ambient air circulation to limit the compressor room temperature rise to 6C. Natural
convection is normally adequate with the outlet vents at a high level to prevent the
temperature building down from the roof.
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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
isolators 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.
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COMMISSIONING
Delivery System
The flexible 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 below.
'X' and 'Y' dimensions for standard units are usually identical but these can be unequal
to suit specific installations.
Whatever dimensions apply at x and y, this instruction remains totally applicable.
For new pipes, x and y are maintained by the presence of "Tie-Bars" to ensure
correct installation. Once installed, the Tie-Bars must be removed before the
machine is operated.
Hose must be mounted in the position shown above, where one leg is completely
horizontal and the other completely vertical and fully supported at its connection: no
other position is allowable.
When fitted statically, hose must be free of all imposed stresses such as 'torsional',
'distortional', 'compressive', 'tensional' etc.
MOVEMENT DURING RUNNING
(A)
During start-up only:
Frequency up to 12.5 Hz.

20 mm movement in any plane
0.5 about any axis
(B)
During normal running
Frequency up to 25 Hz.
< 3 mm movement in any plane
< 0.25 about any axis
The pipe must be well supported to avoid strain on the compressor cylinders, and it's
configuration be such that any expansion effect, due to the air/gas temperature rise for
whatever reason, can adequately be dissipated within the natural elasticity of the
pipework leading from the compressor and cannot act back on the cylinder.
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COMMISSIONING
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.
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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 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 20C to 35C
In situations where the ambient temperature is in excess of 35C., 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.
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COMMISSIONING
3.2.5 Cooling Water (Cont)

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 12C being usual.
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
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. It MUST be noted
that the Centre of Gravity (C of G) for each machine will change depending on whether
the compressor is 'bare-shaft' or fitted with a 'drive unit'.
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).
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Compressor Slinging Diagram (Typical)
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.
a.
b.
c.
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.
In the case of a bare shaft compressor, a sling is passed round the intercooler
pipework.
If the compressor is fitted with a flywheel, a balancing sling is passed around the
shaft.
WARNING!
Under no circumstances use the motor lifting hole for balancing the weight
(this lifting point is for the motor only when detached or detaching from the
compressor).
Care MUST be taken to ensure that no small bore pipes or other components being
trapped by slings.
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3.3.3 Lifting Instructions
Because the type of lifting equipment for each installation will be different the following
instructions have been 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.
2.
3.
4.
5.
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.
Know your equipment, and anticipate potential hazards.
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.
Prepare the installation area before moving the machine.
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.
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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.
2.
3.
4.
5.
Ensure that the underfaces of the compressor feet are clean.

Bolt the anti-vibration mountings on to the compressor feet.
Move the compressor into position and mark on the floor the position of the
holding down bolt holes in the anti-vibration mounting plate.
Remove the compressor and attached mounts and drill the floor for appropriate
size holes for the Raw-bolt shells.
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).
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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.
If any mount is compressed solid, levelling must be carried out on the free
mounts to redistribute the load.
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).
If NOT, then adjust again until satisfied.
3.
4.
5.
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.
2.
3.
4.
5.
6.
Remove the 'mouldable' wrapping from around the piston rods and clean the rod
surfaces.
Remove control piping from cylinder valve covers marked with adhesive labels
and remove the covers.
Extract the silica gel bags from the valve chambers; ensuring that where more
than one bag is present, ALL bags are removed.
Using a plastic or soft metal scraper, remove rust resistant paint from the seating
in the valve chambers.
Remove the valve assemblies from their wrappings.
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.
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COMMISSIONING
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18
19.
20.
Tighten the valve covers and refit the control air pipes
Remove and store the adhesive labels and warning plates with the silica gel
bags.
Check that all gauges and small-bore pipework are undamaged, and are properly
connected.
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.
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.
Ensure free movement of compressor motion by turning the crankshaft round a
number of times in the correct direction of rotation.
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.
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).
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.
Refit the crankcase and crosshead access covers.
Ensure that the compressor pressure instrument isolating cocks are open.
Ensure that the pipes of the rubber filling plugs are removed to vent the gauge
cases and allow correct gauge indication.
Ensure that the pressure signal pipelines of the load control system are open
(i.e., make certain that any isolating valves are fixed open).
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.
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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.
2.
3.
4.
5.
Ensure that the factory delivery mains and air using equipment are safe to
pressurise - and all delivery isolating valves in the system are open.
Ensure that the load control sensing pipework is open to the compressed air
main.
Ensure that the isolating cocks of all pressure gauges are open.
Ensure that the by-pass valves situated at the drain traps are closed.
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.
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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.
8.
9.
10.
Refit the crankcase main doors and reconnect the compressor.

Run the compressor for a further 10 minutes and repeat checks as in step 6.
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.
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.
2.
3.
Run the compressor until it attains operational temperature and check that the oil
pressure settles at a satisfactory level, approx. 3.5 Bar or above; this will depend
upon ambient temperature, oil viscosity at running temperature, and on-load/offload running pattern.
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.
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 10o to 12o C.
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CHAPTER 4
OPERATING INSTRUCTIONS
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CHAPTER 4 - OPERATING INSTRUCTIONS
OPERATING INSTRUCTIONS
These instructions are designed to providing experienced operatives, who are fully
conversant with compressor operating techniques, with operational information for the
Gardner Denver Belliss & Morcom 'PET' range compressors.
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.
It is the customer's responsibility to:
1)
2)
3)
Maintain the inlet filter system and air blast cooler in a clean condition as dictated
by site conditions.
Ensure that the specified, clean lubricant is added to ensure the correct
crankcase oil level is maintained
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.
4.1 Controls and Indicators

4.1.1 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)
2)
3)
4)
Automatic Star/Delta starter.

Pushbutton operated Start and Stop, adjustable timers with overload protection.
'Unload/Manual/Auto' selector switch for operation mode selection.
Transformer providing 110 volts a.c. and 24 volts d.c. for control and fault
protection equipment.
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5)
Four fault protection units giving alarm and shutdown on:

Low lubricating oil pressure
High discharge air temperature - compressor
6)
7)
8)
9)
10)
11)
12)
13)
High outlet air temperature - aftercooler

Low cooling water flow
'Test' pushbutton to check panel lamps.
'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 (with selector in Unload or Manual only).
Pressure switches and solenoid valves to give 3 step load control with automatic
unloaded starting and stopping.
A panel mounted mains isolator, interlocked with the start circuit.
Ammeter for motor drive current.
'Hours Run' meter.
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).
If a plc panel is supplied - please refer to separate instructions.
4.1.2 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
open then the compression can take place. If all suction valves are held open then 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. If only the upper set of suction
valves are held open then the compressor is on 'HALF LOAD'.
Three-Step Load Control means that the compressor is either on:FULL LOAD (compression taking place) - all suction valves being in service
or
HALF LOAD (compression taking place in bottom half of cylinder only) - lower set of
suction valves only in service.
or
OFF LOAD (no compression taking place) - all suction valves being held open.
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A complete 'Full Load' to 'Half Load' to 'Off Load' and return to 'Half Load' and 'Full Load'
sequence occurs as follows:The Compressor is on FULL LOAD
Assuming the compressor is running on Full 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 pressure switch (PS2), PS2 will de-energise
solenoid valve (SV2). This will then allow pneumatic signal to pass into the small-bore
pipework interconnecting the upper set of suction valve actuators. This causes the upper set
of suction valves to be held open and the compressor therefore runs on Half Load.
The Compressor is now on HALF LOAD
Assuming that pressure in the delivery main is still rising - when the pressure rises to the
upper limit of pressure switch (PS1), PS1 will de-energise solenoid valve (SV1). This will
then allow pneumatic signal to pass into the small-bore pipework interconnecting the lower
set of suction valve actuator. This causes the lower set of suction valves to be held open and
the vent valves to vent to atmosphere (blow down), thereby reducing the pressure within the
compressor to atmospheric levels.
The Compressor is now OFF LOAD
Assuming the pressure in the main now begins to fall (as insufficient air is being supplied to
meet the demand), and the low air limit of PS1 is reached, then PS1 will energise SV1. This
will then isolate the pneumatic signal to the lower set of suction valve actuators and the vent
valves. The lower set of suction valves will re-seat, the vent valves close and the compressor
returns to HALF LOAD operation.
The Compressor is back on HALF LOAD
Assuming the pressure in the main is still falling - when the pressure falls to the lower limit of
PS2, then PS2 will energise SV2. This will then isolate the pneumatic signal to the upper set
of suction valve actuators. The upper set of suction valves will re-seat and the compressor
returns to FULL LOAD operation.
The Compressor is back on FULL LOAD
If at any point of the sequence the demand increases or decreases randomly, then the
pressure switches react to maintain the compressor load function at the required level to
meat the change demands.
The set points of the pressure switches are given in Chapter 1 - Technical Data.
4.2 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.
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4.2.1 Before Operating the Machine (Pre-Start Checks)
1)
2)
3)
4)
5)
6)
7)
8)
9)
Establish that it is safe to discharge high-pressure air into the delivery lines.
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.
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.
Ensure that all of the fault warning, annunciators are extinguished and that the
compressor is safe to start.
Check oil level in sump. Correct level is halfway up window nut in front face of
crankcase.
If the machine has been standing idle for some time it may be necessary to prime
the oil pump.
Ensure that the cooling water supply valve is open promoting water circulation
through the compressor jackets, intercoolers, aftercooler and oil cooler.
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.
Ensure that the main air-isolating valve is OPEN.
4.3 Starting the Compressor

4.3.1 Under Normal Conditions
Step
1) Turn the main isolator to the 'ON' position
2) Press the 'CONTROLS ON/RESET'
illuminated pushbutton to reset the Safety
Relay
3) Press the 'RESET' pushbutton to
energise the fault monitoring relays FR1
to FR4. (press the 'RESET' push-button
only with the selector in UNLOAD or
MANUAL)
Supplementary Information
The 'SUPPLY ON' lamp will illuminate.
The hazard lamps will illuminate to
indicate they are all operational.
This removes the supply from the hazard
lights whilst retaining their respective
relays
Ensure that the 'TRIPPED' indicator is extinguished, if illuminated reset thermal

overload (OL1) and/or thermistor relay (THR1).
4) Select 'MANUAL' on the 'UNLOAD/
MANUAL/AUTO' selector switch
5) Press the 'START' pushbutton.
The Hours Run Meter will be energised as

soon as the 'START' pushbutton is pressed.
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 deenergise 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.
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The commissioning timer (CTD) will be energised when the start relay (SR1) is
energised. The commissioning timer (CTD) should be set for approximately 15
seconds. After this time period has elapsed 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.
4.3.2 After An Emergency Stop
Rectify fault condition and proceed from Step 2 of 4.3.1 Starting Compressor Under
Normal Conditions.
4.4 Running
4.4.1 Running Checks
1.
2.
3.
4.
5.
6.
Allow the compressor to run up to full speed and then close the small drain
cocks.
Check the oil pressure. This will fall initially as the oil temperature rises, but
should steady at between 1.8 to 4.0 Bar G even in a hot environment.
Check the cooling water is flowing at the visible outlet or flow indicator. On multicompressor installations balance the flows in the parallel systems of the
compressors (including intercooler) to give equal water temperature rise across
both - ideally 11C.
Check all automatic drain traps for unusual discharge.
Check all temperatures and pressures periodically.
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.
4.4.2 Automatic Operation
Before Automatic Operation is selected, the compressor must be prepared for starting
as described in 4.2.1 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.
4.4.3 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. This will automatically stop the motor via the motor starter.
The compressor will be automatically unloaded via the CTD timer, which will be deenergised by the motor starter.
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4.5 Stopping the Compressor

4.5.1 Normal Stopping
Step
1) Select the 'UNLOAD' position on the
'UNLOAD/MANUAL/AUTO'
selector
switch. The 'NO LOAD' indicator lamp
will illuminate.
2) Press the 'STOP' pushbutton.
This ensures that the compressor is
fully unloaded before stopping. This will
allow moisture to be purged from the
cylinders.
The compressor will stop automatically
in a controlled manner.
3) Close the main isolating shut-off valve.

4) Open vent valves.
To fully de-pressurise system
5) Close the cooling water supply valve.
To prevent unwanted circulation of
water
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.
4.5.2 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.
4.6. 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.
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4.6.1 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
Low first stage delivery
pressure (normal or
low first stage air
delivery temperature).
Low first stage delivery
pressure (high first
stage air delivery
temperature).
High first stage

delivery pressure
(normal or high first
stage delivery
temperature.
High first stage air

delivery temperature
after cooler.
First stage delivery
pressure relief valve
blowing.
Low second stage

delivery pressure
(normal or low second
stage delivery
temperature).
Possible Cause
1) Leaking or broken suction valve
plate in first stage.
Remedial Action
Replace valve plate -examine seat
for damage.
2) One or more 1st stage suction

valve depressor(s) sticking in
"off-load" position.
1) Fouling of inlet filter.
Remove, clean and refit

depressor(s) - examine valve for
damage
Renew filter elements.
2) Leaking or broken delivery

valve plate in first stage.
3) Worn, broken or malfunctioning
piston rings in first stage.
plate in second stage.
2) Second stage suction valve
depressor sticking in "off-load"
position.
piston rings in third or second
stage cylinders.
1) Cooling water flow through first
stage intercooler restricted or
ceased by blockage.
valve plate in second stage.
piston rings in third stage.
3) First stage intercooler tubes
blocked on air side.
4) Relief valve defective.
Replace valve plate - examine seat

for damage.
Renew rings - clean grooves.
Replace valve plate - examine seat
for damage
Examine, clean, and refit valve
plate depressor, also examine
valve for damage
Examine and clean intercooler

tubes (both on air and water sides).
Replace valve plate -examine seat
for damage.
Examine and clean air side of
intercooler tubes.
Repair or fit new valve.
Replace valve plate examine seat
for damage.
2) Second stage suction valve

position.
Remove, clean and refit depressor,

also examine valve for damage.
Low second stage

delivery pressure (high
second valve stage
delivery temperature).


for damage.

piston rings in second stage.
High second stage

delivery air pressure
and temperature

plate in third stage.

for damage.
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Fault
High second stage air
delivery temperature
after intercooler
Second stage delivery
pressure relief valve
blowing.
Low third stage

delivery pressure.
High third stage

delivery temperature.
High third stage

delivery pressure
(relief valve blowing).
Possible Cause
1) Cooling water flow through
second stage intercooler
restricted or ceased blockage.
or delivery valve plate in third
stage.
2) Third stage suction valve
position.
3) Second stage intercooler tubes
blocked on air side.
1) Demand of end using
equipment has overtaken
capacity of compressor.
2) Low setting of load controller.

3) Malfunction of load controller.
valve plate in third stage.
plate in third stage.
3) Third stage suction valve
position
piston rings in third stage.
1) Isolating valve, between
compressor and delivery main
closed or partially closed.
2) Incorrect setting or malfunction
of load controller.
3) Restriction or blockage of
control signal to compressor
unloader system.
4) Aftercooler tubes blocked or
restricted on air side.
5) Seized closed, or partially
closed non-return valve in
delivery main (if fitted).
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Remedial Action
Examine and clean intercooler
cooler tubes (both on air and by
water sides)
for damage
intercooler tubes.
Repair or replace valve.
If none of the previous faults are
present, i.e. compressor running
normally, no remedial action
possible.
When demand reduces, the
pressure will rise to normal level (as
set by the load controller).
Adjust to required pressure.
Repair/replace pressure controller.
for damage.
for damage.
Renew rings and clean piston ring
grooves.
Open valve.
Adjust to required pressure or
repair/replace pressure controller.
Remove restriction.
aftercooler tubes.
Repair valve.
Repair or fit new valve.
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Fault
High final air
temperature from
aftercooler.
Low lubricating oil

pressure.
Loss of oil pressure.
Possible Cause
1) Cooling water flow through
aftercooler is restricted or
ceased by maladjustment of
hand valves.
2) Aftercooler tubes partially
blocked on airside, or waterside
of tubes is fouled.
1) Crankcase oil level is low.
2) Air leakage into suction side of
pumping system.
3) Partially blocked oil pump
suction strainer in crankcase.
4) Oil relief valve set too low or
valve sticking open.
5) Failure or wear of big end or
small end bearings.
6) Partially blocked oil pump
delivery filter element.
1) Compressor rotation incorrect
(first trial run, or after a rebuild).
2) Crankcase oil level very low.
3) Serious air leakage into oil
pump section pipe or complete
disconnection.
4) Complete blockage of oil pump
suction strainer.
5) Oil pump drive failure.
6) Oil pump seizure.
No condensate from
drain trap of interstage
moisture separator or
aftercooler moisture
separator.
Large quantity of
condensate emitted
from drain trap.
1) Drain trap blocked.

2) Separator drain pipe to trap
blocked.
3) Dry atmospheric conditions.
1) This suggests that there is an
internal leakage from the
cooling water spaces into the
air spaces of the compressor
(low pressure stage).
Remedial Action
Check and adjust hand valve
openings.
Examine and clean air and water
sides of tubes.
Check oil level, add oil as required.
Check oil level. Check connecting
unions on suction pipe to pump.
Remove, clean and refit.
Remove, check and reset.
Renew bearing(s). Check
crankshaft for damage.
Replace element.
Change compressor rotation and
recheck
Check oil level, add oil as required.
Check suction pipe and unions to
pump.
Check and clean oil sump.
Remove, clean and refit strainer.
Change oil as necessary.
Examine drive coupling, ascertain
cause of failure and rectify.
Replace pump. Check drive
coupling.
Dismantle, clean and refit.
Dismantle, clean and refit.
Applies to 1st stage only.
Trace the fault and rectify as
necessary.
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.
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CHAPTER 5
COMPRESSOR MAINTENANCE
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CHAPTER 5 - COMPRESSOR
MAINTENANCE
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 guide
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 or adverse environmental conditions.
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.
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.
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MAINTENANCE
EACH DAY
A shutdown of the compressor is not normally required for a Shift inspection.
Tasks
Check all temperature and pressure gauge

readings are normal.
Report immediately any abnormality.
Note: Observe operation of moisture trap drains.
Check for undue noise, oil leakage, vibration or

heat.
Report immediately any abnormality.
Note: Ensure that load control equipment is operating correctly.
Test protection circuits annunciator lamps. All

lamps MUST illuminate
The 'Test' push-button is normally located on the

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

be halfway up the window nut.
Use the breather aperture in the top of the

crankcase to top-up the oil. Refer to the table of
lubricants for oil type.
Note: Where vee belts are fitted check tension and adjust if necessary.
Any aspect of the Shift inspection requiring further attention MUST be reported for action as
required.
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MAINTENANCE
MONTHLY - INSPECTION
A shutdown of the compressor is not normally required for a monthly inspection.
Tasks
Carry out a running examination to ensure

satisfactory operation of all compressor and
ancillary equipment.
Record all temperatures, pressures and hours

run on compressor log sheet.
Note: Check air inlet filter element cleanliness - renew if necessary.
Check the cleanliness and ensure correct

operation of drain traps on compressor and
ancillary equipment where applicable.
Clean drains and renew worn or damaged parts,

as required.
Check all external bolts and nuts on the

compressor including the holding down nuts for
tightness.
Re-tighten or renew any missing nuts and bolts.

Tighten nuts to appropriate torque.
Check air pressure supplied to compressor

unloaders and note pressure drop.
Pressure should be 7 bar minimum at unloader.
Any aspect of the Monthly inspection requiring further attention MUST be reported for action
as required.
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MAINTENANCE
SIX MONTHLY - SERVICE

The compressor is required to be shutdown for two days to perform this service schedule.
Tasks
Carry out a running examination to ensure

satisfactory operation of all compressor and
ancillary equipment.
Record all temperatures, pressures and hours run

on compressor log sheet. A copy of this form is
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

operation of drain traps on compressor and
ancillary equipment where applicable.
Clean drains and renew worn or damaged parts,

as required.
Check all external bolts and nuts on the

compressor including the holding down nuts for
tightness.
Re-tighten or renew any missing nuts and bolts.

Tighten nuts to appropriate torque.
Visually examine (through the valve pockets)

the general surface condition of cylinder bores
for evidence of ring wear or scoring.
Replace worn or damaged parts, as required
Check valve unloaders & interconnecting small

bore pipework for defects.
Clean and service as necessary. Replace worn or

damaged parts as required.
Examine piston rods along gland travel to

ensure no scoring is present.
Clean and service as necessary. Renew worn or

Check that inlet filter is clean
Clean and service as necessary.
Check that inter and aftercooler moisture

drains are operational and that the diffusers on
the blowdown valves are clear and clean..
Clean and service as necessary
Check one suction and one delivery valve from

each stage for cleanliness or fouling.

Renew third stage piston rod packing, piston

rings and rider rings.
Renew worn or damaged parts as required.
Check integrity of all flexible air and water

pipes.
Record condition. Renew worn or damaged parts

as required.
CRANKCASE INSPECTION
Examine crossheads and main guide slipper
paths, condition and clearances.

Check connecting rod bottom end bolts are

pinned.
Rectify as required.
Check that lubrication oil suction strainer is

clean and all pipework to main pump is in good
order and that unions are tight.
Clean and service as necessary. Tighten unions

and renew worn or damaged parts as required.
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MAINTENANCE
SIX MONTHLY - SERVICE (Cont)

Tasks
Check that crankcase oil is clean and no

foreign particles are present. Ensure that oil
delivery filter is clean and that oil pressure is
satisfactory.
If dirty renew crankcase oil and delivery filter

element. If necessary investigate source of any
foreign particles. Refer to table of lubricants for oil
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.
Tasks
Remove all air valves and replace with factory

refurbished units.
Renew crankcase
element.
oil
and
delivery
filter
Refer to table of lubricants for oil type and

quantity.
Inspect connecting rod bottom end shells,

crankpin, top end bearing and gudgeon pin.
Check motion work clearances.

Withdraw pistons and piston rods and examine

wear. Gauge cylinder bores and piston rods for
wear and record readings.
Renew piston rings, piston rod packings, and

piston rod scrapers.
Check condition of water jacket spacers for

fouling from lime deposits.
Report condition.
Check cleanliness of motor ventilation fan and

that air flow paths are clean. Carry out an
insulation resistance check on motor windings
and record readings.

Check all system protection devices and

circuits for correct operation.
Use a calibrated test rig to test the protection

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 jointing 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.
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MAINTENANCE
TABLE OF LUBRICANTS
Lubricant
Crankcase Oil
Recommended Lubricant SAE 30 oil (ISO VG 100)

o
o
(Ambient temperature 0 C to 45 C)
Approved Brands:-
Oil Capacity
91 Litres
BP Vanellus M30
Mobil Delvac 1330
Esso Essolube HDX 30

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.
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MAINTENANCE
JOB No. 001

CRANKCASE OIL CHANGE
LIST OF SPECIAL TOOLS
Description
Thin Spanner (approx. 10 mm thick)
LIST OF CONSUMABLES
Crankcase Oil SAE 30 oil (ISO VG 100) (Normal Operating Conditions)
Industrial cleaning fluid (White Spirit) & lint free cloth
Qty
1
As
required
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.
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 using suitable equipment and clean out the crankcase sump (using
a lint-free cloth, to avoid fouling of the oil strainer).
5)
To avoid oil spillage, never remove the oil suction strainer while oil remains in the
crankcase
6)
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.
7)
Refit the oil strainer and check that all tools and cleaning cloths have been removed
from the crankcase sump.
8)
Refill the crankcase sump with the required quantity of clean, new oil.
9)
Refit the crankcase doors after checking the condition of the door seals.
10)
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.
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MAINTENANCE
JOB No. 001 - CRANKCASE OIL CHANGE (Cont)
Crankcase Assembly
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MAINTENANCE
JOB No. 002

FIT PISTON ROD CLAMPS
Description
Piston Rod Clamps
Qty
1 Set
LIST OF CONSUMABLES
As
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 anti-surge vessel 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.
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MAINTENANCE
JOB No. 003

CYLINDER TOP COVERS - REMOVE & REFIT
Description
Lifting Eye-Bolts
Slings, Lifting Equipment
Qty
1 Set
As
required
LIST OF CONSUMABLES
As
required
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.
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. 004.
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 a new 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.
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MAINTENANCE
JOB No. 003 - CYLINDER TOP COVERS - 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 (centre nuts first), tighten the 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.
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MAINTENANCE
JOB No. 004

PISTON RINGS - REMOVE & REFIT
Piston rod bullet
LIST OF CONSUMABLES
Description
Qty
As
required
To Remove
There are two ways of removing the piston from the compressor: Method 1 is as a unit
without the piston rod (this procedure) and Method 2 as an assembly with the piston rod
attached. This method can be used if the maintenance procedure being performed does not
call for the piston nut to be removed. If Method 2 is to be used the piston removal procedure
is detailed as part of Job No.013 Piston Rod - Remove/Refit.
The '1st stage piston' can only be removed using Method 2.
1)
Remove the cylinder top cover as described in Job No.003.
2)
Remove the crosshead access cover and gasket from the crankcase.
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.
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MAINTENANCE
4)
JOB No. 004 - PISTON RINGS - REMOVE & REFIT (Cont)

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.
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.
7)
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:
8)
Manually 'bar-over' the compressor to turn the piston to TDC and insert diametrically
opposite (IMPORTANT) two equal length pieces of hard wood via valve pockets to
block the piston. Place the wood chocks about 25mm clear of the piston rod sides NOT
at the piston periphery.
9)
Turn the crankshaft to BDC to withdraw the rod.
10)
Carefully turn the compressor back to TDC taking the piston upwards.
11)
Insert longer pieces of hard wood if the piston is still tight on the rod and repeat steps 9
and 10.
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.
12)
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.
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.
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MAINTENANCE

Piston Rings Renew
13) Remove and discard the old piston rings.
14)
Clean piston ring grooves carefully.
15)
Insert the new piston ring squarely into the cylinder bore and check that the bearing
ring standout and axial clearance is correct. Refer to Chapter 1 Technical Data.
Figure Shows Piston Ring Configuration for 1st Stage Piston

16)
Fit the new piston rings by carefully springing them over the piston body (single piece
rings only).
17)
Ensure that the rings are correctly seated in the piston groove.
If the cylinder bore is cored or very lightly polished with no signs of honing marks it may
be necessary to re-hone the bore. (In some cases a flexi-hone can be used!).
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MAINTENANCE
Piston Assembly 1st Stage
Piston Assembly 2nd Stage
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MAINTENANCE
Piston Assembly 3rd Stage

To Refit
1)
Place the piston rod 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.
2)
Fit the top half piston, setting the butt gaps of the pressure rings to opposite sides (i.e.
180o opposed) and carefully lower into place over the rod.
3)
After checking that the pressure relieving hole is clear, fit the top half piston to the
bottom half piston.
4)
Fit the top reinforcing washer onto the piston top half.
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MAINTENANCE

5)
Fit and very lightly tighten the piston nut.
6)
Check that the crosshead locknut is tight in place and, ensuring that the securing pin is
removed from the crosshead, fully tighten the piston nut to the appropriate torque
figure. Refer to Chapter 1 Section 1.1.3.
7)
Measure and record the end ("bumping") clearances with the piston at the top (TopDead-Centre) and bottom (Bottom-Dead-Centre) of its stroke. Refer to Job No.005.
8)
Refit the cylinder top cover as described in Job No.003.
9)
Check the piston bumping clearances against the figures earlier recorded to ensure
that the piston is properly down.
10)
If adjustment is required, adjust as described in Job No.005.
11)
Recheck the tightness of the crosshead locknut and fit and tighten the securing pin with
its locking plate into the crosshead.
12)
Bend over the tab on the locking plate.
13)
Refit the crosshead access cover with gasket and tighten the screws.
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JOB No. 005

PISTON/CYLINDER END CLEARANCES - INSPECTION
LIST OF CONSUMABLES
Description
Sealing Gasket (between 0.8mm - 1.0mm thick)
Qty
As
required
As
required
There are two ways of measuring the piston Top-Dead-Centre (TDC) clearance: Method 1 is
by removing the cylinder top covers 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
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).
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MAINTENANCE
JOB No.005 - PISTON/CYLINDER END CLEARANCES - INSPECTION (Cont)

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
damaged.
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).
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.
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.
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MAINTENANCE
JOB No. 006

PACKING GLAND ASSEMBLY - REMOVE & REFIT
LIST OF CONSUMABLES
Description
Qty
As
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 Only
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.
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.
1st Stage Gland Packing
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MAINTENANCE
JOB No. 006 - PACKING GLAND ASSEMBLY - REMOVE & REFIT (Cont)
7)
2nd Stage Gland Packing

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.
To Refit 1st & 2nd Stage Packing Assemblies Only
CAUTION!
The rings and glands refitted completely without oil (the compressor being an oilfree 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.
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MAINTENANCE
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.
To Remove Third Stage Packing Assembly Only
1)
Drain the cooling water system.
2)
3)
Remove the cylinder top cover, distance piece access doors and the piston and piston
rod assembly. Refer to Job No.004.
3rd Stage Gland Packing

Remove the inlet and outlet cooling water pipes from the packing gland cover.
4)
Whilst supporting the gland assembly, carefully slacken and remove the nuts securing
the gland to the underside of the cylinder.
5)
Slowly lower the gland assembly from its studs into the distance piece, turn the unit
and withdraw it sideways from the machine.
6)
Place the gland assembly onto a clean workbench for disassembly.
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MAINTENANCE
To Refit Third Stage Packing Assembly Only
If refitting 'used' rings first ensure that there is no dirt or grit embedded - examine also the
piston rod surface.
1)
Refit the gland assembly into the pocket on the underside of the cylinder.
2)
Secure in position with nuts and fully tighten.
3)
Refit the inlet and outlet cooling water pipes to the packing gland.
4)
Bar over the compressor a couple of turns to seat the packing rings and ensure
freedom of movement of the line of motion work.
5)
Refit the cylinder top cover, distance piece access doors and the piston and piston rod.
6)
Refill the cooling water system.
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MAINTENANCE
JOB No. 007

PACKING GLAND ASSEMBLY - OVERHAUL
Description
Wear Check Tool
Thread Guard Cap
Qty
1
1
LIST OF CONSUMABLES
As
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 Disassemble
1)
Remove the nuts from the small diameter gland tie studs and separate and
disassemble the containers. As each container ring is lifted off the assembly, take
meticulous care of the precision ground and lapped faces between the containers and
the plates.
2)
Observe carefully that the ring containers and the plates between them are staggered
sequentially, with number 1 being the top container ring.
3)
Observe that the tie studs are unequally spaced to ensure the correct orientation of the
internal water passageways is maintained.
4)
Observe and carefully record the construction and sequence of assembly for the rings,
noting that each ring of segments is marked with matching numbers and letters. In
addition note that there is a peg and hole location in the segmented ring pairs in the
containers with the peg pointing upwards.
5)
As each container is lifted off the assembly, remove and store the packing rings and
carefully retain the various 'O' rings as they become free (it is recommended that 'O'
rings are renewed, if not guard the displaced rings against loss and damage). There is
an 'O' ring on each tie stud as well as around the cooling water spaces (third stage
only)
6)
Observe the condition of the soft metal sealing ring in the top face of the uppermost
gland ring ensure that it is not damaged during handling and storage.
7)
Unscrew the small diameter tie studs from the uppermost container ring.
To Inspect
1)
The packing rings are checked for wear by re-assembling, with garter spring, squarely
around the piston rod, or on the Wear Check Tool and examining the butt clearances.
2)
When parts are new the butts are each approx. 3mm wide; discard the ring when the
butts reduce to 0.5mm.
3)
Examine the soft metal sealing ring on the top-most container of the gland ring to
ensure this is in good condition.
4)
Examine the 'O' rings to ascertain their condition - renew if required. (3rd stage only).
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MAINTENANCE
JOB No. 007 - PACKING GLAND ASSEMBLY - OVERHAUL (Cont)

To Reassemble
Scrupulous cleanliness of all parts is required on assembly, particularly of the lapped faces
between the containers and plates.
1)
Identify and layout the gland components in sequential order in preparation for
reassembly.
2)
Place piston rod/piston assembly onto a clean work-bench resting on the piston crown
with the piston rod pointing upwards so that the rod can be used as an assembly tool.
3)
Thoroughly clean the rod surface and fit the thread guard cap to the rod end.
4)
Thread the packing gland cover plate over the piston rod to rest on the piston.
5)
Locate the lowest ring pair of the packing assembly onto the flange cover recess, first
the ring with the peg pointing upwards, then the ring with the hole located over the peg.
6)
Locate the tie studs (temporarily removed from the top container) in the holes in the
cover to align subsequent containers.
7)
Fit the 'O' rings into the grooves around the cooling water spaces in the cover and
around each tie stud. Great care must be taken not to knock or disturb these during
later stages of assembly (Third stage only)
8)
Progressively build up the gland assembly in the correct numbered sequence of the
plates and containers refitting packing rings and O rings in their correct positions as
noted during dismantling.
9)
When the top container ring is reached, very carefully withdraw the tie studs taking
great care not to shake the assembly.
10)
Firmly screw the tie studs back into their original positions in the top gland ring.
11)
Carefully thread the tie rods back through the gland assembly until the top gland ring
rests squarely onto the top container.
12)
Whilst clamping the assembly firmly to prevent, separation, displacement of 'O' rings or
misalignment, lift the assembly sufficiently to fit the nuts to the tie studs.
13)
Progressively tighten the nuts evenly to clamp the assembly.
14)
Refit the gland assembly as described in Job No.006.
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MAINTENANCE
JOB No. 008

PISTON ROD OIL SHEDDER - REMOVE & REFIT
LIST OF CONSUMABLES
Description
Qty
As
required
The piston rod oil shedder is clamped in halves to the piston rod by socket head screws.
The shedder is fitted so as to run clear of the packing gland and the scraper gland covers. If
the shedder becomes damaged renew as follows:
The oil shedder should only be fitted onto the piston rod when both the oil scraper gland and
packing gland are fully fitted in place.
To Remove
1)
2)
Mark the position of the oil shedder on the rod surface and remove shedder with its two
clamping screws.
To Refit
1)
Place the piston in BDC position and assemble the shedder onto the piston rod with the
hollowed side placed downwards.
2)
Position the shedder 2.5mm above the top face of the scraper gland and lightly but
firmly tighten the two screws.
3)
Turn over the compressor to ensure that the oil shedder does not foul either the upper
packing gland or the lower scraper gland.
4)
When adjustment is satisfactory, fully tighten the shedder clamping screws.
5)
Refit the access cover to the cylinder distance piece.
6)
Two small diameter washers of the required thickness placed either side on top of the
scraper gland are helpful in setting the shedder position - remove the washers
immediately afterwards
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MAINTENANCE
JOB No. 008 PISTON ROD OIL SHEDDER - REMOVE & REFIT (Cont)
Oil Shedder & Scraper Housing
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MAINTENANCE
JOB No. 009

OIL SCRAPER GLAND - REMOVE & REFIT
Description
Wear Check Tool
Qty
1
LIST OF CONSUMABLES
As
required
The support housings of the scraper glands fit directly on to the top of the guide for the
crossheads
To Remove
1)
2)
Lift the plate and slide the upper pair of scrapers up the rod.
3)
Unhook the garter springs and remove the scraper ring segments.
4)
Re-assemble and carefully store each ring of segments immediately upon removal.
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.
5)
Lift the container and slide the lower pair of scrapers up the rod.
6)
Re-assemble and carefully store each ring of segments immediately upon removal.
Oil Scraper Gland - Inspection
7)
The oil scraper rings are checked for wear by re-assembly, with garter spring, squarely
around the piston rod, or on the wear check tool and examining the butt clearances in
the case of ring W1 and W2.
8)
When parts are new the butts of W1 and W2 are each 0.8mm (0.032") wide.
9)
Discard the rings and their sealing rings when the butts reduce to 0.12mm (0.005")
each or a total of 0.36mm (0.015") or less, and replace with a new pair.
The segments of the sealing ring have angle cut contact faces - there are no butt
clearances.
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 (in the case of the inclined cylinders)
positioned lower-most. "TOP" is staggered on the housing.
2)
Remove piston rod clamps.
3)
Bar over the compressor a couple of turns to check for correct operation.
4)
Refit the access covers to the cylinder distance piece.
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MAINTENANCE
JOB No. 010

SUCTION & DELIVERY VALVES - REMOVE & REFIT
LIST OF CONSUMABLES
Description
Grinding Paste
Qty
As
required
As
required
Each valve is installed in an individual pocket. They are fitted with metal-to-metal contact (i.e.
no jointing 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.
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MAINTENANCE
JOB No. 010 SUCTION & DELIVERY VALVES - REMOVE & REFIT (Cont)
1st Stage Delivery Valve (Typical)
1st Stage Suction Valve (Typical)
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MAINTENANCE
JOB No. 011

SUCTION & DELIVERY VALVES - OVERHAUL
Description
Valve Holding Tool
Qty
1
LIST OF CONSUMABLES
As
required
To Remove
1)
Remove the suction delivery valve in accordance with Job No.010.
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.
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MAINTENANCE
JOB No. 011 - 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 (see Chapter 1 - Technical Data).
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MAINTENANCE
JOB No. 012

SUCTION VALVE UNLOADER ACTUATORS - REMOVE & REFIT
LIST OF CONSUMABLES
Description
Qty
As
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
1)
Remove the diaphragm chamber cover and disassemble the unit for examination of the
condition of the diaphragm, spring, bush, spindle and seal ring.
2)
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 buildup).
3)
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.
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MAINTENANCE
JOB No. 012 - 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.
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.
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MAINTENANCE
JOB No. 013

PISTON RODS - REMOVE & REFIT
LIST OF CONSUMABLES
Description
Qty
As
required
To Remove
1)
Remove the cylinder top cover as described in Job No.003.
2)
Remove the piston as described in Method 1, 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 securing pin from the crosshead.
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.
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 guide top.
2)
Remove the cap and fit the crosshead locknut at the crosshead as the rod enters the
guide.
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) 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.
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MAINTENANCE
JOB No. 014

OIL FILTER - REMOVE & REFIT
LIST OF CONSUMABLES
Description
Qty
As
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.
4)
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).
5)
Before assembly of the filter body to its cover, fill the body with clean compressor
lubricating oil.
JOB No. 015

OIL PRESSURE RELIEF VALVE - ADJUSTMENT
LIST OF CONSUMABLES
Description
Qty
As
required
To Adjust
1)
Remove the valve cap.
2)
Slacken the locknut on the adjusting screw and adjust to obtain the required oil
pressure (screw IN to raise the pressure, screw OUT to decrease the pressure).
3)
Tighten the locknut and refit the cap.
4)
Normally adjustment is not necessary after initial setting by the manufacturer. 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 re-assembly is then
required (first noting the valve adjusting screw setting).
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MAINTENANCE
JOB No. 016

LUBRICATING OIL PUMP AND DRIVE - INSPECT & OVERHAUL
LIST OF CONSUMABLES
Description
Qty
As
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.
3)
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.
4)
When refitting the oil pump renew the gasket if the old one has deteriorated.
5)
Prime the suction side of the pump with oil.
6)
Refit the pipework to the oil pump.
JOB No. 017

INTERCOOLER - INSPECT & OVERHAUL
LIST OF CONSUMABLES
Description
Qty
As
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).
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.
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Issue:
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Page:
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88 of 145
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
Standard tool box tools including:A range of open-jaw, ring, and
socket type spanners
A set of hexagonal section
Allen keys (Metric)
Torque wrench
Circlip pliers
Eyebolts
Fitters tools
Long-nosed pliers
Various job locations
Tightening range 0 to 1200 Nm

For removal and refitting crosshead gudgeon pin
retaining circlips.
M24 x 3.0 male thread x 65mm long for cylinder
top cover lifting, M12 x 1.75 (for piston rod lifting).
Feeler (thickness) gauges, standard sizes
Thin ended, for removal of circlip from suction
valve unloader
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Page:
May 2002
89 of 145
MAINTENANCE
5.3.2 Specialist Service Tools List
The following specialised service tools are designed to aid compressor maintenance
work and are available from Belliss & Morcom.
Tool No
MB021-09
MB072-02
MB072-03
MB073-03
PSB038-006
PSB038-008
PSB038-009
PSB038-010
PSB038-011
PSB038-012
PSB038-013
PSB038-014
PSB038-015
PSB038-021
Description
Hexagon nut (M16)
Collared steel eyebolt (M16)
Collared steel eyebolt (M20)
Eyebolt adaptor (M20)
Bearing nut 'C' spanner
Valve cage extractor bridge
Delivery valve cage extractor assembly
Socket spanner - piston rod
Short extension bar 3/4" drive
Drive adaptor
3rd stage valve cage extractor assembly
3rd stage delivery valve extractor stud
3rd stage delivery valve extractor nut
2nd stage (T bar) - delivery valve extractor
Specialist service tools (which can be manufactured locally) or purchased direct from
Gardner Denver Belliss & Morcom, can be used to aid compressor maintenance
work.
Tool
Valve extractor
Valve extractor
Valve holding clamp
Valve supporting details
Piston rod gland wear checking tool
Tool for assembling piston rod packing
gland
Piston rod clamp
Piston rod thread guard cap
Drg No
DD594
DD622
DD816
DD600
DD938
(2nd & 3rd Stage)
(1st Stage)
Use of clamp DD816
DD579
DD615
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Page:
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90 of 145
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.
b.
Avoid contact with the skin and wash off any contamination immediately.
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.
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CHAPTER 6
SPARE PARTS
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CHAPTER 6 - SPARE PARTS
Issue: 1
Date: May 2002
Page: 92 of 145
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 in 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.
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Issue: 1
Date: May 2002
Page: 93 of 145
6.2 Spares List

COMPRESSOR SPARE PARTS
Item
Description
Qty
Part No.
1st Stage Top Cover Gasket
PSB008-108
2nd Stage Top Cover Gasket
PSB008-135
3rd Stage Top Cover Gasket
PSB008-044
3rd Stage Top Cover 'O' Ring
PSB006-008
Crankcase Door Gasket
PSB008-027
Main Guide Door Gasket
PSB008-006
1st Stage Valve 'O' Ring
2-70-310-04
1st Stage Valve Cover 'O' Ring
2-70-310-05
2nd Stage Valve Cage 'O' Ring
MB133-48
10
2nd Stage Valve Cover 'O' Ring
MB133-49
11
3rd Stage Suction Valve 'O' Ring
MB133-56
12
3rd Stage Delivery Valve 'O' Ring
MB133-55
13
Actuator Diaphragm
12
PSB028-003
14
1st Stage Piston Rod Pkg Wrg Parts
1 Set
QAP13-64-C32616A
15
2nd Stage Piston Rod Pkg Wrg Parts
1 Set
QAP13-64-C32616B
16
3rd Stage Piston Rod Pkg Wrg Parts
1 Set
PSB032-061
17
Piston Rod Scraper Wearing Parts
3 Sets
PSB032-004
18
1st Stage Piston Rings
2-28-660-03
19
1st Stage Rider Ring
2-28-660-04
20
2nd Stage Piston Rings
PSB022-027
21
2nd Stage Rider Ring
PSB022-028
22
3rd Stage Piston Rings
PSB022-054
23
3rd Stage Rider Ring
PSB022-055
24
Piston Rod Piston Nut
PSB002-010
25
Oil Suction Strainer
PSB025-005
26
Oil Delivery Filter Element C/W 'O' Ring
PSB025-010
Oil Filter Element 'O' Ring
PSB025-006
Air Inlet Filter Element
NSBP-859-004
26A
27
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Issue: 1
Date: May 2002
Page: 94 of 145
VALVE SPARE PARTS

Item
Description
Qty
Part No.
28
1st Stage Valve Plate
QAP13-70-8754A
29
2nd Stage Valve Plate
PSB027-014
30
3rd Stage Valve Plate
PSB027-006
31
1st Stage Valve Damper Plate
PSB027-074
32
2nd Stage Valve Damper Plate
PSB027-015
33
3rd Stage Valve Damper Plate
PSB027-007
34
1st Stage Suction Valve Spring
48
PSB027-011
35
1st Stage Delivery Valve Spring
48
PSB029-100
36
2nd Stage Suction Valve Spring
32
PSB027-018
37
2nd Stage Delivery Valve Spring
32
PSB029-006
38
3rd Stage Suction Valve Closing Spring
16
PSB027-010
39
3rd Stage Suction Valve Damping Spring
16
PSB027-011
40
3rd Stage Delivery Valve Closing Spring
16
PSB029-006
41
3rd Stage Delivery Valve Damping Spring
16
PSB027-010
42
1st / 2nd Stage Unloader Circlip
PSB027-024
43
3rd Stage Unloader Circlip
PSB027-125
VALVE ASSEMBLIES
Item
Description
Qty
Part No.
44
1st Stage suction valve complete
PSB027-181
45
1st Stage delivery valve complete
PSB029-110
46
2nd Stage suction valve complete
2-70-553-01
47
2nd Stage delivery valve complete
PSB029-085
48
3rd Stage suction valve complete
2-70-517-01
49
3rd Stage delivery valve complete
2-70-518-01
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Page: 95 of 145
6.3 Illustrated Parts List - Main Component Location View
Main Component Location View Key

Fig 1
Fig 3
Fig 5
Fig 7
Fig 9
Fig 11
Fig 13
Fig 15
Fig 17
Fig 19
Fig 21
Fig 23
Fig 25
Fig 27
Fig 29
Fig 31
Fig 33
Fig 35
Fig 37
Fig 39
Crankcase Assembly
Crankshaft Assembly
Bearing End Cover Assembly
Second Stage Piston Rod Assembly
Crosshead Assembly
Piston Rod Scraper Assembly
First Stage Piston Rod Assembly
First Stage Top Cover Assembly
First Stage Piston Assembly
First Stage Suction Valve Assembly
Second Stage Cylinder Assembly
Distance Piece Assembly
Second Stage Packing Box Assembly
Second Stage Delivery Valve Assembly
Third Stage Top Cover Assembly
Third Stage Piston Assembly
Third Stage Suction Valve Assembly
First Stage Interstage Pipework Assembly
Cooling Water Assembly
Unloader Assembly
Fig 2
Fig 4
Fig 6
Connecting Rod Assembly

Main Guide Assembly
Flywheel End Cover Assembly
Fig 8
Fig 10
Fig 12
Fig 14
Fig 16
Fig 18
Fig 20
Fig 22
Fig 24
Fig 26
Fig 28
Fig 30
Fig 32
Fig 34
Fig 36
Fig 38
Fig 40
Third Stage Piston Rod Assembly

Oil Pump and Cooler Assembly
Crosshead Assembly
First Stage Cylinder Assembly
First Stage Packing Box Assembly
First Stage Delivery Valve Assembly
Second Stage Top Cover Assembly
Second Stage Piston Assembly
Second Stage Suction Valve Assembly
Third Stage Cylinder Assembly
Third stage Packing Box
Third Stage Delivery Valve Assembly
Second Stage Intercooler Assembly
Pressure Gauge Assembly
Ancillaries
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Date: May 2002
Page: 96 of 145
Fig 1 Crankcase Assembly (2-03-288)

Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part No.
2-03-288-01
MB013-27
MB118-08
PSB024-001
MB006-05
MB011-05
MB050-03
MB038-10
PSB004-010
PSB008-006
PSB008-026
PSB008-027
PSB009-002
PSB009-007
MB130-01
MB118-11
MB006-07
Description
Crankcase
Bolt M24 x 150 long
Plug, 1/2" BSP
Breather
Setscrew M10 x 20 long
Capscrew-socket M16 x 35 long
Spring washer M16
Locking plate
Gasket-Crankcase guide
Gasket-Big end cover
Gasket-Crankcase door
Door-Main guide
Door-Crankcase
Window nut 1 1/4" BSP
Plug 3/4" BSP
www.belliss.com
Qty.
1
4
1
1
44
36
6
6
2
3
1
2
3
2
1
1
2

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Fig 2 Connecting Rod Assembly (2-76-426)

Item
1
2
3
Part No.
2-05-090
NSBP-220-025
PSB014-004
Description
Connecting rod assembly
Split pin
Bottom end shell
www.belliss.com
Qty.
1
2
1

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Fig 3 Crankshaft Assembly (2-06-383)

Item
1
2
3
4
5
6
7
Part No.
2-06-310-02
2-06-312-02
2-06-383-01
PSB002-008
PSB004-003
PSB014-006
PSB003-010
Description
Driving dog
Motor key
Crankshaft
Locknut
Washer
Roller bearing
Distance piece
www.belliss.com
Qty.
1
1
1
2
2
3
1

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Fig 4 Main Guide Assembly (2-07-280)

Item
1
2
Part No.
2-07-280-01
PSB006-001
Description
Main guide
'O' ring
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Qty.
1
1

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Fig 5 Bearing End Cover Assembly (2-25-121)

Item
1
2
3
Part No.
2-25-121-01
MB046-18
PSB008-023
Description
Bearing housing
Capscrew M8 x 50 long
Gasket - oil pump
www.belliss.com
Qty.
1
8
1

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Fig 6 Flywheel End Cover Assembly (2-25-123)

Item
Part No.
Description
Qty.
1
2
3
4
2-25-123-01
PSB008-028
PSB015-003
PSB007-006
Flywheel end cover

Gasket
Clamping ring
Oil seal
1
1
1
1
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Fig 7 Second Stage Piston Rod Assembly (2-30-144)

Item
1
2
3
Part No.
PSB002-009
PSB002-010
2-30-144-01
Description
Nut
Nut 1 5/8" BSF
Piston Rod
Qty.
1
1
1
Fig 8 Third Stage Piston Rod Assembly (2-30-202)

Item
1
2
3
4
Part No.
2-121-001-09
2-30-202-01
NSBP-220-042
PSB002-009
Description
Castle nut 1 5/8" BSF
Piston rod
Split pin
Nut
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Qty.
1
1
1
1

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Fig 9 Crosshead Assembly (2-31-066)

Item
1
2
3
4
5
Part No.
2-31-045-02
2-31-066-01
MB137-09
PSB001-002
PSB004-001
Description
Gudgeon pin
Crosshead
Circlip
Securing pin
Locking plate
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Qty.
1
1
2
1
1

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Fig 10 Oil Pump and Cooler Assembly (2-34-562)
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Date: May 2002
Page: 105 of 145
Fig 10 Oil Pump and Cooler Assembly (2-34-562)

Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Part No.
2-34-562-01
PSB026-099
PSB026-149
PSB017-011
PSB025-005
PSB025-009
PSB013-033
PSB008-009
2-34-459-02
MB021-06
PSB026-296-04
PSB026-277-04
PSB026-150
MB121-01
2-34-459-05
2-34-562-03
2-34-562-04
2-34-459-03
MB040-63
MB004-03
MB006-03
Description
Oil manifold block
Oil hose assembly
Flexible pipe
Oil pump
Strainer
Filter
Relief valve
Gasket
Stud M10
Nut M10
Union-straight 3/4" BSP
Nipple 3/4" BSP
Stud adaptor
Plug 1/8" BSP
Oil cooler
Hose-inlet
Hose-outlet
Bracket
Washer M27
www.belliss.com
Qty.
1
1
1
1
1
1
1
2
2
2
1
2
2
3
1
1
1
1
4
4
2

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Fig 11 Piston Rod Scraper Assembly (2-63-047)

Item
1
2
3
4
5
6
7
Part No.
MB006-05
MB007-03
PSB008-015
PSB008-016
PSB032-001
PSB032-002
PSB032-003
Description
Gasket
Gasket
Scraper box
Oil shedder
Support plate
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Qty.
6
4
1
1
1
1
1

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Fig 12 Crosshead Assembly (2-31-067)

Item
1
2
3
4
5
Part No.
2-31-045-02
2-31-052-04
2-31-067-01
MB137-09
PSB004-001
Description
Gudgeon pin
Securing pin
Crosshead
Circlip
Locking plate
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Qty.
1
1
1
2
1

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Fig 13 First Stage Piston Rod Assembly (2-30-252)

Item
1
2
3
Part No.
2-30-252-01
PSB002-009
PSB002-010
Description
Piston rod
Crosshead nut
Nut 1 5/8 BSF
www.belliss.com
Qty.
1
1
1

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Page: 109 of 145
Fig 14 First Stage Cylinder Assembly (2-01-908)
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Page: 110 of 145
Fig 14 First Stage Cylinder Assembly (2-01-908)

Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Part No.
2-01-908-01
MB021-11
MB021-13
MB029-10
MB118-04
MB120-01
MB011-10
MB013-08
MB013-10
MB035-11
MB086-27
MB088-09
MB088-22
PSB008-108
PSB008-109
PSB026-143
PSB026-279-05
PSB026-279-07
MB118-08
MB023-10
MB040-16
Description
Cylinder
Nut M20
Nut M24
Self locking, nut M24
Plug 1/4 BSP
Ball valve 1/4 BSP
Bolt M20 x 60 long
Washer M24
Stud M20 x 280 long
Stud M24 x 99 long
Stud M24 x 290 long
Gasket-top cover
Gasket-suction and delivery
Drain cock 1/2 BSP
Plug, csk 1 1/4 BSP
Plug, csk 2" BSP
Plug, 1/2 BSP
Dome nut M24
Washer M24
www.belliss.com
Qty.
1
1
17
4
3
1
12
24
12
12
1
4
19
1
2
1
6
8
1
2
2

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Fig 15 First Stage Top Cover Assembly (2-04-467)

Item
1
2
3
4
Part No.
2-04-467-01
MB011-10
PSB026-280-06
PSB026-279-07
Description
Top cover
Bolt M20 x 60 long
Plug 1 1/4 BSP
Plug 2" BSP
www.belliss.com
Qty.
1
12
1
1

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Fig 16 Distance Piece Assembly (2-07-414)

Item
1
2
3
4
5
6
Part No.
2-07-414-01
2-07-414-02
MB004-01
MB013-11
MB031-13
MB118-04
Description
Cylinder distance piece
Aperture cover
Bolt M24 x 75 long
Washer M24
Plug 1/4" BSP
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Qty.
1
2
16
12
12
1

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Fig 17 First Stage Piston Assembly (2-28-660)

Item
1
2
3
4
5
6
Part No.
2-28-660-01
2-28-660-02
2-28-660-03
2-28-660-04
PSB003-008
PSB003-009
Description
Piston-top half
Piston-bottom half
Piston ring
Bearing ring
Washer-top
Washer-reinforcing
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Qty.
1
1
2
1
1
1

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Fig 18 First Stage Packing Box Assembly (2-64-285)

Item
1
Part No.
2-64-285
Description
Packing Box
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Qty.
1

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Fig 19 First Stage Suction Valve Assembly (2-70-489)

Item
1
2
3
4
5
6
Part No.
2-70-489-01
2-70-310-04
2-70-310-05
2-70-479-03
PSB027-181
PSB028-041
Description
Valve cover
O ring
O ring
Valve cage
Suction valve
Actuator
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Qty.
1
1
1
1
1
1

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Fig 20 First Stage Delivery Valve Assembly (2-70-490)

Item
1
2
3
4
5
Part No.
2-70-310-04
2-70-310-05
2-70-490-01
2-70-480-03
PSB029-110
Description
'O' ring
'O' ring
Valve cover
Valve cage
Delivery valve
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Qty.
1
1
1
1
1

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Fig 21 Second Stage Cylinder Assembly (2-01-531)
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Fig 21 Second Stage Cylinder Assembly (2-01-531)

Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Part No.
2-01-531-01
MB009-11
MB011-05
MB013-06
MB021-11
MB023-09
MB029-09
MB035-11
MB040-15
MB086-08
MB086-22
MB118-04
MB118-07
MB120-01
PSB008-103
PSB008-135
PSB026-279-07
PSB026-280-06
PSB026-143
Description
Cylinder
Bolt M16 x 60 long
Nut M20
Dome nut M20
Philidas nut M20
Washer M24
Washer M21
Stud M20 x 85 long
Stud M20 x 200 long
Plug 1/4" BSP
Plug 1/2" BSP
Ball valve 1/4" BSP
Gasket-suction and delivery
Gasket-top cover
Plug 2" BSP
Plug 1 1/4" BSP
Drain cock 1/2" BSP
www.belliss.com
Qty.
1
16
12
12
14
2
2
12
2
2
16
2
1
1
2
1
6
1
1

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Fig 22 Second Stage Top Cover Assembly (2-04-274)

Item
1
2
3
4
Part No.
2-04-274-01
MB021-11
MB086-04
PSB026-280-06
Description
Top cover
Nut M20
Stud M20 x 65 long
Plug 1 1/4" BSP
www.belliss.com
Qty.
1
12
12
1

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Item
1
2
3
4
5
6
Part No.
2-07-281-01
MB004-01
MB013-11
MB031-13
PSB009-006
MB118-04
Description
Distance piece
Bolt M24 x 75 long
Washer M24
Cover
Plug 1/4" BSP
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Qty.
1
8
12
12
2
1

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Fig 24 Second Stage Piston Assembly (2-28-481)

Item
1
2
3
4
5
6
Part No.
2-28-481-01
2-28-481-02
PSB003-008
PSB003-009
2-28-481-04
2-28-481-03
Description
Piston-top
Piston-bottom
Washer-top
Washer-reinforcing
Piston ring
Bearing ring
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Qty.
1
1
1
1
2
1

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Fig 25 Second Stage Packing Box Assembly (2-64-286)

Item
1
Part No.
2-64-286
Description
Packing Box
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Fig 26 Second Stage Suction Valve Assembly (2-70-503)

Item
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2
3
4
5
6
7
8
Part No.
PSB027-001
PSB028-001
2-70-126-02
2-70-126-01
PSB003-006
MB133-48
MB133-49
2-70-503-01
Description
Suction valve
Actuator
Cover
Cage
Distance piece
'O' ring
'O' ring
Locating peg
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Fig 27 Second Stage Delivery Valve Assembly (2-70-504)

Item
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3
4
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6
Part No.
PSB029-066
2-70-127-02
2-70-129-02
MB133-48
MB133-49
2-70-504-01
Description
Delivery valve
Cover
Cage
'O' ring
'O' ring
Rod
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1
1
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Fig 28 Third Stage Cylinder Assembly (2-01-481)
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Fig 28 Third Stage Cylinder Assembly (2-01-481)

Item
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9
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13
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18
Part No.
2-01-481-01
MB013-04
MB013-08
MB021-11
MB021-13
MB029-09
MB031-13
MB086-06
MB086-09
MB088-15
MB118-07
MB118-03
PSB026-072
PSB026-280-06
PSB008-044
PSB026-279-07
2-01-481-04
PSB026-143
Description
Cylinder
Nut M20
Nut M24
Philidas nut M20
Washer M24
Stud M20 x 75 long
Stud M20 x 90 long
Stud M24 x 129 long
Plug 1/2" BSP
Plug 1/4" BSP
Adaptor
Plug 1 1/4" BSP
Gasket
Plug 2" BSP
Gasket
Drain cock 1/2" BSP
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16
12
64
8
4
12
64
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8
1
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1
1
8
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Fig 29 Third Stage Top Cover Assembly (2-04-305)

Item
1
2
3
4
Part No.
2-04-305-01
PSB026-279-07
PSB006-008
PSB026-279-05
Description
Top cover
Plug 2" BSP
'O' ring
Plug 1 1/4" BSP
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1
1

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Item
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2
3
4
5
6
Part No.
2-07-281-01
MB004-01
MB013-11
MB031-13
PSB009-006
MB118-04
Description
Distance piece
Bolt M24 x 75 long
Washer M24
Cover
Plug 1/4" BSP
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Fig 31 Third Stage Piston Assembly (2-28-523)

Item
1
2
3
Part No.
2-28-430-01
PSB022-054
PSB022-055
Description
Piston
Piston ring
Rider ring
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Fig 32 Third stage Packing Box (PSB032-060)

Item
1
Part No.
PSB032-060
Description
Packing Box
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Fig 33 Third Stage Suction Valve Assembly (2-70-236)

Item
1
2
3
4
5
Part No.
2-70-150-02
2-70-150-03
MB133-56
PSB027-113
PSB028-038
Description
Cage
Cover
'O' ring
Suction valve
Actuator
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1
1
1
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Fig 34 Third Stage Delivery Valve Assembly (2-70-237)

Item
1
2
3
4
Part No.
2-70-151-03
2-70-151-02
MB133-55
PSB029-058
Description
Cover
Cage
'O' ring
Delivery valve
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1
1
1

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Fig 35 First Stage Interstage Pipework Assembly 2-71-780
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Fig 35 First Stage Interstage Pipework Assembly (2-71-780)

Item
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19
20
21
Part No.
2-79-039-01
2-71-780-01
2-71-413-05
MB011-07
PSB008-029
PSB026-281-04
PSB026-281-07
2-74-032-01
2-71-413-06
MB082-13
MB031-07
PSB008-137
MB009-03
MB118-01
MB118-03
2-136-001
2-71-802
MB011-20
MB021-11
MB086-09
Y24664
Description
Vessel-1st stage
Separator
Bottom cover
Gasket
Plug 1/2 BSP
Plug 1 1/4" BSP
Relief valve
Deflector dish
Stud M12 x 95 long
Washer M12
Gasket-relief valve
Plug 1/8" BSP
Plug 1/4" BSP
Temperature gauge
Intercooler Assembly
Bolt M20 x 90 long
Nut M20
Stud M20 x 90 long
Philidas nut M12
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1
1
12
1
3
1
1
1
1
1
1
4
1
1
1
1
12
24
12
1

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Fig 36 Second Stage Intercooler Assembly (2-71-781)
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Fig 36 Second Stage Intercooler Assembly (2-71-781)

Item
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2
3
4
5
6
7
8
9
10
11
12
13
Part No.
2-79-037-02
2-71-781-01
PSB026-281-04
PSB026-281-06
PSB026-281-02
2-74-033-01
PSB026-281-07
2-136-001
2-72-572-07
MB009-03
2-71-803
MB011-22
MB021-11
Description
Vessel-2nd stage
Separator
Plug 1/2 BSP
Plug 1 BSP
Plug 1/4 BSP
Relief valve
Plug 1 1/4 BSP
Temperature gauge
Gasket
Setscrew-M16 x 35 long
Intercooler assembly
Bolt M20 x 100 long
Nut M20
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3
1
1
1
1
1
1
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1
24
24

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Fig 37 Cooling Water Assembly (2-45-2515)
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Page: 138 of 145

Item
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2
3
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6
7
8
9
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11
12
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19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
Part No.
2-45-2515-01
2-45-2515-02
PSB026-277-06
PSB026-142
PSB026-297-06
2-45-2190-01
PSB026-269-29
2-45-2190-02
PSB026-292-04
PSB026-269-17
MB120-03
2-45-2515-03
2-45-1678-06
PSB026-272-07
PSB026-278-13
2-45-2515-04
PSB026-299-04
2-45-2515-05
2-45-2515-06
PSB026-289-06
2-45-2515 07
PSB026-361
2-45-2515-08
2-45-2515-09
PSB026-277-04
PSB026-105
PSB026-223
PSB026-213
PSB026-269-10
PSB026-150
2-45-2515-11
15655/12
15656/12
2-45-2515-10
Description
Inlet manifold
Outlet manifold
Nipple 1 1/4 BSP
Stud adaptor 1 1/4 BSP
Union 1 1/4 BSP
Hose
Bush 2 x 1 1/4 BSP
Hose
Tee-pitcher-1 1/4 BSP
Bush 1 1/4 x 1/2 BSP
Ball valve 1/2 BSP
Hose
Globe valve 1 1/4 BSP
Elbow F 1 1/4 BSP
Nipple 1 1/2 x 1 1/4
Flow indicator 1 1/2 BSP
Union elbow M&F 1 1/4 BSP
Hose
Hose
Tee 1 1/4 x 3/4 x 1 1/4 BSP
Hose
Cone adaptor 3/4 BSP
Hose
Hose
Nipple-hex 3/4 BSP
Nipple 3/4 BSP
Ball valve 3/4 BSP
Strainer
Bush 3/4 x 1/2 BSP
Stud adaptor
Hose
Tubing nut
Tubing sleeve
Hose
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5
12
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1
1
1
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2
3
1
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1
1
1
1
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Fig 37 Cooling Water Assembly - (2-45-2515) Cont.

Item
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36
37
38
39
40
41
42
43
44
Part No.
PSB012-038
PSB026-277-03
2-45-1600-07
2-45-2515-12
MB021-06
2-45-2515-13
PSB026-279-05
PSB026-299-02
MB009-08
MB031-09
Description
Flow indicator 1/2 BSP
Nipple-hex-1/2 BSP
Bracket
U-bolt M10
Nut M10
Gasket 3 ANSI
Plug 1 1/4 BSP
Elbow-union M&F-3/4 BSP
Washer M16
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Fig 38 Pressure Gauge Assembly (2-46-1250)

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9
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11
12
13
Part No.
2-46-1265
2-46-1250-06
MB101-03
MB111-03
MB106-04
MB108-06
MB120-01
MB142-01
PSB012-011
MB128-01
MB129-03
PSB026-347-02
PSB026-110
Description
Gauge panel
Adaptor
Tube
Tee
Stud coupling
Stud elbow
Ball valve, 1/4" BSP M&F
Cock, 1/4" BSP
Pressure temperature switch
Pipe clip
Self tapping screw, No 6 x 1/2 long
Nipple 1/4" BSP
Leather washer
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1
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20
40
1
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Fig 39 Unloader Assembly (2-68-642)
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8
9
10
11
12
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18
19
20
21
22
23
24
25
26
Part No.
MB101-03
MB108-05
MB108-06
MB110-04
MB111-03
MB128-01
MB128-02
11911/3
PSB012-012
PSB012-063
PSB026-277-03
PSB026-349-02
PSB026-350-03
PSB026-269-05
MB124-08
PSB012-064
44110/13
MB031-04
PSB026-347-02
MB021-04
2-68-642-02
2-68-642-01
PSB026-286-19
MB096-03
MB106-05
2-68-642-03
Description
Tube
Elbow-stud, M
Elbow-stud, M
Tee-stud, M
Tee 6mm equal
Pipe clip
Pipe clip
Screw, pan head
Poppet valve
Blow down valve
Nipple 1/2 BSP hex
Union 1/4 M&F
Bush 3/8 x 1/4 BSP
Bush 1/2 x 1/4
Adaptor-M
Diffuser
Stud M6 x 110 long
Washer M6
Nipple 1/4 BSP
Nut M6
Solenoid valve
Poppet valve, 3/2
Tee-1/2 BSP
Coupling-straight
Coupling-stud-M
Coil plugs
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14
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21
1
1
4
2
1
7
1
4
2
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1
2
2
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Fig 40 Ancillaries (2-150-055)

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8
Part No.
2-87-012-01
NSBP-859-004
2-76-419
2-61-209
2-61-210
2-49-128
2-76-427
2-76-429
Description
Filter silencer
Air filter element
Chocking bracket assembly
Index plates
Silica gel bags
Spanners and tools
Crankcase plugging kit
Drain trap fittings
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APPENDICES
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SAFE WORKING LIMITS

Chequers Bridge, Gloucester, GL1 4LL, England
EQUIPMENT MODEL No.. VH40H3N

MAXIMUM COMPRESSOR SPEED:... 750 RPM
1st STAGE MAXIMUM WORKING PRESSURE:.... 3.5 BAR G
2nd STAGE MAXIMUM WORKING PRESSURE:... 14.0 BAR G
3rd STAGE MAXIMUM WORKING PRESSURE:.47.8 BAR G
MAXIMUM TEMPERATURES:
3rd Stage Delivery Pipe. 175 C

3rd Stage Separator Pipe.. 65 C
MAXIMUM AMBIENT TEMPERATURE:.. 45C

COOLING WATER PRESSURE:
Maximum... 7.0 BAR G

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

Minimum... 16C
COOLING WATER MINIMUM:
FLOWS
OIL PRESSURE:
1ST STAGE COOLER/CYLINDERS 10.0 m3/hr

2ND STAGE COOLER. 8.0 m3/hr
AFTERCOOLER.. 9.0 m3/hr
Start-up Maximum 8.0 BAR G
Normal Operation Maximum.. 4.8 BAR G
Shut Down Minimum 1.8 BAR G
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WARRANTY REQUEST CLAIM

FORM

QUALITY MANUAL
CLAIM DATE:
SECTION 1 - Request For Authorisation To

Proceed With Work
Y Number and Category Number
Customer:
Agent:
Site:
Site Address:
Y __ __ __ __ __ / __
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
www.belliss.com
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

failure cannot be allocated to others.
Value of Parts
_________
B-
Warranty claim charged to external suppliers.
Value of Labour
_________
C-
Warranty claim charged to manufacturing, i.e. rework caused by

original manufacturing defect or failure.
Total
_________
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.
X-
Warranty claim that cannot be attributed or deferred to any of the

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

www.belliss.com

WH40H3N Manual

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OPERATION & MAINTENANCE

Gardner Denver Belliss & Morcom Ltd

+44 (0) 1452 338198

How to Use this Instruction Manual

Comments and Suggestions

OPERATION & MAINTENANCE MANUAL

COMPRESSOR TYPE WH40H3N

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

Technical Description of the Compressor .......................................................... 15

Purpose of the Equipment .................................................................................15

Commonplace Hazards .....................................................................................22

INSTALLATION & COMMISSIONING .............................................................27

Handling and Unpacking.................................................................................... 32

Safety Precautions ............................................................................................35

Preparation for Commissioning.......................................................................... 36

Installation Procedure ........................................................................................ 35

Cleaning the Compressor ..................................................................................36

Commissioning the Compressor ........................................................................ 38

Trial Run ...........................................................................................................38

Gardner Denver Belliss & Morcom

DOC REF: WH40H3N - ISSUE 1, MAY 02

OPERATION & MAINTENANCE MANUAL

COMPRESSOR TYPE WH40H3N

Controls and Indicators...................................................................................... 41

Preparation for Starting...................................................................................... 43

Under Normal Conditions ..................................................................................44

Before Operating the Machine (Pre-Start Checks) .............................................44

Starting the Compressor .................................................................................... 44

Running Checks ................................................................................................45

Stopping the Compressor .................................................................................. 46

4.6. Fault Indications ................................................................................................ 46

Fault Finding .....................................................................................................47

Preventive Maintenance .................................................................................... 51

Maintenance Schedule ......................................................................................51

Maintenance Instructions ................................................................................... 56

Lists of Tools ..................................................................................................... 88

Commercially Available Tools List......................................................................88

Waste Products ................................................................................................. 90

Oil - After Oil Changes.......................................................................................90

Gardner Denver Belliss & Morcom

DOC REF: WH40H3N - ISSUE 1, MAY 02

OPERATION & MAINTENANCE MANUAL

COMPRESSOR TYPE WH40H3N

SPARE PARTS ................................................................................................92

Ordering Spares and Spares to be Held in Stock............................................... 92

Safe Working Limits

Gardner Denver Belliss & Morcom

DOC REF: WH40H3N - ISSUE 1, MAY 02

Gardner Denver Belliss & Morcom

DOC REF: WH40H3N - ISSUE 1, MAY 02

OPERATION & MAINTENANCE MANUAL

COMPRESSOR TYPE WH40H3N

CHAPTER 1 - TECHNICAL DATA &

TECHNICAL DATA & COMPRESSOR DESCRIPTION

1.1 Technical Data

Pressure Gauge Range

Air Delivery - 1st stage

2.3 - 2.9 Bar G

Air Delivery - 2nd stage

11.8 - 13.2 Bar G

Air Delivery - 3rd stage

Gardner Denver Belliss & Morcom

DOC REF: WH40H3N - ISSUE 1, MAY 02