Instruction Manual V-Line Water Cooled Compressor: V105, V150, V200, V250, V375

Instruction Manual
V-Line Water Cooled Compressor

V105, V150, V200, V250, V375
PCH 1540
ISSUE 7 0707
Uetersener Maschinenfabrik GmbH & Co. KG Discovery Court Business Centre

Tornescher Weg 5-7 551-553 Wallisdown Road,
25436 Uetersen / Germany Poole, Dorset BH12 5AG, England
Telephone: +49-4122-711 0.. Telephone: +44 (0) 1202 853180

Facsimile: +49-4122-711 330 Service Telephone: +44 (0) 1202 853194
Internet http://www.hatlapa.de Facsimile Spares/Sales/Service: +44 (0) 1202 853191
E-mail: info@hatlapa.de
CAUTION
1. The following manual must be read before proceeding with installation, operation
and maintenance of this equipment.
2. Health & Safety Act Compliance. Before working on this equipment personnel
should be made aware of, and ensure compliance with, the Health and Safety
Regulations appropriate to this class of work.
3. The handling points are indicated on the unit and must be used. The hooks of
slings must be fitted to lifting eyebolts using shackles.
4. Before proceeding with maintenance on the unit, or making adjustments to its
connections and fittings, it must be stopped and isolated electrically and
mechanically and the outlet valves closed. Some units on automatic standby
duty, or isolators are remote from the unit and extra care is then necessary to
ensure that isolation is complete.
HATLAPA Hamworthy Marine Compressors reserves the right to make changes to the design of the machine
without prior notice.
CONTENTS
1 INSTALLATION......................................................................................................................... 1-1
1.1 LOCATION................................................................................................................................. 1-1
1.2 MOUNTING................................................................................................................................ 1-1
1.3 COMMISSIONING ..................................................................................................................... 1-1
1.3.1 Commissioning Procedure......................................................................................................... 1-1
2 OPERATING PROCEDURE...................................................................................................... 2-1
2.1 DESCRIPTION........................................................................................................................... 2-1
2.2 CONTROL AND OPERATING PHILOSOPHY .......................................................................... 2-1
2.3 NORMAL RUNNING PROCEDURE (AUTOMATIC CONTROL) .............................................. 2-1
2.4 MANUAL MODE RUNNING ...................................................................................................... 2-2
2.5 GENERAL .................................................................................................................................. 2-3
3 MAINTENANCE......................................................................................................................... 3-1
3.1 GENERAL .................................................................................................................................. 3-1
3.2 MAINTENANCE INSTRUCTIONS............................................................................................. 3-3
3.2.1 Lubrication Oil Checking ............................................................................................................ 3-3
3.2.2 Lubrication Oil Changing............................................................................................................ 3-3
3.2.3 Air Suction Filter/Silencer Removal and Replacement .............................................................. 3-3
3.2.4 First Stage Concentric Valve Removal/Servicing/Replacement ................................................ 3-3
3.2.5 Final Stage Concentric Valve Removal/Servicing/Replacement ............................................... 3-8
3.2.6 First Stage Cylinder and Piston Removal ................................................................................ 3-12
3.2.7 First Stage Cylinder and Piston Reassembly........................................................................... 3-14
3.2.8 Final Stage Cylinder and Piston Removal ............................................................................... 3-15
3.2.9 Final Stage Cylinder and Piston Reassembly.......................................................................... 3-16
3.2.10 Cooler Tubenest and Header Removal ................................................................................... 3-17
3.2.11 Tubenest Clean/Examine/Replace .......................................................................................... 3-17
3.2.13 Cooler box end cover ............................................................................................................... 3-19
3.2.14 Connecting Rod Big End Bearing Removal ............................................................................. 3-19
3.2.15 Bearing Removal and Reassembly to Connecting Rods......................................................... 3-19
3.2.16 Connecting Rod Assembly Fitment to Compressor................................................................. 3-24
3.2.17 V105, V150, V200, and V250 Drive Motor and Coupling Removal from Compressor ............ 3-24
3.2.18 V105, V150, V200, and V250 Drive Motor and Coupling Assembly to Compressor............... 3-25
3.2.19 V375 Drive Motor and Coupling Removal from, and Assembly to, Compressor..................... 3-26
3.2.20 Flywheel and Drive End Oil Seals Removal from Compressor ............................................... 3-27
3.2.21 Flywheel and Drive End Oil Seal Reassembly to Compressor................................................ 3-28
3.2.22 Crankshaft and Main Bearing Removal from Compressor ...................................................... 3-29
3.2.23 Crankshaft and Main Bearings Reassembly to Compressor ................................................... 3-29
3.2.24 Oil Level Switch Remove/Clean/Replace ................................................................................ 3-30
3.2.25 Air and Water Safety Valves .................................................................................................... 3-30
3.2.26 Separator Bowl Removal, Diffuser Plate Examination and Removal ...................................... 3-30
3.2.27 Diffuser Plate Fitting and Separator Bowl Reassembly ........................................................... 3-31
3.3 WATER CIRCULATING PUMP (if supplied)............................................................................ 3-32
3.3.1 General Overhaul..................................................................................................................... 3-33
3.3.2 Service Information .................................................................................................................. 3-33
3.4 ELECTRICAL MAINTENANCE................................................................................................ 3-33
3.5 FAULT FINDING CHART......................................................................................................... 3-33
3.6 TOOLS REQUIRED FOR COMPRESSOR MAINTENANCE.................................................. 3-35
4 TECHNICAL DATA ................................................................................................................... 4-1
4.1 GENERAL .................................................................................................................................. 4-1
4.2 PERFORMANCE ....................................................................................................................... 4-1
4.3 OTHER DATA ............................................................................................................................ 4-1
4.4 CRANKCASE LUBRICANTS..................................................................................................... 4-3
4.4.1 Approved Oils............................................................................................................................. 4-3
4.4.2 Oil Company Equivalents........................................................................................................... 4-3
4.4.3 Additional Maintenance for Machines Lubricated with Synthetic Oils ....................................... 4-3
5 DRAWINGS ............................................................................................................................... 5-1
FIGURES
Figure 3.1 First Stage Concentric Valve V105/150 3-5

Figure 3.2 First Stage Concentric Valve V200/250 3-6
Figure 3.3 First Stage Concentric Valve V375 3-7
Figure 3.4 Final Stage Concentric Valve V105/150 3-9
Figure 3.5 Final Stage Concentric Valve V200/250 3-10
Figure 3.6 Final Stage Concentric Valve V375 3-11
Figure 3.7 Cooler Header 3-18
Figure 3.8 V105/V150 Fitting and Orientation of Big End Bearings/Conrods 3-21
Figure 3.9 V200/V250 Fitting and Orientation of Big End Bearings/Conrods 3-22
Figure 3.10 V375 Big End Bearings Fitting & Conrod Orientation in the Crankcase 3-23
Figure 3.11 Coupling 3-25
Figure 3.12 Gap Between Coupling and Flywheel 3-26
Figure 3.13 Coupling 3-26
Figure 3.14 Location of Angle Steel on Crankcase Rails 3-27
Figure 3.15 Water Circulating Pump 3-32
Figure 5.1 Typical Arrangement of V-Line Water Cooled Compressor with Gauges 5-1
Figure 5.2 Cooler 5-3
Figure 5.3 Crankshaft and Flywheel 5-4
Figure 5.4 First Stage Cylinder and Piston 5-5
Figure 5.5 Final Stage Cylinder and Piston 5-6
Figure 5.6 Separator 5-7
Figure 5.7 Gauges 5-8
TABLES
Table 3.1 Fastener Torque Settings (unlubricated) 3-1

Table 3.2 Maintenance Schedule 3-2
Table 3.3 Fixtures to Assist Flywheel Removal 3-27
Table 3.4 Items List - Water Circulating Pump 3-32
Table 3.5 Switch Settings 3-33
Table 3.6 Fault Finding Chart 3-33
Table 3.7 Tools Required for Compressor Maintenance 3-35
Table 4.1 Capacity and Power at 30 Bar 4-1
Table 4.2 Operating Parameters 4-1
Table 4.3 Recommended Maximum Wear Clearances 4-2
Table 5.1 List of Parts for Figure 5.1 5-1
Table 5.2 List Of Parts – V-Line Compressors 5-9
Spare Parts and Service
Spare Parts can be ordered direct from the following address:
HATLAPA Hamworthy Ltd. Telephone: +44 (0) 1202 853180

Discovery Court Business Centre Facsimile: +44 (0) 1202 853191
551 553 Wallisdown Road e-mail spares@hatlapa-uk.com
BH12 5AG England
When ordering spare parts, the following information is required to ensure that correct parts are supplied:
Type and serial number of machine: Obtained from machine nameplate
Item Number and full description of part required: Obtained from details in this publication
Technical Service and Advice:
Technical service and advice can be obtained during normal working hours from the above address, on the
following contact numbers
Telephone: +44 (0) 1202 853194
Facsimile: +44 (0) 1202 853191
Email: service@hatlapa-uk.com
Signs used
DANGER
This sign indicates behaviour which if not observed is highly dangerous, or which may lead to
permanent bodily injury.
Observe the warning exactly and pass this to other operators of the equipment also.
CAUTION
This sign indicates behaviour which if not observed may lead to injury to persons, severe
damage, or severe mal-function of the equipment, or to damage to the environment.
PAY ATTENTION
This sign indicates behaviour which if not observed may lead to damage or mal-function of the
equipment.
INFORMATION
This sign indicates tips and useful information which makes the operation of the equipment or
the understanding of the documentation easier.
CHAPTER 1 INSTALLATION
1 INSTALLATION
1.1 LOCATION
The suction inlet should be installed in a well ventilated position so that air drawn into the compressor is as
cool and dry as possible and there is adequate circulation to the drive motor integral cooling fan and all the
compressor external surfaces.
The compressor must be positioned with the axis of the crankshaft and motor fore and aft in the vessel to
ensure adequate lubrication during the vessels normal roll, pitch, list and trim modes.
1.2 MOUNTING
The compressor should be mounted on support plates/pads and supported by a ribbed structure suitable for
the type and weight of the compressor. The pads/plates must be clean and flat to within 0.5 mm (1 mm with
anti-vibration mounts). Shims should be used if necessary. Refer to general arrangement drawing supplied
with the compressor documentation package for mounting feet or anti-vibration mounts dimensions and
positions and weight of the compressor.
1.3 COMMISSIONING
DANGER
1. Do not make any adjustments to the compressor, its connections or fittings whilst
the compressor is running or on standby duty.
2. Do not run the compressor unless all protective guards fitted to it and its prime
mover are in place.
1.3.1 Commissioning Procedure
1. Ensure compressor is isolated from its electrical supply.

2. Check lubricating oil level in crankcase sump.
3. Before initial start up, or after any servicing has been carried out, or when the compressor has not
been run for 5 weeks or more, carry out the following procedures.
Remove the plugs from the side wall of the first stage cylinder and final stage cylinder head.
Pour 20 millilitres of lubricating oil through the exposed holes.
Replace plugs in cylinders.
PAY ATTENTION
After adding oil to the valves, the compressor must be barred over at least
3 complete revolutions to ensure lubrication of the cylinder bores during initial
start up and minimise the risk of the piston causing a hydraulic lock when the
compressor is started.
Open air bleed valve (Item C10 in Figure 5.2) to remove air trapped in water box cooler passages.
4. Remove guard covering barring over access aperture in crankcase.
5. Using a bar (not supplied) in one of the holes in the flywheel turn over the compressor through at least
three complete revolutions.
CAUTION
Take precautions to prevent injury to personnel whilst observing the direction
of rotation of the flywheel through the unguarded barring over access aperture.
Page 1-1
CHAPTER 1 INSTALLATION
6. Connect the electrical supply and carry out a momentary start and stop.
7. Check that rotation of compressor is clockwise looking on the drive end of the compressor (indicated
by cast arrow). If direction of rotation is incorrect, take appropriate steps to correct.
8. Isolate starter, refit guard (170) covering barring over access aperture.
9. Press start button. The compressor is brought on line to charge the air system. Check the following
details within the first minute of the run.
a. Check that the cooling water system is operating and the outlet from the compressor is
registering a flow.
b. Check that final stage air pressure is increasing over ambient pressure values.
10. Allow compressor to continue to run under the control of the system pressure switch and closely
monitor the temperature differential between cooling water inlet and outlet temperatures, adjusting
valves etc as appropriate to adjust the water flow rate to achieve a temperature differential of
approximately 15°C.
This temperature differential equates to the nominal flow rate as specified in

Technical Data
The compressor must run continuously for approximately 30 minutes to reach normal operating
temperature. It may be necessary to bleed off air from the system to prevent the compressor stopping
prematurely.
11. Check the operation of the system pressure switch.
12. After satisfactory operation of the pressure control system, the compressor is now commissioned for
use. The compressor may be either left running (on line) to charge the air system or stopped.
Page 1-2
CHAPTER 2 OPERATING PROCEDURE
2 OPERATING PROCEDURE
2.1 DESCRIPTION
The standard V-Line compressor is supplied with gauges, a dual set point high air temperature switch, a dual
set point low lubricating oil switch and two solenoid operated drain valves.
The high air temperature switch (double pole) is fitted to protect the compressor by shutting it down if the
temperature rises above the normal maximum operating temperature. As an option, the second pole of the
switch may be connected to give a panel indicated warning of approaching shutdown temperature.
The low lubricating oil switch (double pole) will also shut down the compressor if it detects the oil level is
below the minimum requirement. An adjustable time delay is included to overcome false tripping due to the
roll and pitch of the vessel. The second pole may be connected to give a panel warning of approaching
shutdown oil level.
The compressor starting method can be either star/delta or direct-on-line.
The compressor may be supplied with a water circulating pump if required.
2.2 CONTROL AND OPERATING PHILOSOPHY
The compressor is fitted with protection devices which immediately stop and unload the compressor, when it
is connected to a suitable starter, (supplied by Hatlapa Hamworthy or the customer) if any of the following
events occur:
− minimum oil level shutdown and optional pre-alarm
− high final delivery temperature shutdown and optional pre-alarm
− high compressor motor current shutdown only
− high water pump motor current shutdown only (of water circulating pump supplied)
− emergency stop button operation shutdown only
The control panel is capable of the following functions:

− selection of automatic mode local or remote start/stop sequence
− selection of manual mode local start/stop only
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.
2.3 NORMAL RUNNING PROCEDURE (AUTOMATIC CONTROL)
1. Energise the starter panel by operating the main isolator.

Set mode switch S1 to AUTO.
Set local/remote switch S2 as required.
Set drain switch S3 to AUTO (S3 not fitted if hand drain valves supplied)
Press RESET push button.
2. On pressing the START button, the compressor runs off-load for a short time (approximately 15 - 20
seconds) after which the drain/unloading solenoid valves are energised to close to charge the system.
(Note that the compressor will only go on load if the system is not fully charged.)
3. The compressor is now controlled by the air system pressure switch. At 5 minute intervals (adjustable)
the drain solenoid valves are de-energised for 2 seconds (adjustable) to drain the separator bowls. The
drainage interval and duration should be adjusted to suit climatic conditions, eg, high humidity – short
intervals and longer duration.
Page 2-1
4. On air system charged signal, the solenoid valves are de-energised to open to drain and unload the
compressor until a signal is received:
− on recharge signal the solenoid valves are energised to close causing the compressor to charge
the system
− if the recharge signal is not received within 5 minutes (adjustable) of the charged signal, the
compressor stops leaving the solenoid valves open. On recharge signal the compressor starts as
for pressing the START button (and lamp goes out).
5. On pressing the STOP button (or switching S1 to OFF or MAN) the solenoid valves are de-energised
to open to drain the separator bowls, the compressor continues to run-on unloaded for 5 minutes
(adjustable) before stopping. Pressing the START button during this cycle brings the compressor back
on line to recharge the system.
6. If the START button is pressed while the air system is fully charged, the compressor starts as
described in 2. The compressor is then controlled by the air system pressure switch as in 3 and 4
above.
2.4 MANUAL MODE RUNNING
Energise the starter panel by operating the main isolator.

Set mode switch S1 to MAN.
Set local/remote switch S2 to LOCAL.
Set drain switch S3 to AUTO (S3 not fitted if hand drain valves supplied).
Press RESET push button.
The compressor will start and run in this mode overriding the low oil level and high air temperature shutdown
devices. The emergency stop button and motor thermal overloads will still stop and unload the machine.
Compressor and air system protection during manual mode running are given by first and final stage air and
water jacket safety valves and any other safety device fitted to the installed system.
Starting, running and run down cycles are as for normal (automatic) running as described with the exception
of the following:
− oil level switch overridden.
− high air temperature switch overridden.
− remote start/stop function disabled.
Page 2-2
2.5 GENERAL
Individual volt-free change-over contacts and control panel mounted indicator lamps are provided as listed
below:
− compressor running
− water pump running (if fitted)
− low oil level shutdown
− low oil level warning (if fitted)
− high air temperature shutdown
− high air temperature warning (if fitted)
− compressor motor overload
− water pump motor overload (if fitted)
Terminals are provided for a remote emergency stop push-button (if required).
Warning (pre-alarm) oil level and high air temperature indicator lamps and volt free contacts, are an optional
extra and are not fitted as standard.
Page 2-3
CHAPTER 3 MAINTENANCE
3 MAINTENANCE
DANGER
1. Before proceeding with maintenance or overhaul, the compressor must be

stopped and isolated mechanically and electrically, and visible warning notices
displayed.
2. When working on water and/or air passages the compressor must be vented of all
pressurised air and drained of cooling water.
3. Viton o-rings and seals are fitted to this compressor. When viton is subjected to
excessive temperatures (above 400 °C) it decomposes and can cause serious
injury.
When maintaining the equipment protective gloves should be worn.
3.1 GENERAL
Routine maintenance of the compressor should be carried out at the intervals listed in the Maintenance
Schedule under normal conditions. However, the optimum period between servicing will depend upon the
operating conditions.
Before re-assembly, clean all parts with a suitable cleaning fluid and examine for wear, corrosion, cracks,
distortion, or any other damage. Renew as necessary. Refer to the wear tolerances given in Chapter 4 -
Technical Data.
When re-assembling compressor components, renew all joints, gaskets, and O-rings seals. Great care must
be taken to ensure that they are not damaged.
Item numbers in the text refer to items on the Sectional Arrangement Drawings which are at the end of this
manual.
When using Loctite products for nut and screw retention note the following. The shelf life of Loctite is one
year at a storage temperature of 6° - 22°C. All components to be fixed with Loctite should be thoroughly
degreased using a Loctite activator. If cured Loctite is present in a tapped hole or external thread, discard
the bolt or nut, or clean with a die and tap internal threads. All fasteners must be torqued to their specified
level (see Table 3.1).
After any servicing has been carried out, refer to Chapter 1.3.1, Commissioning Procedure, before restarting.
Table 3.1 Fastener Torque Settings (unlubricated)
M6 M8 M10 M12 M16 M20

Standard 6 Nm 16 Nm 32 Nm 70 Nm 170 Nm
Cooler - Header 70 Nm 170 Nm
Gudgeon Pin/Piston
6 Nm 20 Nm 35 Nm
fasteners
Flywheel Cone
35 Nm 71 Nm
Clamping screws
Coupling Pins 220 Nm 500 Nm
Page 3-1
Table 3.2 Maintenance Schedule
Commissioning Normal Operating Services

Period
Every 6 months
or 5000 hours.
Time required
Daily or every
Daily or every
or 2000 hours
Every 2 years
Every 5 years
for operation.
or 500 hours.
At 50 hours
10 hours
10 hours
1. Check oil level on dipstick. 9 9
2. Drain and refill lubricating oil. 9 9
3. Replace air inlet filter. 9
4. Clean and inspect delivery line non- 9 30 mins
return valve.
5. Clean first & second stage valves. 9 4 hours
Renew any parts or complete valve
as necessary. Renew seals/ O-rings.
6. Renew first & second stage valves. 9 2 hours
Renew seals/O-rings.
7. Check settings of all 9 1 hour
pressure safety valves,
replace as necessary.
8. Remove inter/after coolers and 9 4 hours
clean.
9. Dismantle and measure moving 9 6 hours
parts for wear.
10. Check condition of spider in 1st and 9 2 hours
2nd stage separators
11. Replace bearings 9 12 hours
A complete overhaul, including bearing replacement, is recommended every 5 years or 5,000 running hours.
After a major service, follow the commissioning procedure detailed in chapter 1.
Page 3-2
3.2 MAINTENANCE INSTRUCTIONS
3.2.1 Lubrication Oil Checking
Refer to Technical Data chapter for oil capacities and recommended lubricants.
1. Remove filler/dipstick and check oil level.
2. Fill/top up crankcase oil level if necessary with lubricating oil to full level on dipstick.
Periodically examine oil in crankcase and ensure that it is not contaminated with condensate. If the oil is
emulsified (creamy in colour) it must be changed and the crankcase cleaned. To minimise the risk of
emulsification use a recommended oil, ensure that the compressor is not overcooled by fitting a water shut
off valve, and maintaining a 15°C cooling water temperature rise across the machine.
If moisture forms without emulsification, as two separate liquids, condensate may be drained from below the
oil. The oil level should then be restored with fresh oil.
Crankcase oil contamination is often accompanied by an increase in sump oil level, due to oil being
supported by condensate fluid.
3.2.2 Lubrication Oil Changing
1. Remove the drain plug after the compressor has been running, whilst the oil is still warm and drain oil
from the compressor. Dispose of used oil in accordance with local regulations.
2. Clean the magnetic portion of plug before replacing into crankcase.
3. Remove and clean oil level switch, see chapter 3.2.24.
4. Refill with fresh oil.
3.2.3 Air Suction Filter/Silencer Removal and Replacement
1. Before removing the air filter silencer assembly, clean the outside of the filter body.
2. Remove wing nut (F8 – V105/150) (168 – V200/250/375) on top of filter assembly (166).
3. Remove top cover. On V150 only, remove wing nut (F4) on top element (F2).
4. Remove filter body complete, ie, with inlet resonator, hose clip, ‘O’ ring, and element.
5. Unless filter/silencer assembly is to be re-assembled immediately, cover valve cage aperture.
6. Renew element if necessary.
7. Reassemble filter (Hand tighten only).
3.2.4 First Stage Concentric Valve Removal/Servicing/Replacement
1. Remove air suction filter silencer assembly from valve cage as detailed in Chapter 3.2.3.
2. Remove studding (165) and the four nuts (56) and washers (57) from the top of the valve cage (45).
3. Release crankcase breather hose (32) from the hose connector (46). (Not applicable on V375).
4. Remove valve cage complete with concentric valve (50) using M12 or M16 screws (not supplied) in
the two tapped jacking holes. (On V375 use the eyebolt fitted).
5. Cover open bores on cylinder and breather hose.
6. Remove stud connector (54) and washer (55) from concentric valve (A1) central stud.
7. Remove dome nuts (A2) and joint washers (53) from concentric valve outer side.
8. Separate concentric valve from valve cage.
Page 3-3
Dismantling (See Figures 3.1, 3.2 & 3.3)
A valve assembly must not be held directly between vice jaws. Never hammer a spanner
when loosening or tightening the valve nuts.
1. Unscrew and remove nut (9 – V105/150) (10 – V200/250/375).
When dismantling valve, note the method and order of renewal of each valve
component. Refer to the illustration of the valve assembly to ensure that the
components are rebuilt in their correct order.
2. Clean all components thoroughly. Remove grease and carbon deposits with a soft brush using a hot
water and soda solution. Care must be taken during the cleaning operation as any surface scratch
may cause leakage and ultimately a breakage.
3. Inspect each component. If any items appear defective, worn or damaged, replace with new parts.
Re-assembly (See Figures 3.1, 3.2 & 3.3)
1. Assemble the valve components on the lower delivery valve seat (2) and studs.
PAY ATTENTION
Ensure that the components are correctly positioned on their locating pins.
2. Fit the upper suction valve seat (1) in position and fit nut (9 – V105/150) (10 – V200/250/375).
3. Check that the valve functions correctly and that plate movement exists. Extreme care must be taken
to ensure that the valve is not scraped or damaged in this operation.
Valve Replacement
1. Renew ‘O’ rings (48) fitted to valve cage (45) and ‘O’ rings (51 and 52) fitted to concentric valve.
2. Assemble concentric valve to valve cage and loosely fit dome nuts (A2), joint washers (53), stud
connector (54) and washer (55) to concentric valve studs.
3. Fit valve cage and valve to cylinder (39) and re-connect crankcase breather hose (32) to the hose
connector.
V375 only. Refit the valve with the fitting eye uppermost ensuring that the dowel pin
aligns with the mating hole in the cylinder.
4. Tighten stud connector (54) and dome nuts (50B).

5. Fit washers (56) and nuts (55) to studs (42) and tighten nuts. Refer to Table 3.1 for tightening torques.
6. Fit studding (165) to stud connector and tighten.
7. Reassemble suction filter silencer assembly to valve cage as described in 3.2.3.
Page 3-4
Valve Servicing
Figure 3.1 First Stage Concentric Valve V105/150
Page 3-5
*
*
Figure 3.2 First Stage Concentric Valve V200/250
Page 3-6
*
*
Figure 3.3 First Stage Concentric Valve V375
Page 3-7
3.2.5 Final Stage Concentric Valve Removal/Servicing/Replacement
Removal
1. Remove the four nuts (79) and washers (80) from the top of the valve cage.
2. Remove valve cage (70) complete with concentric valve (B1) using screws (not supplied) in the two
tapped jacking holes.
3. Cover bores on cylinder.
4. Remove dome nuts (B2) and joint washers (78) from concentric valve studs.
5. Separate concentric valve from valve cage.
Page 3-8
Figure 3.4 Final Stage Concentric Valve V105/150
Page 3-9
Figure 3.5 Final Stage Concentric Valve V200/250
Page 3-10
Figure 3.6 Final Stage Concentric Valve V375
Page 3-11
Dismantling (See Figures 3.4, 3.5 & 3.6)

1. Unscrew the three socket head cap screws (8 – V105/150)(13 – V200/250)) (Not applicable on V375).
Unscrew the centre nut (9 - V105/150) (10 - V200/250/V375). Note: When dismantling valve, note the
method and order of renewal of each valve component. Refer to the illustration of the valve assembly
to ensure that the components are rebuilt in the correct order.
2. Clean all components thoroughly, remove grease and carbon deposits with a soft brush using a hot
water and soda solution. Care must be taken during the cleaning operation as any surface scratch
may cause leakage and ultimately a breakage.
3. Inspect each component. If any items appear defective, worn or damaged, replace with new parts.
Re-assembly (See Figures 3.4, 3.5 & 3.6)
1. Assemble the valve components on the lower delivery valve seat (2) and studs and ensure that the
components are correctly positioned on their locating pins.
2. Fit the upper suction valve seat (1) in position. Fit the three socket head cap screws. (Not V375)
3. Check that the valve functions correctly and that plate movement exists. Extreme care must be taken
to ensure that the valve is not scraped or damaged in this operation.
Valve Replacement
1. Renew ‘O’ rings (71 and 72) fitted to valve cage (70) and ‘O’ rings (76 and 77) fitted to concentric
valve (B1).
2. Assemble concentric valve (B1) to valve cage (70) and tighten dome nuts (B2) and joint washers (78)
to the valve studs.
3. Fit valve cage and concentric valve assembly to cylinder (66).
4. Fit 4 off nuts (79) and bright washers (80) to studs (67) and tighten nuts. Refer to Table 3.1 for torque.
3.2.6 First Stage Cylinder and Piston Removal
PAY ATTENTION
When removing 1st stage cylinders, it can be difficult to prevent the piston from
dropping out of the bore and falling onto the edge of the cylinder aperture. To ensure
that this does not occur, strategically place an appropriate cushioning material
immediately the cylinder becomes clear of the crankcase so that if the piston does fall
no damage can result.
1. Drain compressor of all cooling water.

2. Remove water outlet connection from cylinder.
3. Remove first stage concentric valve and cage assembly from cylinder as detailed in 3.2.4.
4. Remove guard (170) from crankcase.
5. Using a bar turn over the compressor until the first stage piston (35) is at the top of its stroke in the
cylinder.
If final stage cylinder has been removed take precautions to protect exposed
components in the crankcase.
6. Remove the bolts (101) and washers (102) securing the cooler header (93) to the cylinder.
7. Fit an eyebolt (not supplied) into the tapping in the top of the cylinder and connect to suitable lifting
tackle.
8. Using lifting tackle and by striking the cylinder gently with a soft headed mallet break the seals
between the cylinder and crankcase, cylinder and cooler header.
Page 3-12
9. Lift and guide the cylinder off the piston assembly take care to prevent damage to the piston assembly
as it becomes free from the cylinder.
CAUTION
With cylinder removed protect personnel from injury from the exposed studs
(56) at all times until the cylinder is re-assembled.
10. Identify with non-destructive marker, orientation of piston side and gudgeon pin end towards front of
compressor.
11. Slacken the locknuts (42) which secure the cap head screws, from the underside of the piston.
Remove the 2 cap head screws (41) from the underside of the piston (35) which lock the gudgeon pin
(40) in position.
12. Supporting the piston push gudgeon pin out of piston and connecting rod (15) taking care when the
pin frees to prevent damage of rod striking piston internals and crankcase. Remove piston and pin.
13. Cover the crankcase aperture.
14. Examine removed components replacing worn/damaged parts as necessary. For wear allowances see
chapter 4 - Technical Data.
If required connecting rod small end needle roller bearing (17) may be removed and
refitted without dismantling compressor any further. Chapter 3.2.15 refers.
Page 3-13
3.2.7 First Stage Cylinder and Piston Reassembly
1. Before commencing reassembly ensure that sufficient Loctite sealant and retainer is available to seal
the cylinder to the crankcase and retain the cap head screws in the piston.
a. The minimum amount of Loctite flange sealant number 573 required is 50 millilitres
b. The minimum amount of Loctite nutlock 243 required is 10 millilitres
2. Remove all traces of sealant on joint faces of cylinder to crankcase and ensure surfaces are grease
free. (Ensure sealant does not enter crankcase - remove if necessary.)
3. Remove all traces of gasketing on joint faces of cylinder to cooler header and ensure faces are grease free.
Do not smooth joint faces. Do not use emery cloth or a metal scraper to abrade or clean them. It is
recommended that a chemical such as Loctite ‘Chisel’ is used in conjunction with hand brushing with a wire
brush.
4. Remove Loctite from threads in piston using Loctite ‘Chisel’. If the cap head screws are to be re-used,
clear threads using Loctite ‘Chisel’.
5. If new piston rings are being fitted gap rings to cylinder to a closed gap of 0.175/0.300mm (V105/150),
0.20/0.33 (V200/250) or 0.26/0.39mm (V375). Ensure rings are fitted as follows to the piston.
a. Barrel faced ring top groove.

b. Taper faced ring second groove (this ring can be readily identified against the barrel faced ring
by the internal chamfer on the taper faced ring.)
c. Both rings must be fitted with the face marked “Top” facing towards the piston crown.
d. S.O.C. ring bottom groove.
6. Align adjacent ring gaps on piston at 180° to each other.
7. Ensure threaded holes in piston are clean. Fit lock nut (42) to cap head screw (41) and ensure that it
is fully onto the screw (within 1 – 2mm of the screw head). Screw cap head screw and lock nut into
position such that the end of screw is approximately 1mm from gudgeon pin bore.
8. Fit piston into cylinder bore far enough to enclose the ring pack but to leave the gudgeon pin bore
clear of the base of the cylinder. Care must be taken when passing the ring pack across the cut-out in
the cylinder location spigot. (V200/250 machines only).
9. Using suitable lifting tackle connected to the cylinder lifting eye and exercising caution so that the
piston does not drop out of the cylinder, align cylinder assembly on to studs.
10. Lower cylinder/piston assembly gradually above the conrod and align the gudgeon pin bore of the
piston with the small end of the conrod. Lightly oil the small end roller bearing. Without oiling, fit
gudgeon pin (40) to piston, ensuring dimple timing mark is facing NDE of compressor, with dimples
correctly aligned.
11. Fasten with the 2 cap head screws (Item 41). Tighten cap head screws - see Table 3.1 for Torques.
Ensure that locknuts are loose and have not been clamped by cap head screws. Fasten locknut over
the head of the caphead screw by the use of a bi-hexagonal socket. .
12. Lightly oil piston skirt and cylinder bore above piston crown. Introduce oil into the small end bearing..
13. Coat underside of cylinder (joint face to crankcase) with Loctite flange sealant 573.
14. Lower cylinder into contact with crankcase
15. Fit new gasket (100) between cylinder and cooler header. Do not grease gasket or faces.
16. Fit bolts (101) and bright washers (102) through cooler header into cylinder and tighten finger tight.
17. Fit concentric valve and cage assembly to cylinder as detailed in chapter 3.2.4.
Page 3-14
18. Torque bolts (101) to the appropriate level. Refer to Table 3.1 for torque.
19. Reconnect water outlet pipework/hose to cylinder.
20. Refit guard (170) to crankcase.
3.2.8 Final Stage Cylinder and Piston Removal
1. Drain compressor of all cooling water. Remove water inlet connection from cylinder.
2. Remove concentric valve (B1) and valve cage (70) assembly from cylinder (66) as detailed in
chapter 3.2.5.
3. Remove guard (170) from crankcase.
4. Using a bar turn over the compressor until the second stage piston (60) is at the top of its stroke in the
cylinder.
If the first stage cylinder has been removed, take precautions to protect exposed first
stage components in the crankcase.
5. Remove the 2 screws (117) and washers (118) securing the separator assembly to the cylinder.
Remove the separator from the cooler box by removing the bolts (112) and stud (113) securing the
separator header (E1) to the cooler box (C1).
6. Remove the bolts (106) securing the cooler header (93) to the cylinder.
7. Fit an eyebolt (not supplied) into the tapping in the top of the cylinder and connect to suitable lifting
tackle.
8. Using lifting tackle and by striking the cylinder gently with a soft headed mallet, break the seals
between the cylinder and crankcase, cylinder and separator, cylinder and cooler header.
9. Lift and guide the cylinder off the piston assembly taking adequate precautions to prevent damage to
the piston assembly as it becomes free from the cylinder.
CAUTION
With cylinder removed protect personnel from injury from the exposed studs
(56) at all times until the cylinder is re-assembled to crankcase.
10. Identify with non-destructive marker, orientation of piston side and gudgeon pin end towards front of
compressor.
11. Remove the two socket set screws (65) from the underside of the piston (60) which lock the gudgeon
pin (64) in position.
12. Supporting piston push gudgeon pin out of piston and connecting rod (19) taking care when pin frees
connecting rod to prevent damage of rod striking piston internals and crankcase. Remove piston and
gudgeon pin.
13. Cover the crankcase aperture, connecting rod small end bearing, and passage ways on separator and
cooler header.
14. Examine removed components replacing worn/damaged parts as appropriate. For wear allowances
see Chapter 4 - Technical Data.
If required connecting rod small end needle roller bearing (21) may be removed and
refitted without dismantling compressor any further. Chapter 3.2.15 refers to the
procedure.
Page 3-15
3.2.9 Final Stage Cylinder and Piston Reassembly
1. Before commencing reassembly ensure that sufficient Loctite sealant and retainer is available to seal
the cylinder to the crankcase and retain the hexagon socket set screws in the piston.
Minimum amount Loctite flange sealant 573 required is 50 millilitres.

Minimum amount Loctite nutlock 243 required is 10 millilitres.
2. Remove all traces of sealant on joint faces of cylinder to crankcase and ensure surfaces are grease
free.
3. Remove all traces of gasketing on joint faces of cylinder to cooler header, cylinder to separator and
separator to cooler box, and ensure surfaces are grease free. Do not smooth joint faces.
4. Remove Loctite from threads in piston using a tap. If grub screws are to be re-used clean the threads
using a die.
5. If new piston rings are being fitted gap rings to cylinder to a closed gap of 0.075/0.200mm (V105/150),
0.10/0.23 (V200/250) or 0.11/0.24 mm (V375). Ensure rings are fitted as follows to the piston.
a. Barrel faced ring top groove.
b. Taper faced ring second groove (this ring can be easily identified against the barrel faced ring
by the internal chamfer on the taper faced ring.)
c. Both rings are to be fitted with the face marked “Top” facing towards the piston crown.
d. S.O.C. ring bottom groove.
6. For V105/150
Thoroughly clean tapped holes in piston and grub screws (Items 65) and with Loctite Activator
7471. Insert grub screws into tapped holes after liberally coating with Loctite 243. Screw
through until tip of grub screw is approximately 1mm from gudgeon pin bore.
Introduce oil into 2nd stage small end bearing.
Align 2nd stage piston to conrod small end bore and fit unoiled gudgeon pin (Item 64) through,
ensuring dimple timing mark is facing NDE of compressor, with dimples correctly aligned.
Fasten with the 2 grubscrews (65). See Table 3.1 for tightening torque at 6Nm.
For V200/V250/V375
Thoroughly clean tapped holes in piston. Insert M6 grub screw into tapped holes of the piston.
Screw through until tip of grub screw is approximately 1mm from gudgeon pin bore.
Introduce oil into 2nd stage small end bearing.
Align 2nd stage piston to conrod small end bore and fit unoiled gudgeon pin (Item 64) through,
ensuring dimple timing mark is facing NDE of compressor, with dimples correctly aligned.
Fasten with the 2 grub screws (65). See Table 3.1 for tightening torque.
V375 only -insert M8 grub screws (59) into tapped holes after coating with Loctite 243. See
Table 3.1 for tightening torques.
Loctite nutlock 243 may not cure on components under oily conditions - see General
Notes, chapter 3.
7. Align adjacent piston ring gaps on piston at 180° to each other.

8. Using suitable lifting tackle align cylinder over studs (67) and onto piston, compressing rings to guide
into cylinder.
9. Coat underside of cylinder (joint face to crankcase) with Loctite flange sealant 573.
Page 3-16
10. Lower cylinder into contact with crankcase.

11. Fit new gasket (105) between cylinder and cooler header (93), gasket (116) between cylinder and
separator header (E1) and gasket (111) between separator and cooler box. Do not grease gasket or
joint faces.
12. Fit bolts (106) and bright washers (107) through cooler header (93) into cylinder and tighten finger
tight.
13. Fit screws (117) and washers (118) through separator header into cylinder, tighten finger tight.
14. Adjust gap between final stage cylinder and cooler header using feeler gauges, to give the best
parallel flange seal. This can be achieved by rotating the cylinder to give an equal gap each end.
15. Fit concentric valve and cage assembly to cylinder as detailed in chapter 3.2.5. Torque bolts (106 and
117).
16. Reconnect water inlet connection to cylinder.
17. Refit guard and tighten fasteners.
3.2.10 Cooler Tubenest and Header Removal
1. Drain compressor of all cooling water.

2. Remove gauge pipes.
3. Remove the bolts (101) and washers (102) securing the cooler header (93) to the first stage cylinder
(39).
4. Remove the bolts (106) and washers (107) securing the cooler header to the second stage cylinder.
Fit 2 x M12 eyebolts (V200/250/V375 only) (not supplied) in the top of the cooler header and suspend
the header using a sling.
5. Remove the remaining bolts (94) securing the cooler header.
6. Remove cooler header (93) from tubenest (91) and cylinders by gently tapping with a soft headed
mallet if necessary to separate the gaskets between the cooler header and tubenest, header and first
stage cylinder, header and second stage cylinder.
7. Remove tubenest (91) from cooler box by gently tapping tubeplate with a soft headed mallet to
separate the gasket between the tubenest and cooler box.
3.2.11 Tubenest Clean/Examine/Replace
1. Remove tubenest assembly.

2. Clean the outside of the cooler tubes to remove all traces of scale or other foreign bodies taking care
not to damage the cooler tube surface.
3. Clean the internal faces of the cooler box to remove any scale or sediment.
4. Chemically clean the tube internals using ‘ARDROX’ or similar chemical cleaner.
5. Examine tubes for signs of damage/reduction in tube wall thickness. If there is any doubt in the
condition of the tubenest Hatlapa Hamworthy recommend replacement of the tubenest assembly.
Faulty cooler tubes that are part of a ‘U’ tube nest formation cannot be removed individually, the
complete tubenest assembly must be replaced.
Page 3-17
3.2.12 Cooler Tubenest and Header Assembly to Compressor
The following procedure assumes that the first and final stage cylinder assemblies
have been assembled to the crankcase.
1. To assist alignment of gaskets, tubenest and header insert 2 lengths of studding (not supplied) into the
top 2 outermost tapped holes in the cooler box front face.
2. Ensure all the joint faces are clean and grease free. Do not smooth joint faces.
3. Fit tubenest to cooler box gasket (90) over studs. Do not grease gasket.
4. Fit tubenest (91) over studs.
5. Fit cooler header to tubenest gasket (92) over studs. Do not grease gasket.
6. Fit cooler header (93) over studs.
7. Insert gasket (100) between header and first stage cylinder, loosely fit the bolts (101) and washers
(102) through the header. Do not grease gasket.
8. Insert gasket (105) between header and final stage cylinder, loosely fit the 3 bolts (106) and washers
(107) through the header. Do not grease gasket.
9. Loosely fit all but 2 of the bolts (94) and washers (95) through the cooler header and tubenest to the
cooler box.
10. Remove the lengths of studding used for guidance and insert the remaining 2 bolts and washers.
11. Tighten the bolts (101 and 106) cooler header to cylinders. See Table 3.1 for tightening torques.
12. Tighten the bolts (94) in the cooler header progressively in alphabetical order as shown until they are
torqued correctly. Refer to Table 3.1 for tightening torques.
13. Re-connect the gauge pipes.
Figure 3.7 Cooler Header
Page 3-18
3.2.13 Cooler box end cover
Removal
1. Remove cooler drain plug (C6).
2. Remove the bolts (C4) and washers (C5) and release cooler box end cover (C2).
3. Clean and remove all traces of gasket (C3) from joint faces on end cover and cooler box. Ensure joint
faces are grease/oil free. Do not smooth joint faces.
Re-assembly
4. Assemble gasket (C3) between cover and cooler box. Note: Do not grease gasket or joint faces.
5. Secure cover to cooler box with bolts (C4) and plain washers (C5). Fit cooler drain plug (C6) to cover.
3.2.14 Connecting Rod Big End Bearing Removal
1. Drain compressor of cooling water.

2. Drain oil and dispose of in accordance with local regulations.
3. Remove the first and final stage cylinders and pistons as detailed in Chapter 3.2.6. and 3.2.8
4. Remove the screws (157) and washers (158) securing the crankcase inspection cover.
5. Using a soft headed mallet gently tap the side faces of the crankcase inspection cover to break its seal
with the crankcase. Remove the cover.
6. Remove screw (23), tab washer (24) and retaining washer (22).
7. Using a puller over the second stage connecting rod (19) big end withdraw rod off crankshaft complete
with cylindrical roller (big end) bearing (20).
8. Remove spacer (18) from crankshaft.
9. Using a puller as in 8 withdraw first stage connecting rod (15) complete with cylindrical roller (big end)
bearing (16).
3.2.15 Bearing Removal and Reassembly to Connecting Rods
When the connecting rods have been removed both the big and small end bearings
should be renewed. Gudgeon pins must always be replaced at the same time as the
small end bearings. If the existing big end bearings are undamaged and are to be
refitted, the inner race, rolls and bearing cage must be refitted in the original position.
1. Press out the big and small end bearings from the connecting rod.
2. Clean big and small end bores of connecting rod, ensure all traces of old retaining compound and any
oil or moisture is removed from the big end bore, degrease if necessary.
3.1) V105 and V150
Unwrap big end roller bearings (Items 16 and 20) from protective paper. Degrease conrod big end
bores (Items 15 and 19) and OD of bearings.
Spread Loctite 603 over the outer race of the big end bearing (Items 16 and 20) ensuring no Loctite
enters the bearing.
Press bearings into conrods See sheet 3 for the correct orientation of the circlip side of the big end
bearing to the dipper.
Unwrap small end roller bearings (Items 17 and 21) from protective paper. Press bearings into lightly
oiled small end bores of conrods). Note oil feed hole alignment.
Page 3-19
3.2) V200 and V250

Ensure the relevant con rod (Items 15 and 19) is degreased and cleaned with Loctite Cleaner 7200.
Heat the con rod to 80°C.
enters the bearing.
Position the Con Rod on a flat surface, ensuring the big end bearings will be fitted according to the
orientation shown on sheet 3. Spray the Big End bore with Loctite Activator 7471.
Push the bearing in to the bore by hand to ensure that the bearing has located correctly.
When the con rod has sufficiently cooled, to clamp the big end bearing, push the Small end bearings
(Items 17 and 21)(note: These two bearings are matched) into the housing, ensuring that the
lubrication hole is in line with the oil supply hole in the con rod.
When the assembly is cool, use (compressor) lubricating oil to protect both the big and small end
bearings. Place assembly in a suitable sealed bag for storage.
Do not fit the assembly to the compressor/crankshaft for a further

24 hours.
3.3) V375
Use Con Rod 3413100301 (Item 15) for the first stage assembly and 3413100302 (Item 19) for the
second stage.
Ensure the relevant con rod is degreased and cleaned with Loctite Cleaner 7200.
Heat the con rod to 80°C.
enters the bearing.
For the First Stage Con Rod:
Position the Con Rod on a flat surface with the shoulder face downward. Spray the Big End bore with
Loctite Activator 7471. Position the Big End Bearing in the con rod with the circlip facing up (The circlip
should be on the opposite side to the con rod shoulder.)
Push the bearing in to the counter bore by hand to ensure that the bearing has located correctly.
For the Second Stage Con Rod:
Position the Con Rod on a flat surface with the shoulder face downward. Spray the Big End bore with
Loctite Activator 7471. Position the Big End Bearing in the con rod with the circlip facing down (The
circlip should be on the same side to the con rod shoulder.)
Push the bearing in to the counter bore by hand to ensure that the bearing has located correctly.
When the con rod has sufficiently cooled to clamp the big end bearing, push the Small end bearings
(Items 17 and 21) into the housing, ensuring that the lubrication hole is in line with the oil supply hole
in the con rod.
When the assembly is cool, use (compressor) lubricating oil to protect both the big and small end
bearings. Place assembly in a suitable sealed bag for storage.
Do not fit the assembly to the compressor/crankshaft for a further

24 hours.
Page 3-20
Figure 3.8 V105/V150 Fitting and Orientation of Big End Bearings/Conrods
Page 3-21
Figure 3.9 V200/V250 Fitting and Orientation of Big End Bearings/Conrods
Page 3-22
Figure 3.10 V375 Big End Bearings Fitting & Conrod Orientation in the Crankcase
Page 3-23
On a V200/250/375 compressor only, the bearing is supplied as a matched pair and must be
assembled as such.
3.2.16 Connecting Rod Assembly Fitment to Compressor
When the connecting rod has been fitted, it must be free to slide through the bearing range of
side clearance, from shoulder to circlip. If this is not easily achieved the connecting rod must
be removed, the bearing pressed out and the bore cleaned thoroughly prior to re-assembly.
1. Remove pin (3). Screw a length of M16 x 2 x 185 mm long studding (not supplied) into the tapped hole
in the crankshaft pintle.
2. Arrange the first stage connecting rod (15) with the cast dipper rod pointing downwards and the small
end through the crankcase aperture for the first stage cylinder. Align the big end bearing onto the
crankshaft pintle. Using the retaining washer (22) and an M16 nut (not supplied) wind the nut onto the
studding to push the big end bearing onto the pintle until the washer is flush with pintle end. Remove
washer and nut.
3. Align spacer (18) with big end bearing on pintle and push bearing and spacer onto pintle with washer
and nut as described above.
4. Repeat the procedure for the final stage connecting rod (19) until the assembly is pushed solidly
against the shoulder on the crankshaft. Remove studding, nut and retaining washer.
5. Con rod to crankshaft retaining washer
Strike NEW dowel pin (3), use hammer, into end of crankshaft to secure. Position disc clamp (22) and
NEW tab washer (24) and torque the bolt (23) to the correct value. Fold tab washer to secure bolt.
6. Assemble first stage cylinder components to compressor as detailed in 3.2.7.
7. Assemble second stage cylinder components to compressor as detailed in 3.2.9.
8. Fit drain plug (160) to crankcase.
9. Clean joint faces of crankcase inspection cover and crankcase. Apply Loctite flange sealant 574 to
cover joint face. Fit cover to crankcase and secure with the 4 screws (157) and washers (158) refitting
the 2 cable clips between washer and cover.
10. Recommission compressor as detailed in chapter 1.
3.2.17 V105, V150, V200, and V250 Drive Motor and Coupling Removal from Compressor
For V375, see Chapter 3.2.19.
1. Isolate compressor.
2. On compressors fitted with water circulating pumps only, drain the cooling water.
3. Place a suitable support under the crankcase close to its connection to the drive motor.
4. For compressors mounted on anti vibration mounts, remove the fasteners securing the mount under
the drive motor to the ship's deck, and for those compressors fitted with anti vibration mounts and a
water circulation pump disconnect the water inlet connection to the pump and separate the male union
nut on the connector (205) on the pump.
5. For compressors not mounted on anti-vibration mounts remove the fasteners securing the drive motor
to the ship’s deck.
6. Remove the bolts (191) and washers (192) securing the drive motor to the crankcase.
7. Using suitable lifting tackle, lift and slide the drive motor complete with drive coupling element (G1),
coupling hub (G3), hexagon socket cap screws (G4) out of the crankcase.
Page 3-24
8. If required, remove drive coupling element (G1) from coupling hub (G3) by removing the hexagon cap
screws (G4).
9. If required, remove drive pins (G2) from flywheel.
3.2.18 V105, V150, V200, and V250 Drive Motor and Coupling Assembly to Compressor
For V375, see Chapter 3.2.19.
Important notes for fitting Coupling

In addition to the operational sequence 1 to 9 listed below the coupling must be assembled in
accordance with the following notes:
a. The screws connecting the rubber element to the hubs must be tightened to the torque
stated. Tightening torques which are too low will cause damage to the coupling.
Ensure that on tightening the screws the aluminium bushes in the rubber part are not
twisted. A small amount of grease should be applied under the head of the screw
before fitting. Prevent twisting of the rubber part during tightening of the screws. This is
particularly important with the radial screws. If the coupling is supplied in a pre-
assembled state, do not dismantle it, but fit it in this condition.
b. Fit the hubs onto the motor shaft and lock using the grub screw. The radial bolt holes
should be nearest the motor shaft face. Fit the axial bolts onto the flywheel. Position the
element with the side having the rubber free face of the axial aluminium inserts towards
the flywheel and, using the radial screws, mount it on the cylindrical hub. During this
process, the rubber element is pulled together radially and receives its pre-load. Then
push the coupled elements together, carefully sliding the coupling with light axial
pressure onto the socket bolts. The rubber element is subjected to a little more radial
compression by the socket bolts, and the pre-load is thus increased. The axial bores in
the rubber element should be smeared lightly with grease beforehand to allow the
socket bolts to slide easily in the inserts.
Figure 3.11 Coupling
1. If removed, reassemble drive coupling pins (G2) to flywheel.

Tighten coupling pins. Refer to Table 3.1 for torque.
2. If removed, assemble drive coupling hub (G3) to drive motor shaft. To determine the coupling position
on the motor shaft, measure the distance from the motor fixing flange to the flywheel. Position the
coupling on the motor shaft to give a 1 - 2 mm gap between the coupling extremes (not the hub) and
the flywheel, dimension (A).
Page 3-25
Figure 3.12 Gap Between Coupling and Flywheel
3. If removed, assemble drive element (G1) onto hub (G3) with hexagon socket cap screws (G4).
Tighten screws to torque settings – see Table 3.1.
4. Lightly grease the coupling pins. Using suitable lifting tackle, lift and slide the drive motor whilst
aligning the drive element with the coupling pins, slide the drive element onto the coupling pins and
the motor flange location diameter on the crankcase.
5. Fit bolts (191) and spring washers (192) through drive motors flange onto crankcase.
6. Fit holding down bolts to drive motor or anti vibration mount.
7. On compressors on anti vibration mounts and fitted with water circulating pumps, reconnect union nut
and male connector on the circulating pump and water inlet pipework.
8. Remove support placed under crankcase.
3.2.19 V375 Drive Motor and Coupling Removal from, and Assembly to, Compressor
Figure 3.13 Coupling
Page 3-26
3.2.19.1 V375 Drive Motor and Coupling Removal from Compressor
Follow Steps 1 to 6 in Chapter 3.2.17. Then:

7. Using suitable lifting tackle, lift and slide the drive motor complete with coupling hub (G3) out of the
crankcase.
8. If required, remove drive coupling element (G1) from flywheel (8) by removing the M10 screws.
3.2.19.2 V375 Drive Motor and Coupling Assembly to Compressor
1. If removed, assemble drive coupling element (G1) onto flywheel (8) with M10 screws.
2. Using suitable lifting tackle, lift and slide the drive motor whilst aligning the coupling hub with the drive
coupling element, slide the coupling hub to engage into the drive coupling element and the motor
flange location diameter onto the crankcase.
Then follow Steps 5 to 9 in Chapter 3.2.18.
3.2.20 Flywheel and Drive End Oil Seals Removal from Compressor
1. Remove drive motor and coupling as detailed in chapter 3.2.17 & 3.2.19. Note coupling pins (G2 –
V105/150/200/250) and coupling drive element (G1 – V375) need not be removed from the flywheel.
2. Slacken the 7 clamp screws on drive bush (9).
3. Lay two lengths of 3mm mild steel or similar angle (not supplied) of maximum leg length 30mm on the
2 rails in the crankcase under the flywheel. Alternatively, a fixture can be supplied by Hatlapa
Hamworthy Marine Compressors Ltd.
See sketch.
Table 3.3 Fixtures to Assist Flywheel Removal
Machine Fixture
V150 J31974
V200/250 J32032
V375 J32244
Figure 3.14 Location of Angle Steel on Crankcase Rails
4. Remove 2 of the clamp screws and use in the tapped holes provided in the drive bush to jack the bush
out of the flywheel. Remove drive bush and ease the flywheel onto the two pieces of angle (operation
3 refers.)
Page 3-27
5. Using suitable lifting tackle remove flywheel from crankcase.

(Note tapped hole in periphery of flywheel is M12).
6. Remove the screw (157) and washer (158) securing the crankcase inspection cover (155).
7. Using a soft headed mallet gently tap the side faces of the crankcase inspection cover (155) to break
its seal with the crankcase. Remove cover.
8. Wedge a piece of clean bar (not supplied), through the front of the compressor between the crankshaft
balance weight and one of the cast webs behind the balance weight to prevent the crankshaft from
rotating.
9. Remove grub screw (11). Using a c-spanner or similar tool (not supplied) unscrew the bearing
adjustment sleeve.
10. Lever lip seal (6) out of crankcase with an appropriate tool (not supplied) exercising caution not to
damage the housing bore in the crankcase.
11. Remove ‘O’ ring (7) from crankshaft.
3.2.21 Flywheel and Drive End Oil Seal Reassembly to Compressor
1. Fit new radial oil seal (6) to crankcase.

2. Fit new ‘O’ ring (7) onto crankshaft adjacent to bearing taking care in passing over the thread on the
crankshaft.
3. Wedge a piece of clean bar (not supplied) through the front of the compressor between the balance
weight and one of the cast webs to prevent the crankshaft from turning and carry out the following
operation.
4. Screw the bearing adjustment sleeve onto the crankshaft and engage with the drive end bearing. Use
a c-spanner or similar implement (not supplied).
5. Rotate assembly of crankshaft through two complete turns and check, by trying to rock the assembly,
that the taper roller main bearings are seated correctly (i.e. little or no up and down movement of any
part of the assembly).
6. Attach a dial test indicator to the end face of the crankcase resting on the end of the crankshaft.
7. Push or pull the crankshaft balance weight and note the end float.
8. An end float of between 0.05/0.10mm is required in the main bearings which is to be obtained as
follows:
a. If the end float is greater than 0.10mm, using a c-spanner as in operation 4, screw the bearing
adjustment sleeve further onto the crankshaft until the required end float is achieved. Rotate the
assembly before each reading through two complete revolutions to centralise the bearings.
b. If the end float is less than 0.05mm or the bearings are preloaded (no end float):
Using a c-spanner as in operation 4 unscrew the bearing adjustment sleeve 90°. Lightly tap the
drive end of the crankshaft to loosen the drive end main bearing inner race. If this technique
does not loosen the bearing, the M16 tapped hole in crankshaft big end bearing pintle may be
used to apply tension to crankshaft to loosen the bearing in conjunction with tapping the drive
end.
Carry out adjustment technique as in (a) until required end float is achieved. Replace grub
screw (11).
9. Position the pieces of angle along the rails in the crankcase (refer to chapter 3.2.19 operation 3).
Using suitable lifting tackle locate flywheel onto the pieces of angle and ease the flywheel onto the
crankshaft.
10. Loosen the drive element clamping screws a couple of turns. Lightly oil the clamping element.
11. Slide the clamping element onto the crankshaft and locate in the flywheel. Remove the screws from
the release threads and screw into the clamping holes.
Page 3-28
12. Tighten the clamping screws diagonally by hand while aligning the hub. With a torque wrench tighten
the clamping screws diagonally across with half the tightening torque (see below). Continue tightening
but with the full torque. Refer to Table 3.1 for tightening torque.
13. Tighten the clamping screws one after the other. Repeat several times. The tightening process is only
completed when none of the screws can be tightened any further.
14. Remove the pieces of angle or fixture placed over the rails in the crankcase.
15. Check the flywheel alignment with a dial test indicator does not exceed 0.125mm. If this alignment is
not achieved release the clamping screws, adjust the flywheel and re-tighten screws as above. Re-
check flywheel alignment.
16. Reassemble drive motor and coupling to compressor as detailed in chapter 3.2.18.
17. Clean joint faces of crankcase inspection cover (155) and mating face on crankcase. Apply Loctite
multi gasket 574 to cover joint face. Fit cover to crankcase and secure with the 4 screws (157) and
washers (158) refitting the 2 cable clips (156) between washer and cover.
3.2.22 Crankshaft and Main Bearing Removal from Compressor
If the main bearings are removed it is recommended that they are renewed.
1. Remove the following parts:

First stage cylinder, see chapter 3.2.6
Second stage cylinder, see chapter 3.2.8
Connecting rods, see chapter 3.2.14
Drive motor and coupling, see chapter 3.2.17 (V105/V150/V200/V250) and 3.2.19 (V375)
Flywheel and oil seals, see chapter 3.2.20
2. Screw a length of M16 x 2 studding (not supplied) into the tapped hole in the crankshaft. Place a bar
or similar (not supplied) across open front of compressor, using an M16 nut (not supplied), exert a
force onto the end of the crankshaft.
3. Gently tap the drive end of the crankshaft with a soft headed mallet and tighten the nut as in operation
2, drive the crankshaft out of the inner race of the drive end taper roller main bearing.
4. Taking care to prevent the drive end inner cage dropping off the crankshaft withdraw the crankshaft
complete with non-drive end taper roller bearing inner race.
5. Using a suitable puller (not supplied) or by levering on the inner race lip (not on the rollers) extract the
non drive end taper roller bearing inner race from the crankshaft.
6. Using a mild steel drift (not supplied) drift out the drive end and non drive end taper roller bearing
outer races from the crankcase taking care not to damage the housing bore for the lip seal in the
crankcase drive end.
3.2.23 Crankshaft and Main Bearings Reassembly to Compressor
1. Before reassembly ensure crankcase internals and crankshaft are clean.

2. Lightly oil the drive end main bearing location bore in the crankcase.
3. Using a mild steel drift (not supplied), drift the outer bearing cup of the drive end main bearing (5) into
position in the crankcase.
4. Lightly oil the non drive end main bearing location bore in the crankcase.
5. Fit non drive end main bearing (4) outer race in position as described in operation 3.
6. Preheat non drive end main bearing inner race assembly to 120°C maximum.
Page 3-29
7. Lightly oil crankshaft non drive end bearing journal location.

8. Fit the heated inner race assembly on to the crankshaft journal (crankshaft in vertical position) and
allow to cool before gently tapping home against shoulder with a mild steel sleeve drift (not supplied).
9. Preheat drive end main bearing inner race assembly to 120°C maximum.
10. Insert crankshaft into crankcase, wedge crankshaft into position ensuring that the non drive end main
bearing inner race assembly is mated correctly to the outer race.
11. Lightly oil the crankshaft drive end main bearing journal.
12. Fit the heated inner race assembly onto the crankshaft and into the bearing outer race.
13. Refit oil seal and flywheel as detailed in chapter 3.2.21.
3.2.24 Oil Level Switch Remove/Clean/Replace
1. Drain compressor of lubricating oil as detailed in chapter 3.2.2.

2. Remove the DIN connector.
3. Remove screw (142) and washer (143) securing dual oil level switch (140) to crankcase.
4. Lever switch out of crankcase.
5. Remove the 2 retaining screws and slide sleeve off body.
6. Clean switch by removing all metallic particles.
7. Reassemble switch, fit new O-rings (141), replace DIN connector and re-fill compressor with oil, refer
to chapter 3.2.2.
3.2.25 Air and Water Safety Valves
These valves are all pre-set at the factory to suit the maximum working pressure duty of the compressor.
The air safety valves are statically set at a pressure, which equates to the 10% statutory over pressure
requirement, making allowance for the dynamic pressure pulses found within the compressor.
The safety valves must NOT be tampered with. It is recommended that a replacement valve is fitted should
there be any doubt as to the valve's condition.
Each valve is screwed into position.
Water Jacket Safety Valve (145)
Located on the cooler box behind the first stage cylinder. Associated joint washer (146). When replacing the
water jacket safety valve ensure the outlet port is pointing downwards by using up to 3 joint washers.
First Stage Air Pressure Safety Valve (147)
Located on the front face of the first stage cylinder on the V200/250/375 and the rear face of the cylinder on
the V105/150. Associated joint washer (148).
Final Stage Air Pressure Safety Valve (149)
Located on the inlet to the final stage separator. Associated joint washer (150).
3.2.26 Separator Bowl Removal, Diffuser Plate Examination and Removal
1. Disconnect the ‘DIN’ plug from the solenoid coils (129).

2. Disconnect the drain pipes from the bottom of the separators (if fitted).
3. Remove the bolts (E6) and washers (E7) holding the separator bowl (E2) to the separator header
(E1).
Separate bowl from the header by gently tapping the bowl with a soft headed mallet.
Note:It is advisable to leave 2 opposite corner bolts (E6) screwed into the bowl when splitting this
assembly as this will take the weight of the bowl when it is free.
4. Remove separator bowl.
Page 3-30
5. Clean and remove all traces of gasket from the joint faces of the header and bowl. Ensure faces are
grease/oil free. Do not smooth faces, ie, do not remove machining surface finish markings, use Loctite
‘Chisel’ or similar.
6. Inspect 1st and 2nd Stage diffuser plates for looseness (E3 and E4).
7. If the diffuser plates are not solidly held in position, tighten screws (E13 and E15).
8. If the diffuser plates are fixed solidly, re-assemble separator components as in 3.2.27.
3.2.27 Diffuser Plate Fitting and Separator Bowl Reassembly
1. Fit drain connectors (E8 and E9) to the base of the separator bowl using joint washers (E10 and E11).
Fit diffuser plates (E3 and E4) using screws (E13 and E15) and washers (E12 and E14) see exploded
view Figure 5.6 for position.
2. Position gasket (E5) over bowl (E2). Do not grease gasket. Ensure faces are grease/oil free.
3. Fit bowl (E2) to separator header (E1) using 6 bolts (E6) and washers (E7).
4. Tighten the corner bolts and then the central ones progressively until they are torqued correctly. Refer
to Table 3.1 for torque.
5. Fit separator drain pipes (if fitted).
6. Fit the ‘DIN’ connectors to the solenoid valve coils (129).
Page 3-31
3.3 WATER CIRCULATING PUMP (if supplied)
Figure 3.15 Water Circulating Pump
Item Item
Description Qty Description Qty
No. No.
1 Pump Body 1 14 Bearings – Pump & Fan Side 2
2 Impeller 2 15 Not Applicable
3 Initial Stage 1 16 Plug-in element 1
4 Not Applicable 17 Not Applicable
5 Final Diffuser 1 18 Terminal Box Cover 1
6 Seal Holding Disc 1 19 Terminal Box 1
7 Motor/Pump Support 1 20 Not Applicable
8 Shaft+Rotor+Bearing+Shaft 1 21 Cable Gland 1
9 Motor Case & Wound Stator 1 22 Fill/Drain Plug 2
10 Not Applicable ‘O’Ring 2
11 Fan 1 23 Seal Shoulder Washer 1
12 Fan Cover 1 24 Impeller Fixing Washer 1
‘O’ Ring 2 25 Not Applicable
13
Mechanical Seal 1
Table 3.4 Items List - Water Circulating Pump
Page 3-32
3.3.1 General Overhaul
After 3 - 4 years service the pump should be overhauled, to include changing the mechanical seal and motor
bearings and cleaning. Check for wear and change worn pump parts. Always use new seals on re-assembly.
3.3.2 Service Information
DANGER
Before doing any maintenance or repairs make sure that the electrical supply to the
motor is isolated and cannot be accidentally reconnected. Preferably padlock the
isolator or remove the fuses. If in doubt consult a qualified electrician.
3.4 ELECTRICAL MAINTENANCE
It is recommended that switch settings are periodically checked. Refer to the separate data sheet for
settings:
Table 3.5 Switch Settings
SWITCH SETTINGS
Oil level switch Activates when oil level falls below fill mark.
High air temperature switch Alarm 60°C ± 10%
Shutdown 80°C ± 10%
3.5 FAULT FINDING CHART

Table 3.6 Fault Finding Chart
FAULT POSSIBLE CAUSE REMEDIAL ACTION

Final stage air safety valve
blowing.
Whilst in automatic (default) Air system charged signal and final Reset signal pressure settings lower than safety valve set
mode stage air pressure shutdown settings pressure (Note: maximum working pressure of compressor
greater than safety valve set pressure is 33 bar g)
Whilst running in manual Stop valve closed in final air delivery Open all stop valves in pipework
mode pipework
Non-return valve installed incorrectly. Correct installation.
Air system pressure safety devices set Correct safety device pressure settings as appropriate.
higher than safety valve setting.
First stage air safety valve The first stage air safety valve is unlikely to operate when the compressor is running automatically as
blowing. the compressor will be shut down by the high first stage air pressure transducer first. See below.
High first stage pressure Intercooler blocked Remove cooler header and tubenest. Clean cooler tubes and
(First stage air safety valve first stage air passageways in header, cooler and first stage
blowing) separator.
Suction side of final stage valve leaking Remove valve, clean/inspect/renew.
Delivery side of final stage valve Remove valve, clean/inspect/renew.
leaking
Delivery side of final stage valve Remove valve cage, renew O-rings and check joint washers
leaking to suction side under dome nuts.
Page 3-33
FAULT POSSIBLE CAUSE REMEDIAL ACTION

Internal knocking noise from Worn big or small end bearings Strip down compressor for inspection, renew worn parts.
compressor.
Worn main bearings. Strip down compressor, check crankshaft end float. Renew
worn parts.
Damaged concentric valve. Remove valves, clean inspect and renew if necessary.
Piston slap. Remove cylinders, check clearances, renew worn parts
(cylinder, piston rings.)
Worn drive element. Renew drive coupling element.
Compressor will not achieve Concentric valves damaged or dirty. Remove valves, clean inspect and renew if necessary. (note
operating pressure or is reduced capacity normally indicates first stage fault)
operating at a reduced
capacity.
Solenoid drain/unload valve faulty. Check solenoid valve function, renew parts as necessary.
Worn or damaged piston rings/ piston. Remove cylinders, check rings are free in piston groove,
renew worn, distorted or damaged rings, piston as
appropriate.
Excessive cylinder component wear Remove cylinders, renew cylinder, piston, rings as necessary
Suction filter/silencer blocked. Renew element.
Concentric valves require Non-recommended grade of lubricating Drain lubricating oil, replace with recommended grade.
frequent cleaning. oil used.
Concentric valves overheating. Ensure concentric valves, cylinder components (cylinder,
piston, rings) and cooling water system is maintained in good
working order.
Excessive moisture in final Solenoid drain/unload valve faulty. Check solenoid valves function, renew components as
air delivery pipe work and/or necessary.
final stage cylinder/
intercooler.
Unload drain cycle incorrect for Reprogram solenoid drain/unload valves “dwell” and “spit”
operating conditions. times to suit operating conditions.
Oil seeping out from Drive end lip or O-ring seal adjustment Remove flywheel adjustment sleeve and drive lip seal and
underside of crankcase near sleeve to crankshaft leaking. O-ring. Renew seal and O-ring. Refer to Chapter 3.2.15.
drive motor.
Water jacket safety valve Excessive cooling water inlet pressure. Reduce inlet pressure to 7 bar g maximum that compressor is
blowing. suitable for.
Intercooler/aftercooler tube failure. Remove cooler header and tubenest. Renew/refurbish
tubenest.
Excessive oil consumption. Worn cylinder components. Remove cylinders, check cylinder, piston, rings. Renew
components as appropriate.
Page 3-34
3.6 TOOLS REQUIRED FOR COMPRESSOR MAINTENANCE
Table 3.7 Tools Required for Compressor Maintenance
TOOL V150 V200/250 V375

C spanner 2" - 6" 3 3 3
Fly press 3 3 3
D.T.I. and magnetic base 3 3 3
3
13mm a/f x /8" square drive flank adaptor 3 3 3
19 mm a/f x ½" square drive crowsfoot 3 n/a n/a
24 mm a/f x ½" square drive crowsfoot n/a 3 3
8" screwdriver 3 3 3
Water pump pliers 3 3 3
2 ½ lb steel lump hammer 3 3 3
12" adjustable spanner 3 3 3
Feeler gauges (0.02 - 1.0mm) 3 3 3
24mm a/f combi spanner n/a 3 3
19mm a/f combi spanner 3 3 n/a
13mm a/f combi spanner 3 3 3
24mm a/f ½" square drive socket n/a 3 3
19mm a/f ½" square drive socket 3 3 n/a
13mm a/f ¼" drive socket 3 3 3
3mm a/f hexagon key 3 3 3
4mm a/f hexagon key 3 3 3
6mm a/f hexagon key 3 3 n/a
8mm a/f hexagon key n/a n/a 3
3mm a/f hexagon key x ¼" square drive 3 3 3
4mm a/f hexagon key x ¼" square drive 3 3 3
3
6mm a/f hexagon key x /8" square drive 3 3 n/a
8mm a/f hexagon key x ½" square drive n/a n/a 3
¼" square drive torque wrench (4 - 20 Nm) 3 3 3
3
/8" square drive torque wrench (8 - 54 Nm) 3 3 n/a
½" square drive torque wrench (30 - 150 Nm) 3 3 3
14mm a/f hexagon key x ½" square drive 3 3 n/a
17mm a/f hexagon key x ½" square drive n/a n/a 3
¾" square drive torque wrench (up to 500 Nm) n/a n/a 3
¾" square female x ½" square drive adaptor n/a n/a 3
Page 3-35
CHAPTER 4 TECHNICAL DATA
4 TECHNICAL DATA
4.1 GENERAL
Compressor Type V105/V150/V200/V250/V375
4.2 PERFORMANCE
Maximum working pressure 33 bar.
4.3 OTHER DATA
Table 4.1 Capacity and Power at 30 Bar
Output Absorbed Power

Nominal Speed RPM
M³/hour kW
1000 55 13
1200 70 15.5
V105
1500 85 20
1800 105 22
1000 80 17
1200 100 20
V150
1500 120 25
1800 150 30
1000 110 22
1200 132 26
V200
1500 166 33
1800 200 39
1000 137 28
1200 165 33
V250
1500 207 41
1800 250 49
1000 208 40
1200 250 48
V375
1500 310 60
1800 375 72
Outputs quoted are bottle charging rates.

Noise - 89 dB (A) at 1 Metre
Table 4.2 Operating Parameters
V105/150 V200/250 V375

Maximum air inlet temperature 50°C
Maximum air outlet temperature 20°C over cooling water inlet
Maximum water inlet pressure 7 bar g
Maximum water inlet temperature 45°C
Minimum water inlet temperature 5°C
Cooling water outlet temperature 10°C above water inlet temperature
Nominal cooling water flow rate 20/25 litres/minute 60/70 litres/minute 115/120
litres/minute
Lubrication system Splash
Sump capacity min. 3.5 litres min. 7 litres min. 9 litres
max. 4.5 litres max. 8 litres max. 12 litres
Page 4-1
Table 4.3 Recommended Maximum Wear Clearances
Feature Feature Measured Renew when

Note: All dimensions are in millimetres. V105/V150 V200/250 V375
First stage cylinder
(Nominal bore V105/150 Ø180 / V200/250 Ø200 / V375 Ø260)
Piston A Skirt Ø measured 15mm up from ≤ 179.600 ≤ 199.600 ≤ 259.6
base
Cylinder bore B Maximum diameter at any point ≥ 180.250 ≥ 200.250 ≥ 260.25
Piston to cylinder bore C Clearance between measured > 0.520 > 0.520 > 0.52
values A & B
Top and second D Piston ring width < 3.335 < 3.335 < 4.835
piston rings, piston ring
grooves.
E Piston ring groove width > 3.730 > 3.730 > 5.225
F Clearance between measured > 0.200 > 0.200 > 0.200
values D and E
G Piston ring gap when fitted to bore > 1.07 > 1.150 > 1.450
Conformable slotted oil H Piston ring width < 4.850 < 4.850 < 7.85
control ring, piston ring
groove
I Piston ring groove width > 5.194 > 5.194 > 8.184
J Clearance between measured
> 0.250 > 0.250 > 0.250
values H and I
K Piston ring gap when fitted to bore > 1.07 > 1.150 > 1.450
Gudgeon pin and small L Gudgeon pin Ø < 24.892 < 31.892 < 34.892
end bearing
Final stage cylinder
(Nominal bore V105/150 Ø75 / V200/250 Ø85 / V375 Ø110)
Piston M Skirt Ø measured 15mm up from
≤ 74.830 ≤ 84.830 ≤ 109.730
base
Cylinder bore N Maximum Ø at any point ≥ 75.164 ≥ 85.164 ≥ 110.164
Piston to cylinder bore O Clearance between measured > 0.210 > 0.210 > 0.210
values M & N
Top and second P Piston ring width < 2.350 < 2.350 < 2.850
piston rings. piston ring
grooves
Q Piston ring groove width > 2.660 > 2.660 > 3.160
R Clearance between measured > 0.200 > 0.200 > 0.200
values P & Q
S Piston ring gap fitted to bore > 0.710 > 0.800 > 0.890
Conformable slotted oil T Piston ring width < 4.850 < 4.850 < 4.850
control ring, piston ring
groove
U Piston ring groove width > 5.194 > 5.194 > 5.194
V Clearance between measured > 0.250 > 0.250 > 0.250
values T & U
W Piston ring gap fitted to bore > 0.710 > 0.800 > 0.890
Gudgeon pin and small X Gudgeon pin Ø < 24.892 < 31.892 < 34.892
end bearing
Page 4-2
4.4 CRANKCASE LUBRICANTS
4.4.1 Approved Oils
Shell Corena Oils P100

Castrol Aircol SN100
Extensive tests have been carried out on the V-Line compressor using Shell Corena P100 (mineral) and
Castrol Aircol SN100 (synthetic) lubricants. These oils have been found to give good results over extended
service and Hatlapa Hamworthy recommend their use to ensure satisfactory operation of the compressor.
4.4.2 Oil Company Equivalents
For information regarding oil company equivalents see separate sheet:

Lubricating Instructions for V-line Piston Compressors.
The V-Line compressor is designed to achieve the best possible results using mineral oils. A recommended
lubricating oil should be used at all times to ensure safe and efficient operation with minimum wear. The
suggested maintenance intervals are based on the results of extensive tests using Shell P100 mineral oil.
Specific measures have been taken to ensure extended service before components need cleaning to remove
carbon.
Hatlapa Hamworthy recommend the use of mineral oil as the most economic lubricant. If synthetic oils are to
be used the following maintenance revisions are necessary.
4.4.3 Additional Maintenance for Machines Lubricated with Synthetic Oils
Initial run and oil change periods to be as detailed in Maintenance chapter.

After initial 500 running hours using mineral oil lubricant:
1. Drain the old mineral lubricant completely whilst the oil is warm.
2. Thoroughly clean the crankcase sump.
3. Inspect and thoroughly clean compressor valves (as detailed in Maintenance chapter).
4. Replace all items removed, renew any damaged seals or gaskets.
5. Refill with synthetic oils, and run as normal.
Page 4-3
CHAPTER 5 DRAWINGS
5 DRAWINGS
1 4 8 9
10
11
13
12
7
Figure 5.1 Typical Arrangement of V-Line Water Cooled Compressor with Gauges
Table 5.1 List of Parts for Figure 5.1
Ref Description
1 Gauge panel
2 Suction filter silencer
3 First stage safety valve
4 Final stage safety valve
5 Dual level oil switch
6 Oil drain plug
7 Oil filler/dipstick
8 Final air delivery
9 Motor terminal box
10 Lifting lugs
11 Inter and final stage separator
12 First stage solenoid drain valve
13 Final stage solenoid drain valve
Page 5-1
CHAPTER 5 DRAWINGS
Notes on Figures
Where parts are specific to a particular model, applicable model numbers are shown next to
the item number.
Figure 5.3 Crankshaft and Flywheel:
For V375, the Drive Coupling Sub –assembly (190) is detailed Figure 3.13
Figure 5.7 Gauges:
For V150, steel pipe links adaptors (282), via ball valves (299), to gauges.
For other models, steel pipe runs from adaptors beneath the cooler header (93), via ball
valves (299), to gauges.
Page 5-2
CHAPTER 5 DRAWINGS
Figure 5.2 Cooler
Page 5-3
CHAPTER 5 DRAWINGS
Figure 5.3 Crankshaft and Flywheel

See Notes on page 5-2
Page 5-4
CHAPTER 5 DRAWINGS
Figure 5.4 First Stage Cylinder and Piston
Page 5-5
CHAPTER 5 DRAWINGS
Figure 5.5 Final Stage Cylinder and Piston
Page 5-6
CHAPTER 5 DRAWINGS
Figure 5.6 Separator
Page 5-7
CHAPTER 5 DRAWINGS
Figure 5.7 Gauges

See Notes on page 5-2
Page 5-8
CHAPTER 5 DRAWINGS
Table 5.2 List Of Parts – V-Line Compressors
Where two numbers are shown in the quantity column the first quantity is for the V105/150
compressor, the second refers to the V200/250/375 compressor. Where the quantity for the
V375 is different it is shown in brackets. Items marked with an asterisk (*) are not shown.
Ref Description Quantity

1 Crankcase 1
2 Crankshaft 1
3 Pin spring tension 1
4 Bearing taper roller 1
(main non drive end)
5 Bearing taper roller 1
(main drive end)
6 Oil seal 1
7 ‘O’ ring (adjusting sleeve 1
to bearing & crankshaft)
8 Flywheel 1
9 Bush cone clamping elements 1
10 Bearing adjusting sleeve 1
11 Socket set screw 1
15 Connecting rod (1st stage) 1
16 Bearing - big end cylindrical roller 1
17 Bearing - small end needle roller 1
18 Spacer - connecting rod/crankshaft 1
19 Connecting rod. (2nd stage) 1
20 Bearing - big end cylindrical roller. 1
21 Bearing - small end needle roller. 1
22 Clamping washer - c/shaft-conn. Rod 1
23 Set screw 1
24 Tab washer 1
30 Hose connector (not V375) 1

32 Hose (crankcase breather) (not V375) 30 cm
35 Piston (first stage) 1
36 Piston ring SOC 1
37 Piston ring taper faced 1
38 Piston ring barrel faced 1
39 Cylinder (first stage) 1
40 Gudgeon pin (first stage) 1
41 Hexagon socket set screw 2
42 Locknut 1
43 Stud (first stage cylinder 4
assembly to crankcase)
45 Valve cage (first stage) 1
46 Hose connector (not V375) 1
48 ‘O’ ring (first stage valve 1
cage to cylinder)
50 Concentric valve (first stage) 1
assembly A
51 ‘O’ ring (first stage concentric 1
valve outer groove to cylinder)
52 ‘O’ ring (first stage concentric 1
valve top face to valve cage)
53 Joint washer 4 (8)
Page 5-9
CHAPTER 5 DRAWINGS
Table 5.2 List Of Parts – V-Line Compressors (Cont’d)

54 Stud connector (not V375) 1
55 Bright washer (not V375) 1
56 Nut 4
57 Bright washer 4
59* Socket set screw (V375 only) 2
60 Piston (second stage) 1
61 Piston ring S.O.C 1
62 Piston ring taper faced 1
63 Piston ring barrel faced 1
64 Gudgeon pin (second stage) 1
65 Socket set screw 2
66 Cylinder (second stage) 1
67 Stud (second stage cylinder 4
Assembly to crankcase)
70 Valve cage (second stage) 1
71 ‘O’ ring (second stage valve 1
Cage top groove to cylinder)
72 ‘O’ ring (second stage valve cage 1
Bottom groove to cylinder)
73 Plug 1
75 Concentric valve (second stage) 1
Assembly B 1
76 ‘O’ ring (second stage concentric 1
Valve outer groove to cylinder) 1
77 ‘O’ ring (second stage concentric 1
Valve top face to valve cage) 1
78 Joint washer 4
79 Nut 4
80 Bright washer 4
81 Anti-extrusion ring (V375 only) 1
85 Cooler box assembly C 1
86 Eyebolt 1
87 Set screw/bolt 4/3
88 Spring washer 4/3
90 Gasket (tubenest to cooler box) 1
91 Tubenest assembly 1
92 Gasket (tubenest to cooler header) 1
93 Cooler header 1
94 Bolt/adjusting screw 13
95 Bright washer 13
100 Gasket (cooler header to first stage 1

cylinder) (V105/150/200/250 only)
100A Metal Gasket V375 only) 1
100B Gasket Seal (V375 only) 1
100C PTFE Sealing Ring (V375 only) 1
101 Bolt 3/4
102 Bright washer 3/4
105 Gasket (cooler header to second stage
cylinder) (V105/150/200/250 only) 1
105A Metal Gasket V375 only) 1
105B Gasket Seal (V375 only) 1
105C PTFE Sealing Ring (V375 only) 1
106 Bolt 3
107 Bright washer 3
Page 5-10
CHAPTER 5 DRAWINGS

110 Separator assembly E 1
111 Gasket (separator /header - cooler 1
box)
112 Bolt 3
113 Bolt/stud 1
114 Bright washer 4
115 Nut (not V200/250) 1
116 Gasket (separator assembly to 1
Second stage cylinder)
117 Set screw 2
118 Bright/spring washer 2
120 Joint washer 3
121 Adaptor 1
122 Joint washer 1
123 Solenoid valve body 1
First stage drain/unload
125 Washer 3
126 Nipple 1
127 Washer 1
128 Solenoid valve 1
Final stage drain/unload
129 Coil – solenoid valve 2
140 Oil level switch - crankcase 1
141 ‘O’ ring (oil switch ) 2
142 Set screw 1
143 Bright washer 1
145 Safety valve (air 1st stage cylinder) 1
146 Copper washer 3
147 Safety valve (water jacket safety) 1
148 Copper washer 3
149 Safety valve 1
(Air final stage cylinder)
150 Copper washer 3/1
151 Plug 2
152 Joint washer 2
153* Plug 2
154* Joint washer 2
155 Inspection cover 1
156 Cable clip 2/3
157 Set screw 4/6
158 Bright washer 4/6
160 Magnetic drain plug with seal 1
161 Oil filler/dipstick 1
165 Studding 1
166 Suction filter/silencer assembly F 1
167 Filter element (V200/250/375 only) 1
F2 Filter element (V150 only) 1
168 Wing nut (V200/250/375 only) 1
169 Bright washer (V200/250/375 only) 1
170 Guard – crankcase 1
171 Screw 1
172 Spring washer 1
Page 5-11
CHAPTER 5 DRAWINGS

190 Drive coupling sub-assembly G 1
191* Bolt/set screw 4/8
192* Spring washer 4/8
194* Motor packing piece (V200/250 only) 2
195* Mounting plate drive motor 1
196* Mounting plate drive motor 1
(Water circulating pump models only)
197* Bolt 2
198* Nut 2
199* Spring washer 2
200* Water circulating pump 1
201* Bolt 4
203* Bolt 2
209* Straight male union
Connector 1
210 Joint washer 1
212 Packing piece (V150 only) 2
213 Anti-vibration mount 2
214 Bolt 2
215 Spring washer 2
216* Anti-vibration mount 1
217* Screw 1
222* Flexible hose (water inlet)
To final stage cylinder/
Circulating pump 1
224* Joint washer (hose to 1
cylinder/circulating pump)
225* Flexible hose (water outlet
from first stage cylinder 1
227* Joint washer (hose to cylinder) 1
228* Flexible hose (final air delivery) 1
229 Joint washer (hose to separator) 1
230* Nameplate 1
231* Hammer drive screw 4
245 Washer 4
246 Bolt 4
247 Electrical terminal box 1
248 Stud (Earth) 1
249 Washer 1
250 Nut 1
251 Washer 1
252 Lock washer 1
253 Washer 1
254 Nut 1
255 Nut 1
273 Plug 1
274 Joint washer 1
Page 5-12
CHAPTER 5 DRAWINGS

280* Pressure gauge (direct mount) 0 – 10 bar 1
281* Pressure gauge (direct mount) 0 – 60 bar 1
282 Adaptor 2
283 Joint washer 2
284 Pressure gauge (panel mount) 1
0 –10 bar
285 Pressure gauge (panel mount) 1
0 – 60 bar
286 Gauge panel 1
287 Set screw 2
288 Bright washer 2
289* Legend plate 1
290 Legend plate 1
291 Drive screw 4
292 Steel pipe assembly 50/60 cm
293 Steel pipe assembly 50/60 cm
294 Male stud coupling 2
295 Female stud coupling 2
296 Leather washer 2
298 Joint washer 4(1)
299 Ball Valve 2
300 Plug 2
COMPRESSOR WITH MANUAL DRAINS

301 3 way equal tee 1
302 Adaptor 1
304 Hex adaptor 1

305 Ball valve 1
307 Joint washer 1
311 3 way equal tee 1
312 Adaptor 1
314 Hex Adaptor 1
315 Ball valve 1
317 Joint washer 1
320 Temperature switch 1

321 Joint washer 1
CONCENTRIC VALVE (1ST STAGE) ITEM 50

A1 Concentric valve body assembly 1
A2 Dome nut 4(8)
CONCENTRIC VALVE (2ND STAGE) ITEM 75

B1 Concentric valve body assembly 1
B2 Dome nut 4(6)
Page 5-13
CHAPTER 5 DRAWINGS

COOLER BOX SUB-ASSEMBLY ITEM 85
C1 Cooler box 1
C2 Cover cooler box end 1
C3 Gasket (cover cooler box
end to cooler box) 1
C4 Bolt 11/9
C5 Plain washer 11/9
C6* Plug 1
C7* Joint washer 1
C8* Plug 1
C9* Joint washer 1
C10 Bleed Valve 1
C11 Joint washer 1
SEPARATOR SUB-ASSEMBLY ITEM 110

E1 Separator header 1
E2 Separator bowls 1
E3 Diffuser Plate (first stage) 1
E4 Diffuser Plate (second stage) 1
E5 Gasket (separator header
to separator bowls) 1
E6 Bolt 6
E7 Plain washer 6
E8 Drain Connection (first stage) 1
E9 Drain Connection (second stage) 1
E10 Joint washer 1
E11 Joint washer 1
E12 Plain washer (brass) 2
E13 Screw 1
E14 Plain washer (stainless steel) 2
not V105/150
E15 Screw 1
SUCTION FILTER/SILENCER SUB-ASSEMBLY ITEM 166

V105/150 ONLY
F1 Housing 1
F2 Element 1
F3 Seal 1
F4 Wingnut 1
F5 Seal 1
F6 Top Cover 1
F7 Seal 1
F8 Wingnut 1
F9 ‘O’ Ring 1
F10 Inlet Resonator 1
F11 Clamp 1
SUCTION FILTER/SILENCER SUB-ASSEMBLY ITEM 166

V200/250/V375 ONLY
F1 Housing 1
F2 Inlet Resonator 1
F3 Clamp 1
Page 5-14
CHAPTER 5 DRAWINGS
DRIVE COUPLING SUB-ASSEMBLY ITEM 190

G1 Drive coupling element 1
G2 Drive pin (not V375) 4
G3 Drive coupling hub 1
G4 Hexagon socket cap screw (not V375) 4
SEALANTS/RETAINERS
J1 Loctite 603 high strength 1
Retainer 10ml size
J2 Loctite 243 thread locker 10 ml size 1
J3 Loctite 573 flange sealant 50 ml size 1
J4 Loctite 574 multi gasket 50 ml size 1
Page 5-15

Instruction Manual V-Line Water Cooled Compressor: V105, V150, V200, V250, V375

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Instruction Manual V-Line Water Cooled Compressor: V105, V150, V200, V250, V375

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Instruction Manual

V-Line Water Cooled Compressor

Uetersener Maschinenfabrik GmbH & Co. KG Discovery Court Business Centre

Telephone: +49-4122-711 0.. Telephone: +44 (0) 1202 853180

Figure 3.1 First Stage Concentric Valve V105/150 3-5

Table 3.1 Fastener Torque Settings (unlubricated) 3-1

Spare Parts can be ordered direct from the following address:

HATLAPA Hamworthy Ltd. Telephone: +44 (0) 1202 853180

Technical Service and Advice:

1.3.1 Commissioning Procedure

1. Ensure compressor is isolated from its electrical supply.

This temperature differential equates to the nominal flow rate as specified in

2.2 CONTROL AND OPERATING PHILOSOPHY

The control panel is capable of the following functions:

2.3 NORMAL RUNNING PROCEDURE (AUTOMATIC CONTROL)

1. Energise the starter panel by operating the main isolator.

2.4 MANUAL MODE RUNNING

Energise the starter panel by operating the main isolator.

1. Before proceeding with maintenance or overhaul, the compressor must be

Table 3.1 Fastener Torque Settings (unlubricated)

M6 M8 M10 M12 M16 M20

Table 3.2 Maintenance Schedule

Commissioning Normal Operating Services

3.2 MAINTENANCE INSTRUCTIONS

3.2.1 Lubrication Oil Checking

3.2.2 Lubrication Oil Changing

3.2.3 Air Suction Filter/Silencer Removal and Replacement

3.2.4 First Stage Concentric Valve Removal/Servicing/Replacement

5. Cover open bores on cylinder and breather hose.

8. Separate concentric valve from valve cage.

Dismantling (See Figures 3.1, 3.2 & 3.3)

1. Unscrew and remove nut (9 – V105/150) (10 – V200/250/375).

4. Tighten stud connector (54) and dome nuts (50B).

Figure 3.1 First Stage Concentric Valve V105/150

Figure 3.2 First Stage Concentric Valve V200/250

Figure 3.3 First Stage Concentric Valve V375

3.2.5 Final Stage Concentric Valve Removal/Servicing/Replacement

Figure 3.4 Final Stage Concentric Valve V105/150

Figure 3.5 Final Stage Concentric Valve V200/250

Figure 3.6 Final Stage Concentric Valve V375

Dismantling (See Figures 3.4, 3.5 & 3.6)

3.2.6 First Stage Cylinder and Piston Removal

1. Drain compressor of all cooling water.

3.2.7 First Stage Cylinder and Piston Reassembly

a. Barrel faced ring top groove.

14. Lower cylinder into contact with crankcase

19. Reconnect water outlet pipework/hose to cylinder.

20. Refit guard (170) to crankcase.

3.2.8 Final Stage Cylinder and Piston Removal

3.2.9 Final Stage Cylinder and Piston Reassembly

Minimum amount Loctite flange sealant 573 required is 50 millilitres.

Introduce oil into 2nd stage small end bearing.

Introduce oil into 2nd stage small end bearing.

7. Align adjacent piston ring gaps on piston at 180° to each other.

10. Lower cylinder into contact with crankcase.

3.2.10 Cooler Tubenest and Header Removal

1. Drain compressor of all cooling water.

3.2.11 Tubenest Clean/Examine/Replace

1. Remove tubenest assembly.

3.2.12 Cooler Tubenest and Header Assembly to Compressor

Figure 3.7 Cooler Header

3.2.13 Cooler box end cover