Operation and Maintenance Manual for V19H-AL Compressor

OPERATION AND MAINTENANCE
MANUAL
V19H-AL
compressor
Health & Safety
HEALTH AND SAFETY AT WORK ACT 1974
Where we supply a complete factory built air compressor set, we ensure that measures are taken to com-
ply with our responsibilities in respect of the Act.
In addition, it is essential that the operator is aware of the inherent hazards associated with the use of
compressed air particularly in such applications as breathing or food or drink processing where specialist
filtration is essential.
Also when we supply a bare air compressor unit certain responsibilities under the Act will pass to the
customer and will include that:
1. All drives and moving parts are fully guarded.
2. Our recommendations on operating conditions including maximum pressure and speed are not
exceeded.
3. Any air receiver or pressure vessel used in conjunction with the compressor is constructed to be
suitable for the working pressure of the unit and has been tested to any relevant standard.
4. Interconnecting pipework is adequate in strength.
5. A suitable safety valve, correctly situated, and a pressure control device are included in the in-
stallation.
If in doubt, ask our advice.
H&S 1 14 Nov 97
Health & Safety
WARNING
Misuse of compressed air can be dangerous. It cannot be stressed too strongly the importance of taking every
precaution in the use of compressed air and its associated equipment.
NEVER Commence any maintenance or servicing work on a compressor or compressed air system with-
out ensuring entire system is fully depressurised. Failure to observe this precaution may result
in serious injury.
NEVER Screw down a pipe union that is under pressure.
NEVER Screw down a safety valve beyond the manufacturer ’s setting. A safety valve is fitted to prevent
over pressurising the air receiver and over loading the air compressor. To interfere with its set-
ting could result in serious damage or injury.
NEVER Carry out any work whatsoever unless the electric supply has been switched off at the mains this
applies to electrically driven plants.
NEVER Pass in front of an air receiver wheel valve when compressed air is being released. This is par-
ticularly dangerous as any particles of iron scale in the air stream could become imbedded in the
skin and cause a serious wound.
NEVER Attempt to straighten badly bent pipes or re use damaged union fittings.
NEVER Use worn or damaged components that particularly rely on threads for security ie nuts, bolts,
nipples and drain taps etc.
NEVER Tamper with a live electrical circuit. If in doubt call upon the services of a qualified electrician.
REMEMBER Before opening a manual drain or vent valve, always ensure that valve exhaust port is not
blocked or plugged. Remove any red plastic plugs that may be present.
Determine in which direction air will exhaust through port to atmosphere and avoid positioning
any part of the body in the direction of flow.
ALWAYS open a drain or vent valve SLOWLY and with caution. NEVER open a drain or vent
valve rapidly.
REMEMBER To firmly secure all externally fitted installation pipe work. This will prevent undue vibration
and possible fracture under pressure.
REMEMBER To have your compressors installed in accordance with your local Electrical Authority require-
ments. A piece of three core flex and a three pin plug does not constitute an installation.
REMEMBER COMPRESSED AIR CAN KILL TREAT IT WITH RESPECT
H&S 2 14 Nov 97
V19H--AL COMPRESSOR
TABLE OF CONTENTS
MODEL V19H--AL
TABLE OF CONTENTS
SECTION 1 TECHNICAL DESCRIPTION

1.1 Technical Data
1.2 Introduction
1.3 Principle of Operation
1.4 Mechanical Construction
SECTION 2 INSTALLATION & STORAGE

2.1 Receipt
2.2 Siting
2.3 Electrical
2.4 Setting up Procedure
2.5 Storage
SECTION 3 OPERATION
3.1 General
SECTION 4 MAINTENANCE
4.1 General
4.2 Routine Maintenance Periods
4.3 Overhaul ’A’ Type 800 Hours Running
4.4 Overhaul ’B’ Type 1600 Hours Running
SECTION 5 FAULT DIAGNOSIS

5.1 General
SECTION 6 SPARE PARTS

6.1 Introduction
TOC--1
V19H--AL COMPRESSOR
TABLE OF CONTENTS
TABLES
4.1 Schedule of Limits & Fits
4.2 Torque Loading Chart
5.1 Fault Finding
6.1 Compressor, Model 3S17 50 Parts List
6.2 Valve Assemblies Parts List
6.3 Cooling System Parts List
6.4 Miscellaneous Parts Lists
TOC--2
V19H--AL COMPRESSOR
SECTION 1 -- Technical Description
SECTION 1 -- TECHNICAL DESCRIPTION
1--1
V19H--AL COMPRESSOR
FIGURE 1.1 -- MODEL V19--AL COMPRESSOR
1--2
V19H--AL COMPRESSOR
1.1 TECHNICAL DATA

Compressor Type Model V19H--AL
Number of Compression stages Three
Operating Pressure Range 124 to 345 bar
(1800 to 5000 lbf/in2)
Speed Range 1400 to 1750 rpm
Displacement 29.3 M3/Hr (17.26 c.f.m.) @ 1750 rpm.
Average Charging Rate 18.7 M3/Hr (11 c.f.m.)
Cooling Fan driven airstream
1st stage pressure 8.28 bar (120 lbf/in2)
2nd stage pressure 53.1 bar (770 lbf/in2)
Discharge pressure Up to 345 bar (5000 lbf/in2)
Safety Valve Settings:
1st stage 12.0 bar (175 lbf/in2)
2nd stage 62 bar (900 lbf/in2)
3rd stage 10% above working pressure
Lubrication Controlled splash system
Recommended Oils * Anderol 555 for all applications and
pressures up to 345 bar
Crankcase Oil Capacity 1.2 Litres (2.11 Pints)

Overall Dimensions:
Length 553 mm (21.7 inches)
Width 434 mm (17 inches)
Height 506 mm (19.9 inches)
Unit weight (dry) 50 kg
*Anderol 555 is a synthetic oil suitable for high temperatures and pressures. The use of any other
lubricant will invalidate product warranty.
1--3
V19H--AL COMPRESSOR
FIGURE 1.2 -- MODEL V19H--AL PRINCIPLE OF OPERATION
1--4
V19H--AL COMPRESSOR
1.2 INTRODUCTION (See Figure 1.1)
The Model V19H--AL is a twin Vee Form, double acting, reciprocating machine with two cylinders
giving three stages of compression. A double grooved flywheel carries a segmented fan assembly
for cooling the cylinders, intercoolers and aftercooler. A replaceable air intake filter is fitted in the
inlet duct. Factory set safety valves are fitted in all stages, and air from the second stage is filtered
by a sintered bronze element. Lubrication is by a controlled splash arrangement.
The compressors are used in breathing air charging sets, but also have wide applications in various
other installations. Machines may be driven by petrol, diesel or electric motors to suit site
requirements.
1.3 PRINCIPLE OF OPERATION (See Figure 1.2)
Air is taken in from the atmosphere via a replaceable air filter and passes into the low pressure
cylinder to be compressed to 8.28 bar (120 lbf/in2). The compressed air then passes through a coiled
pipe assembly for cooling. A safety valve in the line is set at 12 bar (175 lbf/in2).
The double acting cylinder then compresses the air to 53.1 bar (770 lbf/in2). A second coiled pipe
assembly is provided for cooling, and a second stage safety valve is set at 62 bar (900 lbf/in2).
Moisture separation is carried out by a vertically mounted coalescing separator, fitted with a
moisture drain point.
The air is compressed to the final maximum delivery pressure of 345 bar (5000 lbf/in2) by the 3rd
stage cylinder. A third coiled pipe assembly is provided for final stage cooling. The final stage safety
valve is set at 10% above the working pressure. The high pressure air then passes to the compressor
outlet.
The unit is belt driven via a flywheel pulley which turns the crankshaft and cooling fan. The
intercoolers and aftercooler coiled pipe assemblies are mounted externally in the airstream provided
by the cooling fan.
Lubrication is by a combination of controlled splash, and crankcase to inlet differential pressure.

Splash lubrication is created by dippers on both connecting rods which pass through the oil in the
crankcase. All parts of the compressor except the upper portions of the first stage are lubricated by
this method. The differential pressure between the crankcase and inlet depression causes oil
vapours to rise up the external breather pipe into the inlet and thus lubricate the first stage valves
and cylinder.
1.4 MECHANICAL CONSTRUCTION
The crankcase is manufactured from high quality aluminium alloy, with a detachable inspection
cover, a combined filler and dipstick plug and a removable magnetic drain plug. Provision is made
to attach an eyebolt for lifting purposes.
The ball bearing mounted crankshaft is manufactured from spheroidal graphite cast iron and
connecting rods are forged from H.T. steel. The first and second stage piston is manufactured from
aluminium, and the third stage piston is manufactured from high quality steel.
Low and high pressure cylinder heads are manufactured from spheroidal graphite cast iron. The first
stage valve assembly is a reed valve which is located between the first stage cylinder head and
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V19H--AL COMPRESSOR
cylinder. The second stage valves are automatic spring controlled plate valves with a one piece valve
retainer. The third stage valve components are held in position under the third stage cylinder head.
The segmented fan assembly is mounted with the flywheel on the crankshaft. Intercooler coiled pipe
assemblies are mounted behind the fan.
One moisture separator is mounted on the side of the compressor fitted with a moisture draining
point.
1--6
V19H--AL COMPRESSOR
SECTION 2 -- Installation & Storage
SECTION 2 -- INSTALLATION AND STORAGE
2--1
V19H--AL COMPRESSOR
ADDITIONAL INFORMATION -- INITIAL STARTING

PROCEDURE
On despatch, compressors are either inhibited for 6 months with oil drained or supplied with a full
charge of oil in the sump, as indicted on label attached to compressor.
On receipt of compressor, examine label to determine which condition applies. If compressor is

drained of oil, fill to the correct level with the correct grade of lubricant. If compressor is filled with
oil, check oil level and replenish if necessary.
IMPORTANT
Compressors supplied with oil in the sump are filled with Anderol 555. This is a synthetic oil and
must NOT be mixed with mineral oil under any circumstances. If synthetic and mineral oils are
mixed, failure of the lubrication system will occur, resulting in
seizure.
2.1 RECEIPT
If packed in a wooden crate, compressor may be manoeuvred on site with a suitable fork lift truck.
Remove packing crate top on receipt, check contents with respect to the packing note and
immediately report any shortages, damage or defects to the manufacturer.
A single eyebolt may be fitted on top of the unit for lifting compressor only. Do not use this eyebolt
for lifting if compressor is attached to a baseplate or charging set.
CAUTION:
This eyebolt is not designed to support the combined

weight of the compressor and baseplate or charging
set.
2.2 SITING
The site should have access to clean, cool atmospheric air, free from fumes, toxic gases, factory
odours, dust and dampness.
Allow at least .75 metres (30”) around the machine to enable all the normal maintenance work,
including major repairs, to be carried out.
When a compressor is to be used for a charging system which supplies air for breathing, it is essential
that a reputable air purifying system is incorporated downstream from the compressor final delivery.
As a general rule, air cooled compressors operating in a room or confined space should be installed
to prevent cooling air recirculation and a build up of the ambient temperature within the room.
Ideally, the cooling fan should be positioned close to an external intake duct and an extractor fan
2--2
V19H--AL COMPRESSOR
positioned in the ceiling or upper part of the confined space, as shown in the diagram. The extractor
fan flow rate should be at least equal to the compressor cooling fan flow rate.
Where two machines are installed in the same room, they should be positioned so that hot air from
one machine is not induced into the other machine. Do not install machines back to back as this will
effect the compressor fan flow rate. If in doubt, consult Hamworthy Compressor Systems
Engineering Department.
2.3 ELECTRICAL
It is strongly recommended that the necessary electrical installation work, where applicable, is
carried out by a competent electrician or electrical engineer.
When a compressor is intended to be driven by an electric motor, the associated motor and
switchgear provided are wound and set for the voltage specified on the motor reference plate. Any
attempt to operate the equipment on other supply voltages will inevitably lead to damage and
premature breakdown.
A combined isolator switch/fusebox should be provided and wired to the starter switch. The wiring
must be capable of carrying the full starting current, and the voltage drop must not exceed 5% of
the rated supply voltage of the compressor. The fuses must not be less than THREE times the full
load current of the motor at up to 10 amps, and TWICE the full load current over 10 amps.
The direction of rotation of the compressor is anti clockwise when viewed from the drive end. When
driven by a three phase motor, the direction of rotation (if seen to be incorrect) may be reversed by
interchanging any two mains supply leads.
CAUTION:
The compressor will be starved of oil if run in the re-

verse direction and the cylinders and interstage cool-
ing pipes will not be effectively cooled.
2.4 SETTING UP PROCEDURE
2--3
V19H--AL COMPRESSOR
To set up the compressor before operation:

1) Ensure that unit is securely bolted down in position on site.
2) Visually check unit for any signs of damage and of possible obstructions to moving parts.
Check that all moving parts such as pulleys and drive belts are properly guarded.
3) The drive motor should be mounted adjacent to the compressor, with belt pulleys correctly
aligned. The motor should be adjusted horizontally to provide the correct belt tension.
Check tension of belts. If necessary, tighten belts by releasing drive motor hold down bolts
and moving motor horizontally until belts are at the correct tension. For an approximate
check of belt tension, twist the belt with finger and thumb equidistant between pulleys. For
a correctly tensioned belt, the twist should be a quarter of a turn ie. 90_.
4) Check air intake filter is correctly fitted and is in good condition.
5) Fill sump with recommended oil as listed in Technical Data Section 1.1.
2.5 STORAGE
The following recommendations are offered if compressors are not to be installed immediately or
if taken out of service for extended periods. The recommendations are based on temperate climatic
conditions and the periods specified may be superseded by alternatives as appropriate for the
prevailing conditions.
The principal objective when storing the compressor for either short or long periods is to remove
all traces of moisture from the machine and to replace the normal lubricating oil with a rust
preventing inhibiting oil. The only inhibiting oil currently approved by Hamworthy Compressor
Systems is Shell Ensis 158.
2.5.1 Shut Down
On manually operated compressors, the unit should be operated for two to three minutes with the
condensate drains open to purge the system of moisture before shut down. If the unit is likely to be
shut down for more than four weeks, it is advisable to carry out the following short term inhibiting
procedure.
2.5.2 Short term Inhibiting
The following recommendations are offered for storing the machine for short term periods of up to
six months:
1) Drain off lubricating oil whilst still warm.
2) Fill crankcase to the maximum level with rust inhibiting oil Shell Ensis 158.
3) Run compressor off load for 20 to 30 minutes with separator drains open.
4) Stop compressor and remove air intake filter. Inject 3 to 4 cc of Shell Ensis 158 into
air intake port and refit air filter. This ensures protection of the valves and upper cyl-
inder components.
5) Run compressor for a further one minute.
2--4
V19H--AL COMPRESSOR
6) Drain off inhibiting oil from crankcase.
7) If compressor is to be removed from the installation, seal all openings with plugs.
8) Remove sintered bronze filter element. Access to the filter is gained by unscrewing
brass cap and removing spring from filter. Wash filter in white spirit or carbon tetra-
chloride, dry thoroughly with a low pressure air jet and reassemble.
CAUTION:
Do not turn crankshaft after draining inhibiting oil or

before carrying out the start up procedure outlined in
Section 2.5.4.
2--5
V19H--AL COMPRESSOR
2.5.3 Long term Inhibiting
The following recommendations are offered when storing the machine for long term periods of over
six months:
1) Carry out the recommended shut down procedure as outlined in Section 2.5.1, but run com-
pressor on a supply of dry air.
2) Carry out the recommended short term inhibiting procedure as outlined in Section 2.5.2.
3) Remove third stage piston. Coat piston with a suitable long term protective such as Shell
Ensis 256 (cold dip) or Shell Ensis 352 (hot dip) in accordance with the supplier’s recom-
mendations. Store piston separately.
4) Clean and re oil all third stage valve parts and cylinder bore with Shell Ensis 158 and re-
place together with the cylinder head.
5) Place complete compressor in a suitable long term storage container, together with suitable
desiccant such as silica gel. Ensure that a humidity indicator is clearly visible for regular
inspection.
2.5.4 Start up, after short term inhibiting
To prepare compressor for operation after a short term period of inhibiting:

1) Remove all plugs from openings.
2) Reconnect compressor into the overall installation.
3) Refill crankcase with lubricating oil as recommended in Technical Data Section 1.1.
4) Run compressor off load for 15 minutes to circulate oil.
CAUTION:
Take precautions to ensure that other equipment in

the area is not contaminated when the compressor is
purged of inhibiting oil.
5) Operate unit in accordance with the overall installation requirements.
2.5.5 Start up, after long term inhibiting
To prepare the unit for operation after a long term period of inhibiting:
1) Remove all plugs from openings.
2) Remove third stage head.
3) Remove protective covering from third stage piston.
4) Lubricate and reassemble third stage piston with valve gear and head. Tighten head bolts.
5) Reconnect compressor into the overall installation.
6) Refill crankcase with oil as recommended in Technical Data Section 1.1.
2--6
V19H--AL COMPRESSOR
7) Remove all valve retainers and the air intake filter. Inject 3 to 4 cc of lubricating oil into
machine. Reassemble.
8) Turn crankshaft by hand for a few revolutions.
9) Run compressor off load for 15 minutes to circulate oil.
CAUTION:
Take precautions to ensure that other equipment in

the area is not contaminated when the compressor is
purged of inhibiting oil.
10) Operate unit in accordance with the overall installation requirements.
2--7
V19H--AL COMPRESSOR
SECTION 3 -- Operation
SECTION 3 -- OPERATION
3--1
V19H--AL COMPRESSOR
SECTION 3 -- Operation
3.1 GENERAL
Before operating, ensure that the compressor has been properly installed and set up as recommended
in Section 2. The compressor should otherwise be operated in accordance with the overall system
operating procedures.
It is particularly important to ensure that accumulated moisture is drained from the compressor
moisture separators every 20 to 30 minutes of running, either by manual operation of the drain valves
or automatically via a timer controlled unloader system.
3--2
V19H--AL COMPRESSOR
SECTION 4 -- Maintenance
SECTION 4 MAINTENANCE
4--1
V19H--AL COMPRESSOR
4.1 GENERAL
Regular servicing in accordance with the recommendations given in this section is essential if the
machine performance, reliability and safety are to be maintained at an optimum level. It is important
to keep the compressor, safety devices, pipework and electrical equipment clean at all times.
Regularly wipe away any oil films, dust and condensate which may collect on the machine.
A daily general visual examination of the machine, coupled with a record of stage pressures, will
indicate possible impending malfunctions. The compressor log sheet (Appendix 1), should be used
to record all maintenance work carried out on the machine. Periodic maintenance procedures
detailed below are recommended as a general guide to routine servicing. As machines may be
operated in different environments, the user should determine the most effective maintenance
periods to suit each particular plant.
Note: Preventative maintenance can be effectively planned from the com-

pleted log sheets over a period of several years.
4.2 ROUTINE MAINTENANCE PERIODS
4.2.1 Daily
1) Check oil level in crankcase and top up if necessary. Maintain oil level at the top notch on dip-
stick, which is the maximum level. The danger level is when oil level is below the bottom of the
dipstick. The combined oil level dipstick and filler plug unscrews from crankcase front cover.
2) If fitted, check operation of the automatic moisture separator drains, or drain manually. Fre-
quency of draining depends on relative air humidity and/or duty cycle. The amount of accumu-
lated moisture should not be allowed to exceed 20 cc. Under normal circumstances, accumu-
lated moisture should be drained every 20 to 30 minutes of running time.
3) Visually examine machine, particularly for any signs of oil or air leaks.
4) Listen for any unusual noises during operation and investigate further, if necessary.
5) Complete compressor log sheet as necessary.
4.2.2 After first 100 Hours
1) Drain off lubricating oil immediately after a run whilst oil is still warm.
2) Clean magnetic drain plug and replace. Care should be taken to ensure that no metal particles
remain in crankcase.
3) Refill crankcase with recommended grade of lubricating oil.
4) Check all valve retainers for tightness.
5) Complete compressor log sheet.
4--2
V19H--AL COMPRESSOR
4.2.3 Every 400 Hours
1) Replace Air intake filter element
2) Remove sintered bronze filter. Wash filter in white spirit or chlorethene VG. Dry with a low
pressure warm air jet. Examine filter seat position and clean if necessary.
3) Reassemble spring onto sintered bronze filter and insert banjo housing, ensuring that bonded
sealing washer is in good condition. Replace banjo cap.
4) Clean all outside surfaces of compressor to remove any traces of oil or dirt from heat radiating
surfaces of cylinders and intercoolers.
5) Check all external fastenings and pipe fittings for tightness.
6) Check drive belts for wear and for correct tension as detailed in Section 2.4.
7) Complete compressor log sheet as necessary.
4.3 OVERHAUL ’A’ TYPE 800 HOURS RUNNING
1) Carry out the 400 hour servicing procedure.
2) Change Lubricating Oil following procedure in section 4.2.2.
2) Check valves and valve springs as follows:
4.3.1 First stage valves
Because of the nature of the first stage valve,

careful cleaning only may be carried out.
Individually worn reed valves or seats
cannot be replaced, therefore the complete
valve plate assembly must be replaced if
necessary.
Scratches to valve seats and discs may be

removed by careful hand lapping with two
grades of valve grinding compound. To
remove deep marks, use Carborundum
Grade 360 FINE, followed by lapping paste
Carborundum H500 OP. Minor surface
marks may be removed using Carborundum
H500--OP only.
CAUTION:
Every trace of grinding and lapping compound must be removed before

reassembly. The most effective way of doing this is by using an ultrasonic cleaner.
Alternatively, thoroughly wash the affected parts in a white spirit and dry with a
low pressure air jet.
4--3
V19H--AL COMPRESSOR
4.3.2 Second stage valves
Note: Mark suction and delivery valves and pockets to facilitate

correct reassembly.
1) Remove valves and examine parts for wear or damage.
2) Where only normal wear is observed, lightly lap valve seats using lap-
ping paste Grade H500 OP, as described in Section 4.3.1.
3) If valves are observed to be deeply pitted, complete replacement will be

necessary. The relatively low cost of a new valve makes servicing un-
economical.
4) If further wear is suspected, strip valves for further examination. Refer

to exploded view illustrations for guidance.
5) To strip a second stage suction valve:
a) Fit a suitable Allen key in countersunk valve screw

and remove split pin and
b) Remove valve screw from valve seat.
c) Lift valve springs, valve plate and valve guard from screw.
d) Examine all parts for wear or damage and service accordingly.
e) To reassemble suction valve, place valve guard onto screw.
f) Replace valve springs on valve guard.
g) Locate valve plate and place valve seat over valve screw.
h) ALWAYS fit a new valve nut, ensuring that springs and plate are correctly
aligned before tightening nut. Valve Nut Part No.Y36366.
Note: DO NOT reassemble using old valve nut.
6) To strip a second stage delivery valve:
a) Fit a suitable Allen key in countersunk valve screw and remove split pin and
valve nut.
b) Lift off valve guard, valve springs and valve plate.
c) Examine all parts for wear or damage and service accordingly.
d) To reassemble, replace valve screw into valve seat.
e) Place interlocked springs on valve guard and valve disc onto springs.
f) Hold valve guard together springs and disc and place onto valve screw.
4--4
V19H--AL COMPRESSOR
g) ALWAYS fit a new valve nut, ensuring springs and plate are correctly aligned
before tightening nut. Valve Nut Part No.Y36366
Note: DO NOT reassemble using old valve nut.
h) Before refitting completed valve in machine, push valve plate away from seat
to ensure freedom of movement and correct seating.
4.3.3 Third stage valves
1) Using a 8mm Allen key, remove four socket cap screws retaining cylinder head.
2) Remove cylinder head. Do not use a screwdriver or similar tool to lever off head. A light tap to
the side of the head with a plastic faced hammer is usually sufficient to break the seal. Recover
delivery valve disc and spring as the head is lifted.
3) Lift out delivery valve seat for access to suction valve components.
4) Examine valve parts and service or replace as required. Reassemble in reverse order. Refer to
exploded view as a guidance to component positioning.
4.4 OVERHAUL ’B’ TYPE 1600 HOURS RUNNING
In addition to the previous checks, it is recommended that the unit is overhauled after every 1600
hours of running time. This major servicing procedure, known as an Overhaul ’B’ Type, enables
checks to be made with reference to the tables of maximum permissible amounts of wear.
4.4.1 To strip down the V19H--AL Compressor
1) Stop machine and drain off the lubricating oil whilst still warm. Remove filler plug/ dipstick to
aid draining.
2) Remove fan flywheel retaining bolts and washers. Withdraw flywheel.
3) Remove air intake filter assembly.
4) Disconnect all intercoolers, aftercooler and breather pipe connections. Plug all apertures to keep
out dirt and foreign bodies.
5) Remove first stage cylinder head retaining screws. Lift off cylinder head assembly, including
valve plate and gaskets.
4--5
V19H--AL COMPRESSOR
6) Remove four socket screws, lift off third stage cylinder head and recover valve parts.
7) Remove third stage cylinder complete with piston and liner.
8) Remove socket screws and withdraw crankcase front cover.
9) Bend up locking tabs on end of crankshaft. Remove two screws and retaining washer from
crankpin.
10) From drive end, turn crankshaft until low pressure piston is at top dead centre.
11) Remove locating nuts on low pressure cylinder and partly withdraw. Note that low pressure pis-
ton assembly is still located inside cylinder.
12) Move cylinder and piston assembly away from drive end of machine and slip connecting rod big
end off the crankpin to free complete assembly.
13) Carefully withdraw cylinder and piston assembly, taking care to support connecting rod still lo-
cated inside cylinder. Place on a clean surface for further dismantling when required.
14) From drive end, turn crankshaft until high pressure piston is top dead centre.
15) Remove locating nuts and lift crosshead guide from crankcase.
16) Slip connecting rod big end off crankpin and withdraw complete assembly.
17) Remove eight nuts from drive end of crankcase and withdraw bearing housing assembly, taking
care to support crankshaft during withdrawal.
4.4.2 Bearing Housing Sub Assembly
With housing assembly removed from crankcase, check for excessive play in bearings. Check that
shaft rotates freely without any signs of roughness. To inspect and renew bearings, proceed as
follows:
1) Remove clamping collar from outside end of shaft.
2) Support housing on large end and press out crankshaft, complete with larger bearing, inner
sleeve and collar.
3) Remove circlip locating smaller bearing from inside housing.
4) Support housing on large end and press out smaller bearing.
5) Press out oil seal.
6) Remove collar, sleeve and larger bearing from crankshaft.
7) Check both bearings for evidence of abrasive wear resulting in increased diametrical clearance
or excessive looseness of the cage. Inspect the ball tracks of the larger bearing for pitting, corro-
sion or heat discolouration. The small bearing has sealing washers making inspection of the
tracks impossible. Both bearings must rotate fully without signs of roughness. Bearing inspec-
4--6
V19H--AL COMPRESSOR
tion is largely a matter of judgement and experience. If the compressor has had extended use
and is not expected to be stripped down again for a considerable time, it is advisable to fit new
bearings.
8) To reassemble, fit a new oil seal in outer end of housing. Press in seal until outer edge is flush
with outside face of housing. Ensure sealing lip faces towards inside of bearing housing. Care
must be taken not to distort the seal or damage the sealing lip.
9) Support housing on small end and assemble smaller bearing from the inside. Ensure bearing fits
fully into recess.
10) Fit bearing retaining circlip. Ensure circlip is fully expanded into groove.
11) Press large bearing onto crankshaft until fully located against web face.
12) Support bearing housing on small end. Fit inner sleeve and collar over shaft and enter shaft
through smaller bearing. Press large bearing into housing by exerting pressure on end of crank-
shaft.
Note: DO NOT press against crankpin.
13) Inspect clamping collar. The outside diameter must be a smooth ground finish to make a suitable
track for housing seal.
14) Inspect ’O’ ring fitted inside clamping collar and renew if necessary.
15) Slide clamping collar onto crankshaft and assemble against outer face of bearing.
4.4.3 First and second stage piston/connecting rod assembly
1) Withdraw first and second stage piston and connecting rod assembly from top end of cylinder.
2) Using circlip pliers, remove piston pin retaining circlips.
3) The piston and pin are supplied as a matched pair. To remove pin, place piston in clean, hot wa-
ter at a temperature of 80_C to 85_C to just cover the pin. After two to three minutes, the pin
may be pushed out with a wooden dowel. Under no circumstances should the piston pin be
drifted out cold, as this will damage the pin bores.
4) Remove piston rings and examing ring grooves and rings for wear. Refer to Schedule of Limits
and Fits Table 4.1 for acceptable tolerances. Individually identify each piston ring to ensure cor-
rect order of reassembly. It is important to replace rings in their original grooves.
5) Check piston and pin bores for wear. Parts worn in excess of the dimensions given in Schedule
of Limits and Fits should be replaced.
NOTE: When fitting a new piston, carefully inspect all ring grooves and
stepped diameters for sharp edges which may scuff the cylinder
bore. If necessary, remove any sharp edges with a fine stone and
thoroughly clean.
6) Remove ’O’ ring seals from within piston pin bosses and replace with new seals.
4--7
V19H--AL COMPRESSOR
7) Check connecting rod big and small ends for wear and surface finish. Renew as necessary. Re-
placed bearings must be fine bored to size after fitting.
4.4.4. Cross head/connecting rod assembly
1) Remove piston pin retaining circlips using circlip pliers and push pin out of crosshead.
2) Check crosshead and pin for wear and renew if necessary.
3) Check connecting rod big and small ends for wear and surface finish. Renew as necessary. Re-
placed bearings must be fine bored to size after fitting.
4.4.5 Third stage piston and liner
The third stage cylinder and piston will have been removed as previously described. The cylinder
liner is removable, but should not be disturbed for initial inspection. Recommended procedures are
as follows:
1) Remove piston and check the condition of piston rings. Replace if rings show excessive wear,
marked variation in radial thickness or pitting and grooving on the rubbing faces. New rings
should be expanded only the minimum amount necessary for fitting in order to avoid permanent
distortion. Fitting may be facilitated by wrapping a thin shim around the piston. Fit the lower
piston ring first and move the shim protection upwards one groove at a time until all the rings
have been fitted.
2) Whether new rings are fitted or not, ensure that all rings are free in their grooves and all groove
side faces are in good condition.
3) Visually check cylinder liner bore. This should be polished and free from blemishes or
scratches. Inspect third stage valve seat, which forms top part of liner. If any re lapping of this
seat is required, liner must be removed from cylinder.
4) Remove liner by pushing out firmly from the bottom. Remove two sealing rings, one under lin-
er top face and one from groove in liner bore. Carry out any lapping of the valve seat as pre-
viously described and thoroughly clean all components.
5) Always fit new sealing rings. Push fit liner into cylinder. Lightly oil third stage piston and insert
into liner from the underside.
4.4.6 First and second stage piston/connecting rod assembly
To reassemble the first and second stage piston and connecting rod assembly:
1) Place piston in hot water at 80_C to 85_C for two to three minutes.
2) Whilst still hot, fit new ’O’ ring seals. Align connecting rod small end with piston bosses.
3) Push in pin. Ensure pin is centrally located in bosses.
4) Wash piston thoroughly in solvent to remove all traces of dirt or oil deposits.
4--8
V19H--AL COMPRESSOR
5) Fit new circlips. Ensure circlips are fully expanded in grooves. Failure to ensure this could re-
sult in major and expensive damage to the compressor.
6) Prior to fitting piston rings check the ring gaps by inserting each ring into its respective cylinder
bore ensuring it is square to the bore and measure the closed gap with a feeler gauge. File the
piston ring butt ends if necessary to give a closed gap of 0.08 mm/0.15 mm (0.003”/0.006”). Re-
place piston rings.
4.4.7 First and second stage cylinder
To reassemble the first and second stage cylinder and piston assembly:
1) Lightly support cylinder in a vice. DO NOT overtighten the vice as this could distort cylinder
bores.
2) Smear clean lubricating oil over piston, stagger the ring gaps around piston diameter and enter
connecting rod and piston into cylinder.
3) Using finger tip pressure, press low pressure rings into grooves and push piston into cylinder.
4) Any indication of obstruction will probably be due to the second stage rings sliding out of their
grooves. To overcome this difficulty, take a length of steel rod 3 mm diameter and approximate-
ly 20 cm long. Measure 10 mm from one end and bend at right angles. Flatten this bent end
with a hammer and file off all sharp edges. The other end of the tool may be bent over to form a
convenient handle.
Note: Welding rod is suitable for this purpose.
5) Place the short end of this tool through valve port in cylinder. With firm pressure, press second
stage rings into their grooves at the same time pushing piston into cylinder.
6) Pull piston down to bottom of cylinder. There should be no evidence of a gap between underside
of first stage piston and step of cylinder when viewed through valve ports.
4.4.8 Crankcase and cylinders
To reassemble the crankcase and cylinders:
1) Smear boiled oil on jointing faces of gaskets. Insert bearing assembly into crankcase and secure
with eight nuts, tighten to correct torque.
2) Place third stage connecting rod through aperture in crankcase. Slide big end into position on
crankpin.
Note: Ensure con rod dipper is pointing downwards.
3) Smear boiled oil on cylinder base gasket faces and fit over studs.
4) Smear clean lubricating oil on crosshead guide bore and assemble over crosshead onto the crank-
case studs. Tighten nuts to correct torque.
5) Smear boiled oil on low pressure cylinder base gasket faces.
4--9
V19H--AL COMPRESSOR
6) Pull low pressure connecting rod and piston down to bottom of cylinder. Pass rod through aper-
ture in crankcase and slide big end onto crankpin.
Note: Ensure con rod dipper is pointing downwards.
7) Press cylinder down over retaining studs and secure in position with nuts and washers to correct
torque.
8) Replace crankpin retaining washer and tab washer. Tighten screws. Bend up ends of tab washer
to lock screws in position. Tighten to correct torque.
Note: Always use a new tab washer.
9) Smear boiled oil on jointing faces to seal gasket. Fit front cover to crankcase and secure with
socket screws, tighten to correct torque.
4.4.9. Third stage cylinder and valves
To reassemble the third stage cylinder and valves:
1) Smear Hermetite RTV instant gasket on top face of crosshead guide. Use sparingly and ensure
no compound runs into cylinder bore.
2) Place the third stage cylinder on a clean surface with suction valve seat facing upwards.
Note: Ensure correct location of piston in cylinder liner.
3) Place sealing ring in recess on suction valve seat. Note that suction valve seat is an integral part
of the third stage cylinder liner.
4) Turn third stage cylinder head upside down and place valve spring
larger diameter into recess in head. Place recessed face of delivery
valve disc onto spring. Place head on a clean surface ready for
final assembly.
5) Take two of the four suction valve springs and inter-

lock so that curved faces lie together. Similarly, inter-
lock the remaining two suction valve springs. Fit the
two sets of springs together with the axis of the
curves at 90_ as shown below. Position springs into
the recess of delivery valve seat. Place suction valve disc
on top of springs. Hold valve disc and springs in place using ei-
ther a 0.012”/0.015” feeler gauge or similar strip of plastic.
6) Place assembly directly over suction valve seat and whilst hold-
ing firmly, withdraw feeler gauge.
7) Ensure that delivery valve seat does not rock. Rocking will indicate that the valve disc and
springs are not positioned correctly.
8) With delivery valve seat held in position, take the cylinder head, complete with delivery valve
disc and spring, and slide head carefully over delivery valve seat. Ensure that head is firmly in
4--10
V19H--AL COMPRESSOR
position. Align screw holes and fit the four retaining screws down through the head and cylin-
der.
9) With head and cylinder held together firmly, place complete assembly in position on the top of
crosshead guide.
10) Screw down socket screws to recommended torque figure.
4.4.10 First stage cylinder and valve plate
To reassemble the first stage cylinder head and valve plate:
1) Place reed plate valve assembly and cylinder to valve gasket on cylinder with the face marked
’Top’ uppermost. The notch on side of valve plate should be to the right of the second stage suc-
tion valve when viewed from top.
2) Place gasket on plate valve and fit on machined face of cylinder head and fit in position. Secure
with cap screws to correct torque figure.
4.4.11 Second stage valves
The suction and delivery valve housings differ in depth. The delivery valve must be fitted into the
deeper hole. Assembled valves are not easily distinguishable, so care should be taken to ensure that
the proper valve is fitted into the correct housing. It is suggested that the appropriate housings are
clearly marked ’S’ and ’D’ before the suction and delivery valves are fitted.
1) Refer to Figure 6.2 and place valve seat washers into correct valve port recesses.
2) Place appropriate valve in position with nut facing outwards.
3) Fit new ’O’ rings to valve retainers. Assemble valve retainers to cylinder and tighten to recom-
mended torque figure.
4.4.12 Final assembly
1) Replace intercooler coils, ensuring that all union nuts and olives are secure. Do not distort coils
when fitting. Secure firmly with support brackets.
2) Fit fan/flywheel key. Replace flywheel and lock with retaining washer, lockwashers and retain-
ing bolts. The threads of the retaining bolts should be lightly smeared with Loctite 241 to pro-
vide added security. Under no circumstances must any other Loctite adhesive be used.
3) Rotate compressor by hand to ensure freedom of rotation and that moving parts are not being
fouled by intercooler coils, brackets, etc.
4) Replace compressor into system. Fit drive belts and check for correct tension. See Section 2.4.
5) Fill the compressor with the correct grade of oil as recommended in the Technical Data Section
1.
4--11
V19H--AL COMPRESSOR
Table 4.1 -- SCHEDULE OF LIMITS AND FITS
ITEM DESIGN SIZE WEAR LIMIT *MAXIMUM TOTAL

INCHES (MM) INCHES (MM) CLEARANCE IN
IN (MM)
Crankpin 1.3776/1.3772 1.376 0.004 (0.10)
(34.991/34.980) ((34.95)
Big end bearing fitted 1.3786/1.3780 1.381

(35.016/35.000) (35.08)
Piston pin dia 0.5906/0.5902 0.5898 0.002 (0.05)

(15.000/14.992) (14.980)
Small end bearing fitted 0.5910/0.5908 0.593

(15.011/15.006) (15.06)
LOW PRESSURE PISTON 3.491/3.487 3.48 0.020 (0.50)

(88.68/88.58) (88.50)
Piston Major Dia
3.501/3.500 3.504
(88.93/88.90) (89.00)
Cylinder diameter
Major dia comp ring 2 per 0.1250/0.1245 0.1225 0.005 (0.14)

groove axial thickness (3.18/3.16) (3.11)
Major dia comp ring groove 0.1264/0.1256 0.128

width (3.21/3.19) (3.25)
Major dia comp ring radial 0.125/0.119 -- 0.020 (0.5)

thickness (3.18/3.02) Ring gap in cylinder
Piston minor dia 3.065/3.062 3.060 0.615 (0.39)
(77.85/77.77) (77.72)
Cylinder diameter 3.072/3.071 3.075

(77.03/78.00) (78.11)
Minor dia comp ring axial 0.062/0.0615 0.0605 0.005 (0.13)

thickness (1.575/1.563) (1.54)
Minor dia comp ring Groove 0.0634/0.0626 0.065

width (1.61/1.59) (1.63)
Minor dia comp ring radial 0.125/0.119 -- 0.020 (0.5)
thickness (3.18/3.02) Ring gap in cylinder
4--12
V19H--AL COMPRESSOR
ITEM DESIGN SIZE WEAR LIMIT *MAXIMUM TOTAL

INCHES (MM) INCHES (MM) CLEARANCE IN
IN (MM)
Minor diameter oil control ring 0.1244/0.1239 0.122 0.005 (0.13)
axial thickness (3.16/3.148) (3.10)
Minor dia oil control ring 0.1264/0.1256 0.128

groove width (3.21/3.19) (3.25)
Minor dia oil control ring ra- 0.1252/0.1189 -- 0.020 (0.5)
dial thickness (3.18/3.02) Ring gap in cylinder
CROSSHEAD PISTON 2.1634/2.1622 2.160 0.007 (0.18)
(54.95/54.92) (54.86)
Piston diameter
2.1665/0.5512 2.169
(55.03/55.00) (55.09)
Cylinder diameter
FINAL STAGE PISTON 0.5508/0.5504 0.549 0.005 (0.13)

(13.99/13.98) (13.94)
Piston diameter below rings
0.5522/0.5512 0.554
(14.025/14.000) (14.07)
Cylinder liner
Compression ring axial thick- 0.09375/0.09275 0.091 0.005 (0.13)
ness (2.381/2.356) (2.31)
Compression ring groove 0.0957/0.0945 0.097

width (2.43/2.40) (2.46)
Compression ring radial thick- 0.025/0.019 -- 0.0015 (0.038)
ness (0.636/0.484) Ring gap in cylinder
* NOTE Maximum clearance can be obtained before either of the mating

parts has reached the wear limit but either one or both parts should
be replaced as soon as the maximum clearance given in the above
table is reached.
4--13
V19H--AL COMPRESSOR
Table 4.2 -- TORQUE LOADING CHART
SIZE DESCRIPTION TORQUE (lb/ft) TORQUE (Kgf M)

M10 Cylinder Head screws 14 -- 16 2 -- 2.2
M10 Cylinder Base Nuts 14 -- 16 2 -- 2.2
M8 Bearing Housing Nuts 10 -- 12 1.4 -- 1.7
M8 Crankcase end cover screws 8 -- 10 1.1 -- 1.4
M8 Fan blade retainer screws 8 -- 10 1.1 -- 1.4
M6 Crankpin Screws 7 -- 9 1 -- 1.3
M6 Crankshaft drive pulley screws 7 -- 9 1 -- 1.3
NOTE: The above torque figures are for specific applications and must be
strictly adhered to. If the threads are lubricated, the nuts and bolts
which are tightened to the recommended torque figures will be in
danger of stripping. Therefore, always wipe all oil and grease from
threads before tightening
The following list is recommended for general use on unspecified

bolts and nuts.
THREAD TORQUE lb/ft TORQUE kgf.M

M5 2.5/3.5 0.35/0.48
M6 4.5/6.5 0.62/0.90
M8 8/10 1.1/1.4
M10 14/16 2/2.2
4--14
V19H--AL COMPRESSOR
SECTION 5 -- Fault Finding
SECTION 5 FAULT FINDING
5--1
V19H--AL COMPRESSOR
5.1 GENERAL
The technical descriptions given in this handbook should enable an experienced technician to trace
any fault to a suspect area and further investigations should pinpoint the fault. Table 5.1 lists fault
symptoms which may arise after long and arduous operations, their possible causes and
recommended remedies. See Section 4 for dismantling and reassembling instructions.
TABLE 5.1 -- FAULT FINDING
Symptom Possible Fault Remarks

1. Low output without a) Filter blocked a) Check air filter for blockage
interstage safety valve
blowing. b) Loose belts b) Check main drive belts
c) Air Leaks c) Check for external air leaks
d) Worn Valves blowing d) Check 1st stage suction and

delivery valves
2. Low output with 1st stage a) Dirt between 2nd stage valve a) Examine the 2nd stage
safety valve blowing. seats, broken or worn suction valves and fix or
springs or chipped valve disc replace as required.
3 Low output with 2nd stage a) Dirt between final stage a) Examine the final stage
safety valve blowing. valve seats, broken or worn suction valves and fix or
springs or chipped valve disc replace as required.
4 Low output persists with a) Cylinder wear, Broken/Worn a) Dismantle and check as
possible high oil piston rings. reccomended in the
consumption Overhaul ’B’ procedure.
5 Cylinder overheating a) Delivery valve leaking a) Check and correct
causing recompression
b) Intercooler pipes coated with b) Clean interccoler pipes

dirt
6 General overheating and a) Oil starvation a) Check oil level
overloading of the prime
mover. b) Restricted cooling to unit b) Check intercooling pipes
c) Low compression speed c) Check drive belts

7 Continuous blowing of a) Faulty safety valve a) Remove safety valve and
safety valves replace
5--2
V19H--AL COMPRESSOR
SAFETY VALVES (RELIEF VALVES)
INTRODUCTION
Due consideration should be taken of climatic, process or other conditions which might adversely
affect the performance of the safety valve. Installation must be undertaken by qualified technicians
and to good engineering practice. In additions, user’s attention is drawn to our joint responsibility
to ensure that the Health and Safety at Work Act is not contravened by incorrect installation,
commissioning or servicing. It is important that the valve to be installed is correct in every aspect,
ie. set pressure, size, material and type etc. for the application.
STORAGE OF VALVE BEFORE INSTALLATION
Valves should be stored preferably between 5_C and 25_C and a relative humidity of less than 75%.
Very moist or very dry conditions should be avoided. If a safety valve is installed after six months,
or more, of storage, it must be subjected to a functional test before commissioning.
Thread protectors should not be removed until immediately prior to testing or installation, as they
also prevent the ingress of foreign matter which could harm the valve.
INSTALLATION VALVE INLET
Under no circumstances should it be possible to isolate the safety valve from the protected system.
Safety valves should be mounted as close as possible to the protected system. The connecting pipe
should be straight and as short as possible. The inlet line to the safety valve should have an effective
area of flow at least equal to that of the safety valve inlet. The manufacturer should be consulted
if the safety valve is to be mounted in any position other than vertically. The maximum pressure
drop through the inlet line to the safety valve should not exceed 3% of the set pressure when the
valve is discharging at its rated capacity.
VALVE OUTLET
No isolating devices shall be fitted to the outlet pipe. Discharge pipes should be as short as possible
and of such a size that the pressure developed therein will not reduce the relieving capacity. Ensure
arrows indicating the direction of the flow are pointing in the correct direction. The cross sectional
area of the discharge pipe should not be less than the area of the safety valve outlet.
Where safety valves are discharged into a manifold, the manifold must be capable of
accommodating simultaneous discharge of all valves connected to the manifold. Atmospheric
discharge or discharge pipes should terminate at a location which will not cause a hazard to
personnel, particular attention being given to hazardous fluids or particles.
GENERAL
Inlet and outlet piping should be capable of supporting the safety valve so that no unacceptable
mechanical load or vibrationis transmitted to the valve and be sufficiently strong to withstand the
effects of the reaction forces when the valve is discharging.
All pipework or pressure vessels to which the safety valve is connected should be thoroughly
cleaned before fitting the safety valve, to ensure that foreign matter does not pass through the valve.
5--3
V19H--AL COMPRESSOR
Particular care should be taken with the use of sealing compounds and P.T.F.E. tape to ensure that
they do not enter the valve.
Atmospheric discharge valves should not be painted or coated with any substance which could
possibly obstruct or restrict free and full discharge through the valve. Suitable protection should
be provided to prevent environmental build up of ingress of foreign matter. Any condition that could
lead to blockage of discharge piping or discharge ports on safety valves must be avoided. Where
appropriate, discharge pipes should be provided to a non hazardous location. Where there is a
possibility of a liquid head forming in a discharge pipe, a drain should be provided which leads to
a safe discharge location. To prevent unnecessary lifting of the safety valve it is recommended that
there is a margin of at least 10% between the maximum operating pressure and the set pressure of
the safety valve.
FUNCTIONAL TESTING
Once installed in service, valves should be tested at least once every six months to ensure free
movement of parts. This should be carried out by operating the easing gear when the valve is under
a pressure of not less than 75% of the set pressure. Where valves are supplied without easing gear,
the test should be in accordance with the full functional test described below. Due regard must be
paid to the safety of personnel. Testing should not create a hazard, particular attention being given
to foreign matter located in discharge outlets.
When valves are installed in extreme operating environments, as listed below, the frequency of
testing must be increased.
a) Hot, dry, dusty or high humidity areas.
b) Oil, tar or gumming deposits.
c) Sand, grit, earth, cement (construction, quarry or similar sites).
d) Pollution laden atmosphere (chemical works).
e) Any area where the valve can become contaminated with foreign matter likely to obstruct free
and full discharge through the valve.
THE FREQUENCY OF TEST MUST BE ESTABLISHED BY THE USER TO SUIT EACH

INSTALLATION OR PROCESS. IT IS IMPORTANT THAT DISCHARGE OUTLETS OF THE
SAFETY VALVE BE KEPT IN A CLEAN CONDITION, FREE FROM DEPOSITS OR BUILD
OF FOREIGN MATTER.
FULL FUNCTIONAL TEST
Safety valves should be checked every 12 months for correct function and test of set pressure, full
flow and reseat pressures. Ideally the valve should be removed from the system and tested on
specific test equipment. Before dismantling any pressurised components, the system must be
effectively isolated from all sources of pressure and completely vented to atmosphere. When safety
valves are taken out of service, care must be taken that the plant remains secure. Parallel or
replacement safety devices of at least the same capacity must be provided. Where a safety valve
does not meet the specification it must be refurbished, or replaced. If the valve is not functioning
correctly, ie. noisy or ’hammering’ refer to the manufacturer.
5--4
V19H--AL COMPRESSOR
IT IS RECOMMENDED THAT ADJUSTMENTS, MAINTENANCE AND REPAIR OF

SAFETY VALVES, INCLUDING CHANGES IN SET PRESSURE, SHOULD ONLY BE
PERFORMED BY THE MANUFACTURER OR AN AUTHORISED REPRESENTATIVE.
5--5
V19H--AL COMPRESSOR
SECTION 6 -- Spare Parts
SECTION 6 -- SPARE PARTS
6--1
V19H--AL COMPRESSOR
6.1 INTRODUCTION
Spare parts for the Model V19H--AL may be obtained from:
Hamworthy Compressor Systems

Chequers Bridge
Gloucester
GL1 4LL
Tel 01452 528431
Fax 01452 507394
Telex 43233 WILJAY G
When ordering spare parts, please give the following information:
1. Name, model number and serial number of compressor. Note that the serial number is stamped
on the metal plate attached to the crankcase.
2. Description of the part required.
3. Part number of part required.
4. Quantity of parts required.
5. Ordering department’s name and full postal address.
The following tables list the component parts of the compressor, which are also illustrated where
possible on the associated exploded views.
6--2
V19H--AL COMPRESSOR
V19H--AL Compressor -- Crankcase and Fan assembly
6--3
V19H--AL COMPRESSOR
TABLE 6.1 -- MODEL V19H--AL COMPRESSOR -- PARTS LIST
REF PART NO DESCRIPTION QTY

1 Y38983 Flywheel Pulley 1
2 Y25013 Blade Retainer 2
3 Y50353 Fan Blade -- Multi Wing 11
4 Y24602/25 Socket Capscrew 6
5 MSWS/8 Washer Spring Single Coil 6
6 Y25015 Flywheel Key 1
7 Y25014 Retaining Washer 1
8 Y25016 Tab Washer 1
9 24565/20 Hex Head Setscrew 2
10 Y25101 Crankcase 1
11 Y25104 Crankcase End Cover 1
12 Y25017 Crankcase End Cover Gasket 1
16 Y17329 Taper Pressure Plug 4
18 Y20478/35 Stud 8
19 Y25020 Bearing Housing 1
20 Y25019 Bearing Housing Gasket 1
21 Y25022 Bearing 1
22 Y25023 Bearing 1
23 Y25024 Circlip 1
24 Y25025 Oil Seal 1
25 Y25026 Bearing Spacer 1
26 Y25027 Clamping Collar 1
27 Y25064 O Ring 1
28 Y25063 Bearing Spacer 1
29 Y29262 Crankshaft 1
30 Y25014 Retaining Washer 1
31 Y25016 Tab Washer 1
32 Y24565/20 Hex Head Setscrew 2
33 MCN8Z Nut Hex head 8
34 MSWS/8 Washer Spring Single Coil 8
35 Y22155/S Sump Plug Sub--Assembly 1
36 10001/9 Bonded Seal 1
37 Y27875 Eyebolt 1
6--4
V19H--AL COMPRESSOR
Section through 1st & 2nd stage cylinder
6--5
V19H--AL COMPRESSOR
MODEL V19H--AL COMPRESSOR -- PARTS LIST Cont’d

101 Y37692 L.P. Cylinder Head 1
102 Y25031 Cyl Head/Valve Gasket 1
103 Y37636 Reed Valve Assembly 1
104 Y35334 Cylinder/Valve Gasket 1
105 Y36364 L.P. Cylinder 1
108 Y35333 Cylinder Base Gasket 1
109 Y25547 Valve Seat Washers 2
110 Y25548 Suction Valve Assembly 1
111 Y25549 Delivery Valve Assembly 1
Y36366 Valve Nut (Spares Item Only) 1
112 Y30378 O Ring 2
113 Y25627 Valve Cage 2
114 Y24601/16* Socket Capscrew 8
115 Y37638/S L.P. Piston Ass’y, comprising items 116 to 1
121
116 Y08082 Compression Ring 2
118 Y35352 Standard Oil Control Ring 1
119 Y36381 Gudgeon Pin 1
120 82017 Circlip 2
121 Y25117 O Ring 2
123 Y28082 Connecting Rod 2
259 Y39284 Air Intake Filter 1
* Not Shown
6--6
V19H--AL COMPRESSOR
Section through 3rd Stage Cylinder
6--7
V19H--AL COMPRESSOR

123 Y28082 Connecting Rod 2
150 Y25070 Cross Head Assembly 1
153 Y25061 Cylinder Base Gasket 1
154 Y25060 Cross Head Guide 1
155 Y25051 HP Piston 1
157 Y25050 H.P. Cylinder 1
158 Y25302 HP Cylinder Head 1
159 Y20503 Socket Capscrew 4
160 Y25045 Seal, Corrugated Valve Seat 1
161 Y16411 Delivery Valve Spring 1
162 Y16413 Delivery Valve Disc 1
163 Y34606 Delivery Valve Seat 1
164 Y16415 Suc Valve Spring 4
165 Y16414 Suction Valve Plate 1
166 Y25046 Cylinder Liner 1
167 Y25047 O Ring 1
168 Y25048 O Ring 1
230 Y39457 Relief Valve 1
231 Y23495 Special Banjo 1
232 Y23497 Retaining Screw 1
233 Y17817 Filter Element 1
234 Y23498 Spring 1
235 10001/15 Bonded Seal 1
236 Y23496 Banjo Cap 1
6--8
V19H--AL COMPRESSOR
V19H--AL General Assembly
6--9
V19H--AL COMPRESSOR

15 Y08085 Oil Filler Cap 1
16 Y17329 Taper Pressure Plug 4
17 Y24579/35 Stud 8
38 Y50376 Intercooler Bracket 1
39 Y13253 Plate -- Direction Arrow 1
40 Y21941 Nameplate 1
41 Y09926 Screw Drive 4
106 Y24691 Spring Washer 4
107 MCN10Z Nut Hex Head 4
151 Y24691 Spring Washer 4
200 Y09623 Male Elbow 1
201 Y14302 Tubing Nut 2
202 Y14303 Tubing Sleeve 2
203 Y50325 Stage 1 Intercooler 1
204 Y35063 Stem Elbow 1
205 Y09557 Male Adaptor 1
206 Y11743 Washer 1
207 Y37293/3 Adaptor 1
209 Y20899 Safety Valve 1
210 Y31090 Pressure Plug 1
211 Y09549 Male Adaptor 1
214 Y50326 2nd Stage Intercooler 1
215 Y26359/1 Pipe Clip 2
216 Y36125 Spacer 1
217 MCS6/16Z Setscrew Hex Head 1
219 Y20549 Nyloc Nut 1
220 Y18600 Stem Elbow Connector 2
221 Y25213 MIG Bracket Clamp 1
222 Y50364 MIG Bracket Clamp 1
223 Y21523 Moisture Separator Sub--Assembly 1
224 Y24578/90 Stud 2
225 MPW8Z Washer Plain 2
227 Y50404 Inlet Pipe 1
228 Y09616 Male Elbow 1
237 Y23968 Elbow -- Positional 1
238 Y23113 Sealing Washer 1
239 Y50327 3rd Stage Aftercooler 1
240 MSWS/8 Spring Washer 2
6--10
V19H--AL COMPRESSOR

250 Y24521 Coupling 1
251 Y50374 Termination Bracket 1
252 MCS6/16Z Setscrew Hex Head 2
253 MPW6Z Washer Plain 2
254 Y25119 Oil Feed Adaptor Assembly 1
255 Y25118 Oil Feed Elbow Assembly 1
258 Y09704L Copper Tube 0.34m
6--11
V19H--AL COMPRESSOR
6--12
V19H--AL COMPRESSOR
SERVICE KITS
Gasket Kit -- 50557

PART NO DESCRIPTION QTY
Y25017 Crankcase end cover Gasket 1
Y25019 Bearing Housing Gasket 1
10001/9 Bonded Seal 2
Y25025 Oil Seal 1
Y25064 ’O’ Ring 1
Y25031 Cylinder Head/Valve Gasket 1
Y35334 Cylinder/Valve Gasket 1
Y30378 ’O’ Ring 2
Y35333 Cylinder Base Gasket 1
Y25061 Cylinder Base Gasket 1
Y25047 ’O’ Ring 1
Y25048 ’O’ Ring 1
Y25045 Seal, Corrugated Valve Seat 1
6--13
V19H--AL COMPRESSOR
VALVE REPLACEMENT KIT -- PART NO. Y50558
6--14
V19H--AL COMPRESSOR
Valve Kit -- Y50558

Y25031 Cylinder Head/Valve Gasket 1
Y37636 Reed Valve Assembly 1
Y35334 Cylinder/Valve Gasket 1
Y25547 Valve Seat Washer 2
Y25548 Suction Valve Assembly 1
Y25549 Delivery Valve Assembly 1
Y30378 ’O’ Ring 2
Y16411 Delivery Valve Spring 1
Y16413 Delivery Valve -- Disc Type 1
Y34606 Delivery Valve Seat 1
Y25045 Seat -- Corrugated Valve Seat 1
Y16415 Suction Valve Spring 1
Y16414 Suction Valve Plate 4
Y25047 ’O’ Ring 1
Y25048 ’O’ Ring 1
Y17817 Filter Element 1
Y39283E Air Intake Filter Element (Spare) 1
6--15
V19H--AL COMPRESSOR
6--16
V19H--AL COMPRESSOR
Major Service Kit -- Y50559

Y50558 Valve Kit 1
Y50557 Gasket Kit 1
Y25016 Tab Washer 2
Y25022 Bearing -- Single Row Ball 1
Y25023 Bearing -- Single Row Ball 1
Y25024 Circlip 1
MSWS/8 Spring Waher 8
Y24691 M10 Spring Washer 8
Y08082 Compression Ring 2
Y35352 Standard Oil Control Ring 1
Y25110 Circlip 2
82017 Circlip 2
Y25051 H.P. Piston 1
Y25046 Cylinder Liner 1
6--17
Appendix 1 – Compressor Log Sheet
Compression Prime Mover Installed At Oil Grade Used

Type Type
Speed B.H.P
Serial No. Drive Date Installed
Date Time Hours Run Room Stage Pressures Oil Level Filter Signature
Temp. 1 2 3 4 Checked

Operation and Maintenance Manual for V19H-AL Compressor

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Operation and Maintenance Manual for V19H-AL Compressor

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OPERATION AND MAINTENANCE

HEALTH AND SAFETY AT WORK ACT 1974

1. All drives and moving parts are fully guarded.

4. Interconnecting pipework is adequate in strength.

If in doubt, ask our advice.

NEVER Screw down a pipe union that is under pressure.

REMEMBER COMPRESSED AIR CAN KILL TREAT IT WITH RESPECT

SECTION 1 TECHNICAL DESCRIPTION

SECTION 2 INSTALLATION & STORAGE

SECTION 5 FAULT DIAGNOSIS

SECTION 6 SPARE PARTS

SECTION 1 -- TECHNICAL DESCRIPTION

FIGURE 1.1 -- MODEL V19--AL COMPRESSOR

1.1 TECHNICAL DATA

Crankcase Oil Capacity 1.2 Litres (2.11 Pints)

FIGURE 1.2 -- MODEL V19H--AL PRINCIPLE OF OPERATION

1.2 INTRODUCTION (See Figure 1.1)

1.3 PRINCIPLE OF OPERATION (See Figure 1.2)

Lubrication is by a combination of controlled splash, and crankcase to inlet differential pressure.

1.4 MECHANICAL CONSTRUCTION

SECTION 2 -- INSTALLATION AND STORAGE

ADDITIONAL INFORMATION -- INITIAL STARTING

On receipt of compressor, examine label to determine which condition applies. If compressor is

This eyebolt is not designed to support the combined

The compressor will be starved of oil if run in the re-

2.4 SETTING UP PROCEDURE

To set up the compressor before operation:

2.5.1 Shut Down

2.5.2 Short term Inhibiting

1) Drain off lubricating oil whilst still warm.

5) Run compressor for a further one minute.

6) Drain off inhibiting oil from crankcase.

Do not turn crankshaft after draining inhibiting oil or

2.5.3 Long term Inhibiting

2.5.4 Start up, after short term inhibiting

To prepare compressor for operation after a short term period of inhibiting:

Take precautions to ensure that other equipment in

2.5.5 Start up, after long term inhibiting

Take precautions to ensure that other equipment in

Note: Preventative maintenance can be effectively planned from the com-

4.2 ROUTINE MAINTENANCE PERIODS

5) Complete compressor log sheet as necessary.

4.2.2 After first 100 Hours

3) Refill crankcase with recommended grade of lubricating oil.

4) Check all valve retainers for tightness.

5) Complete compressor log sheet.

4.2.3 Every 400 Hours

1) Replace Air intake filter element

5) Check all external fastenings and pipe fittings for tightness.

7) Complete compressor log sheet as necessary.

4.3 OVERHAUL ’A’ TYPE 800 HOURS RUNNING

1) Carry out the 400 hour servicing procedure.

2) Change Lubricating Oil following procedure in section 4.2.2.

2) Check valves and valve springs as follows:

4.3.1 First stage valves

Because of the nature of the first stage valve,

Scratches to valve seats and discs may be

Every trace of grinding and lapping compound must be removed before

4.3.2 Second stage valves

Note: Mark suction and delivery valves and pockets to facilitate

1) Remove valves and examine parts for wear or damage.

3) If valves are observed to be deeply pitted, complete replacement will be