Service Manual XW200 - Version 06

36
Service Manual
X-range air compressor
XW200
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!
09.02.2018
www.sperre.com Service Manual XW200 Version 06 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 .................................................................................................... 38
5 Service procedures .............................................................................. 39

5.1 Cover ............................................................................................................................... 39
5.2 Lubricating oil .................................................................................................................. 40
5.3 Air filter ............................................................................................................................ 42
5.4 Safety valves LP and HP ................................................................................................ 43
5.5 Air cooler LP .................................................................................................................... 44
5.6 Air cooler HP ................................................................................................................... 46
5.7 Valve LP .......................................................................................................................... 48
5.8 Valve HP ......................................................................................................................... 50
5.9 Cylinder LP ...................................................................................................................... 52
5.10 Cylinder HP ..................................................................................................................... 53
5.11 Piston, rings and gudgeon bearing LP ............................................................................ 54
5.12 Piston, rings and gudgeon bearing HP ........................................................................... 55
5.13 Bearing fan side .............................................................................................................. 56
5.14 Bearing crank .................................................................................................................. 58
5.15 Electric motor and vibration isolators .............................................................................. 60
5.16 Coupling and sealing flange ............................................................................................ 63
5.17 Crankshaft and bearing motor side ................................................................................. 65
5.18 Cyclone separator and non return valve ......................................................................... 66
5.19 Drain/unload valve........................................................................................................... 69
5.20 Oil pump .......................................................................................................................... 71
5.21 Electrical components ..................................................................................................... 73
6 X-range data ......................................................................................... 74

6.1 Torque tables .................................................................................................................. 74

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 Original instructions in English.
operation or inadequate maintenance. Keep the compressor in good mechanical
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

Note obvious, 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
The item is pressurized from the receiver. running align the plug to find the right insert point
Without the cover the compressor will be on the contact unit, then push the plug
Check manual before dismantling. carefully in and srew the locking ring
damaged after running even for a short
period clockwise to secure it.
To disconnect the signal cable, unscrew
the locking ring counter clockwise to
loosen it. Pull the plug out.
Before using or servicing the compressor The oil has been drained from the Level sight glass
Read and understand the user manual compressor Correct oil level should be in centre of
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
Unloading and drain low pressure Cooling water outlet Cooling water inlet
The lifting eye bolt is certified for lifting Compressor oil type. Attention
the single compressor with el-motor only Always use fully synthetic, ISO 100 grade Dirty environment might harm this
piston compressor oil. equipment. Refer to manual.
Compressor rating plate Rotation direction is counter clock wise,

when looking at compressor front.

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
Please refer to the General
connections.
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
Department for purchasing upgrade kit.
In this example the lead compressor
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
ordering.
• Lead / Follow
If this function is desired later on,
• Sea / Harbour Mode please contact Sperre Aftersales
Department for purchasing upgrade kit.
• Automatic / Manual
• 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' Never carry out the emergency
position. The drain valve will close operation alone. Monitor the air-
and the compressor will start to build receiver pressure and shut down the
pressure. 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
motor overload control, which will be in
5. The pressure increase should be an active state.
monitored during all running period.
6. Stop the compressor by reversing the
above procedure; leaving the switch
in the unloaded position for a few Warning
seconds before stopping the
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. *Use access code 0100 to enter the
Service procedures A2, B, C, D and E are to be performed in the order illustrated above. 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
Oil filter replacement 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 inlet, the cooler must be replaced. Sperre
recommends for this compressor cooler check every 6.000 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 A XAW200-300 50010 4.4

- Service kit A2 XAW200-300 51411 4.4
- Service Kit B XAW200-250 54877 4.4
- Service Kit C XW200-250 54847 4.4
- Service Kit D XW200-250 54746 4.4
- Service Kit E XW200 54976 4.4
MR Kit XW200 XW200-MR 4.4
CR Kit XW200 XW200-CR 4.4
MK Compressor gasket XW200 54916 4.4
a MK Cylinder head LP XW200-250 50347 4.4 5.7
b MK Cylinder head HP XW200-300 50378 4.4 5.8
c MK Valve LP XAW200-250 50440 4.4 5.7
d MK Valve HP XW200-300 50478 4.4 5.8
e MK Cylinder LP XAW200 50569 4.4 5.9
f MK Cylinder HP XAW200-250 50610 4.4 5.10
g MK Piston rings LP XAW200 50639 4.4 5.11
h MK Piston rings HP XAW200-250 50670 4.4 5.12
i MK Piston LP XAW200 50709 4.4 5.11
j MK Piston HP XAW200-250 50740 4.4 5.12
k MK Connecting rod LP XAW200-250 50769 4.4 5.14
l MK Connecting rod HP XAW200-250 50846 4.4 5.14
m MK Crankshaft XAW200-250 50817 4.4 5.17
Sperre Tool Box XAW200-300 50971 4.4 5.14
Control kit 59941
* 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 XW200 50010 Air suction filter and oil filter
Ordering number Description

Kit name
Service kit A2 XAW200-300 51411 Air suction filter with fasteners

Service kit B XAW200-250 54877 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 1+1+1 c Gaskets valve HP 1+1+1

LP
d Oil Filter 1

Service kit C XW200-250 54847 Required parts for service C included
parts for check
a Air Filter 1 d Gaskets valve 1+1+1+ g O-rings cooler 2+2+6+6

LP 1 LP+HP
b Valve LP 1 e Gaskets valve 1+1+1 h Gasket 1
HP crankcase cover
c Valve HP 1 f Fasteners valve 1+1 i Oil filter 1
HP

Service kit D XW200-250 54746 Required parts for service D included parts
for check
a Air Filter 1 h Bearing Crank 2 p Disc springs cooler 8+8

LP + HP
b Valve LP 1 i Bearing fan side 1+1+1 q Studs cooler LP + 4+4
HP
c Valve HP 1 j Gaskets Valve LP 1+1+1+1 r Gaskets bearing fan 1+1+1+1
side +1+1
d Bearing gudgeon 1+1+2 k Gaskets valve HP 1+1+1 s Gasket crankcase 1
LP cover
e Bearing gudgeon 1+1+2 l Fasteners valve HP 1+1 t Oil filter 1

HP
f Non return valve 1 m Gasket cylinder LP 1 u Crankshaft plate 1+6

HP with fasteners
g Drain/unload valve 1+1+2 n Gasket cylinder HP 1 v Crankshaft plate 1+6
HP kit with fasteners
o O-rings cooler 2+2+6+6 w Coupling insert 1
LP+HP

Service kit E XW200 54976 Required parts for service E included
parts for check

a Air filter 1 j Piston rings LP 2+1 s Disc springs cooler 8+8

LP + HP
b Valve LP 1 k Piston rings HP 3+1 t Studs cooler LP + 4+4
HP
c Valve HP 1 l Bearing motor side 1+1+1 u Gaskets bearing fan 1+1+1+1
side +1+1
d Bearing gudgeon 1+1+2 m Gaskets valve LP 1+1+1+1 v Gaskets bearing 1+1
LP motor side
e Bearing gudgeon 1+1+2 n Gaskets valve HP 1+1+1 w Gasket crankcase 1
HP cover
f Non return valve 1 o Fasteners valve HP 1+1 x Oil Filter 1
HP
g Drain/unload valve 1+1+2 p Gaskets cylinder LP 1 y Crankshaft plate 1+6

HP/LP kit with fasteners
h Bearing crank 2 q Gaskets cylinder 1 z Crankshaft plate 1+6
HP with fasteners
i Bearing fan side 1+1+1 r O-rings cooler LP + 2+2+6+6 z2 Coupling insert 1
HP

MR-kit overview

MR Kit XW200 XW200 - MR Air suction filter
CR-kit overview

CR Kit XW200 XW200 - CR Class recommended spare parts
a Gasket cylinder head 1 g Piston rings LP 2+1 l O-ring valve HP 1

LP
b+c Gaskets valve LP 1+1 h Gasket cylinder 1 m Gasket cylinder HP 1
head HP
d Valve LP 1 i Fasteners valve 1+1 n Piston rings HP 3+1
HP
e O-ring valve LP 1 j Gaskets valve HP 1 o O-rings Cooler LP 1+1+3+3
f Gasket cylinder LP 1 k Valve HP 1 p O-rings Cooler HP 1+1+3+3

Maintenance kit overview

MK Compressor gasket XW200 54916 All gaskets

MK Cylinder head LP XW200-250 50347 Cylinder head LP with gaskets
Letter Component Qty.
a Cylinder head top 1

cover LP
b Cylinder head bottom 1
cover LP
c Gasket cylinder head 1
LP
d Gaskets valve LP 1+1+1
e Fittings cylinder head 1+1

LP
f Fasteners cylinder 5+5+6
head LP

MK Cylinder head HP XW200-300 50378 Cylinder head HP, with gaskets
a Cylinder head top 1

cover HP
b Cylinder head 1
bottom cover HP
c Gasket cylinder 1
head HP
d Gaskets valve HP 1+1
e Fasteners valve 1+1

HP
f Fittings cylinder 1+1+1+1
head HP
g Fasteners 6+6+10+4
cylinder head HP

MK Valve LP XAW200-250 50440 Valve LP with gaskets
a Valve LP 1
b Gaskets valve LP 1+1+1

MK Valve HP XW200-300 50478 Valve HP with gaskets
a Valve HP 1
b Gaskets valve HP 1+1+1
c Fasteners valve HP 1+1

MK Cylinder LP XAW200 50569 Cylinder LP, with gaskets
a Cylinder LP 1
b Gasket cylinder LP 1
c Gasket valve LP 1+1+1
d Fasteners cylinder 4+4

MK Cylinder HP XAW200-250 50610 Cylinder HP, with gaskets
a Cylinder HP 1
b Gasket cylinder HP 1
c Gasket valve HP 1
d Fasteners cylinder 4+4

MK Piston ring LP XAW200 50639 Piston ring LP with gaskets
a Piston rings LP 2+1
b Gaskets cylinder LP 1

MK Piston ring HP XAW200-250 50670 Piston ring HP with gaskets
a Piston rings HP 3+1
b Gaskets cylinder HP 1

MK Piston LP XAW200 50709 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 Gaskets cylinder LP 1

MK Piston HP XAW200-250 50740 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 XAW200-250 50769 Connecting rod LP with bearings
a Connecting rod 1
b Bearing crank 1
c Bearing gudgeon 1+1+2

LP
d Gasket cylinder LP 1
e Gaskets bearing 1+1+1+1

fan side +1+1
f Splash pin 1+1+2
g Ring connecting 1+6

rod with screws
h Ring Crankshaft 1
i Gasket cylinder HP 1

MK Connecting rod HP XAW200-250 50846 Connecting rod HP with bearings
a Connecting rod 1
b Bearing crank 1
e Gaskets bearing fan 1+1

side
f Splash pin 1+1+2
h Ring Crankshaft 1
i Gasket cylinder HP 1
j Bearing gudgeon HP 1+1+2

MK Crankshaft XAW200-300 50817 Crankshaft with gaskets
a Crankshaft with 1+1+1+

plates and +1+1+2
fasteners +6+6
b Bearing crank 2
c Bearing fan side 1+1+1
d Bearing motor side 1+1+1
e Gasket cylinder HP 1+1

+ LP
f Gasket bearing fan 1+1+1+
side 1+1+1
g Gaskets bearing 1+1
motor side
h Ring connecting rod 1+6
with screws

Sperre toolbox XAW200-300 50971
a Dismantling tool 1
crankshaft
b Dismantling screw 1
coupling
c Mounting/ dismantling 1
bracket crankshaft
d Fasteners 2
mounting/dismantling
bracket crankshaft
e Mounting tool for seal 1+1
ring
f Dismantling screw 1
fan

Electrical kit overview

Control kit 59941
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 Transmitter oil 1+1
pressure
g DV1 - Drain 1+2
unload/valve HP with
3/4" – M27 copper
rings
h DV2 - Drain 1+2
unload/valve LP with
3/4" – M27 copper
rings
i 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, 64401-2
3,0 m, 64403-2
5,0 m, 64405-2
10 m, 64410-2
15 m, 64415-2
20 m, 64420-2

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
damage caused by use of non-original
aftersales@sperre.com 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 five 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
1. Assemble the two side covers [d] by approved for lifting a single
pushing them carefully into place. compressor.
2. Assemble the front cover [b].

3. Mount the five screws [a].
4. Mount the lifting eye bolt [c].
Spare parts
Ordering number
a Cover Front with grid, 47009
silver
a Cover Front with grid, 47029
munzell
b Cover side, silver 47609
b Cover side, munzell 47629
c Cover Back, silver 47109
c Cover Back, munzell 47129
d Cover Seal, silver 47309
d Cover Seal, munzell 47329
e Cover Base, silver 47209
e Cover Base, munzell 47229
f Cover Stiffener 47709
g Fasteners (cover front) 56011
h Fasteners (cover back) 56048
i Fasteners (cover 56111
seal/base)
j Fasteners (cover 56211
stiffener)
k Fasteners (cover side) 56071
l Lifting eye bolt 43109
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.
[a]
3. Unscrew the six screws and remove Note
the crankcase cover [c].
See chapter 5.5 “Air Cooler LP”.
4. Remove the draining plug [a] and drain
the compressor empty.
5. Clean the magnet plug [e].
6. Unscrew and replace the oil filter [f].
The filter should minimum be
replaced according to the
recommended service schedule in
chapter 4.4.
7. Mount the draining plug [a].
8. Assemble the crankcase cover with
the six screws.
Refilling oil:
1. Fill necessary amount oil through the
oil filling hole [b].
2. Check oil level on sight glass [d].
3. Mount the filling plug [b]
Filling of new oil:
1. Fill approx. 23 L new oil through the oil
filling hole [b] or through the crank
case cover opening [c].
2. Check oil level on sight glass [d].
3. Mount the filling plug [b] and the crank
case cover [c].

Spare parts
Ordering number
a Transmitter oil pressure 51371
b Flex tube1 ventilator, 45163
600mm
c Flex tube2 ventilator, 45164
430mm
d Flex tube3 ventilator, 51311
810mm
e Tube oil refill 51341
f Level sight glass 3634
g Tube oil drain 51211
h Gasket crankcase 35519
cover
i Crankcase cover 32014
j Fasteners 56611
k Ventilator 57140
l Fittings 56841
m Plug (oil refill) 7751
n Plug (oil drain) 7752
o Swivel 90° 7570
p Adapter with gasket 54641
q Oil filter 36205
r Plug 7751

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
3. Mount the two screws [a]. for a longer period than stated in the
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 51411
b Fasteners (air filter) 56371

5.4 Safety valves LP and HP
Service
Inspect and replace Note

1. Replace the safety valves [a], [b] and Perform a visual inspection of safety
[c]. 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 51581
a Safety valve LP 9 bar 51511
b Safety valve HP 13 bar 51621
c Safety valve CW 6 bar 51748

5.5 Air cooler LP
Dismantle Warning
1. Unscrew the four cooling fixing screws
[a].
2. Remove the cooler LP [b]. *Always assemble O-rings as shown.
The high temperature O-ring(s) [b] is
Assemble
packed seperately when ordering spare
1. Assemble the cooler as shown (see parts. Make sure to not mix the high
service) and mount the cooler LP [b]. temperature o-ring(s) with the other o-
rings.
2. Mount the four fixing screws [a].
Warning

cooling water, this will cause damage to
the air coolers.
Service

1. Inspect and change the cooler LP [a] if **If the cooler have high pressure drop,
necessary**. the cooler must be replaced.
2. Replace the high temperature O-rings
[b], the Viton O-rings [c] and the disc
springs [d].
3. Assemble as illustrated *

Spare parts
Ordering number
a Cooler LP with O-rings 51818
b O-rings 57647
c Disc springs 57515
d Fasteners (cooler LP) 57278
e Flexible tube1 LP (air) 45151
f Flexible tube (cooling 45159
water)
g Bracket cooler LP 32327
h Fasteners (bracket cooler 56241
LP)
i Cooler manifold LP 20703
j Adapter 56778
k Bulkhead union with 51871
washers

5.6 Air cooler HP
Dismantle Warning
1. Unscrew the four cooling fixing
screws [a].
2. Remove the cooler HP [b]. *Always assemble O-rings as shown.
The high temperature O-ring(s) [b] is
Assemble
packed seperately when ordering spare
1. Assemble cooler as shown (see parts. Make sure to not mix the high
service) and mount the cooler HP temperature o-ring(s) with the other o-
[a]. rings.
2. Mount the four cooling fixing screws

[a].
Warning

cooling water, this will cause damage to
the air coolers.
Service

1. Inspect and change the cooler HP [a] if **If the cooler have high pressure drop,
necessary*. the cooler must be replaced.
2. Replace the high temperature O-rings
[b], the Viton O-rings [c] and the disc
springs [d].
3. Assemble as illustrated *

Spare parts
Ordering number
a Cooler HP with O-rings 51918
b O-rings 57647
c Disc springs 57515
d Fasteners (cooler HP) 57318
e Flexible tube HP (air) 45153
f Flexible tube (cooling 45157
water)
g Bracket cooler HP 32337
h Fasteners (bracket cooler 56278
HP)
i Cooler manifold HP 20713
j Adapter 56778
k Bulkhead union with 51871
washers

5.7 Valve LP
Dismantle
Note
1. Unscrew the flexible tubes CW outlet
[a], transmitter LP [b] and air breathing Before starting this procedure perform
[c]. the dismantling procedure described in
chapter 5.5 “Cooler LP”.
2. Unscrew the five nuts [d].
3. Remove the cylinder head [e].
Assemble
1. Assemble the cylinder head [e].
Replace gaskets (see service step1)
2. Mount the five nuts [d].
3. Mount the flexible tubes CW outlet [a],
transmitter LP [b] and air breathing [c].
Service

1. Replace the O-ring [a] and the two The gaskets and O-ring must always
copper gaskets [b]. be replaced. Clean the adjacent
2. Inspect the valve [c] and replace if surfaces before the new gaskets are
necessary. fitted.
Sperre recommend complete valve
3. Unscrew the five screws [d] and replacement (Plate valve service kit
remove the cylinder top cover LP [e]. can be supplied).
4. Clean the adjacent surfaces [f] and
replace flat gasket [g].
5. Assemble as shown.

Spare parts
Ordering number
a Valve LP with gaskets 50440
b Gaskets valve LP 52040
c Transmitter LP 56421
d Flexible tube LP, TR 45191
e Flexible tube LP, CW 45158
f Cylinder head top LP 20475
g Cylinder head bottom LP 20445
h Gasket cylinder head 35625
i Fasteners 52077
j Adapter (cooling water) 56771
k Adapter (Flex tube1 56848
ventilator)
l Adapter (transmitter) 56948
m Fittings 57241
n Plug 44302
o Swivel 90° elbow 7563
p Adapter with gasket 52171
- Service kit, plate valve 52140

5.8 Valve HP
Dismantle Warning
1. Unscrew the flexible tubes air delivery
HP [a], CW [b] and transmitter HP [c].
2. Unscrew the six nuts [d]. Always mount the six M12 nuts first
with torque 80Nm and then mount the
3. Remove the cylinder head HP [e]. nut M10 with torque 48Nm
Assemble
1. Assemble the cylinder head HP [e]
(see service)
Note
2. Mount the six nuts [d].
Before starting this procedure perform
3. Mount the 2 nuts [c]. the dismantling procedure described in
4. Mount the flexible tubes air delivery chapter 5.6 “Cooler HP”.
HP [a], CW [b] and transmitter HP [c]
Service

1. Remove the old gaskets, 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 nut [c] holding the valve.
3. Inspect the valve [d], and replace if
necessary. Change the stud [e]. Apply
high temperature thread-locking fluid
on threads to ensure sealing and right
position of stud.
4. Clean the adjacent surfaces [f]
5. Place the new gaskets [g].
6. Unscrew the 14 screws [h], clean
adjacent surfaces [i] and replace the
gasket [j].
7. Mount the 14 screws [h].
8. Assemble

Spare parts
Ordering number
a Valve HP with gaskets 50478
and fasteners
b Gaskets valve HP 52248
c Fasteners (valve HP) 52348
d Transmitter HP 56451
e Flexible tube HP 45191
(transmitter)
f Cylinder head top HP 20575
g Cylinder head bottom HP 20545
h Fasteners (cylinder head 52378
HP)
i Fittings 57211
j Adapter (transmitter) 56948
k Adapter (outlet CW) 57711
l Adapter (inlet air) 56771

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
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: ⌀185
Maximum allowed cylinder diameter:
⌀185,3
Spare parts
Ordering number
a Gaskets cylinder LP with 52610
gaskets valve LP
b Cylinder LP 20325
c Fasteners 57341
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
.
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: ⌀85
Maximum allowed cylinder diameter:
⌀85,2
Spare parts
Ordering number
a Gaskets cylinder HP with 52648
gaskets valve HP
b Cylinder HP 20375
c Fasteners 57341
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 LP piston [c].
Assemble
1. Assemble the piston [c]. Note
2. Mount the gudgeon pin* [b]. * Heat the piston with a heat gun when
dismantling and assembling the
3. Mount the two retaining rings [a]. gudgeon pin.
Service
Gudgeon bearing: Note

1. Replace the gudgeon bearing [a]. Maximum allowed connecting rod
2. Inspect the crank bearing by moving ovality: 0,02mm
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 52809
rings
b Piston rings LP 52839
c Bearing needle LP 52870
MK Piston kit, see chapter 4.6 for ordering
number.

5.12 Piston, rings and gudgeon bearing HP
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 5.10 “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
dismantling and assembling the
3. Mount the two retaining rings [a]. gudgeon pin.
Service
Gudgeon bearing: Note

1. Replace the gudgeon bearing [a]. Maximum allowed connecting rod
2. Inspect the crank bearing by moving ovality: 0,02mm
the 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 52910
rings
b Piston rings HP 52940
c Bearing needle HP 52970
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 a M16 screw* to loosen the fan a part of the Sperre Toolbox, see
from the shaft and remove fan [b]. If chapter 4.6 for ordering number.
the fan is stuck, use a heat gun to
heat the center of the fan. Inspect the
fan***.
Note
3. Unscrew the hose clamps [c]. Unplug
the inlet hose [d]. Unplug the outlet ** For dismantling of the oil pump [e],
hose [e] from the oil pump and the see chapter 5.20.
filter housing [f].
4. Unscrew the four M8 socket head bolts
[g] and remove the oil pump [h]**. Warning
5. Remove the 6mm drive pin from the
crank shaft.
6. Unscrew the eight nuts [i]. ***Inspect the fan for cracks and
damages, especially in the welding
7. Use two M12 screws in the holes [j] to points. Replace the fan if there is any
loosen the front plate [k] from the cracks or damages.
crankcase.
8. Remove the frontplate [k].
Assemble
1. Inspect the gasket (see service step 1)
and replace if necessary.
2. Inspect the oil pump and sealing ring
(see service step 2).
3. Remove the two M10 screws.
4. Mount the front plate [k] with the eight
nuts [i].
5. Inspect the 6mm drive pin (see service
step 3).
6. Mount the oil pump [h] with the four
screws [g]. Make Sure the gear in the
oil pump aligns with the drive pin in
the crankshaft.
7. Turn the in- and outlet connections
upwards and fill them with oil. Rotate
the shaft one turn counterclockwise to
make sure the gears in the pump are
flooded.
8. Connect hose [e] to the filter housing
[f].
9. Top up the connections with oil, then
turn them downwards and connect the
hoses [d and e].
10. Mount the hose clamps [c].
11. Remove the M16 screw and mount the
fan [b].
12. Mount the fan center screw [a], use
hand to prevent fan from rotating
when tightening.

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. To replace the seal ring and gasket [b] assembling on the shaft.
the pump cover [c] must be
unscrewed from the oil pump housing
[d]. See chapter 5.20 for more
information.
3. When mounting the drive pin [k], make
Note
sure the flat areas [j] aligns as ** If replacing the drive pin with an
illustrated.** unused one, the pin will not have the
4. Replace the sealing ring and gasket flat spots before after running the
[h]. compressor.
5. Remove the retaining rings [e].

6. Unscrew the two screws [i]. Use a nail
punch in the holes [f] to remove the
outer bearing [g] from the front plate.
Remove inner bearing ring from the
shaft.
7. Mount the new bearing.
8. Mount the two screws [i].
9. Mount the new reatinaing rings.
Spare parts
Ordering number
a Bearing fan side with 53011
retaining rings
b Gaskets bearing fan 53041
side
c Front plate 20130
d Fasteners (front plate) 57371
e Fan with fasteners 32419
f Fasteners (fan) 57536
g Washer (fan) & 53065
fasteners
h Gaskets oil pump 54532

5.14 Bearing crank
Dismantle Note
1. Mount the counterweight bracket [a] *. Before starting this procedure, perform
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]. counterweight from rotating.
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
the note*** before mounting the LP when dismantling and assembling on
crank bearing. the shaft.
2. Inspect the two splash pin [b], replace
if necessary.
3. Inspect the crankshaft plate [c], the Note
connecting rod ring [d] and the
crankshaft plate [f]. Replace if ** Apply low strength threadlocker fluid
necessary.** on the twelve crankshaft plate
fasteners. Mount the twelve M5 screws
4. To replace the gudgeon bearing refer with torque 8NM.
to chapter 5.11 and 5.12. When mounting the crankshaft plates
[c] and [f] make sure the oil lubricating
holes [e] aligns as illustrated (to
maintain correct lubrication).

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 53111
b Connecting rod 53139
c Crankshaft complete, 54610
icnluded f) and i)*
d Bracket counterweight 53311
with dismantling tool
e Fasteners counterweight 57571
f Crankshaft plate with 53110
fasteners
g Ring crankshaft 32153
h Ring connecting rod with 53240
screws
i Crankshaft plate with 53109
fasteners
j Sleeve for sealing ring** 33185
* Always change both crankshaft and
counterweight. See chapter 5.17 for
crankshaft.
**Apply locking fluid when replacing the
sleeve.

5.15 Electric motor and vibration isolators
Dismantle Note
1. Unscrew the air outlet flexible tube [a], Before starting this procedure perform
drain flexible tube [b] and signal cable the dismantling procedure described in
[c]. chapter 5.20 External pump.
2. Unscrew the seven screws [d] and
remove the back cover.
3. Unscrew the four screws [e] on the Note
coupling cover [l] and remove the
coupling cover.* To disconnect the signal cable,
unscrew the locking ring counter
4. Remove the flexible coupling insert clockwise to loosen it. Pull the plug out.
[k].*
To disconnect the cable contact unit on
5. Unscrew the nuts [f] to loosen the the compressor back cover, unscrew
motor from the motor flange. the locking nut counter clockwise and
pull out the contact unit.
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 nuts [f] to the motor flange.
3. Mount the flexible coupling insert [k] *Note
and the coupling cover [l] and fasten
the four screws [e].*
4. Assemble the back cover with the
seven 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
[k] Coupling insert, [l] coupling cover,
far in as possible on the shaft so that
[e] fasteners coupling cover.
the gap [i] is 0,0mm.
With motor flange [j]:
200 build size electric motor:
Distance [i] shall be 25,0mm.


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)
225 build size 53611
c Support motor
d Fasteners (Electric 53641
motor)
e Vibration isolator 53476
(compr) type 2 with
fasteners**
f Fasteners (vibr. Isol. 53341
compr.)
g Vibration isolator 53476
(compr.) type 2 with
fasteners**
h Vibration isolator (el. 53477
motor) type 1 with
fasteners**
i Fasteners (Vibr. isol. 53371
El.motor)
j Motor flange (Only for 32026
XAW250-300 with 250
or 280 motor size)

XW200 200 build size: XW200 200 build size
Ordering number
a Electric motor *
b Fasteners (Electric
motor)
c Support motor
d Fasteners (Electric
motor)
200 support size 53639
e Fasteners (support) 53646
f Baseplate 32147
g Vibration isolator 53476
(compr) type 2 with
fasteners**
h Fasteners (vibr. Isol. 53341
compr.)
i Vibration isolator 53476
(compr.) type 2 with
fasteners**
j Vibration isolator (el. 53478
motor) type 1 with
fasteners**
k Fasteners (Vibr. isol. 53371
El.motor)
l Motor flange with 53409
fasteners
*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 X-
isolators depends on the compressor
configuration.

5.16 Coupling and sealing flange
Dismantle Note
1. Unscrew the centre screw [a]. Before starting this procedure, perform
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 M30
dismantling screw* to loosen the
coupling from the crank disk.
3. Remove the coupling [b].
Note
4. Unscrew the three screws [c].
* The Sperre M30 dismantling screw
5. Use two M10 screws** [d] to loosen and socket set screw in the Sperre tool
the sealing flange. box, ordering number 50971.
6. Remove the sealing flange [e]. ** After dismantling do not forget to
remove the M10 screws.
Assemble *** Sperre mounting tool for seal ring in
1. Mount the sealing flange [e] with the Sperre tool box.
new gaskets and the seal ring (see
service step1).
2. Mount the three screws [c]. Note:
3. Mount the coupling [b].
4. Mount the centre screw [a].
Use tool [b] to slide the sealing ring [c] on

to tool [a]. Remove tool [b] and use tool [a]
to slide the sealing ring on to the
crankshaft. Make sure the sealing lip is
facing inwards.
Service
Inspect and replace

1. Replace the seal ring and gasket [a].
After the sealing ring is mounted in
the sealing flange, use Sperre
mounting tools*** for the seal ring.
See drawing in the right column.
2. Inspect the coupling and change if
threads are damaged.

Spare parts
Ordering number
a Gaskets sealing flange 53711
b Sealing flange 20147
c Fasteners (sealing 56541
flange)
d Coupling with fasteners
⌀ 55 53748
⌀ 60 53747
⌀ 65 53778
⌀ 75 53777
e Flexible coupling insert 32741
f Fasteners (coupling) 53918
g Coupling cover 24353
*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 Crankshaft and bearing motor side
Dismantle Note
1. Remove the inner retaining ring [a]. Before starting this procedure, perform
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
* Heat the bearing with a heat gun
crankcase.
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 and mount the crank disk
[c] 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 54111
retaining rings
b Crankshaft complete* 54610
c Crankcase 20109
d Lifting bar 20181
e Fasteners lifting bar 54141
* Always change both crankshaft and
counterweight. See chapter 5.14 for
crankshaft counterweight.

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

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

Spare parts HP
Ordering number
a Valve HP non return 54211
b Transmitter HP 56481
temperature
c Cyclone tube HP 32129
d Outlet connector HP with 54241
sensor pocket for
transmitter
e Separator housing HP 20625
f Fasteners (outlet 56641
connector HP)
g Fasteners (separator 57611
housing HP)
h Adapter (outlet connector 56771
HP)
i Plug (outlet connector 44304
HP)
j Adapter (separator 57711
housing HP inlet)
k Swivel male (separator 57018
housing HP drain)
l Swivel 90° elbow (drain) 7570
m Plug (separator housing 57771
HP)
n Sensor pocket for 32099
transmitter

Spare parts LP
Ordering number
a Cyclone tube LP 32129
b Outlet connector LP 20645
c Separator housing LP 20625
d Fasteners (outlet 56641
connector LP)
e Fasteners (separator 57611
housing LP)
f Adapter (outlet connector 56771
LP)
g Adapter (separator 57711
housing LP inlet)
h Swivel male (separator 57018
housing LP drain)
i Swivel 90° elbow (drain) 7570
j Plug (Separator housing 57771
LP)

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 64216
HP / LP
c Drain/unload valve HP/LP 57918
with gaskets
d Fittings 57178

5.20 Oil pump
Dismantle
1. Unscrew the flexible hose clamps [a] Note
and disconnect the hoses [b] from the
oil pump [d]. *If replacing the drive pin with an
unused one, the pin will not have the
2. Unscrew the four M8 socket head bolts flat spots before after running the
[c] and remove the oil pump [d] from compressor.
the compressor.
Assemble
1. When mounting the drive pin [g] make
sure the flat areas [e] aligns as Note
illustrated.*
Normal oil pressure readings during
2. Carefully mount the oil pump [d] to the operation are 0,5-1 bar.
compressor and make sure that the
drive pin [g] engages correctly with Low pressure alarm is 0,3 bar.
the inner gear in the oil pump. Low pressure shut down is 0,2 bar.
3. Turn the in- and outlet connections [f]

upwards and fill them with oil. Rotate
the shaft one turn counterclockwise to
make sure the gears in the pump are
flooded.
4. Top up the connections [f] with oil,
then turn them downwards and
connect the hoses [b]. Mount the
hose clamps [a].
5. Mount fan and compressor cover.
Make sure the fan is not touching the
hoses.
Service
Inspect and replace

1. Remove the oil pump from the
compressor as described above.
2. Unscrew the four M6 socket head bolts
[a] and remove the oil pump cover [b].
3. Take out the inner [c] and outer [d]
gear for inspection. Inspect the oil
pump housing [e] and oil pump
cover[b] for wear. If worn the
complete pump should be replaced.
4. Replace the sealing ring [g]+[f] in the
pump cover [b]. Make sure that the
support ring [g] is mounted correctly,
see illustration..
5. Replace the gaskets [h].
6. Check the drive pin [i] for wear. When
mounting the oil pump it is important
that the drive pin is mounted with it’s
flat area towards the internal gear for
correct operation.

Spare parts
Ordering number
a Oil filter 36205
b Complete oil pump with 54531
gaskets
c Gaskets oil pump 54532
d Transmitter oil pressure 51371
with gasket
e Filter holder with gasket 54538
and fasteners
f Inlet and outlet hoses 54537
with elbows
g Magnet plug 44394
h Fasteners pump housing 54535
i Fasteners pump cover 54536
provided when ordering.

5.21 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
XW200
Component Chapter Quantity Thread diameter Spanner width Torque (Nm)
Enclosure Front / Back 5.1 5/7 M8x15 Unbrako 6 24

Enclosure Base / Seal / 5.1 M8x15 Unbrako 6 24
5/5/6
Stiffener
Crank case cover 5.2 6 M10x20 Unbrako 8 48
Air filter 5.3 3 M8x25 Unbrako 6 24
Cooler bracket LP 5.5 4 M8x12 Unbrako 6 24
Cooler fixing screws LP 5.5 4 Mb 32 mm 24
Cooler bracket HP 5.6 3 M8x12 Unbrako 6 24
Cooler fixing screws HP 5.6 4 Mb 32 mm 24
Cylinder cover LP 5.7 6 M8x25 Unbrako 6 24
Cylinder head LP 5.7 5 M16 24 mm 200
Cylinder cover HP 5.8 14 M8x40 Unbrako 6 24
Cylinder head HP 5.8 6 M12 19 mm 80
Valve HP 5.8 1 M10 17 mm 48
Cylinder LP 5.9 4 M20 30 mm 250
Cylinder HP 5.10 4 M20 30 mm 250
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 M16 24 mm 200
Counterweight 5.14 1 M20x40 Unbrako 17 390
Crankshaft plate fasteners 5.14 6 M5x10 Unbrako 3 8
El-motor 5.15 8 M16 24 mm 200
Sealing flange screws 5.16 3 M8x20 Unbrako 6 24
Coupling (centre screw) 5.16 1 M24x80 Unbrako 19 400
Outlet connector HP/LP 5.18 6 M12x30 Unbrako 10 80

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36

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 XW200 Version 06 3

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

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

5 Service procedures .............................................................................. 39

6 X-range data ......................................................................................... 74

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Draws attention to specific information of technical significance that might not be

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Danger Danger Caution

Compressor rating plate Rotation direction is counter clock wise,

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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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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

Oil filter replacement 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