Service Manual XA060 - Version 05

Service Manual
X-range air compressor

XA060
Congratulations on your X-range compressor!
Innovations:
Patented X-drive Patented cooling Registered design
The extraordinary X-range compressor is a new generation of true 1800 rpm compressors for the marine market. The Sperre
X-range compressor is based on more than 70 years of experience.
This excellent compressor gives you several benefits:
 Safety first – a fully enclosed structure  Easy plug-in for sensors

 Green and clean – no oil mist to the environment  25% fewer wear parts – 50% more reliable
 A new level of control  Best cooling efficiency in the market
 Easy to learn – one common platform  Low vibration level – high grade of isolation
 Less installation time – no special alignment  Improved standard scope of supply
Sperre has developed a unique chain of value, that’s what it takes to produce reliable compressors that function smoothly for the
life of the ship.
Sperre congratulates you on your choice of compressor!
10.04.2018
www.sperre.com Service Manual XA060 Version 05 3

Contents
1 Introduction ............................................................................................ 5
1.1 Purpose ............................................................................................................................. 5
1.2 Annotations ....................................................................................................................... 5
1.3 Abbreviations ..................................................................................................................... 5
1.4 Tags on the compressor ................................................................................................... 6
1.5 Warranty ............................................................................................................................ 7
2 Personal safety....................................................................................... 8
3 Installation and Operation ..................................................................... 9

3.1 Installation ......................................................................................................................... 9
3.2 Before and after operation .............................................................................................. 10
3.3 User interface – main screen .......................................................................................... 11
3.4 Normal operation ............................................................................................................. 12
3.5 Lead / follow and load sharing ........................................................................................ 13
3.6 Remote operation ............................................................................................................ 14
3.7 Emergency operation ...................................................................................................... 15
4 Service and ordering............................................................................ 16

4.1 Service schedule ............................................................................................................. 16
4.2 Service Warnings ............................................................................................................ 17
4.3 Service Alarms ................................................................................................................ 18
4.4 Service procedures overview .......................................................................................... 21
4.5 Kit overview ..................................................................................................................... 22
4.6 Recommended kits and special tools ............................................................................. 24
4.7 Ordering parts and kits .................................................................................................... 36
5 Service procedures .............................................................................. 37

5.1 Cover ............................................................................................................................... 37
5.2 Lubricating oil .................................................................................................................. 38
5.3 Air filter ............................................................................................................................ 40
5.4 Safety valves LP and HP ................................................................................................ 41
5.5 Air cooler LP .................................................................................................................... 42
5.6 Air cooler HP ................................................................................................................... 43
5.7 Valve LP .......................................................................................................................... 44
5.8 Valve HP ......................................................................................................................... 45
5.9 Cylinder LP ...................................................................................................................... 46
5.10 Cylinder HP ..................................................................................................................... 47
5.11 Piston, rings and gudgeon bearing LP ............................................................................ 48
5.12 Piston, rings HP and bearing gudgeon ........................................................................... 49
5.13 Bearing fan side .............................................................................................................. 50
5.14 Bearing crank .................................................................................................................. 52
5.15 Electric motor and vibration isolators .............................................................................. 54
5.16 Coupling and sealing flange ............................................................................................ 56
5.17 Crank disk and bearing motor side ................................................................................. 58
5.18 Cyclone separator and non return valve ......................................................................... 59
5.19 Drain/unload valve........................................................................................................... 61
5.20 Electrical components ..................................................................................................... 62
6 X-range data ......................................................................................... 63

6.1 Torque tables .................................................................................................................. 63

1 Introduction
1.1 Purpose
Sperre has produced this manual to provide information for all users of the compressor
equipment. This includes information about the compressors construction and Note
operation, as well as basic information regarding inspection and maintenance.
Please note that all pictures and
It is important that operators familiarize themselves with the contents of this instruction drawings in this manual are for
manual, to ensure that use and maintenance work are carried out in the correct and illustration only.
safe manner from the outset.
The maintenance intervals and individual technical data are average values based on
experience, and may vary depending on the compressor’s operational parameters. Note
The manufacturer accepts no responsibility for damage resulting from careless
operation or inadequate maintenance. Keep the compressor in good mechanical Original instructions in English.
condition, and remember that preventive maintenance of the equipment reduces the
danger of damage and unnecessary operational interruptions.
Sperre reserves the right to modify details without prior warning.
1.2 Annotations
All safety directions must be respected in order to avoid damage to personnel, the environment and equipment. In this manual the
annotations are used, as illustrated below:
Indicates possibilities for hazards or unsafe practices, which COULD result in fatal or
Warning severe personnel injuries or substantial product or property damage, if the required
precautions are not taken.
Draws attention to specific information of technical significance that might not be obvious,
Note or highlights important remarks in the procedures to follow.
1.3 Abbreviations
Abbreviation Description
Barg Unit of pressure (Barg = Bar gauge)
CFD Computerized Fluid Dynamics
CR Class Recommendation
CW Cooling Water
dBA Decibel
DOL Direct On Load
HP High Pressure
LP Low Pressure
IMO International Maritime Organization
ISC Internal System Control
MR Makers Recommendation
PMS Planned Maintenance System
RPM Revolutions Per Minute
XA X-range compressor Air-cooled
XW X-range compressor Water-cooled

1.4 Tags on the compressor
Danger Danger Caution

The compressor is remotely controlled Hazardous voltage Burn hazard
May start without warning Risk of electric shock Risk of hot surface
Caution The cover must always be on when To connect the signal cable, carefully
This item is pressurized from the running align the plug to find the right insert point
receiver. Without the cover the compressor will be on the contact unit, then push the plug
damaged after running even for a short carefully in and srew the locking ring
Check manual before dismantling. clockwise to secure it.
period
To disconnect the signal cable, unscrew
the locking ring counter clockwise to
loosen it. Pull the plug out.
Compressor oil type. The oil has been drained from the Level sight glass
Always use fully synthetic, ISO 100 grade compressor Correct oil level should be in centre of
piston compressor oil. Do not start the compressor before the level sight glass
correct oil quantity has been added
Drain oil Delivery air outlet Unloading and drain high pressure
The lifting eye bolt is certified for lifting Before using or servicing the compressor Rotation direction is counter clock wise,
the single compressor with el-motor only Read and understand the user manual when looking at compressor front.
Compressor rating plate Attention

Dirty environment might harm this
equipment. Refer to manual.

1.5 Warranty
The X-range compressor has a limited warranty that is valid only with use of
original spare parts purchased through our Sperre office in Norway, Singapore,
the Netherlands or China.
Please note that the warranty will be void if the equipment is misused or not
handled in accordance with prescribed operating and service standards.
Sperre starting air compressors are designed to fulfil requirements from

classification companies and are not supposed to operate continuously.
Sperre type approval and classification certificates are only valid when
genuine Sperre parts are used for maintenance.
Genuine Sperre parts are certified with certificate of conformity and authenticity as shown below.

2 Personal safety
Please make yourself familiar with the content in this user manual before operating the compressor.
It is the responsibility of the user to ensure that appropriate controls and precautions are identified and applied in relation to the
work envisaged by this document in accordance with relevant statutory, legal and industry requirements to protect the health and
safety of the persons undertaking the work.
All operation and service of the compressor is to be carried out by personnel who are familiar with the contents of this manual.
The compressor is a high pressure machine that must only be used to compress air. Unauthorized remodelling or modification of
the compressor may result in a safety hazard, and is not permitted.
The compressor must never be operated without cover: the high temperature machine with rotating parts pose a great risk for the
crew.
Before any form of work is commenced on the compressor, the electrical power must be turned off at the starter panel and at the
main switchboard, and the switch on the main switchboard must be marked with a notice indicating that repair work is in progress.
The manual valve between the compressor and the air receiver must be closed, and the pressure must be released in all
pressurized parts of the compressor.
The safety valves for LP air, HP air, cooling water and any other safety equipment must be inspected regularly. Damaged
components should be replaced with new, original parts. Please note that all safety valves are security sealed and any adjustment
of these valves is not recommended. The compressor must never be used if the safety equipment is defective.

3 Installation and Operation
This chapter provides important information regarding installation, before/after
operation, normal and emergency operation of the compressor as well as information Warning
regarding lead/follow function and remote operation.
Before operating the equipment, please refer to Chapter 2 for the personal safety
instructions. If any malfunction, warning or alarm is
detected during operation, the
malfunction must be given immediate
attention.
3.1 Installation
All deliveries of compressor installations are accompanied by documentation of the
installation’s dimensions and mounting points. The documentation will also include Note
installation instructions, illustrating the recommended assembly of equipment and pipe
connections. Please refer to the General
Arrangement and Installation drawings
To achieve problem-free operation, it is important that the base-plate is sufficiently rigid for specific details.
and free from vibrations caused by other machinery. The base of the compressor must
lie flat on the base-plate.
The normal ambient air temperature is 20-45°C and must not exceed 55°C. Warm
intake air increases the risk of coking. Transmitters and solenoid valves must not be
exposed to temperatures above 80 °C.
The cooling water pipes must be installed correctly to avoid air pockets.
The compressed air outlet temperature should be approximately 15-30°C above
ambient temperature / cooling water inlet temperature.
The compressor installation must not be closely surrounded by other equipment, which
could inhibit maintenance performances. The recommended maintenance space on all
sides is 600 mm.
This manual includes instructions for handling of the compressor after installation. It is
important that the instructions are followed carefully to avoid problems during
commissioning and further use of the compressor.
Air quality and compressor environment
This air compressor consumes large amount of air used for cooling and compression.
Warning
Polluted ambient conditions will require more frequent air filter replacement than stated
in the manual to avoid damage.
Air coolers and internal components must be kept clean to avoid overheating with
following mechanical damages. Dirty environment might harm this
equipment.
Never use the compressor in heavy polluted areas, or when the ambient contains toxic,
flammable fumes, or particles.

3.2 Before and after operation
Before operation
The Sperre compressor sensors and starter are real-time tested in our test facilities
before delivery from the factory. Warning
Before initial start-up, and after long periods out of use, the following operations need to
be carried out in the sequence given:
1. Check the oil level (sight glass). Do not run the compressor without
cooling water, this will cause damage
2. If the compressor has been out of service for more than 6 months, lubricate the to the air coolers.
valves, cylinder walls and crank bearings. Ensure there is water circulation in the
3. Turn the compressor shaft a few revolutions, by turning the fan. system before starting the
compressor.
4. Open valves on the air discharge line between the compressor and the receiver.
5. Ensure that power is available and that the electrical plug-in cables are fitted
properly.
6. Turn the power switch to the “on” position, after a few seconds the controller will
show the normal operating screen. “Ready to start” will be displayed if no alarms or
shutdown conditions are active.
Note
If the compressor control system is not
centralized with the ships central alarm
system, the controller needs daily
inspection to observe fault, warning or
alarm conditions.
7. Start the compressor, by pressing the green start button (if not in standby mode). The
compressor is now in active condition ready to respond to changes in delivery
pressure.
The Sperre compressors are designed to maintain safe operation with a minimum of
maintenance.
The operation procedures for the different modes are described on the following pages.
Preservation
If the compressor is to remain unused for a long period, lubricate the valves and cylinder walls with oil. The compressor must be
started from time to time: please refer to procedure “before operation”.
The following precautions must be taken when storing the compressor:
1. Store in a dry place with the lowest possible relative humidity.
2. Shut off the cooling water circulation. (for water cooled compressors)
3. Coat relevant surfaces, especially unpainted surfaces, with rust inhibiting oil or similar.
4. Turn the compressor shaft a few revolutions, by turning the fan, once a month.
5. For storing longer than six months, lubricate all valves and cylinder walls with corrosion inhibiting oil. Clean and check before
starting up.

3.3 User interface – main screen
*Note
Depending on configuration, this view
will include only functions that are
enabled for the current project.
Letter Description Letter Description
a Start – push to start the f* Lead / Follow

compressor, or to set in a
started condition
b Stop – push to stop the g* Local / Remote
compressor.
c Reset h* Sea / Harbour
d Menu i* Heater on / off
e Auto / Manual
Start [a] and Stop [b] have one defined function and are not used for any other purpose.
Reset [c] will acknowledge and reset any active alarm or shutdown status.
Pressing [d] will enter the menu screen.
Pressing [e-f] will activate / deactivate the function indicated.
Indicators
Steady Compressor motor running

Flashing Compressor in stand-by
Steady One or more alarms active

Flashing New alarm condition not acknowledged
Steady One or more shutdowns active

Flashing New shutdown-condition not acknowledged
Steady Space heater on

3.4 Normal operation
The compressor can be set to two different normal operating modes:
Warning
• Manual mode
• Automatic mode
In the manual mode of operation, the operator can start the compressor and the If any malfunction, warning or alarm is
compressor will only run once and stop when the pressure reach unload pressure. detected during operation, the
malfunction must be given immediate
In auto mode, the delivery pressure controls the start and stop of the compressor once attention.
the operator has pressed start.
Operation mode is selected by sliding the selector switch

located at the main screen to the preferred mode. Warning
When the stop button is pressed, the

compressor will not stop immediately.
It will run unloaded before stopping.
In case of malfunction the

‘Emergency stop’ button must be
used to stop the compressor.
Manual mode
Start:
1. Press the start button to start the compressor
The compressor will achieve the set unload pressure and then stop.
When the operator presses the start button again, the compressor will start if the
receiver pressure is below the unload/stop pressure.
When the unload pressure level is achieved the compressor will stop. The compressor
will only start again if the operator presses the start button again.
Stop:
2. Press the stop button. The operator can stop the compressor at any time.
Auto mode
Start:
1. Press the start button to start the compressor
If the pressure is below the load level the compressor is started and the pressure will
begin to rise. When the unload pressure level is achieved, the compressor will stop and
the compressor will remain active in a standby condition.
The compressor will automatically start again when the delivery pressure falls below the
load pressure level. This cycle will continue until the compressor is stopped by pressing
the stop button.
When the delivery pressure is below the unload level, but above the load level, the
compressor can be started again immediately by pressing the start button. This will
cause the compressor to start and increase pressure to the unload level, without the
need to wait for pressure to decrease to the load level.
Stop:
2. Press the stop button to exit auto operation, and stop the compressor.

3.5 Lead / follow and load sharing
Lead / Follow
Lead / Follow and Load Sharing functionality levels out the running hours on the
compressors and can be configured as explained below. Note
Compressor 1 decides which is lead and follow. Optional functionality only available if
specified by the customer when
Lead and follow pressure settings should be equal for both compressors, as seen in
ordering.
figure below. Pressure settings are found under menu->set-points..
If this function is desired later on,
please contact Sperre Aftersales
In this example the lead compressor Department for purchasing upgrade kit.
will start at 26 Bar and stop at 30
Bar. Follow compressor will start at
25 Bar and stop at 30 Bar.
Normally the unload pressure is set
to the same pressure.
Compressor 1 Compressor 2
Compressor 1 decides if compressor 2 should use its lead or follow pressures, by giving
a signal from one of the relay outputs to one of the digital inputs on compressor 2.
The connection between compressor 1 and compressor 2 is fail-safe. If connection
between compressors is lost, compressor 2 becomes ‘lead’ as default.
Load Sharing
When the lead/follow function is activated a timer switches between lead and follow
pressures for the compressors. Note
The timer can be adjusted in the controller configuration (menu->setup menu). Access code 0100 is required to enter
the setup menu.
The timer counts time and is by default set to 12 hours (720 min).

3.6 Remote operation
Remote operation by IAS or Switches
The compressor can be operated from a remote location by connecting a switch (not
push buttons) or a relay output from IAS to one of the digital inputs DI3 - DI8. Note
‘Local / Remote’ selection does only
affect the ‘Start / Stop’ function.
Remote Start / Stop:
If any of the other functions are set to
As long as the input is closed the compressor will enter standby or running mode remote operation, they remain remote
depending on the current reciver pressure, and then be controlled depending on the controlled even when the controller is
mode selected (Automatic or Manual). set to local.
When the input is opened the compressor will be set to stopped mode.
*Note
The following selections are normally done locally on the display, but can also be
connected to a digital input.* Optional functionality. All inputs for
remote operation are only available if
• Load / Unload
specified by the customer when
• Lead / Follow ordering.
If this function is desired later on,
• Sea / Harbour Mode
please contact Sperre Aftersales
• Automatic / Manual Department for purchasing upgrade kit.
• Local / Remote
When any of these functions are coupled to a digital input, the selector-switch on the
main screen will be dimmed and become inoperatable. It will still indicate the current
state of the input.

3.7 Emergency operation
The system can be overridden using an emergency run switch on the inside of the starter Warning
cabinet. If normal control of the compressor fails, and power is available, the emergency
switch will force the compressor to run.
For emergency operation of the compressor please follow the procedure below:
The compressor must not be left
1. Manually check the oil level, and unattended while running in
visually observe that there are no emergency mode!
abnormalities with the compressor.
2. Turn the emergency switch [a] on the
inside of the starter cabinet to the
‘Unloaded' position. The compressor Warning
will now start.
3. After a few seconds; turn the
emergency switch [a] to the ‘Loaded'
position. The drain valve will close Never carry out the emergency
and the compressor will start to build operation alone. Monitor the air-
pressure. receiver pressure and shut down the
compressor immediately when
4. Observe and manually check that the pressure level is reached.
compressed air temperature is not No surveillance or alarms will function,
above normal. except for local emergency stop and
5. The pressure increase should be motor overload control, which will be in
monitored during all running period. an active state.
6. Stop the compressor by reversing the

above procedure; leaving the switch
in the unloaded position for a few
seconds before stopping the Warning
compressor by turning the switch to
the 'normal' position.
For water cooled compressors:

Do not run the compressor without
cooling water, this will cause damage
to the air coolers.
Ensure there is water circulation in the
system before starting the compressor.

4 Service and ordering
4.1 Service schedule
The following schedule is a guideline for normal service procedures. However, the
compressors operating conditions vary widely from installation to installation, based on Warning
climatic differences. It is very important to adapt the maintenance schedule to the
running conditions of the individual compressor.
The controller will automatically inform the operator when to run scheduled services
according to the manufacturers recommended service cycle and intervals. Before any work is performed the
electrical power must be turned off.
There are four main service routine types; each requires the use of the appropriate
Please refer to chapter 2 for safety
service kit.
instructions.
Indicated service interval in hours or years depending on which comes first.
Note
Sperre takes no responsibility for
damage caused by use of non-original
parts.
Service procedure A is change of filters and running in oil, and should always be
performed 250 running hours after first time start up.
Note
Service procedures should be performed at 750 hour intervals or each 9 months.
Service procedures A2, B, C, D and E are to be performed in the order illustrated above. *Use access code 0100 to enter the
menus.
After service E at 12000 hours proceed to service A2 and repeat the service procedures
as shown.
When a service is complete the service technician must confirm service done for that
service type. The controller will automatically increment to the next service type using
the recommended service interval for the compressor type. Note
Please make sure that a complete
gasket kit always is available.
Service Warning
A service warning will occur 200 running hours or 30 days prior to a service, providing a
pre-warning enabling service arrangements, and/or service kit parts, to be organised
prior to the service becoming due. To see the service warning, press “Menu” -> “Alarms”.
Service Alarm
A ‘Service Alarm’ indication will occur when the ‘service interval’ run hours counter
reaches 0(zero) hours, or the service interval ‘time’ expires (whichever occurs sooner).
The Service Alarm will be displayed on the start screen and in the active alarms list
(Menu->Alarms).
The ‘Service Due’ indication on the start screen will be calculated from ‘next service
hours value’ minus ‘current running hours’.

4.2 Service Warnings
When a service warning appears in the active alarms list
When a service warning occurs the controller will display the “Service Due in 200 Running Hours or 30 days” in the active alarm list
(Menu->Alarms). The service counter on the start screen always shows when the next service is due and which service kit is needed
for the service.
1. Reset the service warning by pressing the “Reset” button in the “Active” alarms
list. The service warnings will not occur again. This facility is intended to provide Note
pre-warning enabling service arrangements.
2. Order the Sperre service kit. Please refer to “Service procedures overview” in the The text line on the display will
compressor service manual for the service kit ordering number. indicate the type of service.
Service A will only appear once,
A Sperre service kit contains all necessary spare parts needed for the service. throughout the life time of the
When a ‘service warning’ is generated no further service warnings for the service type compressor, and will only be indicated
will be generated. A service warning will only be generated once prior to a service with a service alarm.
becoming due and a service alarm being generated.
Service ‘A’:
Service type ‘A’ does not have a ‘Warning’ indication. The controller will show an ‘Alarm’ when the running hours counter reaches 250
hours.
Service type ‘A’ is a unique service type. When a service type ‘A’ has been carried out once no future service type ‘A’ alarms will be
generated. A Service type ‘A’ normally occurs only once in the operational life of the compressor.

4.3 Service Alarms
When a service alarm appears on the display
When a service alarm occurs the controller will display the “Service Due: [servicename]
0 h” message on the start screen. In the active alarms list there will be displayed a
“Service Due Now” message. Note
Please make sure that a complete
gasket kit always is available.
1. The service type displayed must be performed with the relevant Sperre service kit.
Please refer to “Service procedures overview” in the compressor service manual for
service kit information.
2. The Service alarm indication can be reset before the service is completed. In this
case the service alarm indication will re-occur again after 24 hours. This goes on
until the “Confirm Service Done” reset procedure has been carried out.

Service alarm reset
Service alarm reset procedure: Note

Using the menu navigation press “Menu” -> “Setup menu” -> Enter code 0100 –>
Access code 0100 is required to enter
“Confirm Service Done” and then confirm with pressing “OK”.
the setup menu.
When confirming with “OK” the controller will start the reset procedure which applies to
all service types. When the “Confirm service done” has been executed, the service
alarm is reset and the controller will automatically increment to the next service type in
the service cycle.
If the “Confirm Service Done” button is colored light gray there is no service alarm reset procedure necessary or even available.
Service Alarm Overlap:
If a ‘Service Alarm’ indication is still active for more than 200 running hours or 30 days, the service will be logged not done and the
service incremented to the next service.

Service log
Using the menu navigation press “Menu” -> “Service Log” on the startscreen to enter the
service log. In the service log all completed and non-completed services will be stored
with a date, run hours and number of motor starts.
In the service log is also an overview over total running hours, running hours to next
service, time since last service, time to next service and total motor starts.
Service alarm tags
Service alarm tag Text displayed Failure Corrective action

AS1-[service type] “Service [service Service hours countdown has 200 Press the “reset button”. Order service
type] due in 200 RH running hours or 30 days left to next kit. Please refer to “Service procedures
or 30 days” service. overview” in the Service manual.
AS2-[service type] “Service [service Service hours countdown time expired. The service type displayed on the start
type] is due now!” screen/alarm must be performed.
Please refer to “Service procedure
overview” in the Service manual.

4.4 Service procedures overview
Service procedure A A2 B A2 C A2 B A2 D A2 B A2 C A2 B A2 E Chap.
1 1 1
1 2 3 3 4 5 6 6 7 8 9 9
2 7 0 1 2
5 2 0 7 5 2 0 7 5 2 0 7
Running hours 5 5
0 5 0 5 0 5 0 5 0 5 0 5
5 2 0
0 0 0 5 0
0 0 0 0 0 0 0 0 0 0 0 0
0 0 0
Running years 0,5 0,75 1,5 2,25 3 3,75 4,5 5,25 6 6,75 7,5 8,25 9 9,75 10 11,25 12
Oil change X X X X X X X X X 5.2
Air filter replacement X X X X X X X X X X X X X X X X X 5.3
Valve LP replacement X X X X 5.7
Valve HP replacement X X X X 5.8
Bearing gudgeon + pin 5.11

X X
replacement 5.12
Non return valve

X X 5.18
replacement
Drain unload/valve HP +
X X 5.19
coil replacement
Bearing crank replacement X X 5.14
Bearing fan side

X X 5.13
replacement
Coupling insert
X X 5.16
replacement
Piston ring LP replacement X 5.11
Piston ring HP replacement X 5.12
Bearing motor side

X 5.17
replacement
Valve LP check* X X X X 5.7
Valve HP check* X X X X 5.8
Gudgeon bearing + pin 5.11

X X
check** 5.12
Bearing crank check** X X 5.14
Air cooler LP check*** X X X X 5.5
Air cooler HP check*** X X X X 5.6
Flexible tubes check**** X X
Safety valve LP check***** X 5.4
Safety valve HP check***** X X 5.4
Coupling insert check X X 5.16
* Please check the valve LP and HP condition, and if there is carbon deposit, the valve(s) must be replaced. Sperre recommend for
this compressor valve check every 1.500 hours.
** Please check the gudgeon bearing and the crank bearing condition, and if worn or damaged complete bearing(s) must be
replaced. Sperre recommend for this compressor bearing check every 3.000 hours.
***Please check the cooler condition, and if the cooler have particles in the airflow area inside, the cooler must be replaced. Sperre
recommends for this compressor cooler check every 3.000 hours.
**** Please check all flexible tubes for wear and aging every 6.000 hours. Refer to standard BS 5244 for details regarding testing
and checking.
***** Please check safety valves and change if necessary (see chapter 5.4).
Compressor serial number must be provided when ordering!
PMS input
The technical data above is the basis for the onboard planned maintenance system. Contact Sperre for the digital version for direct
implementation.

4.5 Kit overview
The letters on the illustration below refer to service and maintenance kits for the compressor, listed in the table on next page, and
described in chapter 4.4.

Ordering number Chapter
Letter Kit Name
Service Maintenance Recommended kit Service Procedures
Kit kit
- Service Kit A2 XAW060-090 51408 4.4

- Service Kit B XAW060-090 50036 4.4
- Service Kit C XA060-090 50066 4.4
- Service Kit D XA060-090 50105 4.4
- Service Kit E XA060 54765 4.4
MR Kit XA060 XA060-MR 4.4
CR Kit XA060 XA060-CR 4.4
MK Compressor gasket XA060 50905 4.4
a MK Cylinder head LP XA060-090 50336 4.4 5.7
b MK Cylinder head HP XA060-090 50366 4.4 5.8
c MK Valve LP XAW060-090 50436 4.4 5.7
d MK Valve HP XA060-090 50466 4.4 5.8
e MK Cylinder LP XAW060 50565 4.4 5.9
f MK Cylinder HP XAW060-090 50606 4.4 5.10
g MK Piston rings LP XAW060 50635 4.4 5.11
h MK Piston rings HP XAW060-090 50666 4.4 5.12
i MK Piston LP XAW060 50705 4.4 5.11
j MK Piston HP XAW060-090 50736 4.4 5.12
k MK Connecting rod LP XAW060-090 50766 4.4 5.14
l MK Connecting rod HP XAW060-090 50836 4.4 5.14
m MK Crankshaft XAW060-090 50806 4.4 5.17
Sperre Tool Box XAW060-090 50966
Control kit XA060-090 59835
* Safety valve HP / LP 5.4

* Air cooler LP 5.5
* Air cooler HP 5.6
* Compressor serial number must be provided when ordering!

4.6 Recommended kits and special tools
Service-kit overview
Kit name Ordering number Description

Service kit A XA060 51408 Air suction filter with fasteners

Service kit A2 XA060 51408 Air suction filter with fasteners

Service kit B XAW060-090 50036 Required parts for service B included
parts for check
Letter Component Qty. Letter Component Qty. Letter Component Qty.
a Air Filter 1 b Gaskets valve LP 1+1+1 c Gaskets valve HP 1+1

Service kit C XA060-090 50066 Required parts for service C included
parts for check
a Air Filter 1 d Gaskets valve LP 1+1+1 g Gasket crankcase 1

cover
b Valve LP 1 e Gaskets valve HP 1+1
c Valve HP 1 f Fasteners valve 2+2+2
HP

Service kit D XA060-090 50105 Required parts for service D included parts
for check
Sperre Toolbox (ordering nr. 50966) is required for performing this service.
a Air Filter 1 g Rep. kit drain/unload 1+1+2 m Gasket cylinder LP 1

valve HP
b Valve LP 1 h Bearing crank 2 n Gasket cylinder HP 1
c Valve HP 1 i Bearing fan side 1+1+1 o Gaskets bearing fan 1+1
side
d Bearing gudgeon LP 1+1 j Gaskets Valve LP 1+1+1 p Gasket crankcase 1
+2 cover
e Bearing gudgeon HP 1+1 k Gaskets valve HP 1+1 q Crankshaft plate with 1+6
+2 fasteners
f Non return valve HP 1+1 l Fasteners valve HP 2+2+2 r Coupling insert 1

Service kit E XA060 54765 Required parts for service E included
parts for check
Sperre Toolbox (ordering nr. 50966) is required for performing this service.
a Air filter 1 h Bearing crank 2 o Fasteners valve HP 2+2+2

b Valve LP 1 i Bearing fan side 1+1+1 p Gasket cylinder LP 1
c Valve HP 1 j Piston rings LP 2+1 q Gasket cylinder HP 1
d Bearing gudgeon LP 1+1+2 k Piston rings HP 3+1 r Gaskets bearing fan 1+1
side
e Bearing gudgeon HP 1+1+2 l Bearing motor side 1+1+1 s Gaskets bearing 1+1
motor side
f Non return valve HP 1+1 m Gaskets valve LP 1+1+1 t Gasket crankcase 1

cover
g Rep. kit drain/unload 1+1+2 n Gaskets valve HP 1+1 u Crankshaft plate 1+6
valve HP with fasteners
v Coupling insert 1

MR-kit overview

MR Kit XA060 XA060 - MR Air suction filter
CR-kit overview

CR Kit XA060 XA060 - CR Class recommended spare parts
a+b Gasket valve LP 1+1 f Piston rings LP 2+1 j O-ring HP 1

c Valve LP 1 g Gasket valve HP 1 k Gasket cylinder 1
HP
d O-ring LP 1 h Fasteners valve HP 2+2+2 l Piston rings HP 3+1
e Gasket cylinder LP 1 i Valve HP 1

Maintenance kit overview

MK Compressor gasket XA060 50905 All gaskets

MK Cylinder head LP XA060-090 50336 Cylinder head LP with gaskets
Letter Component Qty.
a Cylinder head LP 1
b Gaskets valve LP 1+1+1
c Fittings cylinder head 1+1

LP
d Fasteners cylinder 5+5
head LP

MK Cylinder head HP XA060-090 50366 Cylinder head HP with gaskets
a Cylinder head HP 1
b Gaskets valve HP 1+1
c Fasteners valve HP 2+2+2
d Fittings cylinder head 1+1

LP
e Fasteners cylinder 6+6
head HP

MK Valve LP XAW060-090 50436 Valve LP with gaskets
a Valve LP 1
b Gaskets valve LP 1+1+1

MK Valve HP XA060-090 50466 Valve HP with gaskets
a Valve HP 1
b Fasteners valve HP 2+2+2
c Gaskets valve HP 1+1

MK Cylinder LP XAW060 50565 Cylinder LP with gaskets
a Cylinder LP 1
b Gasket cylinder LP 1
c Gasket valve LP 1+1+1

MK Cylinder HP XAW060-090 50606 Cylinder HP with gaskets
a Cylinder HP 1
b Gasket cylinder HP 1
c Gasket valve HP 1+1

MK Piston ring LP XAW060 50635 Piston ring LP with gaskets
a Piston rings LP 2+1
b Gaskets cylinder LP 1

MK Piston ring HP XAW060-090 50666 Piston ring HP with gaskets
a Piston rings HP 3+1
b Gaskets cylinder HP 1

MK Piston LP XAW060 50705 Piston LP with gaskets
a Piston LP 1
b Piston rings LP 2+1
c Bearing gudgeon LP 1
d Gudgeon pin LP 1
e Retaining rings LP 2
f Gasket cylinder LP 1

MK Piston HP XAW060-090 50736 Piston HP with gaskets
a Piston HP 1
b Piston rings HP 3+1
c Bearing gudgeon HP 1
d Gudgeon pin HP 1
e Retaining rings HP 2
f Gaskets cylinder HP 1

MK Connecting rod LP XAW060-090 50766 Connecting rod LP, with bearings
Sperre Toolbox (ordering nr. 50966) is required for performing this service. Letter Component Qty.
a Connecting rod 1
b Bearing crank 1
c Bearing gudgeon LP 1+1+2
d Gasket cylinder LP 1
e Gaskets bearing fan 1+1

side
f Splash pin with 1+2
screws
g Gasket cylinder HP 1

MK Connecting rod HP XAW060-090 50836 Connecting rod HP, with bearings
a Connecting rod 1
b Bearing crank 1
e Gaskets bearing fan 1+1

side
f Splash pin with 1+2
screws
g Gasket cylinder HP 1
h Bearing gudgeon HP 1+1+2

MK Crankshaft XAW060-090 50806 Crankshaft with gaskets
a Crankshaft with 1+1+1+6

plate and fasteners
b Bearing crank 1+1
c Bearing fan side 1+1+1
d Bearing, motor 1+1+1

side
e Gasket cylinder HP 1+1
+ LP
f Gasket bearing fan 1+1
side
g Gaskets bearing 1+1
motor side

Sperre toolbox XAW060-090 50966
a Dismantling tool 1
crankshaft
b Dismantling screw 1
coupling
c Mounting/dismantling 1
bracket crankshaft
d Fasteners 2
mounting/dismantling
bracket crankshaft
e Dismantling screw 1
fan

Electrical kit overview

Control kit XA060-090 59835
a Cable kit 1
*b Signal cable* 1
c PT13 - Pressure 1+1

sensor LP with M16
copper ring
d PT12 - Pressure 1+1
sensor HP with M12
copper ring
e TT14 - Temperature 1+1
sensor with M14
copper ring
f Oil level sensor 1+3
g DV1 - Drain 1+2
unload/valve HP with
1/2" – M22 copper
rings
h PT11 - Pressure 1+1
transmitter receiver
with 1/2” copper ring
*The signal cable is ordered separately.
Please specify the optional length when
ordering.
Options:
1,5 m
3,0 m
5,0 m
10 m
15 m
20 m

4.7 Ordering parts and kits
Information regarding the compressor type and serial number is stamped on the compressor rating plate [a], which is fixed on the
outside of the back cover and on the side cover, as illustrated below. Compressor serial number must always be provided when
ordering parts and kits.
Letter Description Letter Description
b Type f Compressor capacity

c Serial Number g Speed
d Production year h Compressor power
requirement
e Pressure
The following information must be given when ordering spares:

1. Compressor serial number [c].
2. Quantity, part number and description of the spare parts.
3. Compressor running hours and number of starts/stops (The information is found on the Z-control display).
Your X-range compressor is installed with customer-specific components / parts, some parts therefore require specific ordering
numbers. Please contact Sperre for your customer-specific ordering number when needed.
Contact information
Norway The Netherlands Note

Sperre Industri AS Sperre Rotterdam BV
The listed addresses are the only
Ellingsøy, Norway Rhoon, The Netherlands places you can purchase original parts
Tel: + 47 70 16 11 00 Tel: + 31 10 3030 342 for your X-range compressor.
Fax: + 47 70 16 11 10 rotterdam@sperre.com Sperre takes no responsibility for
aftersales@sperre.com damage caused by use of non-original
parts.
Singapore China Agent Network

Sperre Asia PTE Ltd Sperre China www.sperre.com/agents
Singapore Shanghai, P. R. China
Tel: + 65 6763 6300 Tel: + 86 216 5070436
Fax: + 65 6763 1811 Fax: + 86 216 5070402
asia@sperre.com china@sperre.com

5 Service procedures
5.1 Cover
Dismantle and assemble
Dismantle Note
1. Unscrew the three screws in front [a].
The back cover and base should
2. Remove the front cover [b]. normally not be removed.
3. Unscrew the lifting eye bolt [c].
4. Remove the two side covers [d] by
pulling forward and lifting up. Note
Assemble The lifting eye bolt is certified and
approved for lifting a single
1. Assemble the two side covers [d] by compressor.
pushing them carefully into place.
2. Assemble the front cover [b].
3. Mount the three screws [a].
4. Mount the lifting eye bolt [c].
Spare parts
Ordering number
a Cover Front with grid, 47005
silver
a Cover Front with grid, 47025
munzell
b Cover Side, silver 47505
b Cover Side, munzell 47525
c Cover Back, silver 47105
c Cover Back, munzell 47125
d Cover Seal, silver 47305
d Cover Seal, munzell 47325
e Cover Base, silver 47205
e Cover Base, munzell 47225
f Cover Stiffener 47705
g Fasteners (cover front) 56008
h Fasteners (cover back) 56068
i Fasteners (cover seal / 56111
cover base)
j Fasteners (cover 56168
stiffener)
k Lifting eye bolt 43107
Compressor serial number must be

provided when ordering!

5.2 Lubricating oil
Service
Drain, inspect and clean: Note

1. Before starting this procedure, remove
Always use fully synthetic, ISO 100
cooler LP*.
grade piston compressor oil.
2. Place a tray below the draining plug.
3. Unscrew the six screws and remove
the crankcase cover [c]. Note
4. Remove the draining plug [a] and drain
*See chapter 5.5 “Air Cooler LP”.
the compressor empty.
5. Mount the draining plug [a].
6. Assemble the crankcase cover with
the six screws.
Note
Refilling oil:
Oil level switch LS15 LED indicator [e]
1. Fill necessary amount oil through the
Green light: Oil and temperature level
oil filling hole [b].
normal.
2. Check oil level on Z-control and sight Blinking yellow light fast: Temperature
glass [d]. high
3. Mount the filling plug [b] Blinking yellow light slow: Oil level too
low.
Filling of new oil:
No light: Short circuit or malfunction
1. Fill approx. 8 L new oil through the oil
filling hole [b] or through the crank
case cover opening [c].
2. Check oil level on Z-control and sight
glass [d].
3. Mount the filling plug [b] or the crank
case cover [c].

Spare parts
Ordering number
a Transmitter oil level 56521
b Flex tube1 ventilator, 51236
640mm
c Flex tube2 ventilator, 51266
540mm
d Flex tube3 ventilator, 51306
330mm
e Reduction (ventilator) 56868
f Level sight glass 3634
g Tube oil drain 51208
h Gasket crankcase 35517
cover
i Crankcase cover 32012
j Fasteners 56568
k Tube oil refill with 51336
gasket
l Plug 1” (oil refill) 7751
m Plug (oil drain) 7752
n Ventilator 56668

5.3 Air filter
Service
Inspect and replace Note

1. Unscrew the two screws [a].
Depending on the compressor
2. Replace the air filter unit [b]. environment the air filter can be used
for a longer period than stated in the
3. Mount the two screws [a]. manual.
Warning
Dirty environment might harm this

equipment. See chapter 3.1
“Installation” for more information.
Spare parts
Ordering number
a Air filter with fasteners 51408
b Fasteners (air filter) 56368
c Filter holder 22494
d Fasteners (filter 57266
holder)

5.4 Safety valves LP and HP
Service

1. Replace the safety valves [a] and [b]
Perform a visual inspection of safety
valves and clean for dirt. If clogged
inlet change valve(s).
Perform a function test on safety valve

HP. The valve should blow at
maximum working pressure + 10%.
Change if not functioning correctly.
Spare parts
Ordering number
a Safety valve LP 7 bar 51568
a Safety valve LP 8 bar 51508
b Safety valve HP 11 bar 51606


5.5 Air cooler LP
Dismantle
1. Unscrew the flexible tubes [a] and [b].
2. Unscrew the cylinder nipple [c].
3. Unscrew the cooler LP fixing screws [d]
and remove the cooler LP.
Assemble
1. Mount the cooler LP with the cooler
fixing screws [d].
2. Mount the cylinder nipple [c].
3. Mount the flexible tubes [a] and [b].
Service

1. Unscrew the adapters [b].
*If the cooler have particles in the
2. Inspect and replace the cooler LP [a] airflow area inside, the cooler must be
if necessary*. replaced. Outside, the cooler airflow
area can be cleaned by carefully
3. Mount the adapters [b]. blowing with air or water.
Spare parts
Ordering number
a Cooler LP 37203
b Transmitter LP pressure 56421
c Flexible tube LP (air) 45107
d Flexible tube LP 45190
(transmitter)
e+f Bracket cooler LP with 51866
fasteners (f)
f Fasteners (bracket 56271
cooler LP)
g Fasteners (cooler LP) 56311
h Adapter (cooler inlet) 56708
i Adapter (cooler outlet) 56708
j Adapter (transmitter) 56948
k Fittings (transmitter) 57241

5.6 Air cooler HP
Dismantle
1. Unscrew the flexible tubes [a] and [b].
2. Unscrew the cooler tube HP [c].
3. Unscrew the cooler fixing screws [d]
and remove the cooler HP.
Assemble
1. Mount the cooler HP with the cooler
fixing screws [d].
2. Mount the cooler tube HP [c].
3. Mount the flexible tubes [a] and [b].
Service

1. Unscrew the adapters [a].
*If the cooler have particles in the
2. Inspect and replace the cooler HP [b] if airflow area inside, the cooler must be
necessary*. replaced. Outside, the coolers airflow
area can be cleaned by carefully
3. Mount the adapters [a]. blowing with air or water.
4. Inspect and replace the cooler tube HP
[c], if necessary**. **Always change the fittings when
changing the cooler tube.
Spare parts
Ordering number
a Cooler HP 37213
b Transmitter HP pressure 56451
c Cooler tube HP 51906
d Flexible tube HP (air) 45108
e Flexible tube HP 45190
(transmitter)
f Bracket cooler HP with 51966
+ fasteners (h)
h
g Fasteners (cooler HP) 56341
h Fasteners (bracket cooler 56241
HP)
i Adjust.elbow 44013
j Adapter (cooler outlet) 56708
k Adapter (transmitter) 56948
l Fittings 57211

5.7 Valve LP
Dismantle
1. Unscrew the cooler adapter [a].
2. Unscrew the five nuts [b].
3. Remove the cylinder head [c].
Assemble
1. Assemble the cylinder head [c].
Replace gasket (see service step 1)
2. Mount the five nuts [b].
3. Mount the cooler adapter [a].
Service

1. Replace the O-ring [a] and the two
The copper gaskets and O-ring must
copper gaskets [b].
always be replaced. Clean the
2. Inspect the valve [c] and replace if adjacent surfaces before the new
necessary. copper gaskets are fitted.
Sperre recommend complete valve
replacement (Plate valve service kit
can be supplied).
Spare parts
Ordering number
a Valve LP with gaskets 50436
b Gaskets valve LP 52036
c Cylinder head LP 20413
d Fasteners 57708
e Plug 44301
f Swivel male 57106
- Service kit plate valve 52136

5.8 Valve HP
Dismantle Warning
1. Unscrew the flexible tube air delivery [a].
2. Unscrew the cooler tube [b].
Always mount the six M10 nuts first
3. Unscrew the six nuts [c].
with torque 48Nm and then mount the
4. Remove the cylinder head [d]. two nuts M8 with torque 24Nm.
Assemble
1. Assemble the cylinder head [d].
2. Mount the six nuts [c].
3. Mount the 2 nuts [c].
4. Mount the cooler tube [b].
5. Mount the flexible tube air delivery [a].
Service

1. Remove the old gasket, clean the
The flat gaskets should always be
adjacent surfaces [a] and place the
replaced. Clean the adjacent surfaces
new gasket [b]
before the new gaskets are fitted.
2. Unscrew the two nuts [c] holding the
valve
3. Inspect the valve [d], and replace if
necessary. Change the two studs [e].
Apply high temperature thread-locking
Note
fluid on threads to ensure sealing and After the first warm running the two M8
right position of stud. cap nuts [c] should be re-tightened with
4. Clean the adjacent surface [f]. 24Nm.
5. Place the new gasket [g],

6. Assemble
Spare parts
Ordering number
a Valve HP with gaskets 50466
and fasteners
b Gaskets valve HP 52236
c Fasteners (valve) 52336
d Cylinder head HP 20513
e Fasteners (cylinder 52366
head)
f Plug 44301
g Adapter (inlet) 56708
h Connector (outlet) 56806

5.9 Cylinder LP
Dismantle
Warning
1. Unscrew the four nuts [a].
2. Remove the cylinder LP [b].
Assemble
Be careful not to damage the piston.
1. Mount the cylinder LP [b].
2. Mount the four nuts [a].
Note
Before starting this procedure perform
the dismantling procedure described in
chapter 5.7 “Valve LP”.
Service

1. Inspect for wear inside the cylinder LP
The cylinder should be honed (45
[a] and change if necessary.
degrees stripes) each time piston rings
2. Clean the adjacent surfaces [b]. are replaced. If there are critical vertical
stripes inside the cylinder after honing,
3. Replace the flat gasket [c]. the cylinder must be replaced.
Note
Cylinder diameter:⌀110
Maxiumum allowed cylinder diameter:
⌀110,25
Spare parts
Ordering number
a Gaskets cylinder LP with 52606
gaskets valve LP
b Cylinder LP 20313
c Fasteners 57368
MK Cylinder kit, see chapter 4.6 for
ordering number.

5.10 Cylinder HP
Dismantle
Warning
1. Unscrew the four nuts [a].
2. Remove the cylinder [b].
Assemble
Be careful not to damage the piston.
1. Mount the cylinder [b].
2. Mount the four nuts [a].
Note
Before starting this procedure perform
the dismantling procedure described in
chapter 5.8 “Valve HP”.
Service

1. Inspect for wear inside cylinder [a],
The cylinder should be honed (45
replace if necessary.
degrees stripes) each time piston rings
2. Clean the adjacent surfaces [b]. are replaced. If there are critical vertical
stripes inside the cylinder after honing,
3. Replace the flat gasket [c]. the cylinder must be replaced.
Note
Cylinder diameter:⌀55
Maxiumum allowed cylinder diameter:
⌀55,15
Spare parts
Ordering number
a Gaskets cylinder HP with 52636
gaskets valve HP
b Cylinder HP 20363
c Fasteners 57368
MK Cylinder kit, see chapter 4.6 for

ordering number.

5.11 Piston, rings and gudgeon bearing LP
Dismantle Note
1. Remove the two retaining rings [a].
Before starting this procedure, perform
2. Remove the gudgeon pin* [b]. the dismantling procedure described in
chapter 5.9 “Cylinder LP”.
3. Remove the piston [c].
Assemble
1. Assemble the piston [c]. Note
2. Mount the gudgeon pin* [b]. * Heat the piston with a heat gun when
3. Mount the two retaining rings [a]. dismantling and assembling the
gudgeon pin.
Service
Gudgeon bearing: Note

1. Replace the gudgeon bearing [a].
Maximum allowed connecting rod
Check ovality in small end bore
ovality: 0,02mm
(connecting rod).
2. Inspect the crank bearing by moving
the connecting rod [b] up and down.
To replace the crank bearing refer to
chapter 5.14.
Piston and Piston rings:
1. Inspect the two piston rings and one oil
ring [c], replace if necessary.
2. Inspect for wear outside of the piston
[d], replace if necessary.
Spare parts
Ordering number
a Piston LP with retaining 52805
rings
b Piston rings LP 52835
c Bearing needle LP 52866
MK Piston kit, see chapter 4.6 for

ordering number.

5.12 Piston, rings HP and bearing gudgeon
Dismantle Note
1. Remove the two retaining rings [a].
2. Remove the gudgeon pin* [b]. the dismantling procedure described in
chapter 5.10 “Cylinder HP”.
3. Remove the piston [c].
Assemble
1. Assemble the piston [c]. Note
2. Mount the gudgeon pin* [b]. * Heat the piston with a heat gun when
3. Mount the two retaining rings [a]. dismantling and assembling the
gudgeon pin.
Service
Gudgeon bearing: Note

1. Replace the gudgeon bearing [a].
Maximum allowed connecting rod
2. Inspect the crank bearing by moving the ovality: 0,02mm
connecting rod [b] up and down. To
replace the crank bearing refer to
chapter 5.14.
Piston and Piston rings:
1. Inspect the three piston rings and one
oil ring [c], replace if necessary.
2. Inspect for wear outside of the piston
[d], replace if necessary.
Spare parts
Ordering number
a Piston HP with retaining 52906
rings
b Piston rings HP 52936
c Bearing needle HP 52966
MK Piston kit, see chapter 4.6 for ordering

number.

5.13 Bearing fan side
Dismantle Note
1. Unscrew the fan centre screw [a].
* The Sperre M16 dismantling screw is
2. Use the Sperre M16 dismantling a part of the Sperre Toolbox, see
screw* to loosen the fan from the chapter 4.6 for ordering number.
shaft and remove fan [b]. If the fan is
stuck, use a heat gun to heat the
center of the fan. Inspect the fan***.
Warning
3. Unscrew the nut [c] and eight nuts [d].
4. Use two M10 screws [e] to loosen the
front plate from the crankcase.
***Inspect the fan for cracks and
5. Remove the front plate [f]. damages, especially in the welding
Assemble points. Replace the fan if there is any
cracks or damages.
1. Inspect the gasket (see service step 1)
and replace if necessary.
2. Remove the two M10 screws.
3. Mount the front plate with eight nuts
[d]. Mount the nut [c].
4. Remove the M16 screw and mount fan
[b].
5. Mount the fan centre screw [a], use
hand to prevent fan from rotating.
Service

1. Remove the gasket [a], clean adjacent
* Heat the inner bearing ring with a
surfaces and mount the new gasket.
heat gun when dismantling and
2. Replace the sealing ring [b], and assembling on the shaft.
mount the new sealing ring.
3. Remove the retaining rings[c] , use nail
punch in holes [d] to remove the outer
bearing [e]. Remove inner bearing
ring from shaft*.
4. Mount the new bearing.
5. Mount the new retaining rings.

Spare parts
Ordering number
a Bearing fan side with 53011
retaining rings
b Gaskets bearing fan side 53036
c Front plate 20125
d Fasteners (front plate) 57666
e Fan with fasteners 53066
f Fasteners (fan) 57536
g Washer (fan) & fasteners 53065

5.14 Bearing crank
Dismantle Note
1. Mount the counterweight bracket [a] *.
2. Unscrew the centre screw [b]. the dismantling procedure described in
chapter 5.13 “Bearing fan side”.
3. Use the Sperre dismantling tool* [c] to
loosen the counterweight [d]. Mount
the tool between the counterweight
and crank disk, as close to centre as Note
possible, to split the crankshaft.
* The counterweight bracket and the
4. Remove the counterweight bracket [a]
dismantling tool are delivered with
5. Remove the counterweight [d]. service kit. The bracket is to be
mounted on the crank case and to the
6. Carefully remove the two connecting counterweight to prevent the
rods [e]. Pull the connecting rod off counterweight from rotating.
the crankshaft.
Assemble
1. Carefully mount the two connecting
rods [e].
2. Mount the counterweight [d].
3. Mount the counterweight bracket [a] *.
4. Mount the centre screw [b].
Service

1. Replace the bearing crank [a]*. Read
* Heat the bearing with a heat gun
note*** before mounting the LP crank
when dismantling and assembling on
bearing.
the shaft.
2. Inspect the two splash pins [b], replace
if necessary.
3. Inspect the crankshaft plate [c], Note
replace if necessary.**
** Apply low strength threadlocker fluid
4. To replace the gudgeon bearing refer
on the six crankshaft plate fasteners.
to chapter 5.11 and 5.12.
Mount the six M5 screws with torque
8NM.
Note
*** The crank bearings [i] are slightly
wider than the connecting rods [h] and
it’s important that the LP crank bearing
is mounted flush to the side facing the
the crankshaft plate [j].

Spare parts
Ordering number
a Bearing needle (2 pcs.) 53108
b Connecting rod (1 pcs.) 53136
c Crankshaft complete, 54613
included f) *
d Bracket counterweight 53306
with dismantling tool
e Fasteners 57468
f Crankshaft plate with 53106
fasteners
g Splash pin with screws 53143
* Always change both crankshaft and

counterweight. See chapter 5.17 for
crankshaft.

5.15 Electric motor and vibration isolators
Dismantle Note
1. Unscrew the air outlet flexible tube [a],
To disconnect the signal cable,
drain flexible tube [b] and signal cable
unscrew the locking ring counter
[c].
clockwise to loosen it. Pull the plug out.
2. Unscrew the five screws [d] and To disconnect the cable contact unit on
remove the back cover. the compressor back cover, unscrew
3. Unscrew the three screws [e] on the the locking nut counter clockwise and
coupling cover [k] and remove the pull out the contact unit.
coupling cover.*
4. Remove the flexible coupling insert [l].*
5. Unscrew the four nuts [f] to loosen the
*Note
motor from the motor flange.
6. Unscrew the nut holding the motor
support [g] to isolator [h].
7. Remove the motor.
Assemble
1. Mount the motor with motor support [g]
to the isolator [h].
2. Mount the four nuts [f] to the motor
flange.
3. Mount the flexible coupling insert [l] , [e] Fasteners coupling cover,
the coupling cover [k] and fasten the [k] coupling cover, [l] Flexible coupling
three screws [e].* insert
4. Assemble the back cover with the five
screws [d].
5. Mount the flexible tubes air outlet [a],
drain [b], and signal cable [c].
Coupling flange assembly
No motor flange:
If the electric motor is mounted
directly to the crank house the
coupling flange shall be mounted as
far in as possible on the shaft so that
the gap [i] is 0,0mm.
160 build size electric motor:
Distance [i] shall be 0,0mm.
180 build size electric motor:
Distance [i] shall be 0,0mm.

Service
Inspect and replace

1. Replace the front isolator [b] and back
isolator [a].
Spare parts
Ordering number
a Electric motor *
b Fasteners (Electric motor) 53606
c Support motor (160) 20809
c Support motor (180) 20811
d Fasteners (Electric motor) 53636
e Vibration isolator type 1 53465
with fasteners**
f Fasteners (Vibr. isol. 53336
Compr.)
g Vibration isolator type 1 53465
with fasteners**
h Vibration isolator type 1 53466
with fasteners**
i Fasteners (Vibr. isol. el. 53368
motor)
*Compressor serial number must be
**The X-isolator’s base plate is marked
with identification number 1 or 2, please
check the number and spare parts
illustration/table before assembling to
make sure it’s mounted in the correct
place. Where to mount the different
vibration isolators depends on the
compressor configuration.

5.16 Coupling and sealing flange
Dismantle Note
1. Unscrew the centre screw [a].
2. Use the Sperre dismantling tools* to the dismantling procedure described in
loosen the coupling from the crank chapter 5.15 “El. motor and vibration
disk. First mount the socket set isolators”.
screw*, and then use the M20
dismantling screw* to loosen the
coupling from the crank disk.
3. Remove the coupling [b].
4. Unscrew the three screws [c]. Note
5. Use two M10 screws** [d] to loosen
* The Sperre M20 dismantling screw
the sealing flange.
and socket set screw in the Sperre tool
6. Remove the sealing flange [e]. box, ordering number 50966
Assemble ** After dismantling do not forget to
remove the M10 screws.
1. Mount the sealing flange [e] with the
new gaskets and the sealing ring (see
service step1).
2. Mount the three screws [c].
3. Mount the coupling [b].
4. Mount the centre screw [a].
Service
Inspect and replace

1. Replace the sealing ring and gasket
[a].
2. Inspect the coupling and change if
threads are damaged.

Spare parts
Ordering number
a Gasket sealing flange 53706
b Sealing flange 20145
c Coupling ⌀ 42 with 53742
fasteners
Coupling ⌀ 48 with 53743
fasteners
d Fasteners (coupling) 53905
e Fasteners (sealing 56541
flange)
f Coupling insert 32740
g Coupling cover 24352

*Note
* The flexible coupling insert must be

replaced after 6000 hours or 6 years.
Sperre recommend coupling insert

check every 3000 hours and if worn it
must be replaced.

5.17 Crank disk and bearing motor side
Dismantle Note
1. Remove the inner retaining ring [a].
2. Remove the bearing plate [b]. the dismantling procedure described in
chapter 5.16 “Coupling and sealing
3. Remove the crank disk [c]. flange”.
4. Remove the inner bearing ring [d] from
the crank disk *.
5. Remove the outer retaining ring [e] Note
and the outer bearing ring [f] from the
crankcase. * Heat the bearing with a heat gun
when dismantling and assembling on
Assemble the shaft.
1. Mount the outer retaining ring [e] and
push in the outer bearing ring [f] in the
crankcase.
2. Mount the inner bearing ring [d] on the
crank disk [c] and mount the crank
disk in the crankcase *.
3. Mount the bearing plate [b].
4. Mount the inner retaining ring [a].
Service
Inspect and replace

1. Replace the bearing on the motor side
[a].
Spare parts
Ordering number
a Bearing motor side with 54106
retaining rings
b Crankshaft complete* 54613
c Crankcase 20105
d Lifting bar 32143
* Always change both crankshaft and
counterweight. See chapter 5.14 for
crankshaft counterweight.

5.18 Cyclone separator and non return valve
Dismantle
Warning
1. Unscrew the air outlet flexible tube [a].
2. Unscrew the transmitter plug [b].
3. Unscrew the three screws [c]. Before starting this procedure the
manual valve between the compressor
4. Remove the outlet cover HP [d].
and the receiver must be closed. The
Assemble pressure must be released in all
pressurized parts of the compressor.
1. Mount the outlet cover HP [d].
2. Mount the three screws [c].
3. Mount the transmitter plug [b] and the
air outlet flexible tube [a].
Caution
This item is pressurized from the receiver.
Service
Inspect and replace

1. Replace the copper ring and inspect
the non return valve [a]. Change the
non return valve if necessary.
2. Inspect the cyclone tube [b] for
corrosion, change if necessary.

Spare parts
Ordering number
a Valve HP non return 54208
b Transmitter HP 56481
temperature
c Cyclone tube HP 32125
d Outlet connector HP 54236
with sensor pocket for
transmitter
e Separator housing HP 20613
f Fasteners (outlet 57507
connector HP)
g Fasteners (separator 57466
housing HP)
h Adapter (outlet 56708
connector HP)
i Plug (outlet connector 44304
HP)
j Adapter (separator 56738
housing HP inlet)
k Adapter (separator 57006
housing HP drain)
l Swivel 90° elbow (drain) 8652
m Plug (separator housing 57736
HP)
n Swivel nut tee 44191
o Plug (adapter T drain) 44324
p Sensor pocket for 32099
transmitter
q Screw socket cap 42002
r Plate separator HP 32005

5.19 Drain/unload valve
Service
Inspect and replace

1. Remove the coil plug [a].
2. Remove the coil [b].
3. Unscrew the four screws and remove
the cover [c].
4. Replace the diaphragm, spring and the
two O-rings [d].
5. Mount the cover [c] with the 4 screws.
6. Mount the coil [b].
7. Mount the coil plug [a].
8. Be sure that the manual override is
open. Use a screwdriver to turn the
screw [e] counterclockwise to open
the drain valve.This is normal running
function.
Spare parts
Ordering number
a Coil
110V 64315
220V 64310
b Rep.kit drain/unload valve 64211
c Drain/unload valve HP 57906
with gaskets
d Fittings 57166


5.20 Electrical components
Spare part list with Sperre item numbers for your configuration of electrical components are provided by Sperre in the order
documentation and in the compressor controller cabinet. Please note that compressor serial number must always be provided
when ordering spare parts.
See chapter “4.7 Ordering parts and kits” for contact information and more details regarding compressor serial no.

6 X-range data
6.1 Torque tables
XA060
Component Chapter Quantity Thread diameter Spanner width Torque (Nm)
Enclosure Front / Back 5.1 3/5 M8x15 Unbrako 6 24

Enclosure Base / Seal / 5.1 M8x15 Unbrako 6 24
5/5/6
Stiffener
Crank case cover 5.2 6 M8x20 Unbrako 6 24
Air filter 5.3 2 M8x25 Unbrako 6 24
Air filter holder 5.3 3 M8 Unbrako 6 24
Cooler bracket LP 5.5 2 M8x12 Unbrako 6 24
Cooler bracket LP 5.5 2 M8x25 Unbrako 6 24
Cooler tube HP 5.6 2 Ermeto 41 Tighten
Cooler bracket HP 5.6 4 M8x12 Unbrako 6 24
Cooler bracket HP 5.6 4 M8x25 Unbrako 6 24
Cylinder head LP 5.7 5 M12 19 mm 80
Cylinder head HP 5.8 6 M10 17 mm 48
Valve HP 5.8 2 M8 13 mm 24
Cylinder LP 5.9 4 M16 24 mm 200
Cylinder HP 5.10 4 M16 24 mm 200
Fan centre screw 5.13 1 M12x45 Unbrako 10 80
Fan centre disk screws 5.13 3 M6x16 Unbrako 5 10
Front Plate 5.13 8 M12 19 mm 80
Counterweight 5.14 1 M16x35 Unbrako 14 200
Coupling (side screw) 5.15/5.16 1 M16x60 Unbrako 14 200
El-motor 5.15 4 M16 24 mm 200
Sealing flange screws 5.16 3 M8x20 Unbrako 6 24
Coupling (centre screw) 5.16 1 M16x40 Unbrako 14 200
Outlet connector HP 5.18 3 M12x25 Unbrako 10 80

NOTE:
NOTE:
NOTE:

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Service Manual

X-range air compressor

Patented X-drive Patented cooling Registered design

This excellent compressor gives you several benefits:

 Safety first – a fully enclosed structure  Easy plug-in for sensors

www.sperre.com Service Manual XA060 Version 05 3

3 Installation and Operation ..................................................................... 9

4 Service and ordering............................................................................ 16

5 Service procedures .............................................................................. 37

6 X-range data ......................................................................................... 63

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Danger Danger Caution

Compressor rating plate Attention

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Sperre starting air compressors are designed to fulfil requirements from

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Air quality and compressor environment

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Letter Description Letter Description

a Start – push to start the f* Lead / Follow

Steady Compressor motor running

Steady One or more alarms active

Steady One or more shutdowns active

Steady Space heater on

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Operation mode is selected by sliding the selector switch

When the stop button is pressed, the

In case of malfunction the

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6. Stop the compressor by reversing the

For water cooled compressors:

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When a service warning appears in the active alarms list

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When a service alarm appears on the display

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Service alarm reset procedure: Note

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Service alarm tags

Service alarm tag Text displayed Failure Corrective action

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Oil change X X X X X X X X X 5.2

Air filter replacement X X X X X X X X X X X X X X X X X 5.3

Valve LP replacement X X X X 5.7

Valve HP replacement X X X X 5.8

Bearing gudgeon + pin 5.11

Non return valve

Bearing crank replacement X X 5.14

Bearing fan side

Piston ring LP replacement X 5.11

Piston ring HP replacement X 5.12

Bearing motor side

Valve LP check* X X X X 5.7

Valve HP check* X X X X 5.8

Gudgeon bearing + pin 5.11

Bearing crank check** X X 5.14

Air cooler LP check*** X X X X 5.5