XRV 163 & 204 Service Manual

XRV 163 & 204
COMPRESSOR RANGE
SERVICE MANUAL
INDEX TO SECTIONS
SECTION 1 MAINTENANCE 3
1.1 General Comments 4
1.2 Preparation for Dismantling 5
5
1.3 Precautions During Shutdown
SECTION 2 ANNUAL INSPECTION 6

2.1 Annual Inspection Dismantling 7
2.2 Annual Inspection Re-assembly 13
SECTION 3 OVERHAUL
18
3.1 Overhaul – Dismantling 19
3.2 Preparation for Re-assembly 34
3.3 Overhaul – Re-assembly 34
SECTION 4 SPECIAL INSTRUCTIONS

51
4.1 Torque Specifications
52
4.2 Compressor Clearances 53
4.3 Procedures for fitting Lockwashers 54
4.4 Special Tool List 55
4.5 Procedure for Refitting Inlet Casing 57
4.6 Coupling Alignment 58
4.7 Pipework 59
SECTION 5 SPARES 60
5.1 XRV Compressor Recommended Spares List 61
1
FOREWORD
READ CAREFULLY BEFORE STARTING WORK ON YOUR COMPRESSOR
These instructions relate to XRV 163 & 204 Compressors.
These instructions have been prepared to ensure that your compressor gives long and satisfactory service.
The entire manual should be read before reverting to any one section for specific information.
One copy should be given to the personnel responsible for operating the compressor.
All requests for information, services or spares should be directed to:
Howden Compressors or Howden Compressors LLC

Compressor Business Unit 1850B North Gravers Road
133 Barfillan Drive Plymouth Meeting
Glasgow, G52 1BE PA 19462
United Kingdom USA
Telephone: +44 (0)141 882 3346 Telephone: 001 610 313 9800
Facsimile: +44 (0)141 882 8648 Fax: 001 610 313 9215
e-mail: hcl@aftersales@howden.com E-mail: sales@howdencompressors.com
Web : www.howden.com Web: www.howden.com
All enquiries should be accompanied by the Howden Contract Number and the Compressor Serial Number,
taken from the nameplate on the side of the compressor body.
2
SECTION 1
MAINTENANCE
3
1.1 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 journal
and thrust bearings, balance pistons and seals, and if any wear is found, for these components to be
renewed.
It is not anticipated that a major overhaul will be required for approximately three years of operation.
After this time all bearings must be renewed. The bearings may still be perfectly serviceable, but all
bearings have a finite lifespan and replacement at this point may forestall an expensive compressor
breakdown later.
When the compressor is being inspected or overhauled it must be dismantled in a clean area,
utmost cleanliness is vital for trouble-free operation.
The correct torque should be applied to all fasteners as specified in Section 4.1 using appropriate
torque wrenches.
All lockwashers and ‘O’ rings must be renewed on re-assembly. Section 4.3 describes lockwasher
assembly procedure.
Special tools to ease dismantling and re-assembly can be provided, as listed in Section 4.4. Details
of these can be obtained from the Compressor Business Unit, Howden Compressors.
Section 5 gives information on spare kits required when working on the XRV compressor.
4
1.2 PREPARATION FOR DISMANTLING
Before dismantling the compressor, 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 actuator cylinder when the cylinder cover is removed, or when the casings are
separated.
5. Ensure all lifting equipment, ie eyebolts, slings, and shackles are safe and serviceable.
1.3 PRECAUTIONS DURING SHUTDOWN
The Howden XRV Screw Compressor operates on an oil/gas mixture and short periods of shutdown
will not adversely affect the unit.
If the compressor is shut down for an extended period the suction and discharge valves should be
closed.
Turn the compressor driveshaft a few times every week by hand. This will help to avoid Brinelling of
the anti-friction bearings.
If the shutdown period is three months or more the above procedure should be continued and, in
addition, the compressor set should be run for one hour every three months.
During a shutdown period in cold conditions, any water-cooled items of plant should be drained, or
the cooling water flow maintained to prevent frost damage.
Users may use suitable inhibiting oils in the Howden screw compressor prior to a long shutdown.
If you have any doubts about the compatibility of any inhibiting oils with your gas or existing
lubrication oil, please contact the manufacturer or your dealer.
5
SECTION 2
ANNUAL INSPECTION
6
2.1 ANNUAL INSPECTION - DISMANTLING
1. Place a receptacle under the inlet end casing, remove the hex headed plug from the bottom
of the inlet end casing and allow the oil to drain (Fig. 1).
2. Unscrew the three cap screws securing the microswitch cover and remove the cover from
the rear of the actuator cylinder. Some compressors will have a LPI sensor fitted as an
option instead of switches, and will not have the cylinder switch cover fitted.
3. Disconnect/remove any electrical equipment fitted if it is going to obstruct further

dismantling.
4. Fully unload the capacity control valve by rotating the square screw in a clockwise direction
(Fig. 2).
Fig. 1 Fig. 2
7
2.1 ANNUAL INSPECTION – DISMANTLING (Continued)
5. Remove the cap screws and washers securing the inlet end female shaft cover.
6. Remove the inlet end female shaft cover, using the jacking holes provided. Discard the ‘O’
ring and renew on re-assembly (Fig. 3).
7. Slacken and remove the cap screws and washers on the driveshaft cover (Fig. 4).
8. Remove the driveshaft cover, using the jacking holes provided (Fig. 5). Remove the shaft
seal and discard (Fig. 6). Discard the shaft seal stationary seat and ‘O’ ring which are
housed in the driveshaft cover.
Fig. 3 Fig. 4
Fig. 5 Fig. 6
8
Using extraction tools, remove the balance piston from the driveshaft bore, examine both
piston, and bore for wear and damage (Fig. 7).
9. Remove two diagonally opposing cap screws securing the actuator cylinder cover and
replace them with threaded tie rods and nuts for safety (Fig. 8).
10. Unscrew the two remaining cap screws securing the actuator cylinder cover and release the
cylinder cover using the tie rods and nuts until the tension on the piston return spring is
released (Fig. 9).
11. Remove the tie rods and actuator cylinder cover/indicator spindle assembly (Fig.10). Mark
the groove that the guide pin was running on the indicator spindle, to ease re-assembly. (Not
applicable to models fitted with LPI sensor assembly.) Remove and discard the ‘O’ ring.
Fig. 7 Fig. 8
Fig. 9 Fig. 10
9
12. Unscrew the M5 locking grub screw from the locknut.
13. Unscrew the locknut securing the piston using a locknut spanner.
14. The piston can be removed with the aid of extraction tools (Fig. 11).
(See Section 4.4 for details of the tools available).
15. Locate and remove the indicator spindle guide pin.

(Only fitted to compressors with switches)
Fig. 11
10
16. Examine the indicator spindle guide pin for wear and damage and renew it if necessary.
17. Examine the piston and cylinder bore for wear, scoring and debris (Fig.12).
18. Discard the lip seal and renew it on re-assembly (Fig. 13)
(See lip seal fitting instructions. Sect 2.2 Para 1)
19. If the actuator piston assembly is excessively worn contact the Compressor Business Unit,
Howden Compressors Limited.
Fig. 12 Fig. 13
11
21. The outlet end (OE) clearance should now be checked. Set up a dial indicator at the inlet
end of the male rotor (Fig. 14). Zero the dial and slacken back the cap screws securing the
rotor outlet end shaft cover. The reading obtained on the dial represents the rotor outlet end
clearance. Check this is within tolerance in section 4.2.
22. Repeat the process for the female rotor, using a screw extension as shown (Fig. 15).
Fig. 14 Fig. 15
12
2.2 ANNUAL INSPECTION – RE-ASSEMBLY
1. Lubricate and fit a new actuator piston lip seal on the actuator piston ensuring the lip seal is
fitted the right way round (Fig. 16). Fit piston seal to piston and press firmly on the outer
edge of the entire seal circumference until the seal is heard to “click” into position. Failure to
do so will result in premature failure of the piston seal, and incorrect compressor operation.
2. Refit ‘O’ ring to piston using a small amount of grease to hold it in place. (Fig. 17)
3. Refit the actuator piston seal assembly into the actuator cylinder using the extraction rods
taking care not to damage the lip seal (Fig. 18).
4. Apply Loctite 243 to the locknut and slide valve insert thread, and fit lockwasher and locknut
to shaft. (Lockwasher not required on some compressors. See note below) Use special tool
to centralise piston in cylinder bore, fit support bracket, and secure with capscrews. Insert
locknut socket through support bracket and torque locknut (Fig. 19) to 80Nm for XRV163
compressor or 160Nm for XRV204 compressor. Ensure slot in locknut is aligned with M5
tapped hole in piston. Apply Loctite 243 to grub screw and tighten into piston. Torque to
10Nm.
NOTE: Compressors not requiring lockwasher fitted to actuator piston:

XRV163-MK2C Onwards
XRV204-MK3D Onwards
Fig. 16 Fig. 17
Fig. 18 Fig. 19
13
2.2 ANNUAL INSPECTION – RE-ASSEMBLY (Continued)
5. Remove special tooling used for centralising actuator piston.
6. Fit the indicator spindle guide pin, if fitted into its recess using a small amount of grease to
hold it in place.
7. Lubricate and fit a new ‘O’ ring on the actuator cylinder cover/indicator spindle assembly.
8. Insert the indicator spindle into the piston rod bore, taking care that the guide pin engages in
the groove that was marked on dismantling. For compressors fitted with linear position
indicator insert sensor well into aluminium target tube held in slide valve rod.
9. Fit cylinder minimum capacity stop spacers and use the threaded bar that was used for
dismantling the actuator cylinder cover to draw it back into place (Fig. 20) and fit the
washers and cap screws. Torque them to the recommended value.
Fig. 20
14
10. Lubricate and fit a new ‘O’ ring on the inlet end female shaft cover and refit the shaft cover
(Fig. 21).
11. Refit the washers and cap screws and torque them evenly to the recommended value.
12. Lubricate and refit the labyrinth seal on the driveshaft, ensuring that the notch engages on
the drive pin (Fig. 22 & 23).
13. Fit a new shaft seal ensuring that the seal engages on the drive pin in the labyrinth seal (Fig.
24).
Fig. 21 Fig. 22
Fig. 29 Fig. 24
15
14. Fit new ‘O’ rings and a stationary shaft seal seat on the inlet end driveshaft cover (Fig. 25)
and refit the driveshaft cover (Fig. 26).
Failure to do this carefully may result in damage to the shaft seal (Fig. 27).
16. Refit the oil drain plug to the bottom of the inlet end casing (Fig. 28).
17. If the compressor unit has been removed from its bedplate for inspection, refit it and realign
it using one of the methods described in Section 4.6
Fig. 25 Fig. 26
Fig. 27 Fig. 28
16
18. Refit and reconnect any electrical equipment that was removed when dismantling the
actuator cylinder.
19. Refit the microswitch cover and secure it with cap screws.
NOTE: Reset Vi adjusting screw to original position.
17
SECTION 3
OVERHAUL
18
3.1 OVERHAUL - DISMANTLING
The compressor slide valve is spring-loaded and to avoid injury, the operator should ensure that all
spring tension is released prior to dismantling. This can be done by ensuring that the slide valve is
fully off load (the piston should be at its limit towards outlet) and the volume ratio Vi adjustment is at
its minimum. (The Vi adjustment screw should be turned to its limit in the clockwise direction).
1. Place a receptacle under the inlet end casing, remove the hex headed plug from the bottom of
the inlet end casing and allow the oil to drain (Fig. 1).
2. Unscrew the three cap screws securing the microswitch cover and remove the cover from the
rear of the actuator cylinder. Some compressors will have a LPI sensor fitted as an option
instead of switches, and will not have the cylinder switch cover fitted.
Fig. 1
19
3.1 OVERHAUL – DISMANTLING (Continued)
3. Disconnect/remove any electrical equipment fitted if it is going to obstruct further

dismantling.
4. Fully unload the capacity control valve by rotating the square screw in a clockwise direction
(Fig. 2).
5. Remove the cap screws, washers and the Vi adjusting assembly (Fig. 3).
6. Examine the assembly and its bore for wear and damage. Discard the ‘O’ rings and renew
on re-assembly.
Fig. 2 Fig. 3
20
7. Remove the cap screws and washers securing the inlet end female shaft cover (Fig. 4).
8. Remove the inlet end female shaft cover, using the jacking holes provided. Discard the ‘O’
ring and renew on re-assembly.
9. Slacken and remove the cap screws and washers on the driveshaft cover (Fig. 5).
10. Remove the driveshaft cover, using the jacking holes provided (Fig 6). Remove the shaft
seal (Fig. 7). Discard the shaft seal stationary seat and ‘O’ ring which are housed in the
driveshaft cover.
Fig. 4 Fig. 5
Fig. 6 Fig. 7
21
11. Using extraction tools, remove the balance piston from the driveshaft bore, examine both
piston, and bore for wear and damage (Fig. 8).
12. Remove two diagonally opposing cap screws securing the actuator cylinder cover and
replace them with threaded tie rods and nuts for safety (Fig. 9).
13. Unscrew the two remaining cap screws securing the actuator cylinder cover and release the
cylinder cover using the tie rods and nuts until the tension on the piston return spring is
released (Fig. 10).
14. Remove the tie rods and actuator cylinder cover/indicator spindle assembly (Fig. 11) Mark
the groove that the guide pin was running on the indicator spindle, to ease re-assembly. (Not
applicable to models fitted with LPI sensor) Remove and discard the ‘O’ ring.
Fig. 8 Fig. 9
Fig. 10 Fig. 11
22
15. Unscrew the M5 locking grub screw from the locknut.
16. Unscrew the locknut securing the piston using a locknut spanner.
17. The piston can be removed with the aid of extraction tools (Fig. 12). (See Section 4.4 for
details of the tools available).
18. Locate and remove the indicator spindle guide pin. (Only fitted to compressors with limit
switches)
Fig. 12
23
19. Examine the indicator spindle guide pin for wear and damage, and renew it if necessary.
20. Examine the piston and cylinder bore for wear, scoring and debris (Fig. 13).
21. Discard the lip seal and renew it on re-assembly (Fig. 14).
(See lip seal fitting instructions. Sect 2.2 Para 1)
22. If the actuator piston assembly is excessively worn contact the Compressor Business Unit,
Howden Compressors.
Fig. 13 Fig. 14
24
23. Before removing the outlet end shaft covers mark them in order to ensure re-assembly in the
same position.
24. Remove the cap screws and washers securing the outlet end shaft covers.
25. Remove the outlet end shaft covers. Discard the ‘O’ rings and renew them on re-assembly.
25
26. Remove the spacer sleeve from the outlet end-casing bore (On the female rotor side) (Fig.
15).
27. Use the rotor-locking tool to immobilise the male rotor in preparation for removal of the outlet
end balance piston (Fig. 16).
28. Unlock the lockwasher on the end of the male rotor with a small drift and mallet and remove
locknut (Fig. 17).
29. Extract the balance piston from the balance piston sleeve using extraction tools (Fig. 18).
Fig. 15 Fig. 16
Fig. 17 Fig. 18
26
30. Remove the balance piston sleeve using extraction tools (Fig. 19). Discard the ‘O’ rings and
renew on re-assembly.
31. Examine the piston and sleeve for wear and debris. Particular attention should be paid to
the sealing grooves on both items.
32. Slacken the cap screws securing the inlet end casing and extract the dowel pins locating the
inlet casing to the main casing. Ensure that there is no spring pressure on the assembly
(Fig. 20).
33. Support the inlet end casing using lifting gear and remove the cap screws and washers.
Fig. 19 Fig. 20
27
34. Draw off the inlet casing. Take care that the slide valve stop is supported as the casings is
separated.
NOTE: DO NOT STAND DIRECTLY IN LINE WITH THE SLIDE VALVE STOP.
In the unlikely event that it is not free when the inlet casing is removed. The slide valve
return spring may still be under compression. Attempt to free the slide valve stop by tapping
it on the side with a soft faced mallet. Ensure the stop is protected if it releases suddenly.
35. Remove the slide valve stop (Fig. 21) and return spring (Fig. 22) and examine both for wear
and for damage.
36. Withdraw the slide valve and examine it for wear and damage on the cusps and round the
periphery (Fig. 23).
37. Examine the slide valve bore for wear, damage and debris.
Fig. 21 Fig. 22
Fig. 23
28
38. Prepare an area with either “cradles” to support the rotor shafts when the rotors have been
removed from the compressor casings, or a soft surface to lay the rotors on. The reason for
this is to avoid damage to the rotor tip seals.
39. Fit the rotor-locking tool on the compressor driveshaft to immobilise the rotors. (Fig. 24)
40. Remove the balance piston and spacer sleeve anti rotation pins from the outlet end casing
(Fig. 25).
Fig. 24
Fig. 25
29
41. Unlock the lockwasher securing the angular contact thrust bearings on the male rotor with a
small drift and mallet. (Fig. 26)
42. Remove the locknut, preferably with the aid of a special tool.(See Section 9.3) (Fig. 27)
Prior to removing rotors from the main casing, place a packing piece on the underside of the
cylinder to prevent tilting due to centre of gravity.
43. Fit a rotor extraction tool on the compressor outlet end casing on the male side and press
the rotor out of its thrust assembly.
44. Repeat the process of extraction (subsections 4 to 6) for the female rotor.
Fig. 26 Fig. 27
30
45. When the rotors are free of the angular contact thrust bearing assemblies, extract the male
rotor from the casing bore sufficiently to use lifting gear to remove it from the casing . (The
centre of gravity of the rotor is approximately mid-way along its length)
46. Examine the rotor for wear and scoring then put it aside in a prepared area.
47. Repeat the process of removal for the female rotor.
48. Extract the angular contact bearing cartridges from the outlet end casing bores and discard
the assemblies (Fig. 28).
49. Using a bearing race extraction tool, or inner track-heating element, remove the roller
bearing inner tracks from the rotor shafts and discard them.
Fig. 28
31
50. Extract the roller bearing outer races and oil spacer rings from the compressor outlet end
casing bores and discard the races (Fig 29 & 30).
51. Remove and discard the disc springs from the outlet end bearing bores (Fig. 31).
52. Remove the retainers, floating seals and ‘O’ rings (Fig. 32).
Fig. 29 Fig. 30
Fig. 31 Fig. 32
From the bores of the inlet end casing using circlip pliers, extract the circlips and remove the
bearing races and ‘O’ rings from the bores. Discard the bearing races and ‘O’ rings (Fig.
33).
Fig. 33
32
54. Remove the internal circlip retaining the indicator spindle bearing and extract the
spindle/bearing assembly.
55. Remove the external circlip from the indicator spindle, remove and discard the bearing.
56. Remove and discard the ‘O’ ring from the bore in the actuator cylinder cover.
57. Press out the labyrinth seal from the balance piston sleeve and discard it (Fig. 34).
Fig. 34
33
3.2 PREPARATION FOR RE-ASSEMBLY
On re-assembly, the procedures listed below should be followed:
1. Re-assemble the compressor in a clean area. (Ensure outer race of bearing in question is
identified for future fitting to casing.)
2. Always refer to the relevant drawing.
3. Always replace consumable items on re-assembly.
4. Always keep replacement parts in their protecting wrapping until they are required.
5. Always lubricate the component parts with clean oil before fitting them.
6. Always torque screws to the recommended torque. (Section 4.1)
7. Always use an even heat source such as an oil bath or induction heater to heat bearing
races prior to fitting. This will avoid damage to and distortion of the bearings.
3.3 OVERHAUL – RE-ASSEMBLY
1. Heat a roller bearing inner race using one of the methods described above (See 3.2.7) (Fig.
35) (Ensure outer race bearing in question is identified for future fitting to casing).
2. Fit the bearing race onto a rotor shaft and slide it fully home to the “shoulder”. Hold it in
place until has cooled onto the shaft journal. (It will tend to “creep” out of position as it cools
if this is not done) (Fig. 36).
Fig. 35 Fig. 36
34
3.3 OVERHAUL – RE-ASSEMBLY (Continued)
3. Repeat the process described above for the other three bearing inner races.
NOTE: Ensure that the outer and inner races are not switched between bearings.
4. Lubricate and fit new ‘O’ rings to the floating bush seals and refit the seals in the outlet end
bearing bores.
5. Insert anti-rotation pins into the floating bush retaining plates and fit them in the bearing
bores.
6. Ensure that the anti-rotation pins locate in the slots in the floating bushes (Fig. 37).
7. Lubricate the dished spring washers. Fit a spring washer convex side inboard at the
bottom of male outlet end casing bearing bore (Fig. 38).
8. Fit an oil inlet spacer in each of the outlet end casing bearing bores, slots facing outboard
(Fig. 39).
9. Push fit outer bearing race into male bearing bore of the outlet end casing (Fig. 40)
10. Repeat operations 7, 8 and 9 in female outlet casing bore.
Fig. 37 Fig. 38
Fig. 39 Fig. 40
35
11. Lubricate the rotors and use lifting gear to refit them in the main casing, it is easiest to fit the
female rotor first (The centre of gravity of each rotor is approximately mid-way along its
length).
12. The serial numbers stamped on the rotors should be matched up so that the serial numbers
on the outside edge of one “flute” of the female rotor meshes with the serial number at the
root of one lobe of the male on refitting (Fig. 41). Please note that some rotors do not have
serial numbers imprinted on the lobes.
13. Lubricate the slide valve and refit it in its bore. Move the slide valve into the bore as far as
possible (Fig. 42).
14. Check that the slide valve assembly moves freely in its bore.
Fig. 41 Fig. 42
36
15. Fit new bearing outer races in the inlet casing and secure them with circlips (Fig. 43).
Ensure bearings do not foul the ‘O’ ring and are pushed fully home in their bores.
16. Lubricate and refit the slide valve return spring (Fig. 44).
17. Lubricate and refit the slide valve stop (Fig. 45).
18. Refit the inlet end casing (with a new ‘O’ ring joint) using lifting gear. Secure the casing
loosely with a few washers and cap screws. Drive home the locating dowels with a soft
faced mallet. (Ensure that the threaded extraction hole in the dowel is exposed).
Fig. 43 Fig. 44
Fig. 45
37
19. Refit the rest of the washers and cap screws and torque them to the recommended value.
Refer to the torque sequence shown in Section 4.5 Figure 2.
20. Evenly heat a thrust bearing cartridge inner race to 20 degrees centigrade above ambient
using any of the methods described in Section 3.2.7.
21. Fit the assembly onto one of the rotor outlet end shafts taking care that the cartridge is
correctly oriented. (Fig. 46)
Fig. 46
22. Fit special tool (Disc Spring Loader) into bore and secure to 50Nm using capscrews and
washers (This compresses the disc washer and ensures the correct torque value can be
applied to the thrust bearing-retaining nut.) (Fig 47)
23. Fit retaining nut to shaft without the tab washer and torque to the value specified in Section
4.2-Special Instructions using special tool (Locknut Socket M50 (XRV163) and M65
(XRV204). (Fig 48)
Fig. 47 Fig. 48
38
24. Remove the locknut, fit a lockwasher, refit the locknut and torque it back to the full value.
(Fig 49) (Refer to Section 4.3 for the procedure for fitting lockwashers).
25. Repeat this process (from Subsection 20) for the other thrust assembly.
26. Fit the balance piston and spacer sleeve anti-rotation pins to the outlet end casing (Fig. 50).
27. Insert the balance piston sleeve without ‘O’ rings or Labyrinth insert into the outlet end male
bore, ensuring that it engages on the anti-rotation pin (Fig. 51).
Fig. 49
Fig. 50
Fig. 51
39
28. Set the male rotor outlet end clearance by the following procedure:
Set up a dial indicator as for checking the outlet end clearance. Zero the gauge, fit the cover
plate without an ‘O’ ring and torque the cover plate cap screws and record the reading on
the gauge (Figs. 52 & 53).
Remove the cover plate and balance piston sleeve and grind the sleeve to set the outlet end
clearance.
The amount to be ground off the sleeve is equal to the gauge reading minus the required
rotor outlet end clearance.
Refit the balance piston sleeve and cover plate, set gauge to zero and torque cover plate
cap screws and check that the gauge reading is equal to the required rotor outlet end
clearance.
Fig. 52 Fig. 53
40
28. Remove the cover plate and balance piston sleeve.
29. Fit a replacement labyrinth insert seal to the balance piston sleeve as follows:
Apply Loctite 275 to the outer diameter of the labyrinth insert seal and push fit the seal into
the balance piston sleeve (Fig. 54).
30. Lubricate and fit ‘O’ rings to the balance piston sleeve and rotor cover plate, refit them taking
care not to trap the piston sleeve ‘O’ rings as they pass the oil port. Refit the cap screws,
and torque them fully. See Section 4.1
31. Insert the spacer sleeve into the outlet end female bore, ensuring that it engages on the anti-
rotation pin (Fig. 55).
Fig. 54 Fig. 55
32. Fit the cover plate without an ‘O’ ring and push it home.
33. Repeat the process of setting the clearance. (Subsection 28) for the female rotor and spacer
sleeve, adjust the clearance by grinding the spacer sleeve as required.
34. Remove the cover plate, lubricate and fit an ‘O’ ring and refit with cap screws, torque them
fully.
41
36. Check that the slide valve assembly moves freely in its bore (Fig. 56).
37. Lubricate and refit the return spring and slide valve stop (Fig. 57 & 58).
38. Refit the inlet end casing (with a new ‘O’ ring joint) using lifting gear.
39. Secure the casing loosely with a few washers and cap screws and drive home the locating
dowels with a soft faced mallet. (Ensure that the threaded extraction hole in the dowel is
exposed).
Fig. 56 Fig. 57
Fig. 58
42
40. Check that the rotors can rotate in the casings.
41. Refit the rest of the washers and cap screws and torque them to the recommended value
Refer to the torque sequence shown in Section 4.5 Figure 2
42. Again, check that the rotors can rotate in the casings.
43. Refit the balance piston sleeve ensuring that the sleeve locates on the anti- rotation pin (Fig.
59).
44. Refit the cover plate and check that the rotor outlet end clearance is within tolerance. Set up
a dial indicator at the inlet end of the male rotor (Fig. 60). Zero the dial and slacken back the
cap screws securing the rotor outlet end shaft cover. The reading obtained on the dial
represents the rotor outlet end clearance. Check this is within tolerance in Section 4.2.
45. Repeat the process for the female rotor, using a screw extension as shown (Fig 61)
Fig. 59 Fig. 60
Fig. 61
43
46. Lubricate and fit ‘O’ rings to the balance piston sleeve and refit the sleeve taking care that
the ‘O’ rings are not damaged by the oil port between the two bores (Fig. 62).
47. Repeat the procedure from Step 9 for the spacer sleeve on the female rotor side.
48. Lubricate and refit the balance piston on the male outlet end shaft (Fig. 63) and secure it
with a new lockwasher and locknut (Fig. 64)
49. Using a locknut spanner, torque the locknut (Fig. 65) to the recommended value using the
procedure described in Section 4.1.
Fig. 62 Fig. 63
Fig. 64 Fig. 65
44
50. Renew and lubricate the ‘O’ rings on the Vi adjusting assembly cover.
51. Lubricate and refit the assembly in the inlet end casing taking care that the driving dogs of
the Vi adjusting assembly engages in the slide valve stop (Fig. 66).
52. Refit the cap screws and washers and torque them to the recommended value.
53. Lubricate and fit new ‘O’ rings on the outlet end shaft covers and refit. Ensure that the
marks made when dismantling are matched up on re-assembly (Refer to Section 3.1.23).
Fig. 66
45
54. Refit the washers and cap screws and torque them evenly to the recommended value
(Section 4.1).
55. Lubricate and fit a new actuator piston lip seal on the actuator piston ensuring the lip seal is
fitted the right way round (Fig. 67). Fit piston seal to piston and press firmly on the outer
edge of the entire seal circumference until the seal is heard to “click” into position. Failure to
do so will result in premature failure of the piston seal, and incorrect compressor operation.
Refit ‘O’ ring to piston using a small amount of grease to hold it in place. (Fig 68)
56. Refit the actuator piston seal assembly in the actuator cylinder using the extraction rods
taking care to avoid damaging the lip seal (Fig. 69).
57. Apply Loctite 243 to the locknut and slide valve insert thread. Fit lockwasher and locknut to
shaft. Use special tool to centralise piston in cylinder bore and fit support bracket, securing
with capscrews. Insert locknut socket through support bracket and torque locknut (Fig.70) to
80Nm for XRV163 compressor or 160Nm for XRV204 compressor. Ensure slot in locknut is
aligned with M5 tapped hole in piston. Apply Loctite 243 to grub screw and tighten into
piston. Torque to 10Nm.
NOTE: Compressors not requiring lockwasher fitted to actuator piston:

XRV163-MK2C Onwards.
XRV204-MK3D Onwards.
Fig. 67 Fig. 68
Fig. 69 Fig. 70
46
58. Fit the indicator spindle guide pin, if fitted into its recess using a small amount of grease to
hold it in place.
59. Lubricate and fit a new ‘O’ ring on the actuator cylinder cover/indicator spindle assembly.
60. Insert the indicator spindle into the piston rod bore, taking care that the guide pin engages in
the groove that was marked on dismantling. For compressors fitted with linear position
indicator insert sensor well into aluminium target tube held in slide valve rod.
61. Fit cylinder minimum capacity stop spacers and use the threaded bar that was used for
dismantling the actuator cylinder cover to draw it back into place (Fig. 71 & 72) and fit the
washers and cap screws. Torque them to the recommended value (Section 4.1).
Fig. 71 Fig. 72
47
62. Lubricate and fit a new ‘O’ ring on the inlet end female shaft cover and refit the shaft cover.
64. Lubricate and refit the labyrinth seal on the driveshaft, ensuring that the notch engages on
the drive pin (Fig. 74).
65. Fit a new shaft seal ensuring that the seal engages on the drive pin in the labyrinth seal
(Fig. 75).
Fig. 73 Fig. 74
Fig. 75
48
3.3 OVERHAUL – RE-ASSEMBLY
66. Fit new ‘O’ rings and a stationary shaft seal seat on the inlet end driveshaft cover (Fig. 76)
and refit the driveshaft cover (Fig. 77).
Failure to do this carefully may result in damage to the shaft seal (Fig. 78).
68. Refit the oil drain plug to the bottom of the inlet end casing (Fig. 79).
69. If the compressor unit has been removed from its bedplate for inspection, refit it and realign
it using the method described in Section 4.6 or XRV Installation Manual.
Fig. 76 Fig. 77
Fig. 78 Fig. 79
49
70. Refit and reconnect any electrical equipment that was removed when dismantling the
actuator cylinder (Fig. 80).
71. Refit the microswitch cover and secure it with cap screws (Fig. 81).
Fig. 80 Fig. 81
NOTE: Reset Vi adjusting screw to original position.
50
SECTION 4
SPECIAL
INSTRUCTIONS
51
4.1 TORQUE SPECIFICATIONS
COMPRESSOR TYPE XRV 163
FASTENER TOOL APPLICATION TORQUE (Nm)
Locknut 30 mm Special XR16006J Actuator Piston 80*
Locknut 30mm Special XR16006J O.E Balance Piston 130
Locknut 50mm Special XR16005J Thrust Assy Locknut 175
Hex Head Screw 10mm Socket 17mm Spacer Sleeve Screws 30
Socket cap screw M10 8mm Hex Drive Vi Cover Screws 30
Socket cap screw M12 10mm Hex Drive Cylinder Cover Screws 50
Socket cap screw M12 10mm Hex Drive Thrust Bearing Covers 55
Socket cap screw M12 10mm Hex Drive Rotor Cover Screws 240
Socket cap screw M16 14mm Hex Drive Inlet Casing Screws 240
Socket cap screw M5 4mm Hex Drive Microswitch Cover 5
* Indicates that threads should be coated with Loctite 243
COMPRESSOR TYPE XRV 204
FASTENER TOOL APPLICATION TORQUE (Nm)
Locknut 35 mm Special XR20002J Actuator Piston 160*
Locknut 40mm Special XR20003J O.E Balance Piston 210
Locknut 65mm Special XR20001J Thrust Assy Locknut 250
Hex Head Screw 10mm Socket 17mm Spacer Sleeve Screws 30
Socket cap screw M10 8mm Hex Drive Vi Cover Screws 30
Socket cap screw M12 10mm Hex Drive Cylinder Cover Screws 50
Socket cap screw M12 10mm Hex Drive Thrust Bearing Covers 95
Socket cap screw M12 10mm Hex Drive Rotor Cover Screws 50
Socket cap screw M16 14mm Hex Drive Inlet Casing Screws 240
Socket cap screw M5 4mm Hex Drive Microswitch Cover 5
* Indicates that threads should be coated with Loctite 243
52
4.2 COMPRESSOR OUTLET END (OE) CLEARANCES
XRV 163 Range Compressors

OE clearance 0.100/0.125mm (0.004/0.005”)
XRV 204/110, 145 & 165 Compressors

XRV204/193 (Up to MK3C Serial No 071)
OE clearance 0.100/0.125mm (0.004/0.005”)
XRV 204/193 Compressors from MK3C Serial No 072 onwards.

OE clearance 0.200/0.250mm (0.008/0.010”)
Thrust Bearing Float
XRV163 and XRV204 0.003mm/0.0001”maximum.
53
4.3 PROCEDURES FOR FITTING LOCKWASHERS
This instruction applies to all lockwashers used on Howden compressors for locking shaft locknuts in
place eg thrust bearing locknuts, piston rod locknuts, etc. A typical example is shown below (Fig. 1).
Fig. 1
Assembly Method:
When using this type of lockwasher, the locknut should be assembled to the shaft without the
lockwasher and torqued to the prescribed value. The locknut must then be removed, the lockwasher
dipped in oil and fitted to the shaft, and the locknut replaced and again torqued to the prescribed
value.
This assembly process limits the amount of relative movement between the locknut and lockwasher
and avoids the possibility of the inner tang being damaged during assembly.
54
4.4 SPECIAL TOOL LIST - COMPRESSOR TYPE XRV163
The following list of special tools are those required to allow the correct dis-assembly and re-assembly
of the XRV163 range of compressors.
Failure to use the correct special tool may result in severe damage or premature failure of the unit.
DESCRIPTION OF SPECIAL TOOL QTY PART NUMBER
LOCKNUT SOCKET M50 1 XR16005J
ROTOR ANTI-ROTATION TOOL 1 XR16009J
ROTOR JACKING PLATE (MK.1 / XRV163) 1 XR20008J
ROTOR JACKING PLATE (MK2 / XRV163) 1 XR16019J
LOCKNUT ADJUSTING DRIVE 1 XR20006J
EXPANDING TOOL AUTO Vi ONLY 1 XR16524J
DISC SPRING LOADER 1 XR16020J
PISTON CENTRALISING TOOL 1 XR16533J
LOCKNUT SOCKET SUPPORT 1 XR16534J
55
4.4 SPECIAL TOOL LIST - COMPRESSOR TYPE XRV 204
The following list of special tools are those required to allow the correct dis-assembly and re-
assembly of the XRV204 range of compressors.
Failure to use the correct special tool may result in severe damage or premature failure of the unit.
DESCRIPTION OF SPECIAL TOOL QTY PART NUMBER
ROTOR ANTI-ROTATION TOOL 1 XR20007J
ROTOR JACKING TOOL (MK1 & MK2 / XRV204) 1 XR20008J
ROTOR JACKING TOOL (MK3 / XRV204) 1 XR20021J
LOCKNUT ADJUSTING DRIVE 1 XR20006J
EXPANDING TOOL AUTO Vi ONLY 1 XR20742J
DISC SPRING LOADER 1 XR20022J
PISTON CENTRALISING TOOL 1 XR20753J

LOCKNUT SOCKET SUPPORT 1 XR20754J
56
4.5 PROCEDURE FOR RE-FITTING INLET CASING
1. Ensure that the inlet and outlet casing flanges are free from dirt and metal burrs.
2. Install the ‘O’ rings without using grease or jointing compounds.
3. When replacing the cap screws, ensure they are free of dirt and grit, and always fit new
washers.
4. Tighten the cap screws in two stages, following the sequence shown in Fig. 2 below in both
stages.
Initial Torque 120 Nm

Final Torque 240 Nm
5. On completion, give the cap screws a final check for tightness, working round the flange in a
clockwise direction.
Fig 2.
NOTE: XRV 204 bolt layout is similar but there are 17 bolts of same size and same torque as on
XRV 163.
57
4.6 ALIGNMENT OF COMPRESSOR COUPLINGS
Misalignment causes a vibration that affects other parts of the compressor, leading to premature
failure of bearings, seals, etc. Drive couplings fitted to XRV compressors must be aligned correctly.
The coupling alignment tolerance figures can be seen under the following.
Coupling gap dimensions should be set with the coupling held in a repeatable position, ie, hard
together or hard apart. This ensures that each coupling half is moved to the same axial position as
each check is made.
The actual coupling gap should be correct when the shafts are in their normal running condition.
When setting the gap, the axial float of each shaft should be determined and the "hard together" or
"hard apart" dimensions calculated.
EXAMPLE: Compressor driven directly by turbine
Compressor shaft float 0.000mm (0.000")
Turbine shaft float 0.250mm (0.010")
The normal running position of the compressor shaft is thrusting towards the turbine and the turbine
thrusting towards the compressor.
Required coupling gap 3.175mm (0.125")
If the gap is checked with the coupling "hard apart" it should be :-
Required coupling gap 3.175mm (0.125")

plus Compressor shaft float 0.000mm (0.000")
plus Turbine shaft float 0.250mm (0.010")
===================== ==============
= "Hard apart" gap 3.425mm (0.135")
If the gap is checked with the coupling "hard together", ie in the normal running condition, it should
be equal to the required gap 3.175mm (0.125").
58
4.6 COUPLING ALIGNMENT - BASIC RULES
1. Compressor to be mounted on baseframe and mounting feet checked for soft foot and
corrected where necessary.
2. Alignment to be set before connecting any pipework to the compressor.
Allowable TIR = +/- 0.10mm Radially and Axially.
3. Under no circumstances should suction and discharge piping be strained into position.
Distortion of the casing will cause premature failure of the compressor. A vertical and
horizontal clock gauge must be mounted on the compressor input shaft/coupling hub to
ensure no alteration occurs when pipes are being connected. Only after this is completed,
should the coupling hubs be connected.
NOTE: Coupling hubs must not be hammered onto the compressor shaft.
4.7 PIPING
Note that the oil pipes and fittings used should not restrict flows. To avoid this, always use piping
with an OD 1/4" (6mm) larger than the thread diameter of the compressor port eg connection thread
is 3/4" BSP and so a 1"OD pipe or metric equivalent should be used.
NOTE: If the compressor is being fitted into a system where there is a high inlet pressure and low
pressure difference, then it is advisable to connect the oil drain from the actuator cylinder to
the compressor suction line. This will assist the desired speed of unloading. An example of
this condition would typically be in R717 refrigerant with the inlet pressure of 4 bar A and
delivery pressure of 12 bar A.
Before installing the piping, the compressor gas inlet and outlet ports and oil injection holes should
be inspected to ensure no dirt is present.
NOTE: All piping should be supported so that no strain is transmitted to the compressor casing.
The piping should be inspected for cleanliness before installation. As each pipe is connected to the
compressor, the coupling alignment should be checked to ensure that no alteration has taken place.
If alignment has altered, the compressor is being strained, the pipes should be corrected, and the
supports adjusted accordingly.
It is not acceptable to re-align the drive unit, as this will not correct the strain being imposed on the
compressor. Oil injected refrigeration compressors must have a suction strainer permanently fitted
on the compressor inlet.
When fitting the suction flange to the compressor, ensure that the tapped holes in casing are cleaned
out and free from water. Fit setpins/studs, coating the threads with pipe sealer to prevent ingress of
water into tapped holes.
59
SECTION 5
SPARES
60
RECOMMENDED SPARES LIST
HOWDEN COMPRESSOR MODELS

MK2, 2A, 2B, 2C, 2D, & MK3 XRV 163/165 & 193
Replacement Shaft Seal Kit – KXS163

PART NUMBER DESCRIPTION QUANTITY
G60205 Input Shaft Seal 1
XR16105-3 ‘O’ Ring – Seal Housing 1
Annual Inspection Kit – KX163-2C

M0905010 Grub Screw 1
M1701010 Washer – 10mm Dia. 4
XR16079-3 Actuator Piston Seal 1
XR16102-3 ‘O’ Ring – Piston/Slide Valve 1
XR16105-3 ‘O’ Ring – Covers 3
XR16522-2 Indicator Pin 1
XR16515-3 Locknut M30 (S/Lock) (up to Mk2B) 1
Overhaul Kit – KX163

G33002 Bonded Seal ½” BSP 3
G33003 Bonded Seal ¾” BSP 4
G33010 Bonded Seal 1/8”BSP 2
G51001 Ball Bearing (Actuator Spindle) 1
G57057 Microswitch 2
G60004 Retaining Ring 1
G60175 Circlip 2
Q4521 Lockwasher 50mm 2
XR16029-2 Outlet End Floating Bush 2
XR16047-2 Labyrinth Insert 1
XR16049-4 Thrust Bearing Assembly 2
XR16072-3 Superfeed Joint 1
XR16080-2 Disc Spring 2
XR16531-3 Cylindrical Roller Bearing 4
XR16295-3 Potentiometer (1k OHM) 1
XR16101 - OK ‘O’ Ring Kit 1 Kit containing:
G44005 – ‘O’ Ring – Indicator. Spindle 1
G44065 – ‘O’ Ring – Main/Outlet 2
XR16102-3 – ‘O’ Ring – Piston/Slide Valve 1
XR16101-3 – ‘O’ Ring – Man. Vi Spindle 2
XR16104-3 – ‘O’ Ring – Gas Seals 2
XR16105-3 – ‘O’ Ring – Covers etc. 9
XR16106-3 – ‘O’ Ring – Inlet Bearings 2
XR16460-3 – ‘O’ Ring – Vi Cover 1
Additional Parts: KX163 – AUTO Vi

M1701004 Washer – 4mm. 2
M1701005 Washer – 5mm. 3
G33010 Bonded Seal 1/8” BSP 2
XR20776-3 ‘O’Ring 1
XR16280-3 Variseal 4mm. 1
XR16265-3 Glyd Ring 1
XR16266-3 Slyd Ring 1
61
RECOMMENDED SPARES LIST
HOWDEN COMPRESSOR MODELS

Mk3, 3A, 3B, 3C, 3D & 3E XRV 204/110, 145, 165 & 193
Replacement Shaft Seal Kit – KXS204

G60224 Shaft Seal 1
XR20104-3 ‘O’ Ring - Seal Housing 1
Annual Inspection Kit – KX204-3D

R25065 Indicator Pin 1
XR20100-3 ‘O’ Ring – Slide Valve/Piston 1
XR20104-3 ‘O’ Ring – Act. Cylinder Cover 4
XR20875-3 Actuator Piston Seal 1
XR20782-3 Locknut M35 (S/Lock) (up to Mk 3C) 1
M0905010 Grub Screw 1
Overhaul Kit – KX204

G33002 Bonded Seal ½” BSP 3
G33003 Bonded Seal ¾” BSP 4
G33008 Bonded Seal ¼” BSP 1
G33010 Bonded Seal 1/8”BSP 2
G51001 Ball Bearing (Actuator Spindle) 1
G57057 Microswitch 2
G60017 Circlip 2
XR16295-3 Potentiometer (1k OHM) 1
XR20042-2 Outlet End Floating Bush 2
XR20053-2 Labyrinth Insert 1
XR20237-3 ‘O’Ring – Man. Vi Adjustment 2
XR20060-2 Disc Spring 2
XR20101 - OK ‘O’ Ring Kit 1 Kit containing:
G44005 – ‘O’ Ring – Indicator Spindle 1
G44066 – ‘O’ Ring – Inlet/Main/Outlet 2
XR16105-3 – ‘O’ Ring – Vi Adj. Cover 1
XR20100-3 – ‘O’ Ring – Slide Valve/Piston 1
XR20102-3 – ‘O’ Ring – Gas Seal 2
XR20104-3 – ‘O’ Ring – Covers etc. 8
XR20105-3 – ‘O’ Ring – Inlet Bearing 2
XR20520-4 Thrust Bearing Assembly 2
Additional Parts: KX204 – AUTO Vi

G33010 Bonded Seal 1/8” BSP 2
XR20776-3 ‘O’Ring 1
XR16280-3 Variseal 4mm 1
XR20730-3 Glyd Ring 1
62
Our Compressor Business Unit can offer you a comprehensive range of facilities to ensure the continued
reliable operation of your Howden compressor.
We can supply:
1. A comprehensive range of direct replacement compressors, supplied with a warranty.
2. Approved parts and technical information to allow urgent repairs to be carried out on site.
3. A field engineer to service or supervise the installation and commissioning of compressors.
4. Quotations for price and delivery of spare parts.
5. A comprehensive service contract or survey incorporating full vibration analysis tailored

specifically to meet customer requirements and time schedules.
For further information and details of the above, please contact our Compressor Business Unit directly:
Howden Compressors or Howden Compressors LLC

Compressor Business Unit 1850B North Gravers Road
133 Barfillan Drive Plymouth Meeting
Glasgow PA 19462
G52 1BE USA
UK
Telephone: 001 610 313 9800
Telephone: +44 (0)141 882 3346 Fax: 001 610 313 9215
Fax: +44 (0)141 882 8648 E-mail: sales@howdencompressors.com
E-mail: hcl@aftersales@howden.com Web: www.howden.com
Website : www.howden.com
63
Printed in the UK – Issue HCL/September 2007
© Howden Compressors Limited
64

XRV 163 &amp; 204 Service Manual

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XRV 163 &amp; 204 Service Manual

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XRV 163 & 204

SECTION 2 ANNUAL INSPECTION 6

SECTION 4 SPECIAL INSTRUCTIONS

READ CAREFULLY BEFORE STARTING WORK ON YOUR COMPRESSOR

These instructions relate to XRV 163 & 204 Compressors.

All requests for information, services or spares should be directed to:

Howden Compressors or Howden Compressors LLC

1. Isolate the drive unit.

2. Depressurise and purge the system.

3. Disconnect the drive unit coupling from the compressor.

1.3 PRECAUTIONS DURING SHUTDOWN

3. Disconnect/remove any electrical equipment fitted if it is going to obstruct further

12. Unscrew the M5 locking grub screw from the locknut.

15. Locate and remove the indicator spindle guide pin.

NOTE: Compressors not requiring lockwasher fitted to actuator piston:

5. Remove special tooling used for centralising actuator piston.

NOTE: Reset Vi adjusting screw to original position.

3. Disconnect/remove any electrical equipment fitted if it is going to obstruct further

15. Unscrew the M5 locking grub screw from the locknut.

47. Repeat the process of removal for the female rotor.

On re-assembly, the procedures listed below should be followed:

2. Always refer to the relevant drawing.

3. Always replace consumable items on re-assembly.

6. Always torque screws to the recommended torque. (Section 4.1)

3.3 OVERHAUL – RE-ASSEMBLY

10. Repeat operations 7, 8 and 9 in female outlet casing bore.

28. Remove the cover plate and balance piston sleeve.

40. Check that the rotors can rotate in the casings.

Refer to the torque sequence shown in Section 4.5 Figure 2

NOTE: Compressors not requiring lockwasher fitted to actuator piston:

NOTE: Reset Vi adjusting screw to original position.

COMPRESSOR TYPE XRV 163

FASTENER TOOL APPLICATION TORQUE (Nm)

Locknut 30 mm Special XR16006J Actuator Piston 80*

Locknut 30mm Special XR16006J O.E Balance Piston 130

Locknut 50mm Special XR16005J Thrust Assy Locknut 175

Hex Head Screw 10mm Socket 17mm Spacer Sleeve Screws 30

Socket cap screw M10 8mm Hex Drive Vi Cover Screws 30

Socket cap screw M5 4mm Hex Drive Microswitch Cover 5

* Indicates that threads should be coated with Loctite 243

COMPRESSOR TYPE XRV 204

FASTENER TOOL APPLICATION TORQUE (Nm)

Locknut 35 mm Special XR20002J Actuator Piston 160*

Locknut 40mm Special XR20003J O.E Balance Piston 210

Locknut 65mm Special XR20001J Thrust Assy Locknut 250

Hex Head Screw 10mm Socket 17mm Spacer Sleeve Screws 30

Socket cap screw M10 8mm Hex Drive Vi Cover Screws 30

Socket cap screw M5 4mm Hex Drive Microswitch Cover 5

* Indicates that threads should be coated with Loctite 243

XRV 163 Range Compressors

XRV 204/110, 145 & 165 Compressors

XRV 204/193 Compressors from MK3C Serial No 072 onwards.

Thrust Bearing Float

XRV163 and XRV204 0.003mm/0.0001”maximum.

DESCRIPTION OF SPECIAL TOOL QTY PART NUMBER

LOCKNUT SOCKET M50 1 XR16005J

LOCKNUT SOCKET M30 1 XR16006J

ROTOR ANTI-ROTATION TOOL 1 XR16009J

ROTOR JACKING PLATE (MK.1 / XRV163) 1 XR20008J

ROTOR JACKING PLATE (MK2 / XRV163) 1 XR16019J

LOCKNUT ADJUSTING DRIVE 1 XR20006J

EXPANDING TOOL AUTO Vi ONLY 1 XR16524J

DISC SPRING LOADER 1 XR16020J

PISTON CENTRALISING TOOL 1 XR16533J

XRV 163 & 204 Service Manual

XRV 163 & 204 Service Manual