OPERATING & INSTRUCTION MANUAL

COMPRESSOR MAINTENANCE
GP15 COMPRESSOR

Reference Number: Current Revision Date Issued Manual for DCO Reference Authorisation

OM134 E 08/04/04 GP15 COMPRESSOR MAINTENANCE 2239

GPS15, HICOM15 GAS PREPARATION EQUIPMENT

OPERATING INSTRUCTIONS

COMPRESSOR MAINTENANCE GP15 COMPRESSOR

CONTENTS
Technical Data for Compressors ............................................................................................................................. 3 Introduction .............................................................................................................................................................. 4 Description of compressor parts .......................................................................................................................... 5 Compressor Stages.......................................................................................................................................... 5 Coolers ............................................................................................................................................................. 5 Crankcase Breather ......................................................................................................................................... 5 Motor ................................................................................................................................................................ 5 Oil Filler ............................................................................................................................................................ 5 Microfilter .......................................................................................................................................................... 5 Unloaders ......................................................................................................................................................... 6 Stage Pressure gauges Stage Pressure gauges ............................................................................................. 6 Safety valves Safety valves.............................................................................................................................. 6 Outlet ................................................................................................................................................................ 7 Oil sight glass ................................................................................................................................................... 7 Oil pressure gauge and switch ......................................................................................................................... 7 Oil drain plug .................................................................................................................................................... 8 Maintenance ............................................................................................................................................................ 9 Checking the oil level ........................................................................................................................................... 9 Recommended Lubricating oil:......................................................................................................................... 9 Storage of Compressor........................................................................................................................................ 9 Changing the oil ................................................................................................................................................... 9 Valve Inspection................................................................................................................................................. 11 1st Stage Valves ............................................................................................................................................ 11 2nd Stage Valves ........................................................................................................................................... 11 3rd Stage Valves ............................................................................................................................................ 12 Unloader system inspection............................................................................................................................... 13 General Disassembly ..................................................................................................................................... 13 Unloader valve disassembly........................................................................................................................... 13 Cooler inspection ............................................................................................................................................... 13 Starting compressor after Maintenance............................................................................................................. 13 General maintenance notes............................................................................................................................... 14 Troubleshooting ..................................................................................................................................................... 15 Low output flow or pressure............................................................................................................................... 15 Leakage.......................................................................................................................................................... 15 1st stage cylinder head .................................................................................................................................. 15 Unloader system ............................................................................................................................................ 15 Worn piston rings Worn piston rings .............................................................................................................. 15 Blowing safety Valves ........................................................................................................................................ 15 1st Stage safety valve blowing ....................................................................................................................... 15 2nd Stage safety valve blowing...................................................................................................................... 15 3rd Stage safety valve blowing....................................................................................................................... 16 Leakage from HP receivers ............................................................................................................................... 16 Low oil pressure................................................................................................................................................. 16 Knocking ............................................................................................................................................................ 16 Rumbling ............................................................................................................................................................ 16 Part Lists................................................................................................................................................................ 17 Diagrams ............................................................................................................................................................... 26 Doc. Ref: Revision: OM134 E DC0: Issued: 2239 08/04/04 Models: Authorised: GP 15, HICOM 15

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OPERATING INSTRUCTIONS

Technical Data for Compressors

Type Cooling Number of stages 1st Stage piston displacement - 50 Hz supply 1st Stage piston displacement - 60 Hz supply Piston diameter Piston stroke Compressor Speed (50 Hz supply) Compressor Speed (60 Hz supply) Output acc. to VDMA 4362 (50 Hz supply) Output acc. to VDMA 4362 (60 Hz supply) Max. working pressure Power required at max. working pressure for: Motor with 50 Hz supply Motor with 60 Hz supply Motor power Sump oil capacity Oil quantity between max. and min. oil level Operating range standard design Noise level at 1m distance (approx) Weight approx. (compressor only) Alterations to design subject to change Units GP15 (SV225/350) Air 3 21.9 (12.9) 26.5 (15.6) 90/33/16 40 1450 1750 16.5 (9.7) 19.9 (11.7) 350 (5075) 6 (8) 6.9 (9.2) 7.5 (10) 3.5 2.35 +5 to +40 85 167

m3/hr (cfm) m3/hr (cfm) mm mm min-1 min-1 m3/hr (scfm) 5% m3/hr (scfm) 5% bar (psi) kW (hp) kW (hp) kW (hp) l l C dB (A) kg

Doc. Ref: Revision:

OM134 E

DC0: Issued:

2239 08/04/04

Models: Authorised:

GP 15, HICOM 15

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OPERATING INSTRUCTIONS

Introduction
This section provides detailed information about the high pressure compressor, including:

General information Description of components Servicing Parts lists Drawings

The GP15 compressor is a Three Stage reciprocating Air cooled compressor with a maximum working pressure of 350 Bar (5000 psi). Lubrication is by Integral crankshaft driven oil pump to crankshaft and big end bearings and by splash/oil mist to the cylinder bores and small end bearings. Intercoolers are fitted at each stage of compression, with condensate separators and safety valves. The compressor is driven by a direct coupled induction motor at 1440 RPM (50 Hz power supplies or 1730 RPM (60Hz power supplies). The main compressor components are identified in the photographs below.

Doc. Ref: Revision:

OM134 E

DC0: Issued:

2239 08/04/04

Models: Authorised:

GP 15, HICOM 15

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OPERATING INSTRUCTIONS

Description of compressor parts

Compressor Stages

The Compressor takes gas from the suction vessel at approximately 270 mBarG and compresses it in three stages up to a maximum of 350 Bar (5000 psi). Three stages of compression are used together with the intercoolers, to reduce the temperatures at each stage of compression. The cylinder bores reduce in size from the first to the third stage, as the pressure in-creases. All cylinders have cooling fins to dissipate the compression heat in the blast from the fan. Each stage of compression has a suction valve and a delivery valve located in the cylinder head to prevent the gas from flowing back into the previous stage.
Coolers

After each stage of compression, the gas is passed through the coiled cooling coils at the front of the compressor to remove the heat of compression. In front of the cooling coils is a large air blast fan which blows cooling air first over the cooling coils and then over the finned cylinders and cylinder heads. The cooling coils are stainless steel.
Crankcase Breather

Because the compressor is a gas compressor, the crankcase is connected to the first stage inlet, to prevent wastage of any gas which blows past the piston rings.
Motor

The motor is a three-phase induction motor. It is directly linked via a coupling to the end of the compressor crankshaft. There are no drive belts.
Oil Filler

Direction of rotation
The direction of rotation is CRITICAL to the correct operation of the compressor. The correct direction of rotation is shown on a label on the compressor itself and in the installation section. The direction of rotation is correct when the fan takes air in at the front of the compressor and expels it over the coolers and compressor cylinders. If you stand in front of the fan, the air should be moving AWAY from you.

The oil filler cap is where the lubricating oil is added to the compressor. See later this section for filling and changing instructions.
Microfilter

After the final cooler and condensate separator is a small Microfilter, which removes any remaining oil droplets from the compressed gas. The drain of the filter is piped to the unloader system so that it vents automatically whenever the compressor stops running. It is not necessary to drain this filter periodically. Because of the limited volume of the filter, CGIs control systems Include an Autovent facility to stop the compressor for a short period (normally 1 minute) after a set running time (normally 30 minutes). This ensures that the filter bowl does not become full and prevents oil from being passed over into the high pressure gas line.

Doc. Ref: Revision:

OM134 E

DC0: Issued:

2239 08/04/04

Models: Authorised:

GP 15, HICOM 15

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OPERATING INSTRUCTIONS

Unloaders

Every time the compressor stops, gas pressure is retained in the cylinders and coolers of each stage. This gas pressure must be vented to allow the compressor to be started off-load. The unloader system is an automatic system for venting this pressure. The system is operated by oil pressure from the lubrication system, which prevents the gas from each stage from venting to the unloader vent. Therefore, when the compressor stops and the oil pressure subsides, the unloader valves will open and the gas will be vented. The Microfilter is also connected to the unloader system, and its contents, including any condensed oil, will be vented every time the compressor is stopped.
Stage Pressure gauges Stage Pressure gauges

After each cooler there is a pressure gauge, which shows the gas pressure for each stage when the compressor is running. The gauges should all reduce to zero after the unloader has vented the gas from each stage when the compressor stops.
Safety valves Safety valves

After the cooler at each stage is also fitted a safety valve, which prevents each stage from becoming over pressurised. If a safety valve begins to blow (or vent gas to atmosphere), it is normally a sign that the compressor needs to be serviced.

Doc. Ref: Revision:

OM134 E

DC0: Issued:

2239 08/04/04

Models: Authorised:

GP 15, HICOM 15

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OPERATING INSTRUCTIONS
Outlet

At the compressor outlet, there is a non return valve (check valve). This stops gas from the HP gas receivers and pipes from venting back through the compressors unloader system to atmosphere when the compressor stops.
Oil sight glass

The oil sight glass is used to check the oil level in the compressor sump. It is essential that the oil level is checked regularly and kept between the minimum and maximum marks. Failure to maintain the correct oil level will result in failure of the compressor: If the oil level is too low, it will result in failure of the compressor due to insufficient lubrication and overheating. If the oil level is too high, it is likely that the crankshaft oil seals will fail.

Oil pressure gauge and switch

A pressure gauge indicates the compressors oil pressure. The oil pressure should normally remain between 2 - 4 Bar when the compressor is running. The oil pressure switch provides a signal to the control system. The compressor will be stopped immediately in an alarm state if the compressor oil pressure is lost when the compressor is running.

Doc. Ref: Revision:

OM134 E

DC0: Issued:

2239 08/04/04

Models: Authorised:

GP 15, HICOM 15

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OPERATING INSTRUCTIONS
Oil drain plug

The oil drain plug is used to drain the lubricating oil from the compressor sump. Note that the oil should be drained from the compressor when it is warm. On some systems, where accessibility is limited, a valve and a pipe may be found instead of the drain plug.

Doc. Ref: Revision:

OM134 E

DC0: Issued:

2239 08/04/04

Models: Authorised:

GP 15, HICOM 15

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OPERATING INSTRUCTIONS

Maintenance
It is essential that regular maintenance is carried out. During operation of the compressor, carbon deposits will build up on the compressor valves. If the maintenance is not carried out in accordance with the instructions in this manual, these deposits can cause loss of performance and damage to pistons and cylinders.

Safety Safety
Whenever maintenance is carried out on the compressor, the mains power must be switched OFF, and locked out if necessary.

Checking the oil level

Check the oil level when the compressor is STOPPED. The oil level must be between the minimum and maximum marks on the oil sight glass. If required, top up the oil level using the recommended lubricating oil. Remove the oil filler cap to top up. After topping up, wipe off any spillage to prevent burning of oil lying on hot surfaces.
Recommended Lubricating oil:

Use only the following synthetic lubricating oils: ANDEROL 500 ANDEROL 555 MOBIL RARUS 827 NEVER mix two different oils from the list. If you wish to change to a different lubricant, the oil must be drained first.

Note In this manual, where item nos. are given (eg. 2/140), the first number (i.e. 2) refers to the Fig. number of the diagram at the back of this manual
section on which the item is shown. The second number (i.e. 140) refers to the item on the diagram and in the parts lists.

Storage of Compressor
If the compressor is stored without running for an extended period (i.e. greater than 2 months), the cylinders, cylinder heads and valves must be checked for cleanliness and condition before re-starting. All parts must be lubricated on assembly. See Valve inspection below for more information.

Changing the oil

Run the compressor until warm (about 10 minutes). Stop the compressor and isolate the power. Place a container underneath the drain plug (or drain pipe) to collect the drained oil. Note: the oil sump capacity is 3.5 litres. Unscrew and remove the drain plug (or open the drain valve, if fitted). Allow the oil to drain into the container. Clean the drain plug with petroleum (gasoline), replace and tighten. Remove the oil filler plug and refill with the recommended lubricant, checking for correct oil level using the oil sight glass. Replace the oil filler plug.

Warning
When operating the compressor normally, the valve pin 2/140 MUST be open. Otherwise the compressor will not unload, and the motor may become overloaded.

Doc. Ref: Revision:

OM134 E

DC0: Issued:

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Models: Authorised:

GP 15, HICOM 15

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OPERATING INSTRUCTIONS Microfilter element change

The Microfilter has a replaceable element (Part number 163140, Component item 950). The O ring 169531 and the disc 101184 should be replaced together with the element. To change the element, the compressor must be stopped: Unscrew the locking grub screw 2 turns.

Remove the drain pipe. Using a large spanner, unscrew the filter bowl from the body.

Unscrew and remove the filter element by hand. Clean the inside of the bowl and body with a cloth. Check the condition of the internal O ring. If in doubt, re-place the O ring. Screw on the new filter element by hand. Replace the filter bowl and tighten until the bowl only UNTIL it stops turning. The bowl seals on its O ring, not on the thread or the face. DO NOT OVERTIGHTEN. Replace the drain pipe. If necessary, loosen the Banjo fitting to align the pipe. Tighten the locking grub screw.

Doc. Ref: Revision:

OM134 E

DC0: Issued:

2239 08/04/04

Models: Authorised:

GP 15, HICOM 15

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OPERATING INSTRUCTIONS Valve Inspection

Make sure that the compressor is stopped and the power isolated before carrying out this work.
1st Stage Valves

Disconnect the inlet hose from the cylinder head 6/160 Unscrew the tubing nut of adaptor 6/165 and detach cooler 6/516 from the cylinder head. Unscrew and remove capscrews 6/161 and washers 6/105 evenly. Remove the cylinder head 6/160 from the cylinder 6/155, removing the valve plate 6/158 Carefully clean the valve plate assembly 6/158 using soft scrapers (e.g. copper, wood, plastic) and petroleum (gasoline) to remove carbon deposits and dirt. Ensure that any traces of gasket material are removed and that the mating surfaces are clean and smooth. Clean the inside of the cylinder head 6/160. Ensure that any traces of gasket material are removed and that the mating surfaces are clean and smooth. Clean the mating surface and cylinder bore of the cylinder 6/155. Ensure that no dust or dirt particles remain in the cylinder 6/155. Use compressed air to blow out if necessary. If the valve plate assembly 6/158 is excessively worn it must be replaced. Reassemble in reverse order. Fit new gaskets if the old ones are damaged. When reassembling, lubricate every component (except gaskets) with clean lubricating oil. On reassembly, tighten the cylinder head screws to the correct torque loading.
2nd Stage Valves

Danger
If carrying out maintenance after the compressor has been working, the cylinder heads and coolers will be extremely hot (up to 180 degrees C). Extreme care must be taken to avoid the risk of personal injury.

Unscrew the tubing nut of adaptor 7/182 and detach cooler 7/517 from the cylinder head. Unscrew the tubing nut of adaptor 7/165 and detach cooler 7/516 from the cylinder head. Unscrew and remove capscrews 7/180 and washers 7/181 evenly. Remove the cylinder head 7/179 from the cylinder 7/175, carefully removing the 2nd stage valve plate assembly 7/177 which is located between the cylinder head and cylinder. Carefully clean the valve plate assembly 7/177 using soft scrapers (e.g. copper, wood, plastic) and petroleum (gasoline) to remove carbon deposits and dirt. Ensure that any traces of gasket material are removed and that the mating surfaces are clean and smooth. Clean the inside of the cylinder head 7/179. Ensure that any traces of gasket material are removed and that the mating surfaces are clean and smooth. Clean the mating surface and cylinder bore of the cylinder 7/175. Ensure that no dust or dirt particles remain in the cylinder. Use compressed air to blow out if necessary. If the valve plate assembly 7/177 is excessively worn it must be replaced. Reassemble in reverse order. Fit new gaskets if the old ones are damaged. When reassembling, lubricate every component (except gaskets) with clean lubricating oil. On reassembly, tighten the cylinder head screws to the correct torque loading.

Doc. Ref: Revision:

OM134 E

DC0: Issued:

2239 08/04/04

Models: Authorised:

GP 15, HICOM 15

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OPERATING INSTRUCTIONS
3rd Stage Valves

Unscrew the tubing nut of adaptor 8/199 and detatch cooler 8/518 from the cylinder head. Unscrew the tubing nut of adaptor 8/182 and detatch cooler 8/517 from the cylinder head. Unscrew and remove capscrews 8/190 and washers 8/105 evenly. Remove the cylinder head 8/189 from the cylinder 8/185. Remove the capscrews 8/193 and washers 8/181 from the valve retainers 8/192 and 8/191 on each side of the cylinder head 8/189. Remove the valves 8/194 and 8/197 and seals 8/195 and 8/196 and 8/198 from the cylinder head. Carefully clean the valves 8/194 and 8/197 using soft scrapers (e.g. copper, wood, plastic) and petroleum (gasoline) to remove carbon deposits and dirt. Clean the inlet and outlet valve ports and the mating face of the cylinder head 8/189. Ensure that any traces of gasket material are removed and that the mating surfaces are clean and smooth. Clean the mating surface and cylinder bore of the cylinder 8/185. Ensure that no dust or dirt particles remain in the cylinder. Use compressed air to blow out if necessary. If the valves 8/194 and 8/197 are excessively worn they must be replaced. Seals 8/195 and 8/196 and 8/198 should always be replaced, to avoid premature leakage. When installing these seals, ensure that they are correctly located around the valves. Reassemble in reverse order. Fit new gaskets if the old ones are damaged. When reassembling, lubricate every component (except gaskets, but including O rings) with clean lubricating oil. On reassembly, tighten the cylinder head screws to the correct torque loading. Type of Screw Inner Hex Screw M8 Inner Hex Screw M8 Inner Hex Screw M12 Inner Hex Screw M12 180 193 161 190 Part No 7 8 6 8 Fig Max Torque Applied 24 Nm 24 Nm 75 Nm 75 Nm

Doc. Ref: Revision:

OM134 E

DC0: Issued:

2239 08/04/04

Models: Authorised:

GP 15, HICOM 15

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OPERATING INSTRUCTIONS

Unloader system inspection

General Disassembly

Before the unloader blocks can be re-moved from the compressor, the pipes to them must be removed. Remove the oil pipes from the bottom of the 1st and 2nd stage unloaders. Take care to catch any spilt oil. Remove the gas pipes from the bottom of then 3rd stage unloader. Remove the gas pipe from the top of the 3rd stage unloader.
Unloader valve disassembly

NOTE: When disassembling unloader valves, to avoid confusion and incorrect operation, remove and replace only one unloader at a time. Remove the two outer screws (not the centre screw) which hold the unloader valve onto the separator block. Remove the valve from the compressor. Unscrew and remove the four cover retaining screws and remove the cover from the bottom of the valve. Withdraw the piston and seals from inside the valve, noting the arrangement of parts. Clean the piston and the inside of the unloader valve using a cloth and petroleum (gasoline). Check the piston Orings for wear or damage. Replace any worn or damaged O rings. Check the piston and unloader valve for scoring. If the scoring cannot be removed by rubbing with 800 grade emery paper, replace the parts. Lubricate the piston O rings with acid-free grease (e.g. silicone grease). Reassemble the parts in reverse order. Always renew the cover gasket and the O ring seal between the unloader valve and the separator block.

Cooler inspection
Clean the cooling tubes with a cloth to remove accumulated dirt and dust. Use an airline to blow dirt away, to maintain maximum cooling efficiency. Check all coolers for signs of corrosion or fatigue. Replace any coolers which are cracked or damaged.

Starting compressor after Maintenance

Turn the compressor by hand for a few revolutions. Check that the motion is smooth and free. Re-check all screws and connections for tightness. Run the compressor for 10 - 15 minutes until warm. Re-check all screws and connections for tightness.
Doc. Ref: Revision: OM134 E DC0: Issued: 2239 08/04/04 Models: Authorised: GP 15, HICOM 15

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OPERATING INSTRUCTIONS General maintenance notes

Delivery valves will wear out before suction valves, due to the higher temperatures. When replacing piston rings, ALWAYS replace as a complete set for each stage (i.e. do not mix old and new rings in the same cylinder) Always lubricate components (not paper gaskets) on assembly with clean lubricating oil. Make sure that cylinders and cylinder head components are extremely clean on assembly. Any particles of dirt left inside can score the cylinder bores and reduce the performance of the compressor valves.

Doc. Ref: Revision:

OM134 E

DC0: Issued:

2239 08/04/04

Models: Authorised:

GP 15, HICOM 15

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OPERATING INSTRUCTIONS

Troubleshooting
Low output flow or pressure
Leakage

If gas is leaking from the compressor cylinders or coolers, the output flowrate will fall, resulting in low pressure. Carry out leakage test.
1st stage cylinder head

If the 1st stage cylinder head gasket is leaking, or the valve plate gasket is damaged, the flowrate will fall. Check that the gaskets 6/157 and 6/159 are correctly fitted, and in good condition.
Unloader system

If the unloader valves do not seat correctly, gas from the compressor will vent through the unloader vent when the compressor is running. With the compressor running, check that no gas is venting through the unloader vent. If there is gas venting when the compressor is running, carry out the unloader inspection and replace any worn components.
Worn piston rings Worn piston rings

Worn piston rings will reduce the output capacity of the compressor. Replace the piston rings. Note: Piston rings marked TOP must be installed with the TOP marks facing the top of the piston. Piston ring gaps must be rotated through 90 or 120 degrees from each other.

Blowing safety Valves

Possible reasons for safety valves blowing are given below. In addition to these reasons, it may be possible that the safety valves themselves can be faulty. Safety valve adjustments may change due to vibration, or the valve may be worn. In general, the normal operating pressures of the four stages of the compressor will be as follows: 1st stage: 5.8 - 7.0 Bar 2nd stage: 41 - 63 Bar 3rd stage: 150 - 350 Bar If a safety valve is blowing below the pressures given above for each stage, then it is likely that the valve requires adjustment or replacement. Note: It is extremely dangerous to adjust safety valves pressures without the correct equipment. Replacement is recommended.
1st Stage safety valve blowing

2nd stage cylinder head gasket damaged. Check and replace. 2nd stage suction valve faulty. Check and clean/replace.
2nd Stage safety valve blowing

3rd stage suction valve and/or seals worn or damaged. Check and clean/replace.

Doc. Ref: Revision:

OM134 E

DC0: Issued:

2239 08/04/04

Models: Authorised:

GP 15, HICOM 15

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OPERATING INSTRUCTIONS
3rd Stage safety valve blowing

Outlet Check Valve or outlet pipes blocked. Check and Clean/Replace

Leakage from HP receivers

If the pressure in the HP receivers or pipework reduces, even when no gas is being consumed, it is possible that the compressor outlet check valve is faulty and that gas is leaking back through it and to the unloader vent, when the compressor is not running. Check and replace check valve.

Low oil pressure

Low oil level - Check and refill oil pump suction strainer fitted to drain plug 2/135 is clogged. Drain the compressor oil and clean the strainer. Use compressed air to blow away any dirt, from the inside of the strainer.

Knocking
Hard metallic knocking noises normally indicate worn crankpin journals or big end bearings. If the crankpin journals are excessively worn, the crankshaft 4/206 must be replaced. If the wear is minor, the connecting rods 5/222 (1 pc) and 5/223 (2 pcs) may be replaced.

Rumbling
A deep rumbling sound can indicate that the main bearings 4/212 and 4/217 are worn. Check the crankshaft wear by pulling the shaft from side to side. No movement should be detectable.

Doc. Ref: Revision:

OM134 E

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Models: Authorised:

GP 15, HICOM 15

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Part Lists
ITEM 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 PART NUMBER 3925 161901 165851 074047 076333 094471 080764 138703 001384 094447 073466 039942 153818 157732 162027 162024 002224 125407 162235 160530 82856 150015 096164 156531 095699 001104 071145 160363 108758 001074 088668 001082 96172 030880 138835 161874 125997 001180 030872 148784 161876 GP15 Compressor Parts list DESCRIPTION Compressor unit complete Crankcase Bearing cover O-ring 180 x 3 Screw M12 x 45 5.8 DIN 835 Tight disc D12 Nut M12 DIN 934 Pump cover Screw M 6 x 30 8.8 DIN 912 Tight disc D 6 O-ring 71 x 2 Needle bearing AS 3047 Guard ring 47 x 1.75 Needle bearing AS 6085 Guard ring 85 x 3 DIN 472 Oil sight glass SP100 Screw M 5 x 25 8.8 DIN 931 Tight disc D 5 Extension R 1" x 100 1 Non-return valve 1/4" Fitting WH 8 LR 1/4" A2A Valve housing Pressure spring Valve cone Adjusting screw Screw R 1/2" 5.8 DIN 908 Cut ring DKAZ O-ring 24 x 2.5 O-ring 14 x 2 Screw R1/8" 5.8 DIN 906 Screw R1/4" 5.8 DIN 906 Screw R3/8" 4.8 DIN 906 Screw M 20 x 1.5 DIN 910 Gasket ring 20.7 x 28 x 1.5 Strainer Gasket ring 34.3 x 42 x 2 Extension 1/2 x 50 screw R1/2" DIN 910 Gasket ring 21.5 x 28.7 x 2.5 Valve spindle cpl. Gasket ring 17.4 x 24 x 1.5 QTY 1 1 1 1 4 24 16 1 4 4 1 1 1 1 1 1 6 6 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1

Doc. Ref: Revision:

OM134 E

DC0: Issued:

2239 08/04/04

Models: Authorised:

GP 15, HICOM 15

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OPERATING INSTRUCTIONS
GP15 Compressor Parts list DESCRIPTION Compressor unit complete 8 Fitting WE 4-LLR Tube 4.0 x 0.5 DIN 2391 Insert sleeve E8/5 Screw M 12 x 30 5.8 DIN 835 Screw M 6 x 20 8.8 DIN 835 Blind plug GPN 300 F 18 Type plate 86 x 10 Notched pin 2 x 4 DIN 1476 Cylinder D 90 O-ring 100 x 2 Cylinder gasket D 92 Lamella valve cpl. 415 SFV Cylinder head gasket LV 415 SFV Cylinder head Screw M 12 x 100 8.8 DIN 912 Fitting SWVE 8-LLR Fitting EVW 15-LR Cylinder guidage Screw M 10 x 25 5.9 DIN 939 Nut M 10 DIN 934 Tight disc D 10 O-ring 70 x 2 Cylinder 2nd stage Cylinder gasket D 38 Lamella valve cpl. 111 LV SFV Cylinder head Gasket, 2nd Stage Cylinder head 2nd stage Screw M 8 x 75 DIN 912 Tight disc D 8 Fitting SWVE 12 LR 3/8" A2A Blind plug GPN 300 F 12 Holder for cooling tube 3rd stage Cylinder 3 stage Fitting LE 6-LR Nozzle D0, 4/MB Gasket ring 33 x 40 x 1 AL Cylinder head Screw M 12 x 70 12.9 DIN 912 Cylinder cover Cylinder cover

ITEM 142 143 145 146 147 148 149 150 155 156 157 158 159 160 161 164 165 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192

PART NUMBER 3925 07054 150037 010154 139491 004103 008613 008257 005398 162539 162032 162720 159253 147133 163618 001902 162550 162176 161922 004286 080772 094463 073440 161919 161559 162003 161560 161920 172364 094455 148733 008591 162232 161923 176665 064785 029416 162553 162710 102377 082783

QTY 1 2 0.2 2 12 6 1 1 4 1 3 1 1 1 1 4 1 2 2 12 12 12 2 1 1 1 1 1 4 12 2 1 2 1 1 1 1 1 4 1 1

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OPERATING INSTRUCTIONS
GP15 Compressor Parts list DESCRIPTION Compressor unit complete Screw M 8 x 20 8.8 DIN 912 Suction valve 9 A NR 22 Gasket ring 14.2 x 19 x 0.5 CU Gasket ring 12 x 19 x 0.5 CU Pressure valve 9 A NR 23 Gasket ring 11.2 x 19 x 0.5 CU Fitting SWVE 8 SR 1/4" A2A Screw R 1/8" 5.8 DIN 906 Fitting BUZ 6-L Crankshaft cpl. Screw M 8 x 30 8.8 DIN 912 Tight disc D 8 disc Retainer DG 22 x 35 7S Oil pump NR 320558-155 Cylinder roller bearing NI 2207 Adjusting spring A6 x 6 x 22 Adjusting spring B 5 x 5 x 5 Screw R 1/8" 5.8 DIN 906 Bushing for motor shaft 0.38 Roller bearing NJ 211 Retainer A 55 x 80 x 10 Screw R 1/4" 5.8 DIN 960 Connecting rod cpl. 1st stage Connecting rod cpl. 2nd & 3rd stage Piston 90 AL Piston 33/70 AL Piston 16/70 4th stage

ITEM 193 194 195 196 197 198 199 200 201 206 207 208 209 210 211 212 213 214 215 216 217 218 219 222 223 224 225 226

PART NUMBER 3925 001481 038571 028223 028240 038580 28231 102725 001074 106844 166342 001511 094455 089893 139475 139416 139394 139459 139467 001074 156639 162034 162036 088668 62554 162021 162561 162022 162023

QTY 1 8 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1

Doc. Ref: Revision:

OM134 E

DC0: Issued:

2239 08/04/04

Models: Authorised:

GP 15, HICOM 15

Page 19 of 40

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OPERATING INSTRUCTIONS
GP15 Compressor Parts list DESCRIPTION Compressor block comprising of: Intermediate flange Screw M 12 C15 580 Screw M 12 x 30 5.8 DIN 835 Screw M 12 x 40 8.8 DIN 6912 Spring ring 12 DIN 7980 Nut M 12 DIN 934 Tight disc D 12 Suction filter AB 31 Connecting piece Nave for fan wheel Fan plate type E 189 Screw M 6 x 25 8.8 DIN 912 tight disc D 6 Tube 15.0 x 1.5 DIN 1754 Tube 12.0 x 1.5 DIN 1754 Tube 8.0 x 2.0 DIN 1754 Fitting VSH 15 x 1.5 MS Holder for cooling tube Holder for cooling tube Nut M 6 DIN 934 Tight disc D 6 Mounting bracket D 15/12 Mounting bracket D12/122 Mounting bracket D 8/12 Screw M 5 x 10 8.8 DIN 912 Screw M 5 x 12 8.8 DIN 912 Screw M 5 x 10 8.8 DN 933 Tight disc D 5 Nut M 5 DIN 934 Fitting G 12-L Fitting G 8-S Disc 5.3 DIN 9021 Connecting piece O-ring 12 x 2 Screw M 5 x 60 5.8 DIN 84 Pressure switch 0180 SUCO Gasket ring 14.7 x 22 x 1.5 Gasket ring 10.35 x 16 x 2 Reducing socket R1/8 A x 1/4 I Gasket ring 1/4 CU Pressure gauge 63D 0-10

ITEM 501 502 503 504 505 506 507 510 511 512 513 514 515 516 517 518 519 520 521 522 523 524 525 526 527 528 529 530 531 532 533 534 541 542 543 544 545 546 547 548 549

PART NUMBER 178186 162219 143456 139491 162711 007030 080764 094471 039420 162490 161902 163602 001368 094447 162043 025003 081992 162044 161903 161904 005541 094447 162041 126225 083054 171333 150223 002194 125407 005533 069256 103829 172545 62057 072745 000230 162059 161875 162031 106860 026760 038997

QTY 1 1 1 4 4 4 4 4 1 1 1 6 6 6 5 4.5 6 2 3 3 6 6 9 13 13 9 12 5 27 2 2 2 3 1 1 4 1 1 1 1 1 1

Doc. Ref: Revision:

OM134 E

DC0: Issued:

2239 08/04/04

Models: Authorised:

GP 15, HICOM 15

Page 20 of 40

GPS15, HICOM15 GAS PREPARATION EQUIPMENT

OPERATING INSTRUCTIONS
GP15 Compressor Parts list DESCRIPTION Compressor block comprising of: Tube 6.0 x .5 DI N2391 Non-return valve RHV 6-LR Plate oil pressure Notched pin 2 x 4 DIN 1476 Foot for compressor Silent block D 50 x 40 40Sh crew M 10 x 16 8.8 DIN 933 Screw M 10 x 24 8.8 DIN 933 Nut M 10 DIN 934 Tight disc D 10 Hood for fan wheel Plate rise Notched pin 2 x 4 DIN 1476 Separator block naked Screw M 8 x 20 5.8 DIN 835 Tight disc D 8 Nut M 8 DIN 934 Screw M 5 x 10 8.8 DIN 933 Gasket ring 5.5 x 8 CU 7603 Pressure gauge 63D 0-25 Pressure gauge 63D 0-100 Pressure gauge 63D 0-400 Gasket ring 10 x 13.5 x 2 CU Reducing socket R1/8 A x Gasket ring 1/4 CU Fitting SWVE 6-LR Tube 6.0 x 1.5 DIN 1754 Fitting GE 12-LR Fitting SWVE 12 LR 3/8" A2A Fitting EVW 8-SR Fitting GE 18-LR

ITEM 550 551 552 553 556 557 558 559 560 561 562 563 564 567 568 569 570 571 572 573 574 575 576 577 578 579 580 581 582 583 584

PART NUMBER 178186 016829 162025 008265 005398 162221 -77976 02607 002623 080772 094463 161905 008311 005398 162207 004391 094455 005550 002194 096814 039080 039055 039012 175110 06860 026760 093270 024953 069493 148733 069027 069574

QTY 1 1 1 1 2 1 3 3 4 4 7 1 1 2 1 6 6 6 2 2 1 1 1 2 I2 2 1 1 1 1 1 1

Doc. Ref: Revision:

OM134 E

DC0: Issued:

2239 08/04/04

Models: Authorised:

GP 15, HICOM 15

Page 21 of 40

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OPERATING INSTRUCTIONS
GP15 Compressor Parts list DESCRIPTION Other items including: Piston ring NM 90 x 82.4 x 2 Piston ring M 90 x 82.4 x 2 Piston ring G 90 x 82.4 x 4 Piston ring M 33 x 2 Piston ring M 16 x 2 Fan wheel cpl. - counterclockwise operation Screw R 3/8" DIN 906 Discharge valve cpl. Discharge valve seat Gasket ring 16 x 10 x 1.5 USIT Discharge valve housing Gasket ring A 10 x 10.5 DIN 7603 Screw R 1/8" DIN 910 Pressure spring Lip sealing ring 16 x 10 x 5 x 4.5 Discharge valve piston Lip sealing ring 32 x 24 x 7x 6 P32 Cover gasket Housing cover Screw M 5 x 30 DIN 931 O-ring 10 x 3 Gasket Screw R 3/8" Screw M 6 x 50 DIN 931 Ball dia 12 polyamid Connecting piece Fitting EVT 6-SR1 Tight disc dia 6 Fitting GE 6-SR Fitting ring RI 3/8" x 1/8" Fitting GE 6-LR Nozzle dia 2.0 Fitting SWVE 6-LR Discharge valve cpl. Screw R1/2" DIN 910 Gasket ring A 21 x 26 DIN 7603 Discharge valve housing Discharge valve piston Lip sealing ring 25 x 15 x 5 x 4.5 P32 Cover gasket Housing cover

ITEM 801 802 803 804 805 807 808 809 810 811 812 813 814 815 816 817 818 819 820 821 822 823 824 825 826 827 828 829 830 831 832 833 834 835 836 837 838 839 840 841 842

PART NUMBER 1681 59711 159712 62547 42935 163603 001082 162215 064254 030848 162206 027782 125130 037397 071382 29933 96210 096679 096660 096628 072737 39505 162062 02372 071242 162061 068870 094447 069396 137839 069388 096768 093270 163733 125121 027871 096717 062251 071439 029505 062081

QTY 1 2 1 5 8 1 1 1 3 3 1 3 3 1 3 1 1 1 1 4 5 1 1 4 1 1 1 4 1 1 4 3 1 1 2 2 2 1 2 2 2

Doc. Ref: Revision:

OM134 E

DC0: Issued:

2239 08/04/04

Models: Authorised:

GP 15, HICOM 15

Page 22 of 40

GPS15, HICOM15 GAS PREPARATION EQUIPMENT

OPERATING INSTRUCTIONS
GP15 Compressor Parts list DESCRIPTION Other items including: Screw M 6 x 30 DIN 933 Discharge valve piston Discharge valve cpl. Piston cpl. Piston cpl. Piston cpl. Fitting MAV-EV 6-LR Discharge valve cpl. Discharge valve cpl. Tube socket R 3/8 x 12 Fitting GE 12-L/R Non-return valve R 2/2-way solenoid valve 220V 50 Hz Socket module time tapper Fitting evW 12-L Fitting evL 12-L Reducing socket L 12-6 Connecting piece Fitting EVT 6-LR Gasket ring A 14 x 18 DUB 7603 Screw R 1/4 DIN 910 Gasket ring 10 x 13.5 x 2 CU Reducing socket 1/8 a x 1/4 I Gasket ring 1/4 CU Nozzle dia 1.5 Nozzle dia 1.00 Screw M 5 x 10 DIN 933 Gasket ring 5.5 x 8 DIN 7603 Fitting GE 12-LR Screw R 1/8 DIN 910 Gasket ring 10.35 x 16 x 2 USIT Filter cartridge Pressure maintaining non-return valve Pressure maintaining valve Non-return RHD 12-S Non-return valve 503990 Fitting SWVE 8 S Fitting EVW 8-SR Reducing socket S 12-8 Fitting EVW 12-S Holder

ITEM 843 844 845 846 847 848 849 850 851 852 853 854 855 856 857 858 859 860 861 862 863 864 865 866 867 868 869 870 871 872 873 874 875 876 877 878 879 880 881 882 883

PART NUMBER 002330 062219 096709 177258 177259 177257 119296 163736 096423 067997 163287 191997 171527 163286 069078 068713 069990 163033 068861 027820 001155 175110 106860 026760 163295 162394 002194 096814 69493 001147 162031 39160 158883 33480 108251 173484 102725 119288 070017 069060 162214

QTY 8 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Doc. Ref: Revision:

OM134 E

DC0: Issued:

2239 08/04/04

Models: Authorised:

GP 15, HICOM 15

Page 23 of 40

GPS15, HICOM15 GAS PREPARATION EQUIPMENT

OPERATING INSTRUCTIONS
GP15 Compressor Parts list DESCRIPTION Other items including: O-ring 58 x 4 Safety valve 11 Bar Safety valve 70 Bar Safety valve 270 Bar Safety valve 365 Bar Pressure switch 11 Bar Pressure switch 70 Bar Pressure switch 270 Bar Pressure switch 365 Bar Gasket ring 14 x 18.7 x 1.5 USIT Gasket ring 21.4 x 28.7 x 2.5 USIT Fitting GE 12-L/R Fitting evW 12-L Tube socket R 1/4 x 12 Fitting GE 12-L/R Thermostat Heating cartridge Gasket ring 20.7 x 28 x 1.5 USIT Combistat Micro filter element Connecting piece Silencer KUNSTSTOFF tank 5 l Silencer S.2/N Tecalan tube 6/3,15 Filter Filter set (A + C + 2 x B) O-ring 51 x 2.5 Support ring O-ring 14 x 2 Gasket ring 21.5 x 28.7 x 2.5 USIT Safety valve 330 Bar Measuring connection EMA 3/R Pressure maintaining valve Pressure gauge 0-400 Bar Ventilation connection Fill-up valve 200 Bar Fill-up valve 300 Bar Change-over valve Safety valve 240 Bar Pressure switch 220 Bar Pressure switch 320 Bar Pressure gauge 100D 0-400 Bar Thrust socket Non-return valve RHV 8-SR

ITEM 885 886 887 888 889 890 891 892 893 894 895 896 897 898 899 901 902 903 904 950 951 952 953 954 955 957 958 959 960 961 962 963 964 966 967 968 971 972 973 974 975 976 977 978 979

PART NUMBER 139050 034223 169524 168797 168813 161572-11 161574-70 161575-270 161576-365 166401 030872 082970 069078 155772 082988 103470 142514 030880 162608 163140 163130 143774 087980 039330 032735 175372 170109 173592 174204 108758 030872 168815 169621 033480 039012 178364 163395 163394 112194 68816 163941-220 163941-320 103900 170113 169797

QTY 2 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 1 2 2 1 1 1 2 1 4 4 2 1 1 1 1 1 1 2 2 1 1 1 1 1 4 1

Doc. Ref: Revision:

OM134 E

DC0: Issued:

2239 08/04/04

Models: Authorised:

GP 15, HICOM 15

Page 24 of 40

GPS15, HICOM15 GAS PREPARATION EQUIPMENT

OPERATING INSTRUCTIONS

FIGURE REF 1
2 3 4 5 6 7 8 9 10 11 12 13 15 16

DETAILS Main View Crankcase Crankcase & Motor coupling Crankshaft Pistons and connecting Rods 1st Stage Cylinder Line 2nd Stage Cylinder Line 3rd Stage Cylinder Line Coolers Coolers Coolers Fan and guard Unloaders Other Parts Safety Valves

MANUAL PAGE 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

Doc. Ref: Revision:

OM134 E

DC0: Issued:

2239 08/04/04

Models: Authorised:

GP 15, HICOM 15

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OPERATING INSTRUCTIONS

Diagrams
Fig 1
Compressor Unit Complete

Doc. Ref: Revision:

OM134 E

DC0: Issued:

2239 08/04/04

Models: Authorised:

GP 15, HICOM 15

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OPERATING INSTRUCTIONS
Fig 2
Crankcase

Doc. Ref: Revision:

OM134 E

DC0: Issued:

2239 08/04/04

Models: Authorised:

GP 15, HICOM 15

Page 27 of 40

GPS15, HICOM15 GAS PREPARATION EQUIPMENT

OPERATING INSTRUCTIONS
Fig 3
Crankcase and Motor Coupling

Doc. Ref: Revision:

OM134 E

DC0: Issued:

2239 08/04/04

Models: Authorised:

GP 15, HICOM 15

Page 28 of 40

GPS15, HICOM15 GAS PREPARATION EQUIPMENT

OPERATING INSTRUCTIONS
Fig 4
Crankshaft

Doc. Ref: Revision:

OM134 E

DC0: Issued:

2239 08/04/04

Models: Authorised:

GP 15, HICOM 15

Page 29 of 40

GPS15, HICOM15 GAS PREPARATION EQUIPMENT

OPERATING INSTRUCTIONS
Fig 5
Pistons and connecting Rods

Doc. Ref: Revision:

OM134 E

DC0: Issued:

2239 08/04/04

Models: Authorised:

GP 15, HICOM 15

Page 30 of 40

GPS15, HICOM15 GAS PREPARATION EQUIPMENT

OPERATING INSTRUCTIONS
Fig 6
1 Stage Cylinder Head
st

Doc. Ref: Revision:

OM134 E

DC0: Issued:

2239 08/04/04

Models: Authorised:

GP 15, HICOM 15

Page 31 of 40

GPS15, HICOM15 GAS PREPARATION EQUIPMENT

OPERATING INSTRUCTIONS
Fig 7
2
nd

Stage Cylinder Head

Doc. Ref: Revision:

OM134 E

DC0: Issued:

2239 08/04/04

Models: Authorised:

GP 15, HICOM 15

Page 32 of 40

GPS15, HICOM15 GAS PREPARATION EQUIPMENT

OPERATING INSTRUCTIONS
Fig 8
3 Stage Cylinder Head
rd

Doc. Ref: Revision:

OM134 E

DC0: Issued:

2239 08/04/04

Models: Authorised:

GP 15, HICOM 15

Page 33 of 40

GPS15, HICOM15 GAS PREPARATION EQUIPMENT

OPERATING INSTRUCTIONS
Fig 9
Coolers

Doc. Ref: Revision:

OM134 E

DC0: Issued:

2239 08/04/04

Models: Authorised:

GP 15, HICOM 15

Page 34 of 40

GPS15, HICOM15 GAS PREPARATION EQUIPMENT

OPERATING INSTRUCTIONS
Fig 10
Coolers

Doc. Ref: Revision:

OM134 E

DC0: Issued:

2239 08/04/04

Models: Authorised:

GP 15, HICOM 15

Page 35 of 40

GPS15, HICOM15 GAS PREPARATION EQUIPMENT

OPERATING INSTRUCTIONS
Fig 11
Coolers

Doc. Ref: Revision:

OM134 E

DC0: Issued:

2239 08/04/04

Models: Authorised:

GP 15, HICOM 15

Page 36 of 40

GPS15, HICOM15 GAS PREPARATION EQUIPMENT

OPERATING INSTRUCTIONS
Fig 12
Fan and Guard

Doc. Ref: Revision:

OM134 E

DC0: Issued:

2239 08/04/04

Models: Authorised:

GP 15, HICOM 15

Page 37 of 40

GPS15, HICOM15 GAS PREPARATION EQUIPMENT

OPERATING INSTRUCTIONS
Fig 13
Unloaders

Doc. Ref: Revision:

OM134 E

DC0: Issued:

2239 08/04/04

Models: Authorised:

GP 15, HICOM 15

Page 38 of 40

GPS15, HICOM15 GAS PREPARATION EQUIPMENT

OPERATING INSTRUCTIONS
Fig 15
Other Parts

Doc. Ref: Revision:

OM134 E

DC0: Issued:

2239 08/04/04

Models: Authorised:

GP 15, HICOM 15

Page 39 of 40

GPS15, HICOM15 GAS PREPARATION EQUIPMENT

OPERATING INSTRUCTIONS
Fig 16
Safety Valves

Stage

889

Stage

887

Stage

886

Doc. Ref: Revision:

OM134 E

DC0: Issued:

2239 08/04/04

Models: Authorised:

GP 15, HICOM 15

Page 40 of 40