SECTION 7

MAINTENANCE

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7.1 GENERAL COMMENTS

The compressor is designed to give long periods of trouble free operation with the minimum of
maintenance. A yearly inspection is recommended for all Howden Compressor installations. Some
installations may require an annual statutory insurance survey.

The purpose of the yearly inspection survey is to check if there is any significant wear of the thrust
bearings, slide valve guide block or PTFE seals and, if any wear is found, for these components to
be renewed.

Where axial movement condition monitoring equipment is fitted to the compressor, a continuous
indication of the thrust bearing condition is monitored and the bearing check can be extended to
once every two years.

It is not anticipated, however, that a major overhaul will be required until approximately after four
years operation. After this time the thrust bearings must be renewed.

When the compressor is being inspected or overhauled it must be dismantled in a clean area.

The inspection overhaul procedure is different between the WRV163 & WRV204 compressors and
the, WRVi255, WRVi321 & WRVi365 compressors due to construction variations. Please ensure
that the correct procedure is used for the size of compressor involved.

Always refer to the sectional and external arrangement drawings.

All fasteners should be torqued to the value specified as stated under Torque Specifications in
Section 9.1 using appropriate torque wrenches.

All lockwashers, tabwashers, ‘O’ rings and PTFE seals must be renewed on assembly. Section 9.2
describes lockwasher assembly procedure.

Special tools to ease dismantling and re-assembly can be provided, as listed in Section 9.3. Details
of these can be obtained from the Compressor Business Unit, Howden Compressors. Section 10
details all Part Numbers of normally replaceable components.

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7.2 PREPARATION FOR ANNUAL INSPECTION

Before dismantling the compressor, certain precautions should be taken in the interests of safety:

1. Isolate the drive unit.

2. Depressurise and purge the system.

3. Disconnect the drive unit coupling from the compressor.

4. Place a receptacle under the outlet end of the compressor to catch any oil which may drip
from the hydraulic cylinder when the cylinder cover is removed or when the outlet end cover
is removed.

5. Ensure all lifting equipment, ie, eye bolts, slings, and shackles are safe and serviceable.

To enable a check to be made of floats and condition of seals and guide block on the compressor
during annual maintenance, a certain amount of dismantling is required. This differs slightly between
the 163 compressor and the 204, 255, 321 & 365 compressors.

7.3 DISMANTLING PROCEDURE FOR ANNUAL INSPECTION

Commence at discharge end with the Hydraulic Actuator

No matter which size compressor is involved, extract the 3 off cap screws holding the Aluminium
cover to the cylinder cover, if fitted, and remove. Extract the cap screws securing the Cylinder Cover
to the Hydraulic Cylinder and remove the cover, including the limit switches and indicator spindle
which are attached to it (Fig. 2).

NOTE: Some compressors will have a LPI sensor fitted as an option instead of switches, and will
not have the cylinder switch cover fitted.

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7.3 DISMANTLING PROCEDURE FOR ANNUAL INSPECTION (Continued)

Fig. 2

Fig. 3

NOTE: The indicator spindle has to clear a dowel pin which moves along the spiral groove in the
spindle, therefore this cover must be kept in an axial position when withdrawing until the spindle
clears the dowel pin (Fig 3). The LPI Sensor is housed inside a sensor well attached to the cover
and this must also be removed axially.

IMPORTANT: It is essential that the spiral groove engaging the dowel pin is marked for correct re-
assembly to avoid damage to the potentiometer.

Move the slide valve to bring the actuator piston to the outer end of the cylinder. Do not move the
slide valve past its minimum position at the capacity stop as it may come off the guide block at the
inlet end of the compressor when unlocking the piston lockwasher and locknut.

Fig. 4 Fig. 5

Unlock the piston lockwasher and locknut and remove (Fig. 4).
Remove the actuator stop sleeve, if fitted, from the cylinder bore (Fig. 5).
Withdraw the piston (Fig. 6) using the appropriate tool listed for the compressor size. See Section
9.3.

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7.3 DISMANTLING PROCEDURE FOR ANNUAL INSPECTION (Continued)

Removing the Combined Outlet Cover/Cylinder 163 Compressor

Fit an eyebolt to the tapped hole at the top of the outlet cover, attach a sling to the eyebolt to support
the weight of the cover (Fig. 7).

Fig. 6 Fig. 7

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7.3 DISMANTLING PROCEDURE FOR ANNUAL INSPECTION (Continued)

Extract the set pins securing the discharge cover to the main casing body. (Fig. 8) Push the piston
rod to the bottom of the cylinder.

Carefully draw the cover clear of the piston rod/valve spindle. Care should be taken to prevent
damage to the actuator cylinder which is part of the cover.

At this stage, the slide valve can be withdrawn from the compressor for a visual inspection. (Fig. 9)

Fig. 8 Fig. 9

A light shone from the slide valve bore will permit a visual inspection of the rotors. (Fig. 10-11)

Fig. 10 Fig. 11

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7.3 DISMANTLING PROCEDURE FOR ANNUAL INSPECTION (Continued)

Removing the Cylinder and End Cover WRV204, WRVi255, WRVi321 & WRVi365 Compressors

The hydraulic cylinder and end cover are separate items in the above compressor and are removed
as follows:

Removing the Hydraulic Cylinder

Extract the cap screws or setscrews securing the cylinder to the end cover (Fig. 12). Support the
cylinder with a sling and using the jacking holes provided in the cylinder flange, jack out the cylinder
(Fig. 13).

Fig. 12 Fig. 13

Removing the End Cover

Extract most of the set pins securing the outlet end cover to the main casing (Fig. 14).

Fig. 14

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7.3 DISMANTLING PROCEDURE FOR ANNUAL INSPECTION (Continued)

Fit an eye bolt to the top of the outlet cover flange and use suitable lifting equipment to support the
weight of the cover (Fig. 15).
Remove the set pins locating the cover to the main casing and remove the cover.

Fig. 15 Fig. 16

Take care to avoid damage to the piston rod/valve spindle (Fig. 16).

Removing the Slide Valve

Withdraw the slide valve using suitable lifting equipment to support the weight of the valve,
especially on WRVi255, WRVi321, & WRVi365 compressors (Fig. 17).

Fig. 17

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7.3 DISMANTLING PROCEDURE FOR ANNUAL INSPECTION (Continued)

Now that the slide valve has been removed by shining a light from the valve bore, a visual inspection
of the rotors can be achieved (Figs. 18 - 19).

Fig. 18 Fig. 19

PTFE Seals.
The compressor has now been dismantled enough to permit the inspection and replacement of the
PTFE seals and ‘O’ rings in the actuator cylinder, (Fig. 20) also the piston, should they be required
(Fig. 21).

Fig 20 Fig 21

Fig. 20 Fig. 21

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7.4 CHECKING CLEARANCES

Guide Block

The guide block which locates the slide valve should also be checked for wear every 30,000 hours or
every 4 years whichever comes first. See Fig. 22 and relative table for dimensions.

Guide Block to Slide Valve Slot

Compressor Size
Fig. 22 by Dimension ‘W’ Clearance
Rotor Diameter
163 mm 24.987/24.975 mm 0.046/0.013 mm
(0.984”/0.9833”) (0.0018”/0.005”)
204mm 29.987/29.975 mm 0.046/0.013 mm
(1.181”/1.180”) (0.0018”/0.005”)
255mm 41.262/41.250 mm 0.050/0.013 mm
(1.625”/1.624”) (0.002”/0.005”)
321mm 44.990/44.965 mm 0.060/0.010mm
(1.771”/1.770”) (0.0024”/0.004”)

365mm 49.991/49.965mm 0.065/0.009mm

(0.0025”/0.004”)

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7.4 CHECKING CLEARANCES (Continued)

To check the Thrust Bearing Float

To check the thrust bearing float, set a dial indicator up axially on the shaft end. Access must be
gained to the inlet end of the female rotor by removing the rotor cover. Push or pull the rotor, to its
limit in either direction.

Record the indicator reading and then push or pull the rotor to its limit in the opposite direction. The
difference in indicator readings is the thrust bearing axial float. This procedure must be followed for
both male and female rotors. This reading should not exceed 0.025mm (0.001”). Any increase over
this reading will necessitate replacement of the thrust bearings. The thrust bearings are fitted with a
small pre-load, the maximum float permitted is 0.025mm (0.001”). If in excess of this the bearings
must be changed.

NOTE: Should the thrust bearing float be within limits, no further work on the rotors is
recommended, i.e. journal bearing clearances would not necessarily be measured.
Any increase on this figure will necessitate replacement of the thrust bearings, the procedure for
which is described per Section 8.2-8.3 or 8.4-8.5.

Maximum Thrust Bearing Float

Please note that due to a change in bearing

selection, which now means that bearings are fitted
with a pre-load condition, the maximum float
permitted is 0.025mm (0.001”) regardless of
compressor size.

Fig. 23

NOTES:

It is extremely important that the fasteners on the thrust bearing retaining plates of the WRV163 and
WRV204 compressors are torqued exactly to the specified setting of 14Nm. Over-torquing will not
permit correct operation of the thrust bearing, resulting in premature failure.

Should the thrust bearing float be within limits, no further work on the rotors is recommended, ie,
journal bearing clearances would not necessarily be measured. Where the thrust bearing float is
outside limits and, therefore, the thrust bearings have to be slackened off and removed, the
opportunity would then be taken to measure journal bearing condition, and proceed as for major
overhaul.

Where a compressor is fitted with condition monitoring, no check on the thrust bearings will be
required. See Section 7.1. A 4 yearly check on the guide block wear, and an annual check on the
PTFE seal condition is all that is necessary.

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7.5 RE-ASSEMBLY AFTER ANNUAL INSPECTION

When all checks and corrections have been made, and assuming no major problems have
developed, the compressor can be re-assembled. (Refer to the Sectional Arrangement drawing
supplied and torque specifications as advised under Section 9.1)

WRV163 Compressor

Ensure the guide block is in position in the slide valve bore, insert the slide valve and push it all the
way to the ‘on load’ position (Fig. 24).
Insert an eyebolt into the outlet end cover flange and with the aid of suitable lifting equipment re-
assemble the outlet end cover/hydraulic cylinder (Fig. 25).
Secure with set pins to the main casing. Remove the lifting sling and eyebolt.

Fig. 24 Fig. 25

Refit the piston into place in the hydraulic cylinder. Secure with new lockwasher and locknut (Fig.
26). Replace the actuator stop sleeve. Fit the cylinder end cover, taking care to ensure the dowel is
properly located in the spiral groove of the indicator spindle (Fig. 27).

Fig. 26 Fig. 27

Secure the cover with cap screws. Ensure the limit switches are in position securely fastened,
assemble the limit switch cover, if fitted, and secure with cap screws.

For compressors fitted with LPI sensors, refit the cylinder end cover and secure the cover with
capscrews. Refit and secure the LPI sensor.

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7.5 REASSEMBLY PROCEDURE FOR ANNUAL INSPECTION (Continued)

WRV204, WRVi255, WRVi321 & WRVi365

Ensure the guide block is in position in the slide valve bore, insert the slide valve and push it all the
way to the on load position (Fig. 28).
Insert an eyebolt into the outlet end cover flange and with the aid of suitable lifting equipment re-
assemble the outlet end cover and secure (Fig. 29).

Fig. 28

Fig. 29

Attach a sling to the hydraulic cylinder, re-assemble to the outlet end cover and secure with cap
screws (Fig. 30).

Refit the piston into place in the hydraulic cylinder. Secure with new lockwasher and locknut (Fig.
31). Replace the actuator stop sleeve. Fit the cylinder end cover taking care to ensure the dowel is
properly located in the spiral groove of the indicator spindle (Fig. 32).

Fig. 31

Fig. 30 Fig. 32

Secure the cover with cap screws. Ensure the limit switches are in position securely fastened,
assemble the limit switch cover, if fitted, and secure with cap screws.

For compressors fitted with LPI sensors, refit the cylinder end cover and secure the cover with
capscrews. Refit and secure the LPI sensor.

31