Service Manual XW150 - Version02

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

 Green and clean – no oil mist to the environment  25% fewer wear parts – 50% more reliable
 A new level of control  Best cooling efficiency in the market
 Easy to learn – one common platform  Low vibration level – high grade of isolation
 Less installation time – no special alignment  Improved standard scope of supply
Sperre has developed a unique chain of value, that‟s what it takes to produce reliable compressors that function smoothly for the
life of the ship.
Sperre congratulates you on your choice of compressor!
Mareno K. Nakken
Technical Director
www.sperre.com Service Manual XW150 Version 02 3

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

3.1 Service schedule .......................................................................................................... 9
3.2 Service Warnings: ....................................................................................................... 10
3.3 Service Alarms: .......................................................................................................... 11
3.4 Service procedures overview ...................................................................................... 13
3.5 Kit overview ................................................................................................................ 14
3.6 Recommended kits and special tools .......................................................................... 16
3.7 Ordering parts and kits................................................................................................ 29
4 Service procedures .............................................................................. 30

4.1 Cover.......................................................................................................................... 30
4.2 Lubricating oil ............................................................................................................. 31
4.3 Air filter ....................................................................................................................... 33
4.4 Safety valves LP and HP ............................................................................................ 34
4.5 Air cooler LP ............................................................................................................... 35
4.6 Air cooler HP .............................................................................................................. 36
4.7 Valve LP ..................................................................................................................... 37
4.8 Valve HP .................................................................................................................... 39
4.9 Cylinder LP ................................................................................................................. 41
4.10 Cylinder HP ................................................................................................................ 42
4.11 Piston, rings and gudgeon bearing LP ......................................................................... 43
4.12 Piston, rings and gudgeon bearing HP ........................................................................ 44
4.13 Bearing fan side.......................................................................................................... 45
4.14 Bearing crank ............................................................................................................. 46
4.15 Electric motor and vibration isolators ........................................................................... 47
4.16 Coupling and sealing flange ........................................................................................ 48
4.17 Crank shaft and bearing motor side............................................................................. 49
4.18 Cyclone separator and non return valve ...................................................................... 50
4.19 Drain/unload valve HP ................................................................................................ 52
4.20 Electrical components ................................................................................................. 53
5 X-range data ......................................................................................... 55

5.1 Torque tables.............................................................................................................. 55

1 Introduction
1.1 Purpose
Sperre has produced this manual to provide information for all users of the compressor
equipment. This includes information about the compressor‟s construction and Note
operation, as well as basic information regarding inspection and maintenance.
Please note that all pictures and
It is important that operators familiarize themselves with the contents of this instruction drawings in this manual are for
manual, to ensure that use and maintenance work are carried out in the correct and illustration only.
safe manner from the outset.
The maintenance intervals and individual technical data are average values based on
experience, and may vary depending on the compressor‟s operational parameters.
The supplier accepts no responsibility for damage resulting from careless operation or
inadequate maintenance. Keep the compressor in good mechanical condition, and
remember that preventive maintenance of the equipment reduces the danger of damage
and unnecessary operational interruptions.
Sperre reserves the right to modify details without prior warning.
1.2 Annotations
All safety directions must be respected in order to avoid damage to personnel, the environment and equipment. In this manual the
annotations are used, as illustrated below:
Indicates possibilities for hazards or unsafe practices, which COULD result in fatal or
Warning severe personnel injuries or substantial product or property damage, if the required
precautions are not taken.
Draws attention to specific information of technical significance that might not be

Note obvious, or highlights important remarks in the procedures to follow.
1.3 Abbreviations
Abbreviation Description
Barg Unit of pressure (Barg = Bar gauge)
CFD Computerized Fluid Dynamics
CR Class Recommendation
CW Cooling Water
dBA Decibel
DOL Direct On Load
HP High Pressure
LP Low Pressure
IMO International Maritime Organization
ISC Internal System Control
MR Makers Recommendation
PMS Planned Maintenance System
RPM Revolutions Per Minute
XA X-range compressor Air-cooled
XW X-range compressor Water-cooled

1.4 Tags on the compressor
Danger Danger Caution

The compressor is remotely controlled Hazardous voltage Burn hazard
May start without warning Risk of electric shock Risk of hot surface
Before using or servicing the compressor The cover must always be on when To connect the signal cable, carefully
Read and understand the user manual running turn the plug to find the right insert point,
Without the cover the compressor will be then push carefully until a click appear
damaged after running even for a short To disconnect, pull the ring on the plug
period
The oil has been drained from the Compressor oil type. Level sight glass
compressor For oil reference, visit www.sperre.com Correct oil level should be in centre of
Do not start the compressor before the level sight glass
correct oil quantity has been added
Drain oil Delivery air outlet Unloading and drain high pressure
Unloading and drain low pressure Cooling water outlet Cooling water inlet
The lifting eye bolt is certified for lifting Rotation direction is counter clock wise,
the single compressor with el-motor only when looking at compressor front.
Compressor rating plate

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

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

3 Service and ordering
3.1 Service schedule
The following schedule is a guideline for normal service procedures. However, the
compressors operating conditions vary widely from installation to installation, based on Warning
climatic differences. It is very important to adapt the maintenance schedule to the
running conditions of the individual compressor.
Before any work is performed the
The X-control will automatically inform the operator when to run scheduled services electrical power must be turned off.
according to the manufacturers recommended service cycle and intervals. Please refer to chapter 2 for safety
instructions.
There are three main service routine types; each requires the use of the appropriate
service kit.
Indicated service interval in hours or years depending on which comes first.
Note
A Sperre takes no responsibility for
damage caused by use of non-original
parts.
B C B D B C B E
Note
Service procedure A is change of running in oil, and should always be performed 250 *Use access code 0100 to enter the
hours after first time start up. menus. When in menus access menu
“P04 SERVICE RESET” and then
Service procedures should be performed at 1500-hour intervals. Service procedures B, “RESET” to enter reset code.
C, D and E are to be performed in the order illustrated above.
Use the following six digit reset codes
After service E at 12000 hours proceed to service B and repeat the service procedures for service completion:
as shown. A = 000000
When a service is complete the service technician is required to enter the „six digit ID B = Sperre kit order number or 000000
code* for that service type. The controller will automatically increment to the next service C = Sperre kit order number or 000000
type using the recommended service interval for the type. D = Sperre kit order number or 000000
Please make sure that a complete gasket kit always is available. E = Sperre kit order number or 000000
Service Months Cycle:

When a service cycle counter begins (service cycle counter is 10), the date is noted and
a future date calculated and recorded in memory for each „date critical‟ service type (B,
C, D, C and E). If the actual calendar date (in accordance to the controller real time
clock) indicates that a service is due within 2 months, but the service cycle counter has
not reached the „service warning‟ hours yet the service cycle counter is automatically
increased to a count of SW hours prior to the service. This action will generate a „service
warning‟ for the service type. If the actual calendar date indicates that a service is now
due, but the service cycle counter has not reached the „service due alarm‟ hours yet the
service cycle counter is automatically increased to the service due hours. This action will
generate a „service due alarm‟ for the service type.
Service Hours Until Next service Due (User Menu P00 – Item HS):
The „Hours Until Next Service Due‟ User menu indication will be calculated from:
„next service hours due value‟ minus „current service cycle hours count‟
For example: if the service cycle hours counter is at 7250 hours the next service due will
be at 8000 hours; the „Service Hours Until Next Service Due‟ will show (8000 – 7250) =
750 Hours.

3.2 Service Warnings:
When a service warning appears on the display (SW)
A service warning will occur 200 running hours or 3 months prior to a service, providing a pre-warning enabling service arrangements,
and/or service kit parts, to be organized prior to the service becoming due. The yellow service LED- indicator will appear as slow-flash.
The Service Warning indication will alternate with the normal running display. The „Service Warning‟ code is also displayed in the „User
menu‟ active error list.
Service warning (pre-alarm):

When a service warning occurs the controller will display the “Service Warning”
indicating the service type [3], code [2] and contact details [1] for service arrangements.
5 secs WARNING 2
BAR
SW4824
SPERRE
Tel: +47 70 16 11 00
1 [email protected]
o WWW.SPERRE .COM
C
DEL TEMPERATURE 3 SERVICE 'B'
5 secs
1. Reset the service warning by pressing the reset button on the controller. The Note
service warnings will not occur again. This facility is intended to provide pre-warning
enabling service arrangements. The text line on the display will
2. Order the Sperre service kit. Please refer to “Service procedures overview” in the indicate the type of service.
compressor service manual for the service kit ordering number. Service A will only appear once,
throughout the life time of the
A Sperre service kit contains all necessary spare parts with the relevant step by step
compressor, and will only be indicated
service procedures.
with a service alarm.
When a „service warning‟ is generated no further service warnings for the service type will be generated. A service warning will only be
generated once prior to a service becoming due and a service alarm being generated. If a „Service Warning‟ has not been manually
reset and is still active when a „Service Alarm‟ is generated, the „Service Warning‟ is automatically reset.
Service ‘A’:
Service type „A‟ does not have a „Warning‟ indication. The controller will show an „Alarm‟ when the service cycle counter reaches 250
hours.
Service type „A‟ is a unique service type. When a service type „A‟ has been carried out once no future service type „A‟ alarms will be
generated. When the service cycle counter automatically resets to 0(zero), when it reaches 96000 hours, a service type „A‟ will not be
generated again; the next service due will be a service type „B‟. A Service type „A‟ normally occurs only once in the operational life of
the compressor.
Service Alarm Overlap:
If a „Service Alarm‟ indication is still active when a „Service Alarm‟ for the next service type due is generated, the service alarm will be
automatically reset and no data will be recorded for the service type.

Service warning codes
Service warning code Text displayed Failure Corrective action

SW4824 “SERVICE B” Pre-alarm, service B due soon Press the “reset” button. Order service kit.
Please refer to “Service procedure overview” in
the Service manual
SW4834 “SERVICE C” Pre-alarm, service C due soon Press the “reset” button. Order service kit.
the Service manual
SW4844 “SERVICE D” Pre-alarm, service D due soon Press the “reset” button. Order service kit.
the Service manual
SW4854 “SERVICE E” Pre-alarm, service E due soon Press the “reset” button. Order service kit.
the Service manual
3.3 Service Alarms:

When a service alarm appears on the display (SA)
A „Service Alarm‟ indication will occur when the „service interval‟ run hours counter reaches 0(zero) hours, or the service interval „time‟
expires (whichever occurs sooner). The yellow service LED-indicator will appear as fast-flash. The Service Alarm indication will
alternate with the normal running display. The „Service Alarm‟ code is also displayed in the „User menu‟ active error list.
Service alarm (service due now):

When a service alarm occurs the controller will display the “Service Alarm” indicating the
service type [3], code [2] and contact details [1] for service arrangements.
5 secs ALARM 2
BAR
! SA5824
SPERRE
Tel: +47 70 16 11 00
1 INDUSTRI@SPERRE .COM
o
C WWW.SPERRE .COM
DEL TEMPERATURE 3 SERVICE 'B'
5 secs
1. The service type displayed must be performed with the relevant Sperre service kit.
2. The Service alarm indication can be reset before the service is complete and the
“service interval reset procedure” has been carried out. In this case, the “Service
indicator” (yellow LED) will change to be illuminated continuously. 24 hours after the
alarm has been reset, the indicator will start flashing again and the screen will toggle
again. This goes on until the proper reset procedure has been carried out.

Service alarm codes
Service alarm code Text displayed Failure Corrective action

SA5814 “SERVICE A” Service hours countdown time expired Service A must be performed, refer to
“Service procedure overview” in the
Service manual
SA5824 “SERVICE B” Service hours countdown time expired Service B must be performed, refer to
Service manual
SA5834 “SERVICE C” Service hours countdown time expired Service C must be performed, refer to
Service manual
SA5844 “SERVICE D” Service hours countdown time expired Service D must be performed, refer to
Service manual
SA5854 “SERVICE E” Service hours countdown time expired Service E must be performed, refer to
Service manual
Service Alarm Reset
item# description units step min max default display
SR Service Reset --- --- {-----} RESET {-----} RESET
ST Edit previous service ID --- --- --- --- --- B
Service alarm reset procedure: Note

Using the menu navigation routine, select the „Service Reset‟ item (SR) of menu P04. A Service level „Access Code‟ is
If the item shows {-----}, there is no service alarm reset procedure necessary or even required to access this menu. The
available. When a valid service alarm is active, the item will show “RESET” and allow to service alarm reset item will be locked
push the enter button. until a „Service Alarm‟ is active.
The controller will than start the reset procedure, which applies to all service types:
The display will request the „six digit ID code‟ for the service type:
1. Service Type
2. Indication of current and next service
3. Six digit ID code entry
The first code character will flash; press UP or DOWN to adjust to the required number then press ENTER. The second code
character will flash; press UP or DOWN to adjust to the required number then press ENTER. Repeat this procedure for all six code
characters.
When the service item ID code has been entered, the service alarm is reset and the
controller will automatically increment to the next service type in the service cycle and Note
initiate the appropriate service interval.
ID code is identical to order number on
service order.
If a „service ID code‟ is unavailable,
press ENTER six times repeatedly to
enter six zero‟s as the ID code.

3.4 Service procedures overview
Service procedure A B C B D B C B E Chap.
Running hours 250 1500 3000 4500 6000 7500 9000 10500 12000
Running years - 1,5 3 4,5 6 7,5 9 10 12
Oil change X X X X X X X X X 4.2
Air filter replacement X X X X X X X X 4.3

Valve LP replacement X X X X 4.7
Valve HP replacement X X X X 4.8
Gudgeon bearing + pin X 4.11
X
replacement 4.12
Non return valve replacement X X 4.18
Drain / unload valve HP + coil X
X 4.19
replacement
Bearing crank replacement X X 4.14
Bearing fan side replacement X X 4.13
Piston ring LP replacement X 4.11
Piston ring HP replacement X 4.12
Bearing motor side X 4.17
replacement
Valve LP check* X* X* X* X* 4.7

Valve HP, check* X* X* X* X* 4.8
Gudgeon bearing + pin 4.11
X** X**
check** 4.12
Bearing crank check** X** X** 4.14
Air cooler LP check*** X*** X*** 4.5
Air cooler HP check*** X*** X*** 4.6
Flexible tubes check**** X**** X****
Safety valve LP check***** X***** 4.4
Safety valve HP check***** X***** X***** 4.4
* Please check the valve LP and HP condition, and if there is carbon deposit, the valve(s) must be replaced. Sperre recommend for
this compressor valve check every 1.500 hours.
** Please check the gudgeon bearing and the crank bearing condition, and if worn or damaged complete bearing(s) must be
replaced. Sperre recommend for this compressor bearing check every 3.000 hours.
****Please check the cooler condition, and if the cooler have particles in the airflow area inlet, the cooler must be replaced. Sperre
recommends for this compressor cooler check every 6.000 hours.
**** Please check all flexible tubes for wear and aging every 6.000 hours. Refer to standard BS 5244 for details regarding testing
and checking.
***** Please check safety valves and change if necessary (see chapter 4.4).
Compressor serial number must be provided when ordering!
PMS input
The technical data above is the basis for the onboard planned maintenance system. Contact Sperre for the digital version for direct
implementation.

3.5 Kit overview
The letters on the illustration below refer to service and maintenance kits for the compressor, listed in the table on next page, and
described in chapter 3.4.

Ordering number Chapter
Letter Kit Name
Service Kit Maintenance kit Recommended kit Service Procedures
- Service Kit B XAW120-150 50038 3.4

- Service Kit C XAW120-150 50068 3.4
- Service Kit D XW120-150 50115 3.4
- Service Kit E XW150 50145 3.4
MR Kit XW150 XW150-MR 3.4
CR Kit XW150 XW150-CR 3.4
MK Compressor gasket XW150 50915 3.4
a MK Cylinder head LP XW120-150 50345 3.4 4.7
b MK Cylinder head HP XW120-150 50375 3.4 4.8
c MK Valve LP XAW120-150 50438 3.4 4.7
d MK Valve HP XAW120-150 50468 3.4 4.8
e MK Cylinder LP XAW150 50568 3.4 4.9
f MK Cylinder HP XAW120-150 50608 3.4 4.10
g MK Piston rings LP XAW150 50638 3.4 4.11
h MK Piston rings HP XAW120-150 50668 3.4 4.12
i MK Piston LP XAW150 50708 3.4 4.11
j MK Piston HP XAW120-150 50738 3.4 4.12
k MK Connecting rod XAW120-150 50768 3.4 4.14
l MK Crank Shaft XAW120-150 50808 3.4 4.17
Sperre Tool Box XAW120-150 50968 3.4 4.14
EK DOL XAW120-150 59216 3.4
EK SOFT XAW120-150 59328 3.4
EK CENTRAL XA008-XW500 66720 3.4
EK CONTROL XW120-150 59940 3.4
* Safety valve HP / LP 4.4

* Air cooler LP 4.5
* Air cooler HP 4.6
* Compressor serial number must be provided when ordering!

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

Service kit A XW150 - No parts required

Service kit B XAW120-150 50038 Required parts for service B included
parts for check
Letter Component Qty. Letter Component Qty. Letter Component Qty.
a Air Filter 1 b Gaskets valve LP 1+1+1 c Gaskets valve HP 1+1+1

Service kit C XAW120-150 50068 Required parts for service C included parts
for check
a Air Filter 1 c Valve HP 1 e Gaskets valve HP 1+1+1

b Valve LP 1 d Gasket Valve LP 1+1+1 f Fasteners valve HP 2+2

Service kit D XW120-150 50115 Required parts for service D included
parts for check
a Air Filter 1 g Drain/unload valve 1 m Gasket cylinder LP 1

HP kit
b Valve LP 1 h Bearing Crank 2 n Gasket cylinder HP 1
c Valve HP 1 i Bearing fan side 1+1+1 o O-rings cooler LP + 6+2+8
HP
d Bearing gudgeon LP 1+1 j Gaskets Valve LP 1+1+1 p Disc springs cooler 8+8
LP + HP
e Bearing gudgeon HP 1+1 k Gaskets valve HP 1+1+1 q Studs cooler LP + HP 4+4
f Non return valve HP 1 l Fasteners valve HP 2+2 r Gaskets bearing fan 1+1
side

Service kit E XW150 50145 Required parts for service E included
parts for check

a Air filter 1 i Bearing fan side 1+1+1 q Gaskets cylinder HP 1

b Valve LP 1 j Piston rings LP 2+1 r O-rings cooler LP + 6+2+8
HP
c Valve HP 1 k Piston rings HP 3+1 s Disc springs cooler 8+8
LP + HP
d Bearing gudgeon LP 1+1 l Bearing motor side 1+1+1 t Studs cooler LP + HP 4+4
e Bearing gudgeon HP 1+1 m Gaskets valve LP 1+1+1 u Gaskets bearing fan 1+1
side
f Non return valve HP 1 n Gaskets valve HP 1+1+1 v Gaskets bearing 1+1
motor side
g Drain/unload valve 1 o Fasteners valve HP 2+2

HP kit
h Bearing crank 2 p Gaskets cylinder LP 1

MR-kit overview

MR Kit XW150 XW150 - MR Air suction filter
CR-kit overview

CR Kit XW150 XW150 - CR Class recommended spare parts
a Gasket cylinder head 1 g Piston rings LP 2+1 n Gasket cylinder HP 1

LP
b+c Gaskets valve LP 1+1 h Fasteners valve HP 2+2 o Piston rings HP 3+1
d Valve LP 1 i Gasket cylinder 1 p O-rings Cooler LP 1+3+4
head HP
e O-ring valve LP 1 j+k+m Gaskets valve HP 1+1+1 q O-rings Cooler HP 1+3+4
f Gasket cylinder LP 1 l Valve HP 1

Maintenance kit overview

MK Compressor gasket XW150 50915 All gaskets

MK Cylinder head LP XW120-150 50345 Cylinder head LP with gaskets
Letter Component Qty.
a Cylinder head top LP 1
b Cylinder head bottom 1

LP
c Gasket cylinder head 1
LP
d Gaskets valve LP 1+1+1
e Fittings cylinder head 1+1

LP
f Fasteners cylinder 5+5+5
head LP

MK Cylinder head HP XW120-150 50375 Cylinder head HP with gaskets
a Cylinder head top 1

HP
b Cylinder head 1
bottom HP
c Gasket cylinder 1
head HP
d Gaskets valve HP 1+1+1
e Fasteners valve 2+2

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

MK Valve LP XAW120-150 50438 Valve LP with gaskets
a Valve LP 1
b Gaskets valve LP 1+1+1

MK Valve HP XAW120-150 50468 Valve HP with gaskets
a Valve HP 1
b Gaskets valve HP 1+1+1
c Fasteners valve HP 2+2

MK Cylinder LP XAW150 50568 Cylinder LP with gaskets
a Cylinder LP 1
b Gasket cylinder LP 1
c Gasket valve LP 1+1+1
d Fasteners cylinder 4+4

MK Cylinder HP XAW120-150 50608 Cylinder HP with gaskets
a Cylinder HP 1
b Gasket cylinder HP 1
c Gasket valve HP 1
d Fasteners cylinder 4+4

MK Piston ring LP XAW150 50638 Piston ring LP with gaskets
a Piston rings LP 2+1
b Gaskets cylinder LP 1

MK Piston ring HP XAW120-150 50668 Piston ring HP with gaskets
a Piston rings HP 3+1
b Gaskets cylinder HP 1

MK Piston LP XAW150 50708 Piston LP with gaskets
a Piston LP 1
b Piston rings LP 2+1
c Bearing gudgeon LP 1
d Gudgeon pin LP 1
e Retaining rings LP 2
f Gaskets cylinder LP 1

MK Piston HP XAW120-150 50738 Piston HP with gaskets
a Piston HP 1
b Piston rings HP 3+1
c Bearing gudgeon HP 1
d Gudgeon pin HP 1
e Retaining rings HP 2
f Gaskets cylinder HP 1

MK Connecting rod XAW120-150 50768 Connecting rod LP with bearings
a Connecting rod 1
b Bearing crank 1
c Bearing gudgeon 1+1+2
d Gasket cylinder HP + 1+1

LP
e Gaskets bearing fan 1+1
side
f Splash pin with 1+2
screws

MK Crankshaft XAW120-150 50808 Crankshaft with gaskets
a Crank shaft 1+1
b Bearing crank 2
c Bearing fan side 1+1+1
d Bearing, motor side 1+1+1
e Gasket cylinder HP 1+1

+ LP
f Gaskets bearing fan 1+1
side
g Gaskets bearing 1+1
motor side

Sperre toolbox XAW120-150 50968
a Dismantling tool 1
crankshaft
b Dismantling screw 1
coupling
c Mounting/ dismantling 1
bracket crankshaft
d Fasteners 2
mounting/dismantling
bracket crankshaft
e Mounting tool for seal 1+1
ring

Electrical kit overview

EK DOL XAW120-150 59216
a Thermal overload 1
relay
b Extended rotary 1+1
handle
c Main switch unit 1
d Main contactor 1

EK SOFT XAW120-150 59328
a MCB 1
b Extended rotary 1+1

handle
c Main switch unit 1
d Soft Starter 1

EK CENTRAL XA008-XW500 66720
a Main contactor 1

EK CONTROL XW120-150 59940
a Plug-in connection 1
b Plug-in cable 1
c Pressure sensor LP 1
d Pressure sensor HP 1
e Temperature sensor 1
f Oil level sensor 1
g Drain unload/valve 1
HP kit
h Pressure transmitter 1
receiver

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

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

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

Sperre Industri AS Sperre Rotterdam BV The listed addresses are the only
Ellingsøy, Norway Ridderkerk, The Netherlands places you can purchase original parts
Tel: + 47 70 16 11 00 Tel: + 31 180 463 299 for your X-range compressor.
Fax: + 47 70 16 11 10 Fax: + 31 180 463 264 Sperre takes no responsibility for
damage caused by use of non-original
[email protected] [email protected] parts.
Singapore China Agent Network

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

4 Service procedures
4.1 Cover
Dismantle and assemble
Dismantle Note
1. Unscrew the three screws in front [a]. The back cover and base should
2. Remove the front cover [b]. normally not be removed.
3. Unscrew the lifting eye bolt [c].

4. Remove the two side covers [d] by
pulling forward and lifting up. Note
Assemble The lifting eye bolt is certified and
1. Assemble the two side covers [d] by approved for lifting a single
pushing them carefully in to place. compressor.
2. Assemble the front cover [b].

3. Mount the three screws [a].
4. Mount the lifting eye bolt [c].
Spare parts
Ordering number
a Cover Front with grid 470x7
b Cover side 476x7
c Cover Back 471x7
d Cover Seal 473x7
e Cover Base 472x7
f Cover Stiffener 477x7
g Fasteners (cover front) 56008
h Fasteners (cover back) 56075
i Fasteners (cover 56111
seal/base)
j Fasteners (cover 56168
stiffener)
k Lifting eye bolt 43107
Compressor serial number must be
provided when ordering!

4.2 Lubricating oil
Drain, inspect and clean: Note
1. Before starting this procedure, remove Always use fully synthetic, ISO 100
cooler LP*. grade piston compressor oil.
2. Place a tray below the draining plug. Visit www.sperre.com for
recommended lubricating oil brands.
3. Unscrew the six screws and remove
the crankcase cover [c].
4. Remove the draining plug [a] and drain
the compressor empty.
Note
5. Mount the draining plug [a]. * See chapter 4.5 “Air Cooler LP".
6. Assemble the crankcase cover with

the six screws.
Note
Refilling oil:
1. Fill necessary amount oil through the Oil level switch LS15 LED indicator [e]
oil filling hole [b]. Green light: Oil and temperature level
normal.
2. Check oil level on X-control and level Blinking yellow light fast: Temperature
sight glass [d]. high
3. Mount the filling plug [b] Blinking yellow light slow: Oil level too
low.
Filling of new oil:
No light: Short circuit or malfunction
1. Fill approx. 11 L new oil through the oil
filling hole [b] or through the crank
case cover opening [c]..
2. Check oil level on X-control and level
sight glass [d].
3. Mount the filling plug [b] or the crank
case cover [c].

Spare parts
Ordering number
a Transmitter oil level 56521
b Flex tube1 ventilator 51238
c Flex tube2 ventilator 51268
d Flex tube3 ventilator 51308
e Flex tube oil refill 45195
f Level sight glass 3664
g Tube oil drain 51208
h Gasket crankcase 35517
cover
i Crankcase cover 32012
j Fasteners 56568
k Oil refill box 56308
l Plug (oil refill) 7751
m Plug (oil drain) 7752
n Ventilator 56668
o Reduction (ventilator) 56868
p Adapter (oil refill box) 56908
q Swivel 90° elbow 7562
r Adapter (crank house) 56708

4.3 Air filter
Service
Inspect and replace

1. Unscrew the two screws [a]
2. Replace the air filter unit [b].
3. Mount the two screws [a].
Spare parts
Ordering number
a Air filter 36165
b Fasteners 56368

4.4 Safety valves LP and HP
Service
Inspect and replace Note

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

HP. The valve should blow at
maximum working pressure + 10%.
Change if not functioning correctly.
Spare parts
Ordering number
a Safety valve LP 51xxx
b Safety valve HP 51xxx
c Safety valve CW 51xxx

4.5 Air cooler LP
Dismantle
Warning
1. Unscrew the four cooling fixing screws
[a].
*Always assemble O-rings as shown.
2. Remove the cooler LP [b]. High temperature O-ring [b] is black
and marked with a dot. Viton O-rings [c]
Assemble
are green.
1. Assemble the cooler as shown (see
service) and mount the cooler LP [b].
2. Mount the four fixing screws [a].
Service

1. Inspect and change the cooler LP [a] if ** If the cooler have particles in the
necessary**. airflow area inlet it must be replaced.
2. Replace the high temperature O-ring
[b], the Viton O-rings [c] and the disc
springs [d].
3. Assemble as illustrated *
Spare parts
Ordering number
a Cooler LP with O-rings 51815
b O-rings 57648
c Disc springs 57515
d Fasteners (cooler LP) 57275
e Flexible tube LP (air) 45131
f Flexible tube (cooling 45139
water)
g Bracket cooler LP 32323
h Fasteners (bracket cooler 56278
LP)
i Cooler manifold LP 20701
j Adapter 56715

4.6 Air cooler HP
Dismantle
Warning
1. Unscrew the four cooling fixing screws
[a].
*Always assemble O-rings as shown.
2. Remove the cooler LP [b]. High temperature O-ring [b] is black
and marked with a dot. Viton O-rings [c]
Assemble
are green.
1. Assemble cooler as shown (see
service) and mount the cooler LP [a].
2. Mount the four cooling fixing screws
[a].
Service

1. Inspect and change the cooler HP [a] if **If the cooler have high pressure drop,
necessary**. the cooler must be replaced.
2. Replace the high temperature O-ring
[b], the Viton O-rings [c] and the disc
springs [d].
3. Assemble as illustrated *
Spare parts
Ordering number
a Cooler HP with O-rings 51815
b O-rings 57648
c Disc springs 57515
d Fasteners (cooler HP) 57315
e Flexible tube HP (air) 45133
f Flexible tube (cooling 45137
water)
g Bracket cooler HP 32333
h Fasteners (bracket 56278
cooler HP)
i Cooler manifold HP 20711
j Adapter 56708
k Swivel 90° elbow 7562

4.7 Valve LP
Dismantle Note
1. Unscrew the flexible tubes CW outlet Before starting this procedure perform
[a], transmitter LP [b] and the air the dismantling procedure described in
breathing flexible tube [c]. 4.5 “Cooler LP”.
2. Unscrew the five nuts [d].
3. Remove the cylinder head [e].
Assemble
1. Assemble the cylinder head [e].
Replace gaskets (see service step1)
2. Mount the five nuts [d].
3. Mount the flexible tubes CW outlet [a],
transmitter LP [b] and the air breathing
[c].
Service

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

Spare parts
Ordering number
a Valve LP with gaskets 52008
b Gaskets valve LP 52038
c Transmitter LP 56421
d Flexible tube LP TR 45190
e Flexible tube LP CW out 45138
f Cylinder head top LP 20469
g Cylinder head bottom 20439
LP
h Gasket cylinder head LP 35619
i Fasteners 52075
j Fittings (transmitter LP) 57241
k Adapter (transmitter LP) 56948
l Adapter (outlet) 56708
m Bulkhead union (outlet) 57375
n Swivel 90° elbow 7562
o Plug (cylinder head top) 44301
p Plug (cylinder head 44304
bottom 1)
q Plug (cylinder head 44301
bottom 2)
- Service kit, plate valve 52138

4.8 Valve HP
Dismantle
Warning
1. Unscrew the flexible tubes air delivery
HP [a] and CW [b] and transmitter HP
[c]. Always mount the six M12 nuts first
with torque 80Nm and then mount the
2. Unscrew the six nuts [d]. two nuts M6 with torque 10Nm
3. Remove the cylinder head HP [e].
Assemble
1. Assemble the cylinder head HP [e]
(see service)
2. Mount the six nuts [d]. Note
3. Mount the 2 nuts [c]. Before starting this procedure perform
the dismantling procedure described in
4. Mount the flexible tubes air delivery 4.6 “Cooler HP”.
HP [a], CW [b] and transmitter HP [c].
Service

1. Remove the old gaskets, clean the The flat gaskets should always be
adjacent surfaces [a] and place the replaced. Clean the adjacent surfaces
new gasket [b]. before the new gaskets are fitted.
2. Unscrew the two nuts [c] holding the
valve.
3. Inspect the valve [d], and replace if
necessary. Change the two studs [e].
Apply Sperre thread-locking fluid on
threads.
4. Clean the adjacent surfaces [f]
5. Place the new gaskets [g].
6. Unscrew the 12 screws [h], clean
adjacent surfaces [i] and replace the
gasket [j].
7. Mount the 12 screws [h].
8. Assemble

Spare parts
Ordering number
a Valve HP with gaskets 52208
and fasteners
b Gaskets valve HP 52238
c Fasteners valve HP 52345
d Transmitter HP 56451
e Flexible tube HP (air) 45132
f Flexible tube HP 45190
(transmitter)
g Cylinder head top HP 20569
h Cylinder head bottom HP 20539
i Cylinder head gasket HP 35622
j Fasteners 52275
k Fittings (transmitter HP) 57211
l Adapter (transmitter HP) 56948
m Adapter (outlet) 56708
n Adapter (inlet) 56771
o Plug 44301

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

1. Inspect for wear inside the cylinder LP The cylinder should be honed (45
[a] and change if necessary. degrees stripes) each time piston rings
2. Clean the adjacent surfaces [b]. are replaced. If there are critical vertical
stripes inside the cylinder after honing,
3. Replace the flat gasket [c]. the cylinder must be replaced.
Spare parts
Ordering number
a Gaskets cylinder LP with 52608
gaskets valve LP
b Cylinder LP 20322
c Fasteners 57368

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

1. Inspect for wear inside cylinder [a] The cylinder should be honed (45
replace if necessary. degrees stripes) each time piston rings
2. Clean the adjacent surfaces [b]. are replaced. If there are critical vertical
stripes inside the cylinder after honing,
3. Replace the flat gasket [c]. the cylinder must be replaced.
Spare parts
Ordering number
a Gaskets cylinder HP with 52638
gaskets valve HP
b Cylinder HP 20369
c Fasteners 57368

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

1. Replace the gudgeon bearing [a]. Piston ring wear limits:
2. Inspect the crank bearing by moving Piston ring diameter Ø165
the connecting rod [b] up and down. Maximum allowed end gap: contact
To replace the crank bearing refer to Sperre
chapter 4.14. Piston groove wear limits:
Maximum allowed vertical clearance:
Piston and Piston rings: contact Sperre
1. Inspect the two piston rings and one oil
ring [c], replace if necessary.
2. Inspect for wear outside of the piston
[d] replace if necessary.
Spare parts
Ordering number
a Piston LP with retaining 52808
rings
b Piston rings LP 52838
c Bearing needle LP 52868

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

1. Replace the gudgeon bearing [a]. Piston ring wear limits:
2. Inspect the crank bearing by moving Piston ring diameter Ø70
the connecting rod [b] up and down. Maximum allowed end gap: contact
To replace the crank bearing refer to Sperre
chapter 4.14. Piston groove wear limits:
Maximum allowed vertical clearance:
Piston and Piston rings: contact Sperre
1. Inspect the three piston rings and one
oil ring [c], replace if necessary.
2. Inspect for wear outside of the piston
[d] replace if necessary.
Spare parts
Ordering number
a Piston HP with retaining 52908
rings
b Piston rings HP 52938
c Bearing needle HP 52968

4.13 Bearing fan side
Dismantle Note
1. Unscrew the fan centre screw [a]. * After dismantling do not forget to
2. Use a M16 screw* to loosen the fan remove the M16 screw and the two
from the shaft and remove fan [b]. M10 screws.
3. Unscrew the one nut [c] and eight nuts
[d].
4. Use two M10 screws* [e] to loosen the
front plate from the crankcase.
5. Remove the front plate [f].
Assemble
1. Inspect the gasket (see service step 1)
and replace if necessary.
2. Remove the two M10 screws.
3. Mount the front plate with eight nuts
[d]. Mount the nut [c].
4. Remove the M16 screw and mount fan
[b].
5. Mount the fan centre screw [a], use
hand to prevent fan from rotating.
Service

1. Remove the gasket [a], clean adjacent * Heat the inner bearing ring with a
surfaces and mount the new gasket. heat gun when dismantling and
2. Inspect the seal ring [b], and replace if assembling on the shaft.
necessary.
3. Remove the retaining rings[c], use nail
punch in holes [d] to remove the outer
bearing ring [e]. Remove inner
bearing ring from shaft*.
4. Mount the new bearing.
5. Mount the new retaining rings.
Spare parts
Ordering number
a Bearing fan side with 53011
retaining rings
b Gaskets bearing fan 53038
side
c Front plate 20127
d Fasteners (front plate) 57371
e Fan with fasteners 32417
f Fasteners (fan) 57541

4.14 Bearing crank
Dismantle Note
1. Mount the counter weight bracket [a] *. Before starting this procedure, perform
2. Unscrew the centre screw [b]. the dismantling procedure described in
4.13 “Bearing fan side”.
3. Use the Sperre dismantling tool* [c] to
loosen the counter weight [d]. Mount
the tool between the counter weight
and crank disk, as close to centre as Note
possible, to split the crank shaft.
* The counter weight bracket and the
4. Remove the counter weight bracket [a] dismantling tool are delivered with
5. Remove the counter weight [d]. service kit. The bracket is to be
mounted on the crank case and to the
6. Carefully remove the two connecting counter weight to prevent the counter
rods [e] **. weight from rotating.
Assemble
1. Carefully mount the two connecting
rods [e]. Note
2. Mount the counter weight [d]. ** Be careful when handling the
connecting rod. Pull the bottom first
3. Mount the counter weight bracket [a] *. when removing, and insert the top first
4. Mount the centre screw [b]. when assembling.
Service

1. Replace the bearing crank [a]*. * Heat the bearing with a heat gun
2. Inspect the two splash pins [b], replace when dismantling and assembling on
if necessary. the shaft.
3. To replace the gudgeon bearing refer

to chapter 4.11 and 4.12.
Spare parts
Ordering
a Bearing needle 53108
b Connecting rod 53138
c Crank Shaft counter 20238
weight*
d Sperre Toolbox 50968
e Fasteners 57468
* Always change both crank shaft and
counter weight. See chapter 4.17 for crank
shaft.

4.15 Electric motor and vibration isolators
Dismantle Note
1. Unscrew the flexible tubes air outlet
To loosen the plug-in connection pull
[a], drain [b], and plug-in cable [c].
out the plug-in cable and detach the
Unscrew the five screws [d] and
plug-in connection cable by loosening
remove the back cover..
the inside nut.
2. Unscrew the coupling screw [e].
3. Unscrew the four nuts [f] to loosen the
motor from the motor flange.
4. Unscrew the nut holding the motor
support [g] to isolator [h].
5. Remove the motor.
Assemble
1. Mount the motor with motor support [g]
to the isolator [h].
2. Mount the four nuts [f] to the motor
flange.
3. Mount the coupling screw [e], torque
200 Nm.
4. Assemble the back cover with the five
screws [d].
5. Mount the flexible tubes air outlet [a],
drain [b], and plug-in cable [c].
Service

1. Replace the front isolator [b] and back * Please refer to www.sperre .com for
isolator [a]. instruction regarding the Electric motor
2. Electric motor service*. service.
Spare parts
Ordering number
a X-isolator (compressor) 462xx
b X-isolator (El-motor) 462xx
c Electric motor 6xxxx
d Fasteners (El-motor) 53xxx
e Support motor 208xx
f Fasteners (support motor) 53xxx

4.16 Coupling and sealing flange
Dismantle Note
1. Unscrew the centre screw [a]. Before starting this procedure, perform
2. Use the Sperre M24 dismantling the dismantling procedure described in
screw* to loosen the coupling from 4.15 “El. motor and vibration isolators”.
crank disk. Be careful not to damage
threads.
3. Remove the coupling [b]. Note
4. Unscrew the three screws [c]. * Sperre M24 dismantling screw in
5. Use two M10 screws** [d] to loosen Sperre tool box.
the sealing flange. ** After dismantling do not forget to
remove the M10 screws.
6. Remove the sealing flange [e]. *** Sperre mounting tool for seal ring in
Assemble Sperre tool box.
1. Mount the sealing flange [e] with the

new gaskets and the seal ring (see
service step1).
2. Mount the three screws [c].
3. Mount the coupling [b].
4. Mount the centre screw [a].
Service
Inspect and replace

1. Replace the seal ring and gasket [a].
Use Sperre mounting tools*** for the
seal ring.
2. Inspect the coupling and change if
necessary. Change if threads are
damaged.
Spare parts
Ordering
a Gaskets sealing flange 53708
b Sealing flange 20147
c Coupling with fasteners 53xxx
d Fasteners (coupling) 53xxx
e Fasteners (sealing 56541
flange)

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

1. Replace the bearing on the motor side
[a].
Spare parts
Ordering number
a Bearing motor side 54108
b Crank shaft* 20238
c Crankcase 20107
d Lifting bar 32145
* Always change both crank shaft and
counter weight. See chapter 4.14 for crank
shaft counter weight.

4.18 Cyclone separator and non return valve
Dismantle HP side
1. Unscrew the air outlet flexible tube [a]
and the transmitter plug [b].
2. Unscrew the three screws [c] and
remove the outlet connector HP [d].
Assemble HP side
1. Mount the outlet connector HP [d] with
the three screws [c].
2. Mount the transmitter plug [b] and the
air outlet flexible tube [a].
Dismantle LP side
1. Unscrew the air delivery flexible tube
LP [e] and the three screws [f] and
remove the outlet connector LP [g]
Assemble LP side
1. Mount the outlet connector LP [g] with
the three screws [f] and mount the air
delivery flexible tube LP [e]
Service
Inspect and replace

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

Spare parts HP
Ordering number
a Valve HP non return 54208
b Transmitter HP 56481
temperature
c Cyclone tube HP 32127
d Outlet connector HP 20669
e Separator housing HP 20619
f Fasteners (outlet 57507
connector HP)
g Fasteners (separator 57668
housing HP)
h Adapter (outlet connector 56708
HP)
i Plug (outlet connector 44304
HP)
j Adapter (separator 56738
housing HP inlet)
k Adapter (separator 57018
housing HP drain LP)
l Swivel 90° elbow (drain) 7570
m Plug (separator housing 57771
HP)
n Adapter big (drain LP) 57015
o Swivel 90° elbow (drain 8652
LP)
p Valve LP non return 4769
q Adapter small (drain LP) 57006
Spare parts LP
Ordering number
a Cyclone tube LP 32127
b Flexible tube LP DR 45134
c Outlet connector LP 20643
d Separator housing LP 20619
e Fasteners (outlet 57507
connector LP)
f Fasteners (separator 57668
housing LP)
g Adapter (outlet connector 56708
LP)
h Adapter (separator 56738
housing LP inlet)
i Adapter (separator 57015
housing LP drain)
j Plug big (separator 57771
housing LP)
k Plug small (separator 7750
housing LP)

4.19 Drain/unload valve HP
Service
Inspect and replace

1. Remove the coil plug [a].
2. Remove the coil [b].
3. Unscrew the four screws and remove
the cover [c].
4. Replace the diaphragm, spring and
the two O-rings [d].
5. Mount the cover [c] with the 4
screws.
6. Mount the coil [b].
7. Mount the coil plug [a].
Spare parts
Ordering number
a Coil 64xxx
b Rep.kit drain/unload valve 64216
c Drain/unload valve HP 57911
with gaskets
d Fittings 57171

4.20 Electrical components
Information is given for compressors with working pressure 30 barg, main voltage between 380 - 420VAC / 50Hz and 440 -
480VAC / 60Hz, control voltage 220-240 VAC and ambient temperature 40 °C. For other configurations please provide compressor
serial number when ordering!
Spare parts for starters with DOL start
Ordering number
b Plug-in cable 64405
c Emergency stop 67040
d Thermal overload relay 66324
e Extended rotary handle 66170
f Main switch unit 66115
g Main contactor 66250
h X-control unit 67020
i Emergency run switch 67050
j Current transformer 67164
k Control power 67114
transformer
Spare parts for starters with soft start
Ordering number
d Soft starter 66517
e Extended rotary handle 66170
f Main switch unit 66115
g Motor circuit breaker 66444
h X-control unit 67020
i Emergency run switch 67050
j Current transformer 67164
k Control power 67114
transformer

Spare parts for starters with central start
Ordering number
d X-control unit 67020
e Emergency run switch 67050
f Control power 67110
transformer
g Aux relay 66720

5 X-range data
5.1 Torque tables
XW150
Component Chapter Quantity Thread diameter Spanner with Torque (Nm)
Enclosure Front / Back 4.1 3/5 M8x15 Unbrako 6 24

Enclosure Base / Seal / 4.1 M8x15 Unbrako 6 24
5/5/6
Stiffener
Crank case cover 4.2 6 M8x20 Unbrako 6 24
Air filter 4.3 2 M8x25 Unbrako 6 24
Cooler bracket LP 4.5 3 M8x12 Unbrako 6 24
Cooler bracket HP 4.6 3 M8x12 Unbrako 6 24
Cylinder head LP 4.7 5 M6x20 Unbrako 5 10
Cylinder head LP 4.7 5 M12 19 mm 80
Cylinder head HP 4.8 14 M6x40 Unbrako 5 10
Cylinder head HP 4.8 6 M10 17 mm 48
Valve LP 4.8 2 M8 13 mm 24
Cylinder LP 4.9 4 M16 24 mm 200
Cylinder HP 4.10 4 M16 24 mm 200
Fan 4.13 1 M12x45 Unbrako 10 80
Fan centre disk 4.13 3 M6x16 Unbrako 5 10
Front Plate 4.13 8 M12 19 mm 80
Counter weight 4.14 1 M16x35 Unbrako 14 200
Coupling (side screw) 4.15/4.16 1 M16x60 Unbrako 14 200
El-motor 4.15 4 M16 24 mm 200
Sealing flange 4.16 3 M8x20 Unbrako 6 24
Coupling (centre screw) 4.16 1 M16x40 Unbrako 14 200
Outlet connector HP 4.18 3 M12x25 Unbrako 10 80

NOTE:

Service Manual XW150 - Version02

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Congratulations on your X-range compressor!

Patented X-drive Patented cooling Registered design

This excellent compressor gives you several benefits:

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

www.sperre.com Service Manual XW150 Version 02 3

3 Service and ordering.............................................................................. 9

4 Service procedures .............................................................................. 30

5 X-range data ......................................................................................... 55

www.sperre.com Service Manual XW150 Version 02 4

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

www.sperre.com Service Manual XW150 Version 02 5

Danger Danger Caution

Compressor rating plate

www.sperre.com Service Manual XW150 Version 02 6

www.sperre.com Service Manual XW150 Version 02 7

www.sperre.com Service Manual XW150 Version 02 8

Service Months Cycle:

www.sperre.com Service Manual XW150 Version 02 9

Service warning (pre-alarm):

www.sperre.com Service Manual XW150 Version 02 10

Service warning code Text displayed Failure Corrective action

3.3 Service Alarms:

Service alarm (service due now):

www.sperre.com Service Manual XW150 Version 02 11

Service alarm code Text displayed Failure Corrective action

Service Alarm Reset

item# description units step min max default display

SR Service Reset --- --- {-----} RESET {-----} RESET

ST Edit previous service ID --- --- --- --- --- B

Service alarm reset procedure: Note

www.sperre.com Service Manual XW150 Version 02 12

Running years - 1,5 3 4,5 6 7,5 9 10 12

Oil change X X X X X X X X X 4.2

Air filter replacement X X X X X X X X 4.3

Valve LP check* X* X* X* X* 4.7

www.sperre.com Service Manual XW150 Version 02 13

www.sperre.com Service Manual XW150 Version 02 14

- Service Kit B XAW120-150 50038 3.4

* Safety valve HP / LP 4.4

www.sperre.com Service Manual XW150 Version 02 15

Kit name Ordering number Description

Kit name Ordering number Description

Letter Component Qty. Letter Component Qty. Letter Component Qty.

a Air Filter 1 b Gaskets valve LP 1+1+1 c Gaskets valve HP 1+1+1

Kit name Ordering number Description

Letter Component Qty. Letter Component Qty. Letter Component Qty.

a Air Filter 1 c Valve HP 1 e Gaskets valve HP 1+1+1

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Letter Component Qty. Letter Component Qty. Letter Component Qty.

a Air Filter 1 g Drain/unload valve 1 m Gasket cylinder LP 1

e Bearing gudgeon HP 1+1 k Gaskets valve HP 1+1+1 q Studs cooler LP + HP 4+4

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a Air filter 1 i Bearing fan side 1+1+1 q Gaskets cylinder HP 1

g Drain/unload valve 1 o Fasteners valve HP 2+2

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Kit name Ordering number Description

Kit name Ordering number Description