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Technical Documentation

Deck Machinery - Compressors - Steering gears

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Technical Documentation Piston Compressor

Technical Documentation for

Piston Compressor Type W110

of

Uetersener Maschinenfabrik

GmbH & Co. KG 25436 UETERSEN

GERMANY

Phone: +49-4122-711 0.. Telefax: +49-4122-711 330

Internet http://www.hatlapa.de E-Mail: [email protected]

Ref.-No.: 11.5733 Serial-No.: 11.5733 - 0

This technical documentation belongs NOT in the office, but in the hands of the

operator

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Technical Documentation Piston Compressor

Table of Contents

1 Important Information on this Documentation and Safety 2 Description of Compressor 3 Installation Drawing 4 Operating Instructions 5 Technical Indications 6 Spare Parts List 7 E-Motor 8 Lubricating Instructions 9 Service

We recommend reading these instructions carefully and becoming quite familiar with the

design and operation of the piston compressor before putting it into operation. This will avoid damage through improper handling.

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Important Information on this Documentation and Safety

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1 Information on Manuals ........................................................................................................................... 3 2 Copyright ................................................................................................................................................. 3 3 Guarantee................................................................................................................................................ 3 4 Designations............................................................................................................................................ 4 5 Signs Used .............................................................................................................................................. 5 6 Intended Use ........................................................................................................................................... 5 7 Ban on Arbitrary Modifications................................................................................................................. 5 8 General Safety Instructions ..................................................................................................................... 6 9 Safety Equipment .................................................................................................................................... 6 10 Instruments for Operating Surveillance ................................................................................................... 6 11 Safety Instructions for Assembly ............................................................................................................. 7 12 Additional Safety Instructions for Electrical Installation........................................................................... 7 13 Safety Instructions for Operation and Service......................................................................................... 8 14 Safety Instructions for Maintenance and Repairs ................................................................................... 9 15 Noise Protection .................................................................................................................................... 10 16 Waste Disposal...................................................................................................................................... 10

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1 Information on Manuals This manual includes all information necessary for guaranteeing the safety as well as for the operation and maintenance of the equipment.

It is directed at instructed and trained personnel who are responsible for the operation and maintenance of the equipment.

Only knowledge of this manual can ensure faultless and correct functioning of the equipment, so its contents must be known to the responsible persons. The manual should be kept so that the operating and maintenance personnel have access to it at all times.

2 Copyright The copyright for this technical documentation remains with HATLAPA.

This documentation is intended for the operator and their personnel only.

All rights reserved.

3 Guarantee Guarantee and liability claims for damage to persons and/or objects are excluded, if caused by one or several of the following circumstances:

inappropriate use of the equipment, neglect of the provisions of this documentation, improper assembly, operation or maintenance, operation of the equipment with ineffective protective devices, arbitrary functional or constructive alteration of the equipment, removal of parts or installation of spare parts or additional components,

respectively, which have not been supplied or approved by HATLAPA,

repairs which have not been authorised by HATLAPA, impact of foreign bodies in case of catastrophes or Force Majeure.

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4 Designations Persons are defined as follows:

The operator is the (natural or legal) person on whose behalf the equipment is used, e.g. the ships owner.

Operating personnel are personnel trained for the respective work, and who are authorised to operate the equipment and to remedy disturbances. The operating personnel must be trained for the tasks they are entrusted with, and meet the requirements necessary to handle the equipment.

Assembling personnel are personnel trained for the respective work, and who are authorised to assemble the equipment. They are able to carry out the tasks assigned to them and to recognise possible dangers because of their completed specialised training.

Maintenance personnel are personnel trained for the respective work, and who are authorised to maintain, adjust and modify the equipment. They are able to carry out the tasks assigned to then and to recognise possible dangers because of their completed specialist training.

An electrician has electro-technical skills gained by respective education, masters the legal regulations, and is assigned by the operator to carry out work on their electrical equipment and appliances.

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5 Signs Used

Sign for Danger

Danger!

This sign indicates specific behavioral patterns the non-observance of which is highly dangerous, or which may lead to permanent bodily injury.

Sign for Caution

Caution!

This sign indicates specific behavioral patterns the non-observance of which may lead to injury to persons, severe damage, or severe malfunction of the equipment, or to damage to the environment.

Sign for 'Pay Attention'

Pay Attention!

This sign indicates specific behavioral patterns the non-observance of which may lead to damage or malfunction of the equipment.

Sign for Information

Information!

This sign indicates tips and useful information which facilitate the operation of the equipment or the understanding of the documentation.

6 Intended Use The compressor is exclusively designed for air compression. Any other use is deemed as not being in compliance with the intended use and requires express written approval from HATLAPA.

The intended use also includes compliance with all the regulations contained in this technical documentation, the generally acknowledged rules of technology as well as all the relevant laws, standards and regulations.

7 Ban on Arbitrary Modifications Arbitrary modifications and changes to the machine/system are not permitted, as they may put persons in danger and result in damage to the machine/system.

If you are planning modifications or changes, contact HATLAPA and request written authorisation.

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8 General Safety Instructions Besides the specific safety-related technical notes contained in these instructions and the sub supplier's documentation, you must also observe the generally applicable safety and accident regulations, such as the:

Recognised technical regulations for safe and professional work

Regional and internal regulations

Regulations from the responsible classification authority

Rules and regulations for the prevention of accidents from the professional organisation, in particular concerning compressors

Safety signs and indicator plates on the machine/system

Environmental protection regulations

Incorrect handling or failure to comply with regulations concerning use can result in the risk of physical injury and death and/or damage to property. Observe the limits specified in the technical data.

Find out about the fire detection and fire prevention options, and ensure that these are fully functional and sufficient.

9 Safety Equipment

Danger!

Faulty safety equipment may put lives and equipment at risk.

All safety equipment must always be in a flawless and fully operational condition.

You must not make the safety equipment inoperative in any way.

If a piece of safety equipment is defective, the machine/system must not be operated.

Only remove safety equipment if the machine/system has been isolated and secured.

Perform regular checks on the safety equipment, in accordance with the regulations in this documentation and the sub suppliers' documentation.

10 Instruments for Operating Surveillance

Caution!

If instruments for operating surveillance are out of order, monitoring of the operating conditions of the machine/system may lead to incorrect analyses. This may put lives and/or equipment at risk.

Never decommission any instruments for operating surveillance.

If instruments for operating surveillance are defective, they must be changed as soon as possible. Take utmost care when operating the machine/system until the instruments are exchanged.

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11 Safety Instructions for Assembly

Danger!

During assembly and installation, the functioning of the safety equipment is not guaranteed. Therefore, the safety of the assembling personnel is to a great extent dependent on the proper execution of work.

Only trained and briefed personnel are permitted to carry out assembling and installation work. The personnel must have a specialised knowledge of compressed air and electrical engineering.

Only use suitable and fully functioning tools.

During torching or welding work, ensure that risks of fire or explosion are avoided.

12 Additional Safety Instructions for Electrical Installation All work on the electrical systems is only allowed to be performed by qualified electronics specialists.

Danger!

Deadly voltage!

Before starting to work on electrical equipment, the machine/system must be de-energized. Ensure that

the mains supply is deactivated. Check that the disconnected parts are de-energized before commencing work.

the electricity supply cannot be reconnected unintentionally or without authorization while work is being performed on the electrical installation.

the electricity for parts which must remain connected for the maintenance and repair work only remains connected for as long as is absolutely necessary for the work in question.

Danger!

The main switch remains energized even if it is deactivated.

Work carried out on electrical systems must be done so in accordance with the valid safety regulations, as well as all other relevant state or local regulations.

Under no circumstances repair or tide over defective fuses. Fuses must only be replaced by the same type of fuses.

When working on electrical systems, only use permitted and suitable tools. Only use voltage-free tools.

When taking measurements with the voltage supply of >65 V activated,

you must under no circumstances touch the electrical connection points, the inspection equipment must be in good condition and safe to operate, you must not wear any jewelry on fingers or wrists, you must stand on insulated ground.

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13 Safety Instructions for Operation and Service

Danger!

The machine/system must only be operated by trained and briefed operating personnel.

New personnel may only use the machine/system under the constant supervision of trained and briefed operating personnel.

Give regular briefings on accident regulations and the requirements stated in this documentation.

Danger! Drawing in into moving parts!

Body parts or clothing may get caught at the flywheel.

Prior to start-up, check that the flywheel cover is fitted!

Caution! Burn hazard!

The compressor housing and the pressure pipes become hot during operation.

Wear protective gloves!

Caution! Drawing in into moving parts!

Long hair or loose clothing may get caught at the air intake filter.

When the compressor is in operation, maintain a safe distance to the compressor housing!

Caution!

In automatic operation mode, the compressor starts automatically without warning.

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14 Safety Instructions for Maintenance and Repairs

Danger!

The machine/system must only be maintained and repaired by trained and briefed maintenance personnel. The personnel must have a specialised knowledge of hydraulic and electrical engineering.

Optionally, the compressed air pressure gauges can be equipped with gauge valves. In this case, the compressor may be under pressure although the compressed air pressure gauges show a pressure of 0 bar.

Before starting any repair work, shutdown the machine/system and secure it against unintentional restarting. If the work can only be carried out while the machine/system is running, make the necessary safety arrangements. A second person must monitor the work, and be ready to intervene if needed.

When carrying out maintenance and repair work, do not decommission more than one piece of safety equipment at a time.

Only use suitable and fully functioning tools.

Caution! Burn hazard!

The compressor housing and the pressure pipes become hot during operation.

Before beginning maintenance work, allow the compressor to cool down for approx. 2 hours!

Caution!

Besides the information contained in this documentation, you must also observe the regulations of the classification authorities and professional organisations in order to determine the inspection and maintenance intervals.

After disassembly, always exchange self-locking nuts and gaskets. They are not designed for repeat use.

If leaks occur at couplings which are sealed with resilient joint gaskets, the leaks cannot be eliminated by retightening the coupling because the resilient joint gaskets are damaged or hardened. Exchange the resilient joint gaskets.

Pay particular attention to cleanliness. Cover any openings to prevent the ingress of dirt.

Ensure that tools, loose parts or cleaning cloths are not left in or on the compressor.

Dispose of old oils and grease in an environmentally friendly manner in accordance with national regulations.

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15 Noise Protection Refer to the technical data for information about the noise level.

Caution!

Make sure to wear ear protection in the vicinity of the compressor when it is in operation.

16 Waste Disposal The following substances which are caused by the operation of the machine/system must be disposed of in an environmentally friendly manner, in accordance with the applicable laws:

used oils and grease as well as cloths with such substances on them; cleaning agents, and cloths with cleaning agents on them.

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05.01.99

M. Frse

Beschreibung des Kompressors Comm.-no.:

11.5733 description of compressor

174648-06060

Kompressor Typ/compressor type : W110

Drehzahl,

speed : 1450 1/ min

Enddruck,

final pressure : 30 bar

Lademenge (vom Ansaugezustand)

F.A.D. from 0

to final pressure : 106 m/h (based on suction conditions)

Bauart: structual features: zweistufig, stehend, einkurbelig two staged, vertical construction with

Leichtmetall-Stufenkolben one-throw crankshaft, light alloy

differential piston

Ventile: valves: kombinierte Saug- und combined suction and pressure

Druckventile in beiden Stufen valves in both stages

Wasserkhlung: water cooling:

Zwischenkhler: intercooler: eingebauter Rhrenkhler built-in tubular cooler

Endkhler: after cooler: eingebauter Rhrenkhler built-in tubular cooler

Druckumlaufschmierung: force feed lubrication: Von der Kurbelwelle direkt ange- Gear pump directly driven by the crankshaft.

triebene Zahnradpumpe. ldruckber- Oil pressure indication by means of

wachung durch ldruckmanometer und pressure gauge and low pressure switch.

ldruckschalter. lstandskontrolle Oil level inspection glass. Crankcase venting

durch lstandsauge. Kurbelgehuseent- through vent filter on oil filler. Cylinder lub-

lftung ber Entlftungsfilter am leinfll- rication by means of lubrication oil piston

stutzen. Zylinderschmierung durch Kolben- pump with sight glass at the cylinder.

schmierpumpe mit Sichtkontrolle an dem

Zylinder.

Lager: bearings: Kurbelwelle: Gleitlager crankshaft: slide bearings

Pleuel: Gleitlager connecting rod: slide bearings

Kolbenbolzen: Gleitlager wrist pin: slide bearings

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Instruction manual

Piston compressor

W80 - W420

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Type Instruction manual W80 - W420 Piston Compressors

2 Rev.: 07.09.1999

INTRODUCTION: This Instructions Manual contains a brief technical description and important instructions on commissioning, maintenance and servicing of the compressor. We recommend to read this manual carefully in order to be able, in case of trouble, to detect the cause quickly and care for remedy and, in case of repairs, to make provisions for proper mounting acc. to the instructions. This manual assumes a general technical knowledge of piston compressors and does not claim to be complete. If repairs become necessary, only original HATLAPA spare parts must be used in order to maintain the operational reliability and efficiency of the machine. For identification and supply of spare parts, an order must contain the following information:

1. Serial No. and type designation (see name plate). 2. Ident No. from the spare parts list. 3. Method of the required dispatch, as well as consignee and address for the invoice. 4. Name of the vessel (ex-name), Yard No., and Shipyard.

In order to receive spare parts with the least possible delay, get in touch direct with

Uetersener Maschinenfabrik GmbH & Co. KG Tornescher Weg 5-7 D-25436 Uetersen / Germany D-2549 Uetersen / Germany

Phone: (+49) 4122 / 711- 0 Telex: 218510 htlu d Cable: HATLAPA Uetersen Fax: (+49) 4122 / 711 - 330 E-mail: [email protected] Internet: http://www.hatlapa.de

or with our accredited agents, after-sales service stations or licensees/co-operators as per attached list. We wish to point out that repairs and/or modifications to the compressor which are carried out without our approval during the guarantee period, will release us from our guarantee obligations. The manufacturer cannot be rendered liable for damage to the compressor which can be shown to have been caused by the use of unsuitable lubricants or failure to comply with the operating instructions.

Reprint of the text or illustrations, or even extracts therefrom is prohibited. Subject to alterations at all times due to technical development.

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Instruction manual Type Piston Compressors W80 - W420

Rev.: 07.09.1999 3

TABLE OF CONTENTS:

Page:

Introduction .................................................................................................................... 2

1 Description .................................................................................................................. 4 1.1 Design ....................................................................................................................... 4 1.2 Specifications ............................................................................................................ 4 1.3 Working Method ........................................................................................................ 5 1.4 Cooling ...................................................................................................................... 5 1.5 Lubrication of Working Parts ..................................................................................... 5 1.6 Lubrication of Cylinders ............................................................................................. 6 1.7 Condensate Separation ............................................................................................. 6 1.8 Starting without Back-Pressure ................................................................................. 6

2 Setting-Up and Installation ........................................................................................ 7

3 Commissioning ........................................................................................................... 8 3.1 Safety References ..................................................................................................... 8 3.2 Before Starting ........................................................................................................... 9 3.3 After Starting .............................................................................................................. 9 3.4 During Operation ....................................................................................................... 9 3.5 After Stopping .......................................................................................................... 10

4 Servicing and Maintenance ..................................................................................... 11 4.1 General Servicing Instructions ................................................................................. 11 4.2 Servicing Schedule .................................................................................................. 12 4.3 Overhaul of Valves .................................................................................................. 14 4.4 Overhaul of Pistons and Cylinders .......................................................................... 14 4.5 Overhaul of Crankshaft and Connecting Rods ........................................................ 17 4.6 Protection against Corrosion during prolonged Shut-Down ..................................... 18

5 Trouble Shooting ...................................................................................................... 19

6 Spare Parts ................................................................................................................ 20

7 Instructions for Correctly Ordering Spare Parts .................................................... 21

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1 Description 1.1 Design The compressors W80 to W420 are two-stage, water-cooled differential piston machines with vertical cylinders in tandem arrangement.

Direction of rotation of the crankshaft on the standard model: clockwise- when facing the fly-wheel (see arrow indicating direction of rotation). The equalization of mass guarantees vibration reduced operation and allows problem-free flexible mounting. The amply-dimensioned and force-feed lubricated slide bearings for crankshaft conn. rods make the machine insensitive to inner and outer vibration stress at standstill and during operation. 1.2 Specifications

Type W80 W110 W140 W220 W280 W330 W420

Number of Cylinders 1 1 1 2 2 3 3

Cylinder Bore 1st Stage [mm] 120 130 150 130 150 130 150

Cylinder Bore 2nd Stage [mm] 105 117 132 117 132 117 132

Piston Stroke [mm] 106 116 116 116 116 116 116

Crankshaft-Axial Clearance [mm] 0.2-0.3

0.2-0.3

0.2-0.3

0.2-0.3

0.2-0.3

0.3-0.4

0.3-0.4

Quantity of Lub. Oil min. [l] 2.8 2.8 2.8 4.8 4.8 6.5 6.5

Quantity of Lub. Oil max. [l] 4.0 4.0 4.0 7.1 7.1 10.5 10.5

Weight without E-Motor [ca. kg] 200 250 250 440 440 660 660

Setting Oil pressure at warm Machine [approx. bar]

4 4 4 4 4 4 4

Setting Oil Pressure Control Switch [approx. bar]

1 1 1 1 1 1 1

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1.3 Working Method

The compressor sucks in ambient air through the air-intake filter with silencer and compresses it in two stages to the mentioned final pressure. Combined concentric ring plate valves with large flow cross-sections control automatically the air change gas from one compression chamber to the other. After each stage, the warmed-up compressed air flows through an amply dimensioned cooler. Proper functioning of the compressor is controlled by pressure gauges and a thermometer downstream each compression stage. Safety valves, one for each compression stage, prevent the pressure from rising inadmissibly.

1.4 Cooling

The heat created in the compressor by air compression and mechanical friction, is dissipated to the cooling water. Check immediately after starting whether sufficient cooling water is delivered to the compressor. Under regular operating conditions and with the prescribed cooling water supply as well as with clean cooling chambers, the temperature rise between cooling water inlet and outlet is 10 to 15 C. The temperature of the cooling water must not exceed 50 C at its outlet. A thermometer and a temperature control switch should be provided for controlling the temperature of the discharged cooling water at the outlet pipe.

1.5 Lubrication of Working Parts

Only compressor oils according to the enclosed oil specification chart may be used. Crankshaft and conn. rod bearings are force-feed lubricated by means of a gearwheel oil pump driven directly by the crankshaft. This pump sucks the oil from the crank-case through a sieve and forces it to the two main bearings of the crankshaft, as well as to the conn. rod bearings. The lub. oil pressure is limited by a spring-loaded pressure limiting valve and is indicated by a pressure gauge. The lub. oil pressure is monitored by a pressure switch, which switches off the compressor in case of insufficient oil pressure.

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1.6 Lubrication of Cylinders

For lubrication of cylinders the compressor is fitted with an additional dosage pump. For running periods of up approx. 1.5 hours the dosage pump is to be set to feed approx. 1 to 1.5 drops per minute for every 100 compressor revolutions. For operation of more than 1.5 hours the dosage pump can be reduced to 0.7 to 0.8 drops per 100 r.p.m. The drops can be counted at the drip sight glass (cylinder head).

1.7 Condensate Separation

Together with the moist ambient air which is sucked in, water enters the compressor in form of vapour. By compression and subsequent cooling of the compressed air, this water vapour condenses. The water separated from the compressed air blends with the oil which is entrained in very small quantities from the lubricated working surfaces of the cylinders. This water-oil mixture is extracted from the compressed-air stream after the 1st and 2nd stage in special condensate collector chambers. At regular intervals after every 15 min. for about 10 sec. - as well as on starting and stopping of the compressor, the collector chambers must be drained by opening the manual valves or optionally by automatic devices. Such condensate separation reduces wear and tear due to corrosion in the compressor components, and in the connected pipelines and prevents the compressor from damage due to water shocks. Disposal of the condensate has to be carried out according to the locally valid prescriptions.

1.8 Starting without Back-Pressure

During starting-up, the driving motor must be relieved by opening the drain valves. In automatically controlled compressors, relief occurs by delayed closing of these valves.

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2 Setting-Up and Installation

Where the drive is provided by a directly-coupled motor through a flexible coupling, the shaft centres of motor and compressor must lie in exactly the same axis. Under no circumstances may the shaft centres be offset. The common baseplate for motor and compressor is torsion-free and must be properly aligned on its foundation and fully supported at all points. If the foregoing instructions are disregarded and if any modifications of the foundation or of the common baseplate are done, this may result in inadmissible strain on the shafts due to incorrect alignment. In case of resilient mounting there must be sufficient room for movement. All pipelines must then be connected to the consumer system by flexible hoses, strictly adhering to the installation instructions. All drain pipelines are to be laid with constant descent and must discharge into an open funnel after the shortest possible distance. Each compression stage needs a separate drain pipeline in order to guarantee perfect drainage of the individual stages; stop valves are to be installed as closely as possible to the compressor. Further instructions on the installation of valves, pipelines, and control equipment are to be taken from the enclosed piping diagrams with their respective descriptions.

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3 Commissioning 3.1 Safety References

The compressor has been produced according to the State-of-art and is operationally reliable. The compressors are a source of danger if inexpertly or improperly used. Only authorised and trained persons are allowed to operate and repair the

machine or to do maintenance work. Make sure that these persons have read and understood the complete operating instructions and safety instructions.

The compressor may only be used for compressing air. The compressor may not be operated without safety or protecting devices. Only sealed safety valves may be used, readjustment is not allowed. They

have to be replaced immediately when defective. Before starting any maintenance work it is necessary to stop the compressor

system and to prevent it from re-starting. The system has to be voltagefree, all parts containing compressed air have to be depressurized.

The compressor system may only be operated in perfect working condition. It must be free of foreign parts.

Rebuilding or any other changes to the compressor system that may influence the safety are strictly prohibited.

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At initial commissioning, after a several months` interruption in operation, or after extensive repair work the operator must observe the following points (see also 4.6 Protection against corrosion during prolonged Shut-Down).

3.2 Before Starting

The compressor must be filled to the upper oil level mark with prescribed compressor oil (see list of recommended oils).

Check that the crankshaft is moving easily by turning over the flywheel by hand; but make sure that the compressor set cannot be started unintentionally.

Open the shut-off valve in the pipeline leading to the compressed-air receiver.

Open drain valves. Open the shut-off valves in the cooling water pipes.

3.3 After Starting

Check the direction of rotation of the shaft (see also arrow). Watch the pressure gauge for rise in oil pressure. Check the cooling water flow. Close the drain valves and check for leakage.

3.4 During Operation

Once the final pressure is attained, check the safety valves for proper functioning: Slightly turn the knurled nut until the valve blows off. After closure, check for leakage.

Observe the compressed-air temperature and cooling water temperature at the thermometers.

After fitting of new working parts (repair), run in the compressor for about one hour at low final pressure (5 to 10 bar).

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3.5 After Stopping

Open the drain valves at the condensate separators. Check that the automatic drain valves open properly. Check the non-return valve in the pipe to the compressed-air receiver for

leakage.

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4 Servicing and Maintenance

For trouble-free operation, it is necessary to check regularly and carefully the safety devices and the wear and tear parts of the compressor as well as the functioning of fitted valves and instruments. Regularly check the stock of spare parts and seals which must be protected against corrosion, and stock up to the specified quantity again after any servicing and overhaul work. The following maintenance and overhaul instructions must be adhered to. However, they do not claim to be complete. Observance of the servicing intervals as mentioned below guarantees great reliability and long service life of the compressor. In this connection, reference is made to the requirements of the rules of the classification societies and seafarer unions.

4.1 General Servicing Instructions a) Check the oil level daily. Fill the crankcase with the prescribed compressor oil,

however, not exceeding the top oil level mark. Too much oil results in foaming due to immersion of rotating parts, with the compressor at extremely inclined position. Intense misting of the oil and uncontrolled cylinder lubrication would result in increased oil consumption and coking of the working valves.

b) Drain off the lub. oil at the prescribed intervals - when the compressor is still hot from running - and fill in fresh compressor oil after having cleaned the oil sieve.

c) Regularly and carefully check the oil pressure as well as the air pressure of all stages. Varying operating pressure values indicate anomalies in the lubricating system and valves, as well as leaks in the piping system.

d) At regular intervals dismantle and strip down the combined suction and pressure valves and clean all parts. Packing rings between valve and cylinder head must be replaced in sets only. For details, see 4.3 Overhaul of Valves.

e) Check the safety valves on the compressor by slightly turning the knurled nut at short intervals.

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4.2 Servicing Schedule

After first commissioning, after a general overhaul, and after repairs to the crank mechanism or cylinder, the following maintenance work should be done:

After 100 working hours 1.) Change the oil. 2.) Clean the oil suction sieve. 3.) Check the safety valves. 4.) Check the bolts and nuts on crankcase, cylinders, and pipelines for

tightness (See list of tightening torques). 5.) Check the drainage system.

After that the following intervals are to be kept:

After every 500 working hours: 1.) Check the safety valves 2.) Check and clean the cooling water chambers and pipes 3.) Check and if necessary replace the zinc protection 4.) Check the drainage system

After every 1000 working hours (however, at least once a year):

1.) Change the oil. 2.) Clean the oil suction sieve. 3.) Clean the air-intake filter

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After every 1000 working hours: 1.) Clean the combined suction and pressure valves and check for wear. 2.) Check parts which come into direct contact with hot compressed air, such

as valves, cylinder heads and compressed-air pipelines for carbon residues and, if necessary, clean them with solvents.

The admissible servicing intervals of the valves are determined above all by the operating conditions and by the properties of the lubricant used. We recommend to reduce the servicing intervals in case of severe operating conditions.

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4.3 Overhaul of Valves

The combined suction and pressure valves of the compressor require conscientious care and maintenance. Their springs and plates are the most intensely stressed parts of the compressor. For cleaning, the concentric valves have to be dismantled by removal of the fitting bolt. Soaking of the components in paraffin facilitates removal of coked deposits. Care should be taken that the ground sealing surfaces, and valve plates are neither scratched nor damaged. Springs and valve plates should be checked for damage and wear and replaced, if necessary. For reassembly, adhere strictly to the assembly diagram (parts list). Parts of different valves must not be mixed. Tighten the fitting bolt with the prescribed torque. After reassembling check the soft running of the valve plates against the spring pressure using a rounded pin. Valves or valve parts must be clamped in a vice with smooth jaws only. When fitting the valves, use new packing rings in sets and see that they are properly positioned.

4.4 Overhaul of Pistons and Cylinders

All components must first be marked so as to maintain pairings (association of pistons and cylinders) and the positioning of the parts during reassembly. To measure clearance and wear, first of all, all parts must be cleaned and checked for damage. The cylinder diameter is measured by means of a precision internal gauge inside the working area of the piston rings. To check the joint clearance all the piston rings have to be removed by means of piston ring pliers and should be pushed at a right-angle into the top cylinder aperture and positioned there where the cylinder liner shows no traces of wear. The joint clearance is measured with a feeler gauge.

Parts whose wear limits are reached or exceeded have to be replaced (see list of wear limits).

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When reinstalling the cylinder liner, the overflow bore holes in the area of the 2nd stage valve must match. When fitting the cylinder liner the bearing surfaces in the cylinder block must be cleaned and applied with sealing grease so that the liner slides into the cylinder without dislodging the O-rings. Only grease may be used which is non-aggressive to the O-rings. Do not grease the cylinder liner, otherwise the grease will be pushed up when fitting the liner, preventing correct contact at the cylinder recess.

When fitting the piston observe Fig. Piston Assembly. Clean the piston again after having removed the piston rings by means of piston ring pliers. Oil must be applied to piston and piston rings before the piston is fitted into the cylinder. The piston must be installed with mounted connecting rod. When fitting the piston proceed as follows:

Before fitting make sure that the joints of the rings are staggered and that they are on alternate sides, outside the bores for the valves 2nd stage. Take care that the piston rings, particularly those of the 2nd stage, are placed centrically in the piston. Regular radial projection is necessary, see detail at A of Fig. Piston Assembly .

Insert the well-oiled piston with its rings and connecting rod from the top of the cylinder liner. Once the piston rings 1st stage have been introduced, the piston has to be pushed downwards until the first ring of the 2nd stage touches the chamfer C.

By applying slight pressure to the piston head, the piston can now be twisted about 15 to the left and right and worked easily ring by ring into the cylinder runway of the 2nd stage.

Do not introduce the piston with force in order to avoid jams or breaking of piston rings. If the piston jams, it must to be removed again and the piston rings centered again exactly.

After fitting of piston and connecting rod turn the compressor by hand to see that nothing jams.

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16 Rev.: 07.09.1999

Piston-Assembly Instructions

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Rev.: 07.09.1999 17

4.5 Overhaul of Crankshaft and Connecting Rods

Crankshaft and connecting rods move in force-feed lubricated slide bearings. Bearing covers are identified by punched figures. Association and location of the covers must not be changed. Mark the individual parts to maintain correct positions during reassembly. After disassembly, clean all parts, check all bearings and journals for wear and damage and measure the wear. Check the axial and radial clearance by means of a precision gauge (see list of wear limits).

Refitting of the crankshaft:

Clean the oil ducts and blow through compressed air. Thoroughly oil the bearings and journals as well as the associated components before assembly. Insert the crankshaft in the crankcase first without shaft seals and then screw on the housing cover with its gasket. Check the axial clearance of the crankshaft whether the admissible clearance is not exceeded. To increase the axial clearence of the crankshaft an additional gasket can be fitted between crankcase and cover. Fit the shaft seals and tighten the housing cover screws to the prescribed torque. When fastening the flywheel and the fan wheel, secure the crankshaft against rotation by inserting a rod from outside through the opening of the flywheel housing into the flywheel bore.

Refitting of the connecting rods:

Before starting refitting, do not forget to oil crank pin and bolt threads. Place the upper part of the connecting rod with bearing shell on the crank pin and see that the shell is correctly positioned in the connecting rod. Put the lower part of the connecting rod with bearing shell from the opposite side, pass through the fitting bolts and screw them into the upper part of the connecting rod. After initial tightening of the two fitting bolts to approx. 30 Nm, tighten them with a torque spanner to the prescribed torque (see list of torques). Afterwards check the axial soft running of the connecting rod on the crank pin by moving to-and-fro.

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18 Rev.: 07.09.1999

4.6 Protection against Corrosion during prolonged Shut-Down

Compressors must be stored in a dry room. In case of long storage a protection of all inner components should be carried out according to the manual at least every 8 months. Before first commissioning, the compressors must be checked by a trained engineer for damage which may result from long storage. A report of inspection must be sent to HATLAPA. Noticed damage during this check are not covered by our guarantee. The date of commissioning or supply of the vessel to owner must be advised to us.

Compressors which will be put out of operation for several months must be protected against corrosion.

Internal protection: Open drain valves of 1st and 2nd stage under pressure. Run the compressor without pressure while the drain valves are open. Close the drain valves. Remove the air-intake filter-and pour about 250 cm of anti-corrosion oil into the

air-intake socket within approx. 2 minutes. Shut down the compressor and open the drain valves.

External protection: After cleaning, apply rust-preventive paint to all parts. Components made of light alloy, copper or brass need no treatment.

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Rev.: 07.09.1999 19

5 Trouble Shooting

The following details are intended to provide a brief guide to determining the cause of abnormal operation. We do not claim that this information is complete. It only deals with the faults most frequently encountered, as known from experience.

a) Oil pressure too low:

Too low oil level in the crankcase (oil pressure display fluctuating). Clogged suction sieve. Leaking oil pressure limiting valve (dirt). Damaged bearing (in general together with knocking noise).

b) Intermediate pressure too low after 1st stage:

Leaking suction/pressure valve 1st stage Leaking drain valve 1st stage

c) Intermediate pressure too high after 1st stage (safety valve blowing off):

Leaking suction valve 2nd stage

d) Compressed-air delivery too low: Still open or leaking drain valves. Combined suction/pressure valve damaged or leaking. Leaking cooler or compressed-air delivery line. Clogged cooler or compressed-air delivery line (at the same time, pressure at the compressor considerably higher than in the compressed-air receiver).

e) Safety valve blowing off although pressure is normal: Defective safety valve.

f) Safety valve of final stage blowing off, final pressure too high :

Closed valve on compressed-air receiver / non-return valve does not open. Blockage of cooler or of compressed-air delivery line . Defective pressure control switch (of the automatic system).

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20 Rev.: 07.09.1999

6 Spare Parts

We recommend to keep some spare parts in stock in order to allow quick remedy of minor failures due to the natural wear and tear.

1 set of valve plates and valve springs for each stage

1 set of piston rings incl. oil scraper ring for each stage

1 set of sealing rings and gaskets for each stage

If the compressor is intended for continuous operation, in addition stock:

1 combined suction and pressure valve for each stage

1 set of crankshaft bearings and connecting-rod bearings

1 piston with wrist pin and piston rings for each stage

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Rev.: 07.09.1999 21

7 Instructions for Correctly Ordering Spare Parts

When ordering spare parts, the following details must be given: 1.) Serial No. and type designation (see name plate). 2.) Ident. No. from the spare parts list. 3.) Method of the required dispatch, as well as consignee and address for the

invoice. 4.) Name of the vessel (ex-name), Yard No., and Shipyard.

In order to receive spare parts with the least possible delay, get in touch direct with

Uetersener Maschinenfabrik GmbH & Co. KG Tornescher Weg 5-7 D-25436 Uetersen / Germany D-2549 Uetersen / Germany

Phone: (+49) 4122 / 711- 0 Telex: 218510 htlu d Cable: HATLAPA Uetersen Fax: (+49) 4122 / 711 - 330 E-mail: [email protected] Internet: http://www.hatlapa.de

or with our accredited agents, after-sales service stations or licensees/co-operators as per attached list.

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Wasser

Technische Hinweise Technical Indications


Kolbenkompressor Piston compressor

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Wasser


Inhaltsverzeichnis / Table of Contents

Zeichnungs-Nr.: Drawing No.:

Rohrschema / piping diagram 175000 ldruckwchter / oil pressure control switch 176083 Druckluftschlauch / hose for compressed air 173986 Khlwasserschlauch / hose for cooling water 174557 2/2- Wege-Magnetventil / 2/2 - way solenoid valve 176006 2/2- Wege-Magnetventil / 2/2 - way solenoid valve 174767 Temperaturschalter / temperature control switch 177148 Kontroll- und Betriebsempfehlung / control and operating

logic recommendation 179717

Wartungsvorschrift fr lschmierpumpe / maintenance

instructions for the lubricating oil pump

Anzugsdrehmomente / tightening torques Verschleigrenzen / wearing limits Montagehinweise fr Schlauchleitungen / flexible hose

installation guidelines

Sicherheitshinweise fr Schlauchleitungen / Safety Instructions for Hoses

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179717-06060

Control and Operating Logic Recommendation HATLAPA Water Cooled Compressors

REV 05/11

1 General Description 1.1 HATLAPA water cooled W compressors are reciprocating type air compressors,

directly coupled to a motor, rigidly mounted or resiliently mounted by means of Anti-Vibration mounts.

The equipment is designed to be operated via a remote mounted starter/control panel (supplied by either HATLAPA or the Customer). The compressor's rotating and reciprocating elements are lubricated by force feed lubrication by means of a gear wheel pump or splash lubricated (W55 only) via 'dippers' on the con-rods, hitting the oil surface. The compressor is arranged with a water cooling system. This system cools both the air interstage and after coolers. An integrally mounted water circulating pump can be supplied by HATLAPA. This pump is directly driven by the crankshaft of the compressor. 1.2 Pressure gauges are provided for monitoring the air interstage and final stage

pressures (PI1, PI2) as well as for the oil pressure (PI4) (not for splash lubricated compressor W55).

1.3 Safety valves are fitted to each air stage of the compressor (SV). 1.4 It is recommended to fit the compressor with the following protection devices:

Minimum oil pressure (F2): alarm/shutdown High compressed air temperature (F3): alarm/shutdown High compressor motor current: alarm/shutdown

(must be incorporated into contactor cabinet) Note:

The low oil pressure and the high air temperature switch are closed under normal running conditions and open on fault.

The low oil pressure switch is connected via a 5 sec. timer delay on start-up, to enable building up of the oil pressure.

1.5 The starter/controller should be capable of the following functions: Selection of manual mode local start/stop only Selection of automatic mode local start/stop sequence

controlled by air pressure switch Selection sequence of operation - if more than one compressor is charging the system, a

selector switch should be fitted enabling the sequence in which the compressors should work i.e. lead and follow.

optional: Emergency stop operation Selection of remote control

2 Operation 2.1 Normal Running Procedure (Automatic Control) Note: The manual drain valves installed in-line with the solenoid valves should be open.

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179717-06060

Control and Operating Logic Recommendation HATLAPA Water Cooled Compressors

REV 05/11

On switching to AUTOMATIC mode, the following events occur: 2.1.1 The compressor starts and runs off load (open solenoid drain valves (NO)).

The water shut off valve Y5 (optional) is energised to open (when fitted). The compressor will run off load for 5 seconds after which solenoid valves are energised to close to charge the air system. Note: If a visual flow indicator (FI) is fitted to the compressor cooling water outlet, this should be checked to ensure that water is circulating through the compressor. In the event that there is no flow, the compressor should be stopped and the cause investigated.

2.1.2 The compressor is now controlled by the air system pressure switch. At 20 minutes intervals (adjustable dependant on ambient conditions) solenoid drain valves are de-energised to open for 5 seconds to drain moisture collected in the interstage and final stage separator.

2.1.3 On air system charged signal, from the air system pressure switch, solenoid drain valves are de-energised to open to drain and unload the compressor. The compressor stops. With a 2 minute delay the water shut off valve Y5 (optional, NC) is de-energised to close. On recharge signal the compressor starts running again.

2.1.4 On pressing the STOP button solenoid drain valves are de-energised to open to drain the separators and the compressor stops off load. With a 2 minute delay the water shut off valve Y5 (optional) is de-energised to close.

2.2 Sequence Selector Switch If more than one compressor is charging the receiver, the Sequence Selector Switch changes which compressor is the lead and which is the follow machine. 2.3 Manual Mode Running 2.3.1 On switching to MANUAL mode, the following events occur: The compressor will start and run in this mode only if the high air temperature switch is not indicating alarm. After 5 sec. of running the oil pressure monitoring is also active in manual mode. The Stop button and motor overloads will still stop and unload the compressor. Under manual mode the final pressure will not stop the compressor! The solenoid drain valves will close 5 seconds after start and will open at compressor stop. The interval drainage is not active in Manual Mode. 2.4 Emergency Stop (optional) Upon activating the emergency stop the compressor stops immediately, the solenoid drain valves open unloading the compressor and the water shut off valve Y5 closes without delay.

3 General 3.1 It is recommended that individual control panel indicator lamps (or text display

indications) are provided as follows: Compressor running Low oil pressure alarm/shutdown, respectively low oil level alarm/shutdown High air temperature alarm/shutdown Compressor motor overload

3.2 It is recommended that following floating contacts are provided for ships monitoring system:

Compressor running signal (NO = open, when not running) common alarm (NC = closed, if no alarm) in special cases individual alarm contacts for motor overload, low oil pressure or high air

temperature are required by the customer (NC = closed, if no alarm)

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Wartungsvorschrift fr lschmierpumpe Maintenance instructions for the lubricating oil pump

Instructions dentretien pour la pompe huile de graissage

Wartung: Eine besondere Wartung der Schmierpumpe whrend des Betriebes ist nicht notwendig. Sie mu aber mindestens einmal im Jahr grndlich mit Benzin oder Petroleum durchgepumpt werden. Eine Reini-gung ist auch dann notwendig, wenn die Schmierpumpe erst lngere Zeit nach Ablieferung in Betrieb genommen wird oder mehrere Monate nicht gearbeitet hat. Die in den Steuerkanlen befindlichen lrckstnde knnen sich verhrtet haben und stren die Funktion der Pumpe. Das Nichtbeachten dieser Vorschrift kann zum Versagen der Schmierpumpe fhren.

Maintenance: A particular maintenance of the lubricating pump is not required during the operating of the pump. lt is necessary, however, at least once a year, to flush the pump thoroughly with gasoline or petroleum, by pumping it through the pump. A cleaning is also required when the pump is put into Operation only a long time after its delivery, or when it has been left unused during several months. The oil residues which are in the distribution lines may have turned hard and disturb the Operation of the pump. The non-observance of the foregoing instructions may lead to a failure of the lubricating pump.

Entretien: Un entretien spcial de la pompe de graissage pendant le fonctionnement nest pas ncessaire. Mais on doit, au moins une fois par an, la laver fond avec de l essence ou du ptrole en pompant ce liquide travers de la pompe. Un nettoyage est galement ncessaire lorsque la pompe nest mise en service quau bout d une priode de temps aprs sa Iivraison ou lorsquelle na pas fonctionne pendant plusieurs mois. Les rsidus dhuile se trouvant dans les canaux de distribution peuvent avoir durci et perturbent le fonctionnement de la pompe. La non-observation de ces instructions peut avoir pour consquence une panne de la pompe de graissage.

Einstellen der Frdermenge:

Mit der Regelschraube, die sich im Pumpenkolben befindet, wird der Hub verstellt. Beim Rechtsdrehen wird die Frdermenge grer, beim Linksdrehen kleiner. Erforderliche Tropfenanzahl siehe Kapitel "Zylinderschmierung"!

Adjustment of the Delivery: The stroke can be varied by means of the adjusting screw

in the pump piston: Increase in delivery by clockwise turning and decrease in delivery by anti-clockwise turning.

Refer to chapter "Lubrication of cylinders" for the number of drops required.

Rglage du Refoulement: La course de piston est rgle laide de la vis de rglage se trouvant dans le piston. Tourner droite pour augmenter le refoulement, tourner gauche pour diminuer le refoulement.

Voir chapitre "lubrification des cylindres" pour le nombre de gouttes ncessaire.

Kompressortyp W 80 - W 420

weniger l decrease in

delivery pour diminuer le refoulement

mehr l increase in

delivery pour augmenter le refoulement

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Wartungsvorschrift fr lschmierpumpe Maintenance instructions for the lubricating oil pump

Instructions dentretien pour la pompe huile de graissage

Wirkungsweise: Der Antrieb erfolgt ber ei:n Schneckengetriebe, das die verzahnte Hubscheibe mit der Steuerwelle antreibt. Fr jeden Ausla befindet sich im Pumpenkrper ein Frderkolben (bei 4 Auslssen fr je 2 Auslsse), der von der Hubscheibe, die zwischen einer Regeischraube und der Druckkante des Kolbens luft, bewegt wird. Beim Saughub, bei dem die Druckbohrung vollkommen geschlossen ist, saugt der Pumpenkolben aus einem lbehlter oder aus dem lsumpf der Maschine das l ber eine Saugbohrung an. Die Steuerung erfolgt durch die Drehbewegung der Steuerwelle ber eine Nut und eine Bohrung. Nach Beendigung des Saughubes verschliet die Steuerwelle die Saugbohrung und gibt die Druckbohrung frei, damit die jetzt folgende Hubbewegung des Pumpenkolbens das l unter Druck der Schmierstelle zufhren kann. Mode of Operation: The pump is driven via a worm gearing which drives the distribution shaft together with the toothed cam plate. In the pump body, there is one piston for each outlet port (or for 2 outlets each in case of 4 outlets). The piston is moved up and down by the cam plate rotating between adjusting screw and actuacting shoulder of the piston. During the suction stroke, when the outlet port is completely closed, the piston sucks oil from an oil tank or the machine sump through the inlet port. This is controlled by the rotating distribution shaft fitted with groove and bores. On termination of the suction stroke, the distribution shaft closes the inlet port and opens the outlet port in order to allow the piston, during the now following stroke, to deliver the oil under pressure to the point of lubrication. Mode de Fonctionnement: La pompe est entrane par un engrenage vis sans fin entranant larbre de distribution ensemble avec le disque came du type engrenage. Dans le corps de pompe, il y a un piston pour chaque orifice de refoulement (ou pour 2 orifices de refoulement, sil y en a 4). Le piston est actionn par le disque came qui tourne entre une vis de rglage et le chant de commande du piston. Lors de la course daspiration quand Iorifice de refoulement est compltement ferme, le piston aspire de lhuile dun rservoir huile, ou bien de la cuvette-carter huile de la machine, travers dune orifice daspiration sous la conduite de larbre de distribution tournant et tant muni dune rainure et de canaux. La course daspiration une fois termine, larbre de distribution ferme Iorifice daspiration et ouvre lorifice de refoulement pour permettre le piston, lors de la course suivante, de refouler lhuille sous pression vers le point de lubrification.

1 Pumpengehuse pump body

corps de pompe

2 Pumpendeckel pump cover

couvercle de pompe

3 Steuerwelle operating shaft

arbre de distribution

4 Hubscheibe cam plate

disque came

5 Kolben piston

piston

6 Regelschraube adjusting screw

vis de rglage

7 Kontermutter locknut

contre-crou

8 Feder spring

ressort

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Anzugsdrehmomente Typ Tightening Torques

Couples de serrage W110 - W420

Stand: 24.09.1999

Zylinderkopf

cylinderhead 370 Nm

culasse de cylindre

Zylinder cylinder 370 Nm

cylindre

Pleuel connecting rod 83 Nm 1)

bielle

Ventilzentralschraube 1. Stufe / 1st Stage / 1re tage 100 Nm valve fitting bolt 2. Stufe / 2nd stage / 2me tage 22 Nm

goujon de soupape

Lagerdeckel Kurbelgeh. crankshaft bearing cover 78 Nm

couvercle palier/carter

Ventildeckel 2. Stufe valve cover 2nd stage 78 Nm

couvercle de soupape 2me tage

1) Kurbelzapfen und Gewinde einlen Oil crank pin and bolts threads

Huilage tourillon de vilebr. et filetage

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Verschleigrenzen Typ Wearing limits

Limites dusure W110 W220 W330

Stand: 24.09.1999

Durchmesser Zylinder / Zylinderlaufbuchse 1. Stufe diameter cylinder / cylinder liner 1st stage 130,50 mm diamtre du cylindre / chemise du cylindre 1re tage

2. Stufe 2nd stage 117,3 mm 2me tage

Kolbenringspaltma von oben nach unten 1. Stufe 1,3 mm piston ring gap clearance from top to bottom 1st stage 1,3 mm jeu de joint des segments du piston de haut en bas 1 re tage 1,3 mm 2. Stufe 1,2 mm 2nd stage 1,2 mm 2me tage 1,2 mm 0,9 mm

radiales Lagerspiel Kurbelwellenhauptlager 1) radial bearing clearence crank shaft main bearing 1) 0,3 mm jeu radial du palier principale de vilebrequin 1) radiales Lagerspiel Pleuelhauptlager 1) radial bearing clearence connecting rod main bearing 1) 0,3 mm jeu radial du palier principale de la bielle 1) radiales Lagerspiel Pleuelbuchse 1) radial bearing clearence connecting rod wrist pin bushing 1) 0,15 mm jeu radial de la douille du pied de la bielle 1) 1) Um das radiale Lagerspiel zu bestimmen, zieht man den gemessenen Zapfendurchmesser vom

gemessenen Lagerdurchmesser ab. 1) In order to find out the radial bearing clearance, subtract the measured journal diameter from the measured

bearing inside diameter. 1) Pour trouver le jeu du palier radial, dduire le diamtre mesur du tourillon du diamtre dalsage mesur

du palier.

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178483 FLEXIBLE HOSE

INSTALLATION GUIDELINES

16.01.2006

Flexible hoses are used for connecting a flexible mounted compressor assembly to a rigid piping system. When a hose is installed, it must allow the compressor to move in all three directions. See typical applications below, which show a single bend, to achieve this. The diagrams apply to both air and water. Note: The following diagrams show flexible hoses with threaded end connections, however flanged end connections may be supplied. These guidelines apply to the flexible part of the hose, regardless of the type of end fitting supplied.

No pressure High pressure

To allow the flexible part of the hose to move when pressurised, ensure no supporting clamps are located on the bends.

incorrect correct

On installation, ensure that the flexible part of the hose is not twisted, this could result in hose damage and, when pressurised, it could untwist, loosening the connections.

122/Pitrowski 1/4

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16.01.2006

incorrect correct

Use angle adaptors to eliminate tight bend radii and sharp twists occurring in the hose.

incorrect correct

If the installation bend radius is less than the minimum allowed, use angle adaptors to eliminate tight bend radii.

122/Pitrowski 2/4

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16.01.2006

incorrect correct

Ensure the hose is installed with a smooth bend, avoiding any tight corners, which could cause the flexible part of the hose to collapse.

incorrect correct

In a collinear application, do not install the hose in a straight line or with kinks, use angle adaptors.

122/Pitrowski 3/4

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16.01.2006

incorrect correct Ensure the hose is kept away from hot surfaces by using suitable clamps. High ambient temperatures can reduce the life of the flexible part of the hose.

122/Pitrowski 4/4

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Safety Instructions for Hoses

1 General Hose pipes are safety relevant parts which may endanger persons and the environment in case of failure.

1.1 Installation and maintenance

During installation the hoses must in no way be damaged, bent, twisted or exerted to pressure. They must not be painted or have contact with sharp objects! For cleaning hose pipes and hoses neither aggressive cleaning agents nor pressure cleaners may be used. They can damage the hose surface resp. hose line!

Hose pipes must be inspected visually by the assembly/service personnel before commissioning and once a year. Inspection is carried out under the following aspects:

Damage to the outer layer Decay of the outer layer Deformation of the hose or hose pipe (alteration of the geometry, layer

separation, forming of blisters) Damage or deformation of the hose fitting Corrosion of the fitting (impairs function and strength) Installation (chafing at sharp edges or smooth surfaces) Exceeding the admissible storage resp. operational duration (stated below)

1.2 Storage and durability According to DIN 7716 proper storage is to be understood as follows:

max storage time 2 years dry, cool, dust-free no direct sunlight or UV light protection against ozone protect against heat store lying and without tension

According to EN 982 resp., DIN 20066 following must be observed: 1. Once installed, the hoses have a durability of 6 years and must be replaced after

this period. 2. If the max. storage time of 2 years is exceeded, then the hose may no longer be

used. If the hose is installed within this period, the durability of 6 years is reduced by the period of storage accordingly.

It lies within the responsibility of the user that all hoses mentioned in this manual are checked at regular intervals, and to guarantee correct and safe function once the guarantee period has elapsed, thus preventing damage to persons and the environment.

date 18.04.2005 page 1 of 1 Created by Tanz

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Ersatzteil-VerzeichnisList of spare parts

Liste des pices de rechange

KolbenkompressorPiston compressor

Compresseur piston

W 110 W 140

Zum Ersatzteil-Verzeichnis To the list of spare parts

Vers la liste des pices de rechange

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-

2

1

Stand: 02.03.09

Ersatzteilverzeichnis

List of spare parts Liste des pices de rechange

Kompressor W110-140 Compressor W110-140 Compresseur W110-140

Benennung / designation / dsignation Tafel / table / planche Kurbelgehuse / crank case / carter ...............................................................1-300-010 Kurbelwelle / crankshaft / arbre manivelle.....................................................2-501-010 Zylinder und Zylinderkopf / cylinder and cylinder head / cylindre et culasse ...........................................................................................1-597-020 Ventile / valves / soupapes..............................................................................2-597-020 Kolben und Pleuelstangen / piston and connecting rod / piston et bielle...3-597-020 Leitungssatz (ohne Khlwasserpumpe) / set of pipes (without cooling pump) / Jeu de tuyaux (sans pompe d'eau rfrigrante) ..............................1-597-030 Armaturen / fittings / robinetterie....................................................................1-597-040 Schmiersystem / lubrication system / systme de lubrification ..................2-597-040 Schwungrad und Kupplung / flywheel and coupling / Volant et accouplement ...................................................................................1-597-014 Khlwasserversorgung (mit Pumpe) / cooling water supply (with pump)/ alimentation dau rfrigrante (avec pompe) ................................................1-597-022 Ansaugsystem / suction system / systme daspiration ..............................1-597-032 Grundrahmen starr gelagert / base frame rigidly mounted / Chssis suspension rigide ...........................................................................1-597-041 Grundrahmen elastisch gelagert / base frame resiliently mounted / Chssis suspension lastique .....................................................................1-597-042 Anbau ldruckwchter / oil pressure switch mounting / pressostat 1-1100-052 mont sur lhuile ............................................................................................2-1100-052 Automatische Entwsserung / automatic drainage / vidange automatique .......................................................................................1-303-053 Entwsserung / drainage / vidange 2-505-053

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Kurbelgehusecrank case

carter

W110-W140

Tafel / Table / Planche 1-300-010

Teil-Nr. / Part-No. Ident-Nr. / Ident-No. Benennung / Designation Menge / Qty.

No. de pices No. didentific Dsignation Qt.

1-15 10.10.10 Kurbelgehuse vormontiert 1

crank case, preassembled

carter, mont lavance

1 10.10.10.10 Kurbelgehuse 1

crank case

carter

5 10.10.10.50 Gerade Einschraubverschraubung 1

straight male stud coupling

union simple mle

6 10.10.10.60 lsaugsieb 1

oil sieve on the suction side

tamis dhuile au cte daspiration

7 10.10.10.70 lschauglas 1

oil level inspection glass

verre de regard de niveau dhuile

8 10.10.10.80 Verschluschraube 1

screw plug

vis de fermeture

9 10.10.10.90 Dichtring 1

packing ring

rondelle de joint

10 10.10.10.100 Hutmutter 1

cap nut

crou borgne

11 10.10.10.110 Einstellschraube 1

threaded pin

cheville filete

12 10.10.10.120 Sechskantmutter 1

hexagon nut

crou hexagonal

13 10.10.10.130 Druckfeder 1

pressure spring

ressort

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carter

W110-W140




14 10.10.10.140 Kugel 1

ball

boulet

15 10.10.10.150 Dichtring 2

packing ring

rondelle de joint

16 10.10.20.10 Lagerdeckel 1

bearing cover

chapeau de palier

17 10.10.20.20 Gleitlager 1

sleeve

douille

18 10.10.30 Dichtung 1

gasket

joint

19 10.10.40 Sechskantschraube 6

hexagon head bolt

vis hexagonale

20 10.10.50.10 Schaulochdeckel 1

inspection hole cover

couvercle de visire

21 10.10.50.20 Prallblech 1

baffle plate

platte de chicane

22 10.10.50.30 Gewindestift 3

threaded pin

cheville filete

23 10.10.50.40 Sechskantmutter 3

hexagon nut

crou hexagonal

24 10.10.60 Schaulochdeckel 1

inspection hole cover

couvercle de visire

Orig

inal

201

1-10

-21


carter

W110-W140




25 10.10.70 Entlftungsstutzen 1

vent socket

raccord de dgagement dair

26 10.10.80 Dichtung 2

gasket

joint

27 10.10.90 Ovaldichtung 1

oval packing

joint ovale

28 10.10.100 Stiftschraube 8

stud bolt

goujon prisonnier

29 10.10.110 Sechskantschraube 2

hexagon head bolt

vis hexagonale

30 10.10.120 Entlftungsfilter 1

vent filter

filtre de passage dair

40 10.30.10 Gehuse 1

housing

carter

41 10.30.20 Zylinderschraube 4

cylinder head bolt

vis tte cylindrique

42 10.30.30 Dichtung 1

gasket

joint

43 10.30.40 Deckel 1

cover

couvercle

44 10.30.50 Dichtung 1

gasket

joint

Orig

inal

201

1-10

-21


carter

W110-W140




45 10.30.60 Zylinderschraube 4

cylinder head bolt

vis tte cylindrique

46 10.30.70 Dichtring 4

packing ring

rondelle de joint

47 10.30.80 Verschluschraube 2

screw plug

vis de fermeture

48 10.30.90 Dichtring 2

packing ring

rondelle de joint

49 10.30.100.10 Pumpengehuse 1

pump casing

corps de pompe

50 10.30.100.20 lpumpenzahnrad 1

gear wheel for oil pump

roue dente de la pompe huile

51 10.30.100.30 Antriebswelle 1

driving shaft

arbre de commande

52 10.30.100.40 Deckel 1

cover

couvercle

53 10.30.100.50 O-Ring 1

o-ring

joint torique

54 10.30.100.60 Dichtung 1

gasket

joint

55 10.30.100.70 Zylinderschraube 4

cylinder head bolt

vis tte cylindrique

Orig

inal

201

1-10

-21


carter

W110-W140




56 10.10.130 Wellendichtring 1

radial packing ring

bague dtancheite radiale

57 10.10.160 Hutmutter 8

cap nut

crou borgne

Orig

inal

201

1-10

-21

Orig

inal

201

1-10

-21

Kurbelwelle crank shaft

arbre manivelle

W110-W140




2 10.10.10.20 Gleitlager 1 sleeve

douille

37 10.20.10 Kurbelwelle vormontiert 1

crank shaft, preassembled

arbre manivelle, mont lavance

39 10.20.10.30 Pafeder 1

fitting key

clavette dajustage

41 10.20.10.20 Scheibe 1

disc

disque

42 10.20.10.50 Sechskantschraube 1

hexagon head bolt

vis hexagonale

61 10.20.10.60 Sicherungsring 1

securing ring

rondelle de sret

Orig

inal

201

1-10

-21

Orig

inal

201

1-10

-21

Zylinder und Zylinderkopf cylinder and cylinder head

cylindre et culasse

W110-W140




1 20.10.10.10 Zylindermantel vormontiert 1 cylinder jacket, preassembled

corps du cylindre, mont lavance

2 20.10.10.20 Stiftschraube 4

stud bolt

goujon prisonnier


stud bolt

goujon prisonnier


stud bolt

goujon prisonnnier


stud bolt

goujon prisonnier

6 20.10.10.60 Verschluschraube 1

screw plug

vis de fermeture

7 20.10.10.70 Dichtring 1

packing ring

rondelle de joint

8 20.10.10.80 Laufbuchse 1

cylinder liner

chemise de cylindre

9 20.10.10.90 O-Ring 2

o-ring

joint torique

10 20.10.10.100 O-Ring 5

o-ring

joint torique

11 20.10.20 Zylinderkopf 1

cylinder head

culasse

Orig

inal

201

1-10

-21


cylindre et culasse

W110-W140




12 20.10.20.20 Verschluschraube 5 screw plug

vis de fermeture

13 20.10.30 Ventildeckel 1

valve cover

chapeau de soupape

14 20.10.40 Druckstck 1

thrust member

membre de pression

15 20.10.50.10 Deckel 1

cover

couvercle

16 20.10.50.20 Rundflansch 1

round bride

bride ronde

17 20.10.50.30 Distanzrohr 2

distance tube

tuyau de distance

18 20.10.50.40 Zinkschutz 1

zinc protection

protection en zinc

19 20.10.50.50 Schutzkappe 1

protective cap

capot de protection

20 20.10.50.60 Sprengplatte 3

burst plate

pastille de sret

21 20.10.150 Ringschraube 1

eye bolt

piton


hexagon head bolt

vis hexagonale

Orig

inal

201

1-10

-21


cylindre et culasse

W110-W140




23 20.10.50.90 Sicherungsring 6 securing ring

segment de scurit


hexagon head bolt

vis hexagonale


hexagon head bolt

vis hexagonale

26 20.10.60 Tellerfeder 2

spring plate

ressort belleville

27 20.10.70 Dichtung 1

gasket

joint

28 20.10.80 O-Ring 4

o-ring

joint torque

29 20.10.90 Dichtung 1

gasket

joint

30 20.10.100 Dichtung 1

gasket

joint

31 20.10.110 Dichtung 1

gasket

joint

32 20.10.120 Sechskantmutter 8

hexagon nut

crou hexagonal

33 20.10.130 Sechskantmutter 4

hexagon nut

crou hexagonal

Orig

inal

201

1-10

-21


cylindre et culasse

W110-W140




34 20.10.140 Sechskantmutter 10 hexagon nut

crou hexagonal

Orig

inal

201

1-10

-21

Orig

inal

201

1-10

-21

Ventilevalves

soupapes

W110-W140

Tafel / Table / Planche2-597-020


No. de pices No. didentific Dsignation Qt.35 20.20.10 komb. Saug.-und Druckventil 1. Stufe 1

comb. suction and pressure valve 1st stagesoupape combine 1er etage

36 20.20.20 Rechteckring 2packing ring

rondelle de joint37 20.20.30 Sicherheitsmutter 1

safety nutcrou de blocade

38 20.20.40 komb. Saug.- und Druckventil 2. Stufe 1comb. suction and pressure valve 2nd stage

soupape combine 2me tage39 20.20.50 Dichtring 1

packing ringrondelle de joint

40 20.20.60 O-Ring 1o-ring

joint torique41 20.20.70 O-Ring 1

o-ringjoint torique

42 20.20.80 O-Ring 1o-ring

joint torique54 20.20.10.10 1 Satz Ventilplatten u. Federn 1

1 set of valve plates and springs1 jeu de disques et ressorts de soupape

55 20.20.40.10 1 Satz Ventilplatten u. Federn 11 set of valve plates and springs

1 jeu de disques et ressorts de soupape

Orig

inal

201

1-10

-21

Orig

inal

201

1-10

-21

Kolben und Pleuelstangepiston and connecting rod

piston et bielle

W110-W140



No. de pices No. didentific Dsignation Qt.43 20.30.10 Kolben kompl. 1

piston compl.piston compl.

44 20.30.10.20 Kolbenbolzen 1wrist pin

axe du piston

45 20.30.10.30 Sicherungsring 2securing ring

anneau se scurit46 20.30.10.40 lschlitzring 1

oil scraper ringracleur dhuile

47 20.30.10.50 Verdichtungsring 3piston ring

segment de piston48 20.30.10.60 Verdichtungsring 3

piston ringsegment de piston

49 20.40.10 Pleuelstange kompl. 1complete connecting rod

bielle complte50 20.40.10.10.20 Paschraube 2

fitting boltboulon ajust

51 20.40.10.20 Pleuellager 1connecting rod bearing

coussinet de bielle

52 20.40.10.30 Pleuelbuchse 1wrist pin bushing

boite de bielle

53 20.40.10.40 Spannstift 1spring dowel

manchon

Orig

inal

201

1-10

-21

Orig

inal

201

1-10

-21

Leitungssatz (ohne Khlwasserpumpe)set of pipes (without cooling water pump)

jeau de tuyaus (sans pompe de rfrigerante)

W110-W140



No. de pices No. didentific Dsignation Qt.1 30.10.10 Ovalflansch 1

oval bridebride ovale

2 30.10.30 Ovaldichtung 1oval packingjoint ovale

3 30.10.40 Sechskantschraube 2hexagon head bolt

vis hexagonale4 30.20.10 Flansch 1

flangebride

5 30.20.20 O-Ring 1o-ring

joint torque6 30.20.30 Zylinderschraube 2

cylinder head boltvis tte cylindrique

7 30.20.40 Verschluschraube 1screw plug

vis de fermeture

8 30.20.50 Dichtring 1packing ring

rondelle de joint9 30.20.60 Gerade Einschraubverschraubung 1

straight male stud couplingunion simple mle

Orig

inal

201

1-10

-21

Orig

inal

201

1-10

-21

Armaturenfittings

robinetterie

W110-W140



No. de pices No. didentific Dsignation Qt.1 40.10.10 Manometer 1. Stufe 1

pressure gauge 1st stagemanomtre 1er tage

2 40.10.20 Manometer 2. Stufe 1pressure gauge 2nd stagemanomtre 2me tage

3 40.10.30 ldruckmanometer 1oil pressure gauge

manomtre de pression dhuile4 40.10.40 Anschlustck 2

fittingraccord

5 40.10.50 Anschlustck 1fitting

raccord

6 40.10.60 Wika Dichtring 3Wika packing ring

rondelle de joi

hatlapa w series

Documents

additional safety instructions

general safety instructions

safety original

operating instructions

safety equipment

lubricating instructions

technical indications

important information