Download Maintenance and Repair Manual: For JGC:D:F Heavy Duty Balanced Opposed Reciprocating Compressors...
Maintenance and Repair Manual For JGC:D:F Heavy DutyCompressors Balanced Opposed Reciprocating
ARIEL CORP ARIEL CORPORATI ORATION ON 35 BL BLAC ACKJ KJAC ACK K ROA ROAD, D, MOUN MOUNT T VE VERN RNON, ON, OHI OHIO O 4305 43050 0 TELEPH TEL EPHONE: ONE: 740 740-397 -397-031 -0311 1 FAX FAX:: 740740-397397-3856 3856 VISI VI SIT T OUR WEB SI SITE TE:: ww www. w.ari arielc elcorp orp.co .com m
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For models models JGC:D:F JGC:D:F
Table of Contents Table of Contents
i
General Sa S afety for Reciprocating Compressors
vi
Throw and Data Plate Locations
vii
Other Ariel Resources
viii
Ariel Website Ariel Ariell Technical and Arie and Service Schoo Schools ls Ariell Contact Information Arie Information
viii viii viii
SECTION 1 - TOOLS
Ariel Optional Furnished Tools
1-1
Ariel Separately Purchased Tools
1-2
Ariell Separately Arie Separately Purch Purchased ased Tool Tool Kits
Recommended Tools
1-2
1-3
SECTION 2 - INSTRUMENTATION
Digital No-Flow Timer (DNFT) DN FT Installation Programmable DNFTs DN FT Battery R eplacement Troubleshooting DN FT’s
Proximity Switch A-18255 Proximity Sw itch Installation Troubleshooting Proximity Sw itches
Prof ofllo Lubr briicator Fluidd-Fl Flo ow Moni nittor or//NoNo-Fl Flo owTimer Sw Swiitch Normally Open and No Normally Closed D De efinition Proflo Installation Proflo Button Operation Display Errors Proflo Battery R eplacement
Proflo Jr. No-Flow Switch Proflo Jr. Installation Proflo Jr. Bat tery Replacement
2-4 2-4 2-6 2-8 2-9
2-10 2-10 2-12
2-13 2-13 2-14 2-14 2-15 2-16
2-17 2-17 2-18
Main Bearing Temperature Alarms and Shutdown
2-19
Thermocouples - J (Iron-C onstantan) or or K (Chromel-Alumel) Resistance Temperature D evices (R TD’s)
2-19 2-19
SECTION 3 - MAINTENANCE
Initial Maintenance
3-1
Daily Maintenance Monthly Maintenance Six-Month (4,000-Hour) Maintenance One-Year (8, 000-Hour) Maintenance
3-3 3-3 3-4 3-4
Tw o-Year (16,000-Hour) Maintenance Three-Year (24,000-Hour) Maintenance Four-Year (32,000-H our) Maintenance Six-Year (48, 000-Hour) Maintenance
3-5 3-6 3-6 3-6
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For models models JGC:D:F JGC:D:F
Frame Oil Viscosity Oil Pressure Oil Temperature Oil Maintenance Dry Sump Oil System Cleanliness
3-7 3-7 3-7 3-7 3-9 3-9 3-9
Frame Oil System Components
3-11
Flushing to Change to a PAG Lu Lubricant
3-13
Recommended Flushing Oil Flushing Procedure Flushing the Force Feed Lubrication System Common Oil Supply Independent Oil Supply Oil Temperature Control Valve Oil Filter Simplex Spin-on Filter Replacement Simplex Filter C artridge Replacement
3-13 3-13 3-14 3-14 3-15 3-16 3-16 3-16 3-17
Duplex Filter Cartridge Replacement Compressor Pre-lube Syst em Oil Heaters
3-18 3-18 3-19
Oil Strainer Oil Pump & R egulating Valve Oil Cooler
Force Feed Lubrication System Components Force Feed Lubricat or Priming the Pump Pump Adjustment Force F Fe eed Lu Lube B Bllow-Out Fittings, Rupture Di D isks, and Tu Tubing Distribution Blocks Distribution Block Assembly Divider Valve Bypass Pressure Test Balance Valves Adjustment Adjustme nt of Balance Valves Fed by a Divider Block Adjustment Adjustme nt of Balance Valves Fed by Primary/Seconda Primary/Secondary ry Divider Blocks Subsequent Compressor Start-Up
Force Feed System Design & Operating Parameters Common Oil Supply Independent Oil Supply
Force Feed Lubrication Conditions Lubricator Cycle Time Under/Over Lube Cylinder Lubricat ion Paper Test Coolant System Requirements
3-12 3-13 3-13
3-19 3-20 3-20 3-20 3-21 3-22 3-22 3-23 3-24 3-25 3-2 5 3-26 3-26 3-26
3-27 3-28 3-29
3-30 3-30 3-31 3-31 3-32
SECTION 4 PART REPLACEMENT
Positioning a Throw
4-1
Variable Volume Clearance Pocket (VVCP)
4-2
VVCP Removal VVCP Disassembly VVCP Reassembly
ii
4-2 4-2 4-4
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For models models JGC:D:F JGC:D:F
VVCP Installation VVCP Adjust ment
Compressor Valves - Removal a an nd Installation
4-5 4-5
4-6
Required Tools and Materials Valve Cap R emoval Va Valve lve Cap Caps s on Cast Iron Iron Cyli Cylind nder ers s or Hig Highh-Pr Pressu essure re Cap Caps s withou withoutt Spri Spring ng Ener Energi gized zed Seal Seals s Valve Cap with Spring Energized Seal
4-6 4-7 4-7 4-7 4-8
Valve Removal Valve Installation Valve Cap Installation Torque Va Valve lve Cap Caps s on Cast Iron Iron Cyli Cylind nder ers s or Hig Highh-Pr Pressu essure re Cap Caps s withou withoutt Spri Spring ng Ener Energi gized zed Seal Seals s Valve Caps w ith Spring Energized Seals Gas C ontainment Fast ener Torque Checks
4-8 4-9 4-9 4-10 4-10 4-10 4-11 4-11
Piston and Rod
4-12
Piston and Rod Removal Hydraulic Torque Tools Hydraulic Torque Tool Repair Kits Piston a an nd R Ro od D Diisassembly wit h H Hy ydraulic Torque T To ool Piston and Rod Reassembly with H ydraulic Tool Piston and Rod Inst allation
4-12 4-13 4-13 4-13 4-15 4-17
Piston Rod R unout
4-18
Piston Rings High-Pressure Face-Cut Pist on Rings Wear Bands
Piston Rod Packing Piston Rod Packing Removal Piston Rod Packing Reassembly Long Two-Compartment Intermediate Packing Types of Piston Rod Packing Rings “P” Pressure Breaker “UP” Pressure Breaker “P1U” Pressure Breaker “BTR” Single-Acting Seal Set “BD ” D ouble-Acting Seal Set "WAT" D ouble-Acting Seal Set “AL” Double-Acting Seal Set “BTU” Single-Acting Seal Set “BTUU” Single-Acting Seal Set “CU” Single-Act ing Seal Set “STU” Single-Acting Seal Set “CR” Single-Act ing Seal Set “3R WS” Oil Wiper Set Arrang Arr angeme ement nt of Piston Rod Packing Rings Piston Rod Packing Ring Material
Water-Cooled Piston Rod Packing Reassembly Testing
Cro eeaad Cs rossh sh ds Removal Crosshead Installation
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4-19 4-19 4-20
4-20 4-20 4-21 4-22 4-22 4-23 4-23 4-23 4-23 4-24 4-24 4-24 4-24 4-25 4-25 4-25 4-25 4-26 4-26 4-2 6 4-26
4-26 4-26 4-27
44--2278 4-29
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For models models JGC:D:F JGC:D:F
Connecting Rods
4-31
Connecting Rod Removal Connecting Rod Bearing Removal Connecting Rod Bearing Installation Connecting R Ro od Bu Bushing Re Removal and In Installation Connecting Rod Installation Connecting R o od d Bearing V e errtical Jack Clearance M e ea asurement Connecting R Ro od Th Thrust (Side) Cl Clearance Me Measurement
4-32 4-32 4-34 4-35 4-36 4-37 4-37
Measuring Head End Measuring E nd Clearance for Forged Steel Tandem Cylinders Cylinders wit with h Concentric Valves
4-38
Crankshaft
4-40
Crankshaft Removal Oil Slinger Replacement Main Bearing Removal Main Bearing Installation Main Be Bearing Ve Vertical Jack C learance M Me easurement Crankshaft Thrust (End) Cl Clearance M Me easurement Crankshaft Installation
4-40 4-41 4-41 4-42 4-42 4-43 4-43
Chain Drive System
4-44
Chain and Sprocket Replacement
4-45
Chain I dl dler S pr procket Replacement (Eccent ric Adjustment Caps) Lube Oil Pump Sprocket R eplacement Force F Fe eed L Lu ubricat or Ch Chain Sp Sprocket R eplacement Crankshaft Chain Sprocket R eplacement Chain Adjustment
4-46 4-46 4-47 4-48 4-48
Component Compone nt Cleani Cleaning ng & Thread Thread Lube Lube for for Non-Lube Non-Lube Compressor Compressor Cylinder Cylinders s
4-49 4-49
SECTION 5 - START UP Warranty Notification - Installation List Dat a
5-1
SECTION 6 - COMPRESSOR TROUBLESHOOTING APPENDIX A - ARIEL FASTENERS AND TORQUES
Recommendations for Torque Accuracy
A-2
APPENDIX B - CLEARANCES APPENDIX C - FRAME SPECIFICATIONS
JGC:D:F Frame Specifications
C-1
Opposed Throw - Reciprocating Weight Balancing
C-3
APPENDIX D - COMPRESSOR CLEARANCE, OIL, AND TEMPERATURE RECORD APPENDIX E - BALANCE VALVE LOG APPENDIX F - ER-34.1
Cleaning, Handling, and Assembly Assembly Lubricants Lubricants for for Non-Lubricated Non-Lubricated Compressor Cylinders
F-1
APPENDIX G - ER-82
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For models models JGC:D:F JGC:D:F
Soft Foot and Top Plane Flatness Checks for Proper Main Bearing Bore Alignment in Reciprocating Compressors
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v
General Safety for Reciprocating Compressors CAUTION: Gas compressor packages are complicated and dangerous to those unfamiliar with their operation. Only properly trained personnel should operate or maintain this equipment. Before starting: • Carefully study start-up start-up and shut-down information for both package and compressor. DO NOT attempt to start-up compressor without referring to the StartUp Checklist in the appropriate Ariel Maintenance and Repair Manual and the Packager’s Operating Manual. • Sufficiently purge the compressor compressor of any explosive explosive mixture mixture before loading. A gas/air gas/air mixture under pressure can explode and cause severe injury or death! • Follow in detail all all start-up requireme r equirements nts for the other package components. components. When the symbol to the right appears on a compressor or control panel, consult the appropriate Ariel Maintenance and Repair Manual for specific information before proceeding. The Maintenance and Repair Manual applies to current design and build; it may not apply to equipment built prior to the date on the front cover and is subject to change without notice. For questions of compressor safety, operation, maintenance, or repair, contact your packager or Ariel.
CAUTION: Severe personal injury and property damage can result if the compressor is not completely vented before loosening bolts on flanges, heads, valve caps, or packing. Consult the appropriate Ariel Maintenance and Repair Manual before performing any maintenance. CAUTION: Noise generated by reciprocating machinery may damage hearing. See Packager information for specific recommendations. Wear hearing protection during compressor operation. CAUTION: Where applicable, compressor installation must conform to Zone 1 requirements. A Zone 1 environment requires installation of proper intrinsically safe or equivalent protection to fulfill electrical requirements. CAUTION: Hot gas temperatures (especially the cylinder discharge), 190°F (88°C) oil, and high friction areas. Wear proper protection. Shut down unit and allow to cool before maintaining these areas. CAUTION: Suction or discharge valves installed in improper locations may result in severe personal injury and property damage.
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For models models JGC:D:F JGC:D:F
Throw and Data Plate Locations When conta When contact cting ing Ariel Ariel with compr compres esso sorr questi questions ons,, know know thro throw w locati locations ons and inform informati ation on on data data pl plate ates s fasten fas tened ed to the machin machine. e. Thi This s da data ta helps helps Ariel Ariel repres represent entati ative ves s an answer swer quick quickly ly an and d ac accu curate rately ly.. Contac Contactt Ariel for replacem replacement ent if any data plates plates are mis missing sing..
1. VVCP Dimension Plate 2. VVCP Data Plate 3. Mechanical Inspect Inspector or Plate and Frame Fram e Serial Number Stamp 4. Compressor A Auxiliary uxiliary End
5. Rotation Direct Direction ion Plate 6. Cylinder Data Plate 7. Cylinder S Serial erial Number, MAW MAWP, P, and Hydrotest St Stamp amp (requires head removal to view)
8. VVCP Hydrotest Stamp Stamp 9. Compressor Dat Data a Plat Plate e 10. Force Feed Lubricator Data Plate 11. Compressor Drive End 12. Oil Filter Change Inst Instruction ruction Plate
FIGURE i-1 Separable Guide Compressor Throw and Data Plate Locations - Typical
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vii
For models models JGC:D:F JGC:D:F
Other Ariel Resources Ariel Website Visit Vis it www.arielc www.arielcorp orp.co .com m to view view and and print print the lates latestt docume documenta ntatio tion, n, such such as as:: • Customer Technical Technical Bulletins Bulletins (CTB’s (CTB’s)) provid provide e importa important nt inform informati ation on on chan changes ges,, correc correctio tions ns,, or additi add itions ons to Ariel Ariel produ products cts or servi service ces. s. Read these these bu bulle lletin tins s be before fore op opera eratin ting g or servi servicin cing g eq equip uipmen ment. t. • Engineering References (ER’s (ER’s)) provi provide de stand standard ard proce procedu dures res and other other us usefu efull inform informati ation on for operati ope ration, on, maint mainten enanc ance, e, or repair repair of Arie Ariell comp compres resso sors rs or comp compone onents nts.. Read an and d follow follow thes these e proce pro cedur dures es for long long and troubl trouble-fre e-free e servi service ce from your your Arie Ariell compr compres esso sor. r. • Maintenance Maintenance and Repair Repair Manuals pro provi vide de detail detailed ed mainte maintena nanc nce e and repair repair informa informatio tion n on spec specifi ific c Ariel compress compressor or models. models. • Packager Packager Standards Standards pro provi vide de detail detailed ed require requiremen ments ts and recomm recommen endat dation ions s on the instal installa latio tion n of an Ariel compress compressor. or. • Application Manual Manual prov provide ides s detail detailed ed informa informatio tion n on the us use e of Ariel Ariel comp compres resso sors rs in differe different nt applications.
Ariel Technical and Service Schools Ariel schedul schedules es several several in-plant in-plant schools schools each each year, year, which include include classroo classroom m and hands-on hands-on training. training. Ariel also als o sends sends repres represent entati ative ves s to provi provide de custo customiz mized ed trainin training g on locati location on.. Contac Contactt Ariel Ariel for de detai tails. ls.
Ariel Contact Information Contact
Telephone
Fax
E-Mail
Ariell Response Center Arie
888-397-7766 (toll (toll free USA & Can Canad ada) a) or 740-397740397-3602 3602 (Internationa (International) l)
740-397-1060
arc@a c@arrie ielc lco orp.com .com
740-393-5054
[email protected]
740-397-3856
--
740-397-0311
740-397-3856
Spare Pa Parts Order Entry Ariell World HQ Arie Technical Services
[email protected] [email protected]
Website: www.arielcorp.com Website:
Ariel Response Response Center Technici Technicians ans or Switchb Switchboard oard Ope Operators rators answer telephon telephones es during during Ariel busines business s hours hours,, East Eastern ern Time Time - USA or afte afterr hours hours by vo voic ice e mail mail.. Conta Contact ct an au auth thor oriz ized ed dist distrib ribut utor or to pu purc rcha hase se Ariel parts. parts. Always provide provide Ariel equipme equipment nt serial serial number(s) number(s) to order spare spare parts. parts. The after-hours after-hours Teleph Tel ephone one Emerge Emergenc ncy y System System works as fol follows lows:: 1. Follow Follow autom automate ated d instru instructi ction ons s to Techn Technica icall Servic Services es Emerge Emergenc ncy y Assis Assistan tance ce or Spare Spare Parts Parts Emerge Eme rgenc ncy y Service Service.. Calls Calls are an answere swered d by voic voice e mail. mail. 2. Le Leav ave e a messa message ge:: calle callerr name name an and d tel telep ephon hone e nu numbe mber, r, serial serial nu numbe mberr of equipm equipmen entt in questi question on (frame, (fra me, cylin cylinder der,, un unloa loader der), ), an and d a bri brief ef descri descripti ption on of the emerge emergenc ncy. y. 3. Your Your vo voic ice e mail mail route routes s to an on-c on-cal alll repres represen enta tati tive ve who respo respond nds s as so soon on as po poss ssib ible le..
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Section 1 - Tools Ariel Ari el Optional Furnished Tools Tools Ariel offers offers an optional optional tool kit with every every comp compress ressor. or. For JGC:D:F JGC:D:F compress compressors, ors, it contains contains the tools tools sh shown own belo below, w, which which are sp spec ecif ific ical ally ly desi design gned ed for for use use on Ariel Ariel un unit its. s. Clean Clean all all to tool ols s be befo fore re us use e an and d ve verif rify y full full to tool ol enga engage geme ment nt with with the the part part bein being g remo remove ved d or inst instal alle led. d. If th the e To Tool ol Kit is miss missin ing g or if a sing single le to tool ol is miss missin ing, g, worn, worn, or broke broken, n, ca callll yo your ur dist distrib ribut utor. or. Do not not use use worn or broke broken n to tool ols, s, or su subs bsti titu tute tes s fo forr Ariel Ariel furnis furn ished hed tools tools.. See Parts List List for indiv individu idual al tool tool pa part rt nu numbe mbers. rs. 1. Tool Box 2. Peg Wrench 3. Cross Crosshead head P Pin in Alig Alignment nment Tool 4. 3/4" x 1" UNC Valve Tool (f (for or CT valves) 5. 5/8" x 3/ 3/4" 4" UNF Valve T Tool ool 6. 5/32" Allen wrench (5 pr provided) ovided) 7. 3/16" Allen wrench (5 pr provided) ovided) 8. 1/4" Allen wrench (2 provided) 9. 3/8" Allen wrench (1 provided) 10. 1/2" Allen wrench (2 provided) 11. 3/4" Allen wrench (1 provided) 12. Conrod Cap Removal Tool 13. Forged 3/8-16 UNC Eyebolt (6 provided) 14. Forged 1/2-13 UNC Eyebolt (2 provided) 15. Forged 5/8-11 UNC Eyebolt (2 provided) 16. 110° Turn Indicator 17. 17. Ariel Ariel Bore & Threa Thread d Gau Gauge ge 18. Pist Piston on Nut Spanner 19. Crosshead Installation Tool 20. Valve Removal Tool (included only for compressors with forged steel cylinders - tool size and style varies with cylinder size and valve center connection) 21. 2-Piece Piston Rod Entering Sleeve 22. 22. Ariel Ariel ER-63 Fastener Torque Chartt (not sho Char shown) wn) 23. CTB CTB-132 -132 (not shown)
FIGURE 1-1 Optional Furnished Tools for JGC:D:F Compressors
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Page 1-1 of 3
Section 1 - Tools
For models JGC:D:F
Ariel Separately Purchased Tools
or hydraulic cros crosshead shead balance nut 5. Hand Pump ffor 1. Main Bearing Removal T Tool ool torquing tool and piston rod tensioning tool (includes 2. Force Feed Lubrication Hand Purge P Pump ump hand pum pump, p, hose, hose , coupler cou pler, , and gauge) gauge ) 3. Hydraulic Pist Piston on Rod T Tensioning ensioning Tool, without pump Feed eed Lubricator Bearing Housing Wrench Wrench 4. Hydraul Hydraulic ic Cros Crosshead shead Bal Balance ance Nut Tor Torquing quing To Tool, ol, with without out 6. Force F pump(includes tool and ram)
FIGURE 1-2 Ariel Separately Purchased Tools for JGC:D:F Compressors
Ariel Separately Purchased Tool Kits 1. Ariel SAE Hand Meas Measurem urement ent Tool Tool Kit a. .0005” .0005” ne needl edle e type type dial dial indic indicato ator. r. b. .001 .001”” 1-i 1-inc nch h travel travel dial dial indic indicato ator. r. c. Magne Magnett base base for dial dial indic indicato ator. r. d. 3/ 3/8” 8” drive drive ca calilibra brate ted d torqu torque e wre wrenc nch, h, 40 to 200 200 in x lbs. lbs. e. 1/ 1/2” 2” drive drive ca calilibra brate ted d torqu torque e wre wrenc nch, h, 50 to 250 250 ft x lbs. lbs. f. 3/ 3/4” 4” drive drive ca calilibra brate ted d torqu torque e wre wrenc nch, h, 120 120 to 600 600 ft x lbs. lbs. g. 1” drive drive ca calilibra brate ted d torq torque ue wrench wrench,, 200 200 to 1000 1000 ft x lbs. lbs. 2. Ariel Ariel SAE Hand Hand Tool Tool Kit Kit a. 15 15-pi -piec ece e combi combinat nation ion ope open/b n/box ox en end d wrench wrench set, set, 5/16” 5/16” through through 1-1/4”. 1-1/4”. b. 8-piec 8-piece e sl slot ot and Philli Phillips ps screwdri screwdrive verr set. set. c. 3/8" 3/8" squar square e drive drive wrench wrench set, set, inclu includin ding: g: • 12-pie 12-piece ce,, 12 12-po -point int sock socket et set, set, 5/1 5/16” 6” thro throug ugh h 1”. • Ball type type unive universa rsall joint. joint. • 7” ratche ratchet. t.
• 3/ 3/8” 8” to 1/ 1/2" 2" drive drive ad adap apte ter. r.
• Speed handle. handle.
• 1/4” 1/4” he hex x key key sock socket. et.
• Exte Extens nsio ions ns,, 1-1/2 1-1/2”, ”, 3”, 6”, and and 12”. 12”.
• 8-1/2” 8-1/2” break breaker er bar. bar.
d. 1/2" 1/2" squar square e drive drive wrench wrench set, set, inclu includin ding: g:
Page 1-2 of 3
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For models models JGC:D:F JGC:D:F
Section Sectio n 1 - To Tool ols s
• 14-piece 14-piece,, 12-point 12-point socket socket set, 7/ 7/16 16”” th throu rough gh 1-1/4 1-1/4”” with with cl clip ip rail. rail.
• Speed handle. handle.
• Extens Extensio ions ns,, 1-1/2”, 1-1/2”, 5”, and 10”.
• Ball type type unive universa rsall joint. joint.
• Drive Drive adap adapte ters: rs: 1/2” 1/2” to 3/8" 3/8" and and 1/2” 1/2” to 3/4" 3/4"..
• 18” break breaker er bar. bar.
• 1-1/4 1-1/4”” open open end end crow’ crow’s s foot foot adap adapte ter. r.
• 1/2 1/2”” an and d 5/ 5/8” 8” he hex x ke key y so sock cket ets. s.
• 10-1/4” 10-1/4” ratchet. ratchet.
e. 3/4" 3/4" squa square re dri drive ve wrench wrench set, set, inclu includin ding: g: • 1 18-p 8-piec iece, e, 12-poi 12-point nt sock socket et set, set, 3/4 3/4”” thro throug ugh h 2”. • 24” ratche ratchet. t. • Extens Extensio ions ns,, 3-1/2”, 3-1/2”, 8”, and 16”.
• 22” break breaker er bar. bar.
• Drive Drive ad adap apte ters rs:: 3/4” 3/4” to 1/2" 1/2",, 3/4” 3/4” to 1" 1",, an and d 1” to 3/ 3/4" 4" f. 1" square square drive drive wrench wrench set, set, includ including ing:: • 14-piec 14-piece, e, 12-poi 12-point nt sock socket et set, set, 1-7 1-7/16 /16”” thro throug ugh h 2-5/8”. 2-5/8”. • 30” ratche ratchet. t. • Exten Extensi sions ons:: 8” and 17 17”. ”. • 22” sl slid idin ing g T. g. Adjusta Adjustable ble wrenche wrenches: s: 12" an and d 18". 18". h. Dead Dead bl blow ow se semi mi-so -soft ft face faced d hamm hammers ers:: 3 lb. lb. and and 6 lb lb.. i. 3/4” 3/4” x 36” pry bar. j. 12” lo long ng fe feel eler er gage gage se set. t. k. 12” mach machini inist st scale scale with .01” .01” inc increme rements nts.. l. 13-pi 13-piec ece e Allen Allen wrench wrench se set, t, .050 .050 - 3/8”. 3/8”.
Recommended Tools Ariel compress compressor or maintena maintenance nce and repair repair norma normally lly requires requires only Ariel furnished furnished tools and separatel separately y purchas purc hased ed tools tools an and d tool tool ki kits. ts. However, However, Ariel Ariel also also recomm recommend ends s purch purchas asing ing the ad addit dition ional al tools tools be below. low. Conta Con tact ct Ariel Ariel fo forr ques questi tion ons s abou aboutt tool tools s for for Ari Ariel el unit units. s. 1. 12-poi 12-point nt box en end d torque torque adapte adapterr ex exten tensi sion on wrench wrench set, set, includ including ing 1-1/2 1-1/2 and 2-1/4 2-1/4 in inch ch size sizes. s. 2. Tape measure. measure. 3. Flashlight. 4. Small Small mirro mirrorr on a flex flexib ible le exte extens nsio ion n rod. rod. 5. Small Small magne magnett on a fle flexib xible le ex exten tensi sion on rod. rod. Electric and/or and/or pneumat pneumatic ic drill. 6. Electric 7. Twist Twist dr drililll se set. t. 8. Torque multipli multiplier. er.
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Page 1-3 of 3
Section 2 - Instrumentation Several Seve ral opti option onal al in inst strum rumen ents ts ca can n aid aid in the the opera operati tion on of an Ariel Ariel co comp mpres resso sor. r. Th Throu rough gh th the e da data ta th they ey provi pro vide, de, some some instrum instrument ents s can can he help lp decrea decrease se mainte maintena nanc nce e costs costs an and d downtim downtime, e, an and d he help lp di diagn agnos ose e lu lubri brica cati tion on and and ot othe herr type types s of probl problem ems. s. The The use use of “ala “alarm” rm” in inst stea ead d of “s “shu hutd tdown own”” fo forr an any y mini minimu mum m instrumen ins trumentatio tation n requiremen requirementt may result result in equipme equipment nt damage. damage. NOTE: Ariel recommends the use of shipboard or armored cabling as opposed to wiring in conduit to minimize nuisance shutdowns due to wire chafing and shorts. Cable in cable trays also facilitates maintenance access. CAUTION: DO NOT drill holes in cylinders or other pressure containing components for any purpose. Epoxy-mounted clamps (to bare metal) for wiring and tubing are a suitable alternative. See Ariel ER-89.10. ER-89.10.
CAUTION: Any arc welding on the skid and/or associated equipment and piping can permanently permanen tly damage solid-state electronic equipment. Welding can cause immediate failure or reduce electronic equipment life and void the warranty. To protect electronic equipment prior to any arc welding (including repair welding), disconnect all electrical connections including ground, and remove batteries, or completely remove the electronic equipment from the compressor. It is good practice to attach the welding ground clamp as close as possible to the area where the welding will occur and to use the lowest practical welder output setting. Welding must not cause a current flow across any compressor bearing surface, including but not limited to crankshaft and crosshead bearing surfaces.
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Page 2-1 of 19
Section 2 - Instrumentation
For models JGC:D:F
TABLE 2-1 Required Instrumentation Summary INSTRU MENT
SUPPLIER
SETTING/REQUIR EMENT
3 ) ) Frame Oil System (see Section (see Section 3 Oil Pressure
PKGR
• Start Start Per Permissive missive with Prelube Pre lube Pump
• Run Permissive Permissive • Alarm
30 psi psig g (2.1 (2.1 barg barg)) for 2 min minut utes es
45 psi psig g (3.1 (3.1 barg barg)) with within in 10 second seconds s of start start 50 psi psig g (3.4 (3.4 barg barg))
• Shutdown
Oil Filter D ififferential
45 psig psig (3.1 (3.1 barg barg))
Ariel
• JGC:D:F/2 JGC:D:F/2 an and d smaller smaller
• JGC:D:F/4 an and d lar large ger r
Cha Chang nge e at 10 psi (0.7 (0.7 ba bar) r) or 40 4000 00 ho hour urs s
Oil Temperature
Cha Chang nge e at 15 psi (1.0 (1.0 ba bar) r) or 40 4000 00 ho hour urs s
PKGR
• Minimum, start up
See See for for ma max. x. oi oill viscosity viscosity based based on fram frame e size size..
• Minimum, to load
See See for for ma max. x. oi oill viscosity viscosity based based on fram frame e size size..
• Minimum, operating
150°F (66 150°F (66°C) °C)
• Maximum, shutdown
190°F (88 190°F (88°C) °C)
Crankcase Le Level • Low Level Shutdown
PKGR
Main Bea Bearin ing g Temp. mp.
Ar Arie iell
• Alarm
1/2 tto o2 2//3 s siight glass level 1/4 sight glass level
(Standard on B:V:Z:U. Recommended, Recommended, but optio nal on JG:A:R:J: JG:A:R:J:H:E:K:T:C:D:F) H:E:K:T:C:D:F)
• Shutdown
+20°F +20°F (12° (12°C) C) above above no norm rmal al no nott to exceed exceed 220° 220°F F (104 (104°C) °C)
+30°F +30°F (18° (18°C) C) above above no norm rmal al no nott to exceed exceed 230° 230°F F (110 (110°C) °C)
• Differential Alarm
20°F (12 20°F (12°C) °C)
• Differential Shutdown Packing Case Temp.
A riel
• Alarm
(Optional )
• Shutdown Packing Case Vent
+20°F +20°F (12° (12°C) C) ab above ove no norm rmal al
+30°F +30°F (18° (18°C) C) ab above ove no norm rmal al
PK GR
• Vent Flow Alarm • Vent Flow Shutdown Scru Scrubb bber er Li Liqu quid id Lev Level
30°F (18°C) 30°F (18°C)
(Optional )
2 - 4 scf scfm m (per thr throw) > 4 scfm (per (per thr throw) ow)
PKGR PKGR
• High Liqu Liquid id Level Contro Controll • High Liqu Liquid id Level Shutd Shutdown own Gas C onditions
PK GR
• Inlet Tempe Tempera rature ture Indicator, Indicator, ea each ch cylinder • Inlet I nlet Pre Pressure ssure Indicator, Indicator, each stage • Discharge Discharge Pre Pressure ssure Indicator, Indicator, each cylinder • Dischar Disc harge ge Temp Tempera erature ture Indicator, Indicator, each cylinder • High Discharg Discharge e Temper Temperatur ature e Shutdown, Shutd own, ea each ch cylinder Lubricated Cylinder Cylinders s • Lubricated • Non-Lube/PRC Cylinders
Page 2-2 of 19
10% above nor normal mala (Nott to exce (No exceed ed the maximum maximum temp temper eratu ature res s be below) low)
350°F (177°C) (177°C)
325°F (163°C) (163°C)
REV: 10/14
For models models JGC:D:F JGC:D:F
INSTRU MENT
SUPPLIER
SETTING/REQUIR EMENT
• Hydroge Hydrogen n Rich > 50% 50% < 0.41 Specific Gra Gravity vity
• Air
Up to 150: 50: 15 psi psig g (1.0 barg) barg)
(not (not to exceed exceed MAWP)
High Vibrat Vibration ion Shutdown Overspeed
300°F (149°C) (149°C)
Not to exceed auto autoignitio ignition n tempe temperatu rature re of cylinder lubr lubricant icant at discharge pressure pressure
• Reli Relief ef Valve Valve Setting Setting ab above ove normall oper norma operating ating pressure
Cylinder Rod Load Protection Protection
Section Sectio n 2 - Instr Instrum umen entatio tation n
to 25 2500 00:: 10%
to 3500 3500:: 8% to 5000 5000:: 6%
Over 5000: 5000: As agreed agreed
ER-56.04.. See ER-56.04 PKGR PKGR PK GR
As close to nor normal mal level as practical. practical. See "Vibra "Vibration tion Pro Protection" tection" in ER-56.07. ER-56.07.
10% 10% over over rated rated speed speed for shutdo shutdown wn
a. Exam Example: ple: Norma Normall Discharge Tem Temp. p. = 270°F; Shut Shutdown down Sett Setting ing = 270 x 1.1 = 297°F.
Notes 1. In Inst stal alll th the e co comp mpres resso sorr frame frame low low lub lube e oil oil press pressure ure sh shut utdo down wn se sett to st stop op th the e un unit it if oi oill press pressur ure e downs downstre tream am of the the filt filter er fall falls s belo below w 45 psig psig (3.1 (3.1 barg) barg).. Compr Compres esso sorr op opera erati tion on fo forr on only ly a fe few w se seco cond nds s witho wit hout ut oi oill press pressure ure ca caus uses es majo majorr dama damage ge.. Normal Normal oil oil pre press ssure ure is ab abou outt 60 ps psig ig (4.1 (4.1 ba barg) rg) at fu fullll rated rate d spee speed d and normal normal operati operating ng temper temperatu ature. re. The low oil pre press ssure ure shutd shutdown own must must ac activ tivate ate aft after er oi oill pressur press ure e exce exceed eds s 45 psig psig (3. (3.1 1 barg) barg) at st start art-up -up.. Ari Ariel el pr prov ovid ides es a 1/ 1/4 4 in inch ch tu tubi bing ng fitt fittin ing g to co conn nnec ectt th the e lo low w lu lube be oi oill press pressur ure e sh shut utdo down wn and and ties ties a tag tag to this this co conn nnec ecti tion on be befo fore re ea each ch co comp mpres resso sorr sh ship ips. s. Do not not opera operate te th the e co comp mpres resso sorr for for prolo prolong nged ed perio periods ds at le less ss th than an 50 ps psig ig (3.4 (3.4 ba barg rg)) oil oil pr pres essu sure. re. 2. Auto Automat mated ed pre-lu pre-lube be syste systems ms require require a start start permis permissi sive ve to sens sense e minim minimum um requi required red press pressure ure/ti /time me at th the e oi oill gall gallery ery in inle let. t. See “Compres “Compresso sorr Pre-l Pre-lub ube e Sys System tem”” on pag page e 3-1 3-18 8. The The unit mus must shut down own if th the e sy syst stem em fa failils s to achi achiev eve e 45 psig psig (3. (3.1 1 barg) barg) oil oil press pressure ure withi within n 10 se seco cond nds s af afte terr cr cran anks ksha haft ft st start arts s to turn. 3. Moun Mountt overh overhea ead d lube lube oil oil su supp pply ly tank tanks s high high enou enough gh to pro provi vide de oi oill flow flow to to th the e le leve vell co cont ntrol rol at all all ambi ambien entt temperatures. 4. On multi multi-no -nozz zzle le cylin cylinder ders, s, Ariel Ariel strongl strongly y recom recommen mends ds a temper temperatu ature re device device in bo both th disch discharge arge nozzles. 5. Instal Installl the high high lube lube oil inlet inlet tempe temperatu rature re shutd shutdown own at the filter filter inlet inlet conne connecti ction. on. 6. At a mini minimu mum, m, in inst stal alll one one vi vibra brati tion on sh shut utdo down wn for for two an and d fo four ur th throw row frame frames s an and d two fo forr six six th throw row frame fra mes. s. Moun Mountt vi vibra brati tion on devi device ces s near near the the top top of th the e frame frame with with th the e se sens nsit itiv ive e ax axis is pa paral ralle lell to th the e pist piston on rod ax axis is.. 7. Install Install all safety safety shutdowns shutdowns,, controls controls,, instrumen instrumentatio tation, n, ignition ignition systems systems,, electrical electrical device devices, s, and high tempe tem peratu rature re piping piping (gas (gas disch discharg arge e an and d engine engine ex exhau haust) st) in ac acco corda rdanc nce e with good good en engin gineer eering ing practi pra ctice ce an and d applic applicab able le codes codes for the area area cl clas assi sific ficati ation on at the end us user er locati location. on. Ensure Ensure compa compatib tibili ility ty of all syste systems ms for area cla class ssifi ifica catio tion. n. 8. If pa pack cking ing vent vent tempe temperatu rature re is monit monitore ored, d, ala alarm rm an and d shutd shutdown own set set po point ints s shoul should d be confi confirme rmed d through throug h vent vent flow rates. rates.
REV: 10/14
Page 2-3 of 19
Section 2 - Instrumentation
For models JGC:D:F
Digital No-Flow Timer (DNFT) on page page 2-1. 2-1. CAUTION: See arc welding caution on A DNFT is a totally totally enclose enclosed d electroni electronic c devi device, ce, combini combining ng the latest latest technolo technology gy in microproc microprocess essor or and transi tran sisto storr comp compone onents nts to detec detectt slow-flo slow-flow w an and d no no-flo -flow w of divide dividerr block block lu lubric bricati ation on sy syste stems ms.. The DNFT us uses es an os oscil cillat lating ing cryst crystal al to ac accu curat rately ely monito monitorr the lubric lubricati ation on sy syste stem m cy cycl cle e time time to en enabl able e preci precisio sion n timed tim ed shutd shutdown own capab capabili ility ty.. The magne magnett as asse sembl mbly y an and d contro controll housi housing ng mount mount direc directly tly to a divide dividerr valve valve.. Lu Lubric brican antt flo flow w through through a divid divider er valv valve e as asse semb mbly ly forces forces the piston piston to cycl cycle e back back an and d forth forth caus causing ing a latera laterall move mo veme ment nt of th the e DNFT magn magnet et link linked ed to the the pist piston on.. The The DNFT micr microp oproc roces esso sorr moni monito tors rs pi pist ston on move mo veme ment nt and and reset resets s the the time timer, r, ligh lights ts the the ligh lightt em emit itti ting ng diod diode e (LED), (LED), an and d al allo lows ws th the e un unit it to co cont ntin inue ue op opera eratio tion, n, indica indicatin ting g one comp complet lete e cycl cycle e of the lubric lubricati ation on sy syste stem. m. If the microp microproc roces esso sorr fai fails ls to receiv receive e thi this s cycle cycle within within a predet predeterm ermine ined d time, time, a shutd shutdown own oc occu curs. rs. The DNFT autom automati atica cally lly resets resets the alarm alarm circu ci rcuit it when no normal rmal divide dividerr valve valve operati operation on resume resumes. s. DNFTs ut utililiz ize e an LED LED to indi indica cate te each each cy cycl cle e of the the divi divide derr va valv lve, e, which which al allo lows ws ea easy sy ad adju just stme ment nt an and d monit mo nitorin oring g of lubric lubricati ation on rates. rates. Programm Programmab able le model models s di disp splay lay tot total al pints, pints, cy cycl cle e time time of divide dividerr valve valve,, tot total al cy cycl cles es of di divi vide derr va valv lve, e, or pint pints s per per day day pump pump flow flow rate rate on a liqu liquid id cryst crystal al disp displa lay y an and d op opera erato tors rs ca can n ad adju just st al alarm arm time time from from 20 to 255 255 se seco cond nds. s.
DNFT Installation 1. Loos Loosen en th the e Allen Allen se sett sc screws rews on the the DNFT and and remov remove e magn magnet et hous housin ing. g. Do not not remov remove e magn magnet et,, sp sprin ring, g, or sp spac acer er fro from m magn magnet et housing. 2. Remove Remove pi pisto ston n enclos enclosure ure plu plug g from end of des desired ired divid divider er va valv lve. e. Th The e DNFT in inst stal alls ls on any any of the the divi divide derr va valv lves es of th the e di divid vider er block block.. The DNFT requir requires es the correc correctt magne magnett as asse sembl mbly y to match match the divide dividerr valve valve manufa manufactu cturer. rer. NOTE: Do not install a DNFT on Lincoln divider valves with cycle indicator pins. 3. If appl applic icab able le,, ve verif rify y o-rin o-ring g or me meta tall gask gasket et is in plac place e on ma magn gnet et ho hous using ing.. Thread Thread magnet magnet housi housing ng into into en end d of div divid ider er valv valve. e. Torq To rque ue to 15 lb lbs s x ft maxi maximu mum. m. 4. Sl Slid ide e DNFT al alll th the e way onto onto hex hex of magn magnet et hous housin ing. g. Torqu Torque e Allen set screws screws on hex of magnet magnet housing housing to 25 lbs x inch, inch, maximum.
Trabon Style O-Ring Seal 7/16-20
Trabon Metal Metal Gasket Seal 7/16-20 (1994 or earlier)
Lincoln O-Ring Seal 7/16-20 Extended Nose
FIGURE 2-1 Typical DNFT Magnet Assemblies
5. The LED on the DNFT indic indicate ates s each each divide dividerr valv valve e cycl cycle e to allow allow lub lubric ricato atorr pu pump mp adjus adjustme tment nt for Ariel Ariel recomm rec ommen ended ded cycl cycle e time time an and d oil cons consum umpti ption. on. If the LED fai fails ls to blink blink du during ring compre compress ssor or operati operation on or by manua manually lly pu pumpi mping ng oil into into the divid divider er valv valve, e, then then the DNFT requir requires es ad adjus justme tment. nt. 6. Th The e di divi vide derr va valv lve e must must cy cycl cle e durin during g DNFT adju adjust stme ment nt.. To cy cycl cle e it, it, eith either er run th the e co comp mpres resso sorr or manu ma nual ally ly pump pump oi oill throu through gh the the dist distrib ribut utio ion n bloc block k wit with h a purge purge gu gun. n.
Page 2-4 of 19
REV: 10/14
For models models JGC:D:F JGC:D:F
Section Sectio n 2 - Instr Instrum umen entatio tation n
7. To ad adju just st,, sl slid ide e DNFT all all the the way way on onto to hex of magne magnett ho hous using ing.. Tighte Tighten n Allen Allen set set scr crew ews s to 25 lbs lbs x inch inch maxi maximu mum. m. A blinkin blin king g LED indicates indicates correct correct adju adjust stme ment nt.. If th the e LED LED fail fails s to blin blink k with with divid div ider er valv valve e cycl cycling ing,, slide slide DNFT ba back ck on th the e he hex x of th the e magn magnet et ho hous usin ing g in 1/16" 1/1 6" increm incremen ents ts un until til it does. does. 8. Make Make all cond conduit uit an and d conne connecti ctions ons appropriat appro priate e for area classi classifica fication tion.. Suppo Sup port rt condu conduit it and fit fittin tings gs to av avoi oid d bending bend ing the magnet magnet housing housing.. 9. After After DNFT in insta stalla llatio tion n an and d be before fore compr compres esso sorr start-up start-up,, pu purge rge all air from divid div ider er block block lub lubric ricati ation on syste system m with a purge pur ge gun. gun.
1. Divider Valve Piston 2. Magnet 3. Magnet Magnet Housing
4. 5. 6. 7.
Set Screws Screws (2) LED Control Housing Wire Leads
8. O-Ring 9. Divider Valve 10. Piston Enclosure Plug
FIGURE 2-2 Typical DNFT Installation NOTE: When installing multiple DNFTs, wire each to a separate alarm circuit of the control panel, annunciator, or PLC to simplify lubrication system and DNFT troubleshooting. Always secure green ground wire to "earth ground" in the control panel. Do not ground to electrical conduit. Improper grounding can result in unreliable monitor operation.
FIGURE 2-3 A-10754 Programmable DNFT Wiring Connections for Unit in Operation
FIGURE 2-4 A-10753 and A-10772 DNFT Wiring Connections for Unit in Operation
REV: 10/14
Page 2-5 of 19
Section 2 - Instrumentation
For models JGC:D:F
FIGURE 2-5 A-20513 24 VDC Programmable DNFT Wiring Connections for Unit in Operation
FIGURE 2-6 A-20514 24 VDC DNFT Wiring Connections for Unit in Operation
Programmable DNFTs Programmab Program mable le DNFTs come come with a small small liquid liquid crysta crystall displ display ay (LCD)) sc (LCD scree reen n to di disp spla lay y tota totall divi divide derr va valv lve e cy cycl cles es (Mode (Mode 1), cy cycl cle e time ti mede of 3), di divi vide derpump r va valv lve eflow in se seco cond (Mo to l pint pide nts s4). of O oil oiperat l used us edors (Mode (Mo or pu mp flow rate rat ends inspint pi(Mode nts s de per per2), day datota y tal (Mode (Mo pe rators ca can n al also so adju adjust st al alarm arm time time in Mode Mode 1. CAUTION: Program DNFT before install installing ing it on a divider valve. DO NOT insert programming magnet into 1/8” recessed opening while the compressor is operating; it causes the DNFT to shut down the compressor. Programming modes cannot be changed while the compressor is operating. To program a DNFT, first remove it from the divider valve. To prog program ram:: 1. Insert Insert the progra programmi mming ng magne magnett into into the 1/8" 1/8" rec reces esse sed d open openin ing g on th the e fa face ce of the the DNFT. The The cu curre rrent nt progra programm mmin ing g
Page 2-6 of 19
1. Magnet 2. Magnet Housing 3. Allen Set Screws 4. LED 5. Control Housing 6. LCD
7. 1/8" recessed opening for programming magnet 8. Wire Leads 9. Programming Magnet
FIGURE 2-7 Typical Programmable DNFT
REV: 10/14
For models models JGC:D:F JGC:D:F
Section Sectio n 2 - Instr Instrum umen entatio tation n
mode (1, 2, 3, or 4) imme mode immedi diat atel ely y disp displa lays ys on the the LCD fo follllowe owed d by "0 "0"" 2 se seco cond nds s late later. r. "0 "0"" indi indica cate tes s th the e curren currentt mode mode is ready ready for pro progra grammi mming. ng. 2. If the de desir sired ed program programmin ming g mode mode does does not displa display, y, remov remove e and re-ins re-insert ert the progra programmi mming ng magnet magnet into into the reces recesse sed d openin opening g un until til it does. does. Leave Leave the program programmin ming g magne magnett in the reces recesse sed d openin opening g when the desired desired progra programm mming ing mode mode di disp splay lays. s. 3. Selec Selectt on one e of the progra programmi mming ng modes modes be below: low: a. Mode 1 - LCD displays displays total divider divider valve cycles cycles;; program alarm time. • To set set al alarm arm time, time, press press and releas release e the sprin spring-lo g-load aded ed magne magnett as asse semb mbly ly until until the de desi sired red alarm alarm ti time me in sec econ onds ds disp displa lay ys on the the LCD. LCD. Set Set alar alarm m time time fr from om a mini minimu mum m of 20 seco second nds s to a maxi ma ximu mum m of 255 255 se seco cond nds. s. If not not se set, t, devi device ce defa defaul ults ts to 12 120 0 se seco cond nds. s. • Remov Remove e progr program ammi ming ng ma magn gnet et.. DNFT disp displa lays ys to tota tall divi divide derr va valv lve e cy cycl cles es if le left ft in th this is mode mode an and d al alarm arm time time is now now se set. t. b. Mode 2 - LCD LC D displays cycle cycle time of divider valve in seconds. seconds. • Remov Remove e program programmin ming g magne magnett when Mode Mode 2 displ display ays. s. LCD coun counts ts ea each ch di divid vider er valve valve cycl cycle e in seco seconds nds,, coun countin ting g up from zero zero until until the divide dividerr valve valve compl complete etes s one full full cy cycl cle. e. When When di divid vider er va valv lve e co comp mple lete tes s one one full full cy cycl cle, e, the the LCD rese resets ts to ze zero ro an and d repea repeats ts th the e co coun untt un unti till an anot othe herr cy cycl cle e is compl complete eted. d. The LED blink blinks s in all modes modes to indica indicate te ea each ch divide dividerr valve valve cy cycl cle. e. This This blink blink en enabl ables es th the e opera operato torr to se sett pump pump flow flow rate. rate. c. Mode 3 - LCD displays displays total pints used; used; program divider valve total. total. • To se sett di divi vide derr va valv lve e tota total, l, add add the the si size zes s of the the divi divide derr va valv lve e se sect ctio ions ns on which which th the e DNFT will will be in inst stal alle led. d. Exam Exampl ple: e: 24 + 24 + 24 = 72. • Press Press and and relea release se the the sp sprin ringg-lo load aded ed magn magnet et unti untill th the e di divi vide derr va valv lve e tota totall disp displa lays ys on th the e LCD. Maxi Ma ximu mum m va valu lue: e: 120. 120. If not not se set, t, devi device ce defa defaul ults ts to ze zero ro an and d preve prevent nts s Mode Mode 4 flow flow rat rate e disp displa lay. y. • Remov Remove e progr program ammi ming ng ma magn gnet et.. The The DNFT disp displa lays ys to tota tall pint pints s on th the e LCD if le left ft in th this is mode mode.. d. Mode 4 - LCD displays pump flow rate in pints per day. • Remov Remove e program programmin ming g magne magnett with Mode Mode 4 displa displays ys.. LCD displa displays ys pu pump mp flo flow w rate in pints pints per day day base based d upon upon the the divi divide derr va valv lve e tota totall se sett in Mode Mode 3. Mode Mode 4 requi requires res a mini minimu mum m 4 se seco cond nd cy cycl cle e time. The DNFT stores stores all progra programme mmed d inform informati ation on un until til the operato operatorr inserts inserts the progra programmi mming ng magnet magnet into into the reces rec esse sed d open openin ing, g, se sele lect cts s Mo Mode de 1 or Mode Mode 3, and and press presses es th the e sp sprin ring g lo load aded ed magn magnet et as asse semb mbly ly.. Th This is acti action on reset resets s th the e unit unit to ze zero ro and and allo allows ws entry entry of a new new va valu lue. e. NOTE: Power interruption to the DNFT requires reprogramming Mode 1 and Mode 3.
REV: 10/14
Page 2-7 of 19
Section 2 - Instrumentation
For models JGC:D:F
DNFT Battery Replacement The DNFT operate operates s on a fie field-r ld-repl eplac aceab eable le lit lithiu hium m battery battery that that sh shou ould ld la last st si six x to te ten n ye years ars.. If batt battery ery vo volt ltag age e drops drops belo below w norma normall opera operati ting ng le leve vels ls,, the the DNFT sh shut uts s down down and and the the comp compres resso sorr cann cannot ot be restart restarted ed un until til the battery battery is replac replaced ed.. CAUTION: Do not open a DNFT in an explosive gas atmosphere. 1. Shut Shut do down wn comp compres resso sor. r. 2. Disconn Disconnec ectt DNFT wiring wiring 3. Use 1/ 1/8 8 in inch ch Allen Allen wrenc wrench h to loos loosen en Allen Allen se sett sc screws rews and and remov rem ove e contro controll ho hous using ing to a safe safe atmos atmosph phere ere.. 4. Use Use 3/ 3/8 8 in inch ch ratch ratchet et wrench wrench to remov remove e pipe pipe plug plug.. 5. Remove Remove ba batte ttery ry and di disc scon onnec nectt from po polari larize zed d connector. 6. Connect new battery battery to polarized polarized connect connector. or.
1. Magnet Magnet Housing 2. Magnet 3. O-Ring 4. Control Housing 5. Polarized Connector
6. Field Replaceable Battery 7. 1/2" Pipe Plug 8. #22 A AWG WG 18" (0. (0.46 46 m) Leads 9. Allen Set Screws Screws
FIGURE 2-8 Typical Digital No-Flow Timer Switch (DNFT)
7. Insert Insert new ba batte ttery ry an and d rei reins nstal talll pipe pipe plug. plug. 8. Pl Plac ace e DNFT co cont ntrol rol hous housin ing g on the the magn magnet et hous housin ing g in its its origi origina nall posi positi tion on an and d tigh tighte ten n se sett sc screws rews.. Reattac Reat tach h wiring wiring and condu conduit. it. 9. Progra Programm mmab able le DNFTs requ require ire reprog reprogram rammi ming ng of the the alarm alarm time time (Mode (Mode 1) an and d divi divide derr va valv lve e to tota tall (Mode (Mo de 3) aft after er a po power wer interru interrupti ption. on. See program programmin ming g secti section on of thi this s docume document. nt. 10. To ve 10. verif rify y DNFT opera operati tion on,, pre-l pre-lub ube e the the sy syst stem em and and ch chec eck k fo forr LED bli blink nk..
Page 2-8 of 19
REV: 10/14
For models models JGC:D:F JGC:D:F
Section Sectio n 2 - Instr Instrum umen entatio tation n
Troubleshooting DNFT’s NOTE: When installing multiple DNFTs, wire each to a separate alarm circuit of the control panel, annunciator, or PLC to simplify lubrication system and DNFT troubleshooting. Problem
Possible Cause Improperly adjusted DNFT.
LED does not blink and control panel indicates lube no-flow. (see also Erratic Erratic Shutdown)
Solution
Lo Loose osen n set scre screws, ws, slide DNFT all the the way onto onto he hex x of magne magnett housing housing an and d torq torque ue to 25 lb lbs s x iinch nch ma max. x. (Do (Do not over tighten). tighten). Eithe Eitherr pump pump clean clean oi oill thro throug ugh h lu lubr brica icatio tion n syste system m with a purg purge e gun gun or run run the compr compresso essorr to cycle the the dividerr valve. If necessary, divide necessary, slide DNFT back in 1/16 1/16““ iincre ncrements ments until until L LED ED bl blin inks ks with each each di divid vider er val valve ve cycle cycle..
Lo Loose osen n set s scre crews, ws, remo remove ve DNFT from from mag magne nett ho housin using. g. Remove magne magnett Broken sprin Broken spring g ho housin using g from from divid divider er valve valve.. Remove mag magne net, t, sprin spring, g, and and spa spacer cer an and d check check for or magnet magnet in damage dam age.. R Repla eplace ce damaged damaged compo componen nents. ts. Re-install Re-install magnet magnet housing on divider divider magnet valve an and d DNFT on ma magn gnet et ho housin using. g. If necessary, necessary, adjust adjust DNFT, che check ck for LED housing. bl blin ink. k. Pu Purg rge e ai airr from from system system with purg purge e gun. gun. Low battery voltage.
Bent magnet housing.
Rupture Ruptur e disc blows and divider divid er valve seizes after DNFT installation.
Wrong magnet housing installe insta lled d on divide divi derr valve valve..
Remove ba Remove batter ttery y from from DNFT an and d test it. Replace Replace batter battery y with with a factory factory recommen recommended ded rep replaceme lacement nt lithiu lithium m batter battery y if voltage is below below 2.5 volts. Lo Loose osen n set screws, rem remove ove DNFT from from mag magne nett housi housing ng.. Check for da damag maged ed or bentt magnet ben magnet housing housing.. Remove magn magnet et assembly from divider divider valve. Replace magne magnet housing, magnet, net, an and d spacer. new magn magnet et FT, housing on divide divi derr tvalve and and mag DNFT onspring, magne magnet t housi housing ng.. IfRe-install necessar necessary, y, adjust adju st DN check for for LED LED bl blin ink. k. Purg Purge e ai airr from from system system with purg purge e gun. gun. Lo Loose osen n set screws and remove remove DNFT from from ma magn gnet et ho housin using. g. Check for corre correct ct magn ma gnet et housi housing ng for divi divide derr valve man manufa ufactur cturer er.. Remo Remove ve an and d repla replace ce with correct corr ect magnet hou housing. sing. Re-install DNFT on new magn magnet et housing housing.. If necessary necessary ad adjust just DNF DNFT, T, che check ck for LED bli blink. nk. Purg Purge e air from from system with pu purg rge e gun. gun.
Check s Check system ystem pressur pressure e to ver verify ify oil flows to divide dividerr valves. valves. If ne need eded ed,, install pressur pressure e ga gaug uge e to mo monito nitorr lub lubrica rication tion system oper operatio ation: n: Air or • Lo Loose osen n ou outlet tlet plugs plugs in fro front nt of of valve valve blocks. blocks. Purge Purge lubri lubricatio cation n system with a debris in purge pur ge gun until cle clean, an, clea clear, r, air air-fre -free e oil flows from from plugs. plugs. Loose osen, n, but do not not remo remove, ve, each piston piston en enclosu closure re plug plug individ individua ually lly to pu purg rge e air divide divi derr valve • Lo fro from m be behin hind d piston. pisto n. Tigh Tighten ten all divide divi der r valve plugs. plu gs. Adjust Adju st DNFT. assembly. To ensure proper lubrication system operation, all tubing and components MUST be filled with oil and free of air before start-up.
• A-10753 A-1075 3 Faulty wiring A-1077 A-1 0772 2 • fr from om DNFT DNFT to A-2051 A-2 0513 3 control panel or air in • system syste m (see (see A-1075 A-1 0754 4 Erratic ab abo ove for for air in A-2051 A-2 0514 4 shutdo shu tdown wn or • system). LED blink.
Faulty lube pump.
REV: 10/14
Norma Normally lly Op Open en - Atta Attach ch ohmm ohmmet eter er to red red wir wires. es. Shoul Should d read read 10 megao meg aohm hms s in op oper eratio ation n an and d less than than 10 oh ohms ms in ala alarm rm.. Norma Normally lly Clos Closed ed - Attach ohmme ohmmeter ter to oran orange ge wire wires. s. Should Should read read less th than an 10 oh ohms ms in op oper eratio ation n an and d infinity infinity in in alarm alarm.. Norma Normally lly Op Open en - Attach oh ohmme mmeter ter to oran orange ge wire wires; s; insulate insulate violett wires viole wires from ea each ch other other.. Sho Should uld read read 10 oh ohms ms or less in alarm. Norma Normally lly Clos Closed ed - Attach ohmme ohmmeter ter to oran orange ge wire wires. s. Short Short violet violet wires togethe together. r. Should Should rea read d infinity in alarm. alarm.
Check system pressur Check pressure e to ver verify ify oil fl flows ows to pump pump an and d divi divide derr valves. valves. If neede needed, d, installll pressur insta pressure e ga gaug uge e to mon monitor itor lubri lubricatio cation n system op oper eratio ation. n. Check ga gaug uge e to verify pump pump build builds s sufficient pre pressure ssure to inject inject oil into cylinder cylinder.. Do not remove remove tubing tub ing from from che check ck valve valve and and pu pump mp oil to atmosp atmosphe here re to che check ck oil oil flow into cylinder.. Replace cylinder Replace pump. pump.
Page 2-9 of 19
Section 2 - Instrumentation
For models JGC:D:F
Proximity Switch A-18255 CAUTION: See arc welding caution on page 2-1. on page 2-1. A proximity proximity switch installs installs into a divider divider valve valve in place place of a piston piston end plug and can be used used to actuate actuate any devi device ce.. It co cons nsis ists ts of a reed reed switc switch h and and a magn magnet et.. When When inst instal alle led, d, th the e magn magnet et rests rests ag agai ains nstt th the e divi divide der r va valv lve e pi pist ston on and and paral paralle lell to the the reed reed swi switc tch. h. With With every every divi divide derr va valv lve e cy cycl cle, e, th the e pi pist ston on move moves s th the e magn magnet et,, which whic h op opens ens and close closes s the reed reed swit switch ch conta contacts cts.. Th The e time time fo forr th the e proxi proximi mity ty switc switch h to repea repeatt a co cont ntac actt trans transit itio ion n (ex. (ex. from from op open en to clos closed ed)) is kn known own as th the e cy cycl cle e time time of th the e di divi vide derr va valv lve e asse assemb mbly ly.. The The proxi proximi mity ty switc switch h must must work with with a PLC or or so some me ot othe her r coun counter/ ter/tim timer er de devi vice ce to produ produce ce a shutd shutdown. own. See "Instru "Instrume menta ntatio tion" n" in the Ariel Ariel Pac Packa kage gerr Standar Standards ds for interp interpreta retatio tion n of proxi proximit mity y switch switch pu pulse lse outpu output. t.
Proximity Switch Installation 1. Loos Loosen en th the e Allen Allen se sett sc screws rews on the the proxi proximi mity ty switc switch h hous housin ing g and and remov remove e magn magnet et hous housin ing. g. Do not not remov remove e magn magnet et,, sp sprin ring, g, or spac spacer er from magne magnett ho hous using ing.. 2. Remove Remove pi pisto ston n enclos enclosure ure plu plug g from end of des desired ired divid divider er va valv lve. e. Th The e proxi proximi mity ty switc switch h inst instal alls ls on any any of the the divi divide derr va valv lves es of the di divid vider er block block.. The proxim proximity ity switch switch require requires s the correc correctt magne ma gnett as asse sembl mbly y to match match the divide dividerr valve valve manufa manufactu cturer. rer. NOTE: Do not install a proximity switch on Lincoln divider valves with cycle indicator pins. applic icab able le,, ve verif rify y o-rin o-ring g or me meta tall gask gasket et is in plac place e on ma magn gnet et 3. If appl ho hous using ing.. Thread Thread magnet magnet housi housing ng into into en end d of div divid ider er valv valve. e. Torq To rque ue to 15 lb lbs s x ft maxi maximu mum. m. 4. Sl Slid ide e proxi proximi mity ty switc switch h all all the the way onto onto hex hex of magn magnet et hous housin ing. g. To Torq rque ue Allen Allen se sett sc screw rews s on hex hex of magn magnet et hous housin ing g to 25 lb lbs s x in inch ch,, maxi maximu mum. m.
Trabon Style O-Ring Seal 7/16-20
Trabon Metal Metal Gasket Seal 7/16-20 (1994 or earlier)
Lincoln O-Ring Seal 7/16-20 Extended Nose
FIGURE 2-9 Typical Magnet Assemblies
5. Conne Connect ct an oh ohm m meter meter ac acros ross s the two yello yellow w swit switch ch leads leads ex exiti iting ng the proxi proximit mity y switch switch ho hous using ing..
Page 2-10 of 19
REV: 10/14
For models models JGC:D:F JGC:D:F
Section Sectio n 2 - Instr Instrum umen entatio tation n
6. The divide dividerr valve valve must must cycl cycle e du during ring proxi pro ximit mity y switch switch adjus adjustme tment. nt. To cycl cycle e it, eithe eitherr run the compre compress ssor or or manua manually lly pump pum p oi oill throug through h the distrib distributi ution on block block with a purge purge gun. gun. 7. To adju adjust st,, sl slid ide e proxi proximi mity ty switc switch h all all the the way onto ont o hex of magne magnett ho hous using ing.. Tighte Tighten n All Allen en set set scr crew ews s to 25 lbs lbs x inch inch maxi maximu mum. m. The The ohm meter meter showin showing g the switch switch chan changin ging g state as the di state divid vider er valve valve cycl cycles es indica indicates tes correc correctt ad adjus justme tment. nt. If the switch switch state state fai fails ls to chan change, ge, slide slide proxim proximity ity switch switch ba back ck on th the e hex hex of th the e magn magnet et hous housin ing g in 1/16 1/16"" increm inc remen ents ts un until til it does. does. 8. Make Make all cond conduit uit an and d conne connecti ctions ons appropriat appro priate e for area classi classifica fication tion.. Suppo Support rt cond conduit uit an and d fit fittin tings gs to av avoid oid be bendi nding ng the magnet magn et housing. housing.
1. Divider Valve Pist Piston on 2. Magnet 3. Magnet Magnet Housing 4. Allen Set Screw Screw ((2) 2) 5. Spacer 6. Spring
7. Switch Housing 8. Wire Leads (yellow) 9. Ground Wire (green) 10. O-Ring 11. Divider Valve 12. Piston End Plug
9. After After proxi proximit mity y switch switch instal installat latio ion n and before bef ore compr compres esso sorr start-up start-up,, pu purge rge all air FIGURE 2-10 Typ. Proximity Switch from divide dividerr bl bloc ock k lubric lubricati ation on syste system m with a purge pur ge gun. gun. Installation NOTE: When installing multiple proximity switchs, wire each to a separate alarm circuit of the control panel, annunciator, or PLC to simplify lubrication system and proximity switch troubleshooting. Always secure green ground wire to "earth ground" in the control panel. Do not ground to electrical conduit. Improper grounding can result in unreliable monitor operation.
FIGURE 2-11 A-18255 Proximity Switch Wiring Connections for Unit in Operation
REV: 10/14
Page 2-11 of 19
Section 2 - Instrumentation
For models JGC:D:F
Troubleshooting Proximity Switches NOTE: When installing multiple proximity switches, wire each to a separate circuit in the control panel, annunciator, or PLC to simplify lubrication system and proximity switch troubleshooting. Problem
Possible Cause Improperly adjusted proximity switch.
Switch does does not not cycle and and control panel indicates lube no-flow. (see also Erratic Erratic Operation)
Erratic Operation.
Lo Loose n set slid slide proxim prsoximity ity ma switch all not the the way on to hex hex of mag magne t mp housi hoosen using ng and andscrews, torq torque ue to 25elb lbs x inch inch max. x. (Do (Do overonto tighten) tighten). . Either Eith ernet pu pump clean cle an oi oill thr throu ough gh lu lubr brica icatio tion n syste system m with a purg purge e gun gun or run run the compr compresso essorr to cycle the divide dividerr valve. valve. If necessar necessary, y, slide proxim proximity ity switch ba back ck in 1/16“ 1/16“ increm incr emen ents ts un until til th the e switch open opens/close s/closes s with each each divide dividerr valve cycle.
Loosen set screws, rremove Loosen emove proximity proximity switch from mag magnet net housing. housing. Check Check for damage dam aged d or ben bentt magnet magnet hou housing. sing. Remove Remove magn magnet et assembly from divider divider valve. Replace mag magnet net housing, housing, magn magnet, et, s sprin pring, g, and spacer spacer.. Re-install Re-install new magn ma gnet et ho housin using g on divid divider er valve an and d proxim proximity ity switch on magne magnett hou housing sing.. If ne necessar cessary, y, ad adjust just pro proximity ximity switch and and test switch function functionali ality. ty. Purge Purge air from from system syste m with purg purge e gun. gun.
Lo Loose osen n set sc scre rews ws an and d remo remove ve proxim proximity ity switch from from magn magnet et hou housing sing.. Check Check Wrong mag Wrong magnet net for cor corre rect ct ma magn gnet et ho housin using g for divi divide derr valve manufa manufactur cturer er.. Remo Remove ve an and d repla replace ce housing with correct correct magn magnet et hou housing. sing. Re-install Re-install proximity proximity switch switc h on new magne magnett installe insta lled d on housing. hou sing. If necessary necessary adjust adjust proximity proximity switch and test switch functionality. functionality. divide divi derr valve. valve. Purg Purge e ai airr from from system system with purg purge e gun. gun. Check s Check system ystem pressur pressure e to ver verify ify oil flows to divider divider valves. valves. If ne need eded ed,, install pressu pressure re gaug gauge e to mon monitor itor lubrica lubrication tion system oper operatio ation: n: • Lo Loose osen n outlet outlet plugs plugs in fro front nt of of valve blocks. blocks. Purge Purge lub lubri ricatio cation n system with a Air or purge pur ge gun until cle clean, an, clea clear, r, air air-fre -free e oil flows from from plugs. plugs. debris deb ris in divide divider r • Loo Loosen, sen, but do not remove, remove, each piston enclo enclosure sure plug individual individually ly to purge purge valve air fro from m be behin hind d piston. piston. Tigh Tighten ten all divider divider valve plugs. plugs. Adjust proximity proximity assembly. switch. To ensure proper lubrication system operation, all tubing and components MUST be filled with oil and free of air before start-up. Faulty wiring from pr proximity oximity switch swi tch to control panel or air air in syst system em (see (se e above above for air air in syste system) m)..
Faulty lube pump.
Page 2-12 of 19
Solution
Loosen set screws, rremove Loosen emove proximity proximity switch from mag magnet net housing. housing. Remove Remove magnet net housing housing from divider divider valve. Remove magnet, magnet, spring, spring, and spacer and Broken Bro ken sprin spring g mag f or dam damage age.. Repla Replace ce damage damaged d componen components. ts. Re-install Re-install magnet magnet housing or magnet magnet in check for on divide dividerr valve and and proxim proximity ity switch on ma magn gnet et hou housing sing.. If ne necessar cessary, y, ad adjust just magnet proxim proximity ity switch and and test switch fun function ctionali ality. ty. Purge Purge air from from system with housing. purge pur ge gun gun..
Bent magnet housing.
Rupture Ruptur e disc blows and divider valve seizes after proximity switch installation.
Check Che ck ele electrica ctricall wiring and and con conne nection ctions s for da dama mage ge or po poor or con contact. tact. See FIGURE 2-11 2-11..
Check system pressur Check pressure e to ver verify ify o oilil flows to pu pump mp an and d divid divider er valves. valves. If needed nee ded,, iinstall nstall pre pressure ssure gau gauge ge to moni monitor tor lubr lubrication ication system syst em opera operation. tion. Check ga gaug uge e to verify verify pum pump p bu build ilds s sufficien sufficientt pre pressure ssure to inj inject ect oil into into cylinder cylinder.. Do not not remo remove ve tubing tubing fro from m check check valve valve an and d pu pump mp oil to atmosph atmospher ere e to check check oil oil flow into cylinder cylinder.. Replace Replace pump. pump.
REV: 10/14
For models models JGC:D:F JGC:D:F
Section Sectio n 2 - Instr Instrum umen entatio tation n
Proflo Lubricator Fluid-Flow Monitor/No-Flow Timer Switch CAUTION: See arc welding caution on on page page 2-1. 2-1. The battery-powere battery-powered, d, programmab programmable le Proflo is annses electronic elec microproc micro ed switch that sens se estronic slow-fl slow-flow ow orprocess no-flo no-essor-bas flow wor-based cond conditi itions ons in the compress comp ressor or cylinde cylinderr force feed lubricati lubrication on syste system m to facili facilitat tate e al alarm arm and/or and/or shutd shutdown. own. It eases eas es force force feed feed lube lube syste system m op opera eratio tion n by ac accu curate rately ly monito monitorin ring g cycl cycle e time time and syste system m perform perf orman ance ce.. Opera Operators tors us use e thi this s inform informati ation on to optimi opt imize ze forc force e feed feed lube lube an and d reduc reduce e op opera eratin ting g costs.
1. Hex-Socket Hex-Socket Set Screws (2) 2. Magnetic Pin Housing (attaches to divider valve) 3. Liquid Crys Crystal tal Display (LCD) 4. Infrared Wireless Connection IrDA Port (t (to o download data to a hand-held computer) 5. Set But Button ton 6. Mode But Button ton
Th The e Profl Proflo o moni monito torr works works thro throug ugh h a magn magnet etic ic pin pin th that at cy cycl cles es back back and and forth forth as the the divi divide der r valve valve piston piston moves moves.. The ma magne gnetic tic pin hou housi sing ng normall norm ally y thread threads s into into the divide dividerr valv valve. e. The monito mon itorr box ho hous using ing sl slide ides s on onto to the pin ho hous using ing and and two hexhex-so sock cket et se sett sc screws rews hold hold it in plac place. e. The liq liqui uid d crysta crystall displa display y (LCD) indic indicate ates: s: 1. Total Total opera operati ting ng time time of the the forc force e feed feed lube lube syste system m in ho hours urs..
FIGURE 2-12 Proflo Electronic Lubricator Fluid Flow Monitor and No-Flow Timer Switch
2. "Avera "Average ge", ", "L "Las ast" t" an and d "Current" "Current" cycl cycle e time time of the divide dividerr valve valve in seco second nds. s. 3. Total Total di divid vider er valv valve e cycl cycles es.. 4. Remaini Remaining ng ba batte ttery ry lif life e in perce percent. nt. 5. Alarm set set time time for no no-flo -flow w indic indicati ation on (progra (programma mmable ble from 30 to 240 seco seconds nds). ). 6. Alarm Alarm wiring wiring mode mode:: Normal Normally ly Open pen or Normal Normally ly Close Closed. d. Proflo electro Proflo electronic nics s come come with revers reverse e po polari larity ty protec protectio tion/c n/corre orrecti ction on that that au autom tomati atica cally lly correc corrects ts a revers reverse e polarit pol arity y outpu outputt conn connec ectio tion n on bo both th pulse pulse an and d alarm alarm ou outpu tputs ts..
Normally Open and Normally Closed Definition Most electri Most electrica call compo componen nents ts define define Normally Normally Open Open (NO) and Normally Normally Closed Closed (NC) op opera eratio tion n as the defa defaul ultt st stat ate e or “on the the sh shel elf” f” stat state. e. Exam Exampl ple: e: A NO so sole leno noid id va valv lve e is op open en when when th the e co coilil is no nott en energ ergiz ized ed,, and and cl clos osed ed when when th the e co coilil is energ energiz ized ed.. A NC sol solen enoi oid d va valv lve e is clos closed ed when when th the e co coilil is no nott en energ ergiz ized ed,, an and d open open when when th the e co coilil is energ energiz ized ed.. This This is not not tru true e of DNFT or Profl Proflo o elec electri trica call co cont ntac acts ts.. Both Both th the e DNFT and Proflo Proflo switch switch conta contacts cts are defin defined ed as switch switch state states s aft after er the divide dividerr valv valve e cy cycle cles. s. Normally Open Open when runnin running; g; switch switch is open open while while the di divid vider er valve valve cy cycl cles es.. This This is non-fai non-fail-s l-safe afe NO = Normally opera operati tion on.. If a wire fall falls s off off while while the the unit unit runs, runs, the the co cont ntro roll sy syst stem em will will no nott alarm alarm/s /shu hutd tdown own.. NC = Normally NC= Normally Closed Closed when runnin running; g; swit switch ch is cl clos osed ed while while the divid divider er valv valve e cy cycl cles es.. This This is fai fail-s l-safe afe opera operati tion on.. If a wire fall falls s off off while while the the unit unit runs, runs, the the co cont ntro roll sy syst stem em will will al alarm arm/s /shu hutd tdown own.. Ariel recommends NC operation.The operation.The Prof Proflo lo is pre-pro pre-progra gramme mmed d for NC ope operati ration on..
REV: 10/14
Page 2-13 of 19
Section 2 - Instrumentation
For models JGC:D:F
Proflo Installation 1. Loos Loosen en th the e two hexhex-so sock cket et se sett sc screw rews s on top top of Profl Proflo o ca case se and and remov remove e magn magnet et ho hous using ing.. Do not remove remove magne magnet, t, spring spring,, an and d spac spacer er from magne magnett ho hous using ing.. 2. Remove Remove en end d plug plug from desire desired d divide divider r va valv lve. e. Th The e Profl Proflo o in inst stal alls ls on eith either er si side de of an any y divide dividerr valv valve, e, but require requires s the co correc rrectt magne ma gnett hou housi sing ng for ea each ch div divide iderr va valve lve manufac man ufacturer turer (Trabon (Trabon,, Linc Lincoln) oln) NOTE: Do not install the Proflo on any divider valves with cycle indicator pins. 3. Ve Verif rify y O-ri -ring ng is in pl plac ace e on Profl Proflo o magn magnet et ho hous using ing.. Screw Screw magnet magnet ho hous using ing into into end of di divid vider er valv valve. e. Torque Torque magne magnett housi housing ng to 15 foot-poun foot -pounds ds max. max. 4. Sli Slide de Profl Proflo o al alll th the e way onto onto magn magnet et hous ho usin ing. g.max. To Torq rque ue se set t sc screws rews 15 inch in pounds pou nds max . DO NOT NOT ov over er to tig tighte hten nchset se-t screws.
1. End Plug 2. Divider Valve 3. Magnet Housing
4. O-Ring 6. LCD Display 5. Hex-Soc Hex-Socket ket Set 7. Wire Leads Screws (2)
FIGURE 2-13 Typical Proflo Installation
5. Th The e Proflo Proflo LCD indica indicates tes cycl cycle e time. time. Verify Verify correc correctt op opera eratio tion n by pumpin pumping g oil throug through h the divide dividerr valv valve e asse assemb mbly ly.. Th The e LCD enab enable les s the the oper operat ator or to adju adjust st the the lu lubr bric icat ator or pu pump mp fo forr co corre rrect ct cy cycl cle e time time.. Th The e force forc e feed feed lubric lubricato atorr da data ta plate plate on the lubric lubricato atorr box indic indicate ates s eithe eitherr normal normal and break break-in -in cy cycl cle e times times at maxi maximu mum m rated rated sp spee eed, d, or norma normall cy cycl cle e time time for for appl applie ied d sp spee eed. d. Use break break-in -in cy cycl cle e time times s on only ly fo forr th the e first first 200 200 hours hours of opera operati tion on befo before re ch chan angi ging ng to the the norma normall cy cycl cle e time time.. If un unab able le to de dete termi rmine ne cy cycl cle e time, tim e, conta contact ct the Ariel Ariel Respons Response e Center. Center. 6. All condu conduit it and conn connec ectio tions ns shoul should d be ap approp propria riate te for are area a class classifi ifica catio tion. n. Use fle flexib xible le condu conduit it to ease ease insta installa llatio tion. n. Suppor Supportt cond conduit uit an and d fit fittin tings gs to min minimi imize ze vib vibrati ration. on. 7. After After Proflo Proflo instal installa latio tion n or perform performan ance ce of an any y mainte maintena nanc nce e on the lube lube sy syste stem, m, compre compress ssor or cylinde cyl inders, rs, or packing packing,, pre-lube the complete system with a purge gun to purge air from the divider valves and all components BEFORE COMPRESSOR START-UP.
Proflo Button Operation 1. Push Push SET butt button on to cl clea earr ALARM. ALARM. When When the the LCD disp displa lays ysLAST LASTand and AVG AVG,, th the e alarm alarm ou outp tput ut co cont ntac actt ente enters rs th the e “as runni running ng”” st stat ate; e; se sett opera operati tion on to NC NC to cl clos ose e the ou outpu tputt al alarm arm conta contact ct.. LAST is th the e last last di divid vider er valv valve e cycl cycle e time time in seco second nds. s. AVG is the the avera average ge time time of th the e la last st six six (6) divi divide derr va valv lve e cy cycl cles es in seconds. 2. Push Push MODE MODE button button;; the LCD di disp splay lays s NOW NOW,, which which is cu curre rrent nt divi divide derr va valv lve e cy cycl cle e time time in se seco cond nds. s. This Thi s mode mode allows allows op opera erators tors to ac accu curate rately ly chan change ge cycl cycle e time time by adjus adjustin ting g the force force feed feed lu lubric bricato ator r pump pump.. Th The e fo force rce fe feed ed lubr lubric icat ator or data data plat plate e on the the lubr lubric icat ator or bo box x in indi dica cate tes s eith either er no norma rmall an and d break break-in -in cy cycl cle e time times s at maxi maximu mum m rated rated sp spee eed, d, or norma normall cy cycl cle e time time fo forr ap appl plie ied d sp spee eed. d. Use break break-in -in cy cycl cle e time times s only only fo forr th the e first first 200 200 hours hours of opera operati tion on befo before re ch chan angi ging ng to th the e norma normall cy cycl cle e time time.. Compre Compress ssor or sp spee eed d is di direc rectl tly yelpropo pro onal alk to cycl eetime tiof me; ; at 50% 50 rated rat ed spee d, th the lube lu be cy cycl cle ede time time do doub uble les scle (s (see ee lube lu,be sh shee eets in th the e Ariel Ari Parts Paporti rtsrtion Book Boo for forcy tabl tacle ble sp spee eeds ds% vs vs. . cy cycl cle esp time tieed, mes). s). Ifeun unab able le to dete termi rmine ne cy cycl e time ti me, co cont ntac act tts the Ariel Ariel Respon Response se Center. Center.
Page 2-14 of 19
REV: 10/14
For models models JGC:D:F JGC:D:F
Section Sectio n 2 - Instr Instrum umen entatio tation n
3. Push Push MODE MODE bu butto tton n again; again; the LCD di disp splay lays s RUN TIME, TIME, whic which h is th the e to tota tall ru run n time time of th the e lube lube sy syst stem em in hours hours si sinc nce e the the last last rese reset. t. 4. Push Push MODE MODE butto button n a third third time time;; the the LCD disp displa lays ysCYCLE CYCLE TOTAL, TOTAL, which which is th the e to tota tall di divi vide derr va valv lve e cy cycl cles es si sinc nce e th the e last last res reset et.. Test Test Profl Proflo o for for reli reliab abililit ity y if if CYCLE CYCLE TOTAL TOTAL dis displa plays ys ov over er two millio million. n. 5. Push Push MODE MODE butto button n a four fourth th time time;; the the LCD disp displa lays ysBATTERY BATTERY - PCNT, PCNT, which which indic indicate ates s pe perce rcenta ntage ge of remain remaining ing ba batte ttery ry lif life. e. If ba batte ttery ry volta voltage ge drops drops be below low safe safe operati operating ng levels levels the monito monitorr en enters ters ALARM mode. mode. 6. Th The e di disp spla lay y mode mode ch chan ange ges s to ALARM ALARM when when an alarm alarm is trigg triggere ered. d. Th The e disp displa lay y de defa faul ults ts to toLAST LAST and AVG whi while le th the e di divi vide derr va valv lve e cy cycl cles es.. To se sett alar alarm m time time an and d mode mode:: Push SET. SET. a. Push b. Push Push MODE MODE si six x times times un until til LCD di disp splay lays s SETUP? SETUP?.. c. Push SET. The LCD displa displays ysSET SET ALARM TIME. TIME. d. Push Push SET agai again n to disp displa lay y cu curre rrent nt alarm alarm time time.. e. Push Push and and relea release se SET butt button on to ch chan ange ge alarm alarm-sh -shut utdo down wn from from 30 to 24 240 0 se seco cond nds s in 5 se seco cond nd increm inc remen ents. ts. Ariel Ariel ty typic picall ally y sets sets it to 12 120 0 seco second nds. s. Ariel recommends setting alarm time to 2 times normal cycle time rounded up to the nearest 5 seconds. Minimum: 30 seconds; maximum 180 seconds. Find Find norma normall cy cycl cle e time time on th the e fo force rce fe feed ed lubri lubrica cato torr da data ta pl plat ate. e. f. Pus Push MODE MODE two more more ti time mes s to scro scroll ll the the LCD LCD toSET to SET ALARM MODE, MODE, which which confi configur gures es the co cont ntrol rol sy syst em shut utdo down wnrmally the thelly co comp mpres resso sor r for for arecommends no no-fl -flow ow indi indica cati tion on.. Push Pus h SET to to togg ggle le from fro m N/O (norma (no rmally llystem op open) en)toorsh N/C (norma (no close clo sed). d). Ariel N/C operation. operation. After Af ter setting sett ing wirin wir ing g mode mode,, eith either er push push MODE MODE two ti time mes s or si simp mply ly wait wait 30 seco second nds s to re retu turn rn to th the e LAST and AVG di disp spla lay. y. The The Profl Proflo o record records s any any se setu tup p ch chan ange ges s to th the e EEPROM. EEPROM.
Display Errors ALARM - Display Displays s when divide dividerr valve valves s are no nott cycli cycling. ng. Program Programme med d divid divider er valv valve e cycl cycle e time time ha has s expired. ALARM fla flash shes es ev every ery 2 seco second nds s du durin ring g compr compres esso sorr shutd shutdown. own.To To cl clea earr al alarm, arm, press press SET. Alarm will clear clear and again again indicate indicate cycle cycle time upon compress compressor or re-start. re-start. OVERLOAD - In OVERLOAD Indi dica cate tes s a wiring wiring sh short ort or ci circ rcui uitt switc switchi hing ng of to too o la large rge a lo load ad.. To co corre rrect ct th this is,, ch chec eck k wiring wirin g insul insulati ation on for ba bare re wires touch touchin ing g ground ground or ea each ch other. other. Insula Insulate te un unus used ed wires or re-termin re-terminate ate wires.. Self-res wires Self-resett etting ing fuses fuses on the inputs inputs protec protectt Profl Proflo o electro electronic nics; s; they they auto auto reset reset 45 seco second nds s aft after er fix fixing ing a sh short ort.. LOW BATT - In Indi dica cate tes s 20% 20% remai remaini ning ng batt battery ery life life.. At 10% 10% remai remaini ning ng ba batt ttery ery life life,, th the e Profl Proflo o sh shut uts s do down wn the compre compress ssor or an and d fla flash shes es ALARM and LOW BATT unt untilil batteri batteries es are replac replaced. ed. See ba batte ttery ry replaceme repla cement nt procedure procedure below. below. RESET X - In Indi dica cate tes s an inte interna rnall Profl Proflo o faul fault. t. No alarm alarm disp displa lays ys;; th the e Profl Proflo o st stililll co coun unts ts divi divide derr va valv lve e cy cycl cles es and contro controls ls in input puts s and outpu outputs. ts. While While the di divid vider er valv valve e cy cycl cles es,, the Proflo Proflo count counts s pu pulse lses s and measu measures res time tim e between between divide dividerr valve valve cycl cycles es.. At 30 30-min -minute ute interv interval als, s, the proce process ssor or writes writes data data stored stored in memor memory y to on-bo on-board ard EEPROM EEPROMS. S. If there there is a probl problem em with with this this,, the the Profl Proflo o is issu sues es a Reset Reset error error.. 1. RE RESE SET T 1 - Proflo Proflo proce process ssor or un unabl able e to determ determine ine if the EEPROM EEPROM conta contain ins s valid valid confi configur gurati ation on in info forma rmati tion on.. Reset Reset 1 usua usualllly y occu occurs rs afte afterr a RESET RESET 3 oc occu curs. rs. Upo Upon n reboo reboot, t, th the e Profl Proflo o lose loses s st store ored d and confi configur gurati ation on data; data; progra programm mmed ed inform informati ation on must must be re-ente re-entered red.. 2. RE RESE SET T 2 - Profl Proflo o proce process ssor or unab unable le to dete determi rmine ne st stora orage ge of an any y da data ta or loca locati tion on fo forr ne next xt da data ta.. Upon Upon reboot reb oot,, the Proflo Proflo loses loses stored stored da data, ta, but retain retains s confi configur gurati ation on data; data; progra programme mmed d in inform formati ation on ne need ed not be re-ente re-entered red.. 3. RE RESE SET T 3 - In Inte terna rnall Profl Proflo o faul fault. t. The The Profl Proflo o proce process ssor or tried tried an and d fa faililed ed th thre ree e reset resets. s. Th The e most most like likely ly caus cause e is fa fail ilur ure e to write write to the the EEPRO EEPROM. M. To try try to corre correct ct th the e pr prob oble lem: m:
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Page 2 15 of 19
Section 2 - Instrumentation
For models JGC:D:F
a. Remove Remove Proflo batteries. batteries. b. Pre Press ss SET butt button on for for 45 se seco cond nds s to disc discha harge rge inte intern rnal al ca capa paci cito tors rs an and d en ensu sure re a co comp mple lete te re rese set. t. c. Re-inse Re-insert rt batteri batteries es to reboo reboott the Proflo. Proflo. • If th the e error error was a one-t one-tim ime e probl problem em,, the the Profl Proflo o reboo reboots ts as no norma rmal. l. • If di diag agno nost stic ics s dete detect ct an error error on reboo reboot, t, the the Profl Proflo o disp displa lays ys a co cons nsta tant nt RESET error error ag agai ain. n. Repla Rep lace ce th the e Profl Proflo o and and co cont ntac actt Ariel Ariel.. Somet Sometim imes es on reboo reboot, t, th the e Profl Proflo o flas flashe hes s RESET. RESET. Th This is is normal. NOTE: Moisture on Proflo circuitry causes most reset errors. Several design precautions keep moisture from the circuit board: • The Proflo housing is completely sealed sealed in a low humidity room. • There is a desiccant desiccant pack pack in the circuit board chamber. chamber. • The circuit boards have have a protective conformal conformal coating.
Proflo Battery Replacement The Proflo Proflo formerl formerly y us used ed alkal alkaline ine batteri batteries es.. Someti Sometimes mes,, alkali alkaline ne batteri batteries es leak, leak, releas release e ac acid, id, an and d corrod corrode e the ba batte ttery ry comp compartm artmen ent, t, an and d their their servi service ce po poten tentia tiall di dimin minis ishe hes s at ex extrem treme e temper temperatu atures res.. The Proflo Proflo now us uses es Lithiu Lithium m batteri batteries es,, which which provi provide de super superior ior lea leaka kage ge resis resistan tance ce,, greate greaterr servi service ce advant advantag age e at tempe tem peratu rature re ex extrem tremes es,, and longe longerr shelf shelf an and d servi service ce lif life. e. Arie Ariell hig highly hly recom recommen mends ds AA Energiz Energizer er Lithium/FeS2, mode modell L91 L91 batt batteri eries es to reduc reduce e main mainte tena nanc nce e co cost sts. s. Th This is is a true true Li Lith thiu ium m ba batt ttery ery,, un unlilike ke several other several other brands. brands. While not recomm While recommend ended ed,, us use e replac replaceme ement nt al alka kalin line e ba batte tteries ries only only when Lithiu Lithium m batteri batteries es are unava unavaila ilable ble.. Compon Comp onen entt da damag mage e du due e to battery battery leaka leakage ge is no nott no norma rmally lly cove covered red under under warranty. warranty. Front Front cove coverr remov removal al vo void ids s th the e warran warranty ty,, exce except pt on olde olderr Profl Proflo o moni monito tors rs ma made de prior prior to 3/ 3/20 2003 03 whe where re ba batt tteri eries es may may be loca locate ted d un under der the front front cove cover. r. CAUTION: EXPLOSION HAZARD! Disconnect/lockout electrical power to control circuits before battery cover removal. Power connected to the Proflo presents a potential of fire, electrical shock, personal injury, or death. Change batteries only in a non-hazardous area. Earlier Proflo models use a front battery access cover while later models use a rear access cover to reduce potential risk. Disconnect power to Proflo to replace batteries regardless of battery access location 1. Remove Remove the si six x battery battery cove coverr screws. screws. 2. Remove Remove ba batte ttery ry cove coverr and ga gask sket. et. 3. Remove Remove ol old d batteri batteries es.. Remove Remove plasti plastic c protec protectiv tive e slee sl eeve ves s from old ba batte tterie ries. s. Save Save the sl slee eeve ves s an and d di disc scard ard the ol old d batteri batteries es in a respon responsi sible ble manne manner. r. 4. Press Press SET for 45 45-60 -60 seco second nds s without without batteri batteries es insta installe lled d to dissi dissipat pate e store stored d ene energy rgy an and d allow allow the ba batte ttery ry displa display y to up updat date e immed immediat iately ely aft after er new ba batte ttery ry instal installat latio ion. n. This This step step is op optio tional nal;; the monito monitor r au autom tomati atica cally lly up updat dates es the battery battery displa display y within within 30 minutes minu tes of operation operation..
1. Battery compartment compartm ent cover with gasket 2. AA Energizer lithium L91 batteries batt eries with plastic sleeves 3. Battery cover screw 4. Battery clips
FIGURE 2-14 Proflo Rear Battery
Compartment 5. ve Th The eyoute ou co cove ver r of batt ba tteri isratch the thched e posi po tive ve te rmina nal; verif rify it ter isrunsc un scrat ratch ched ed. .eries If aes sc scrat edsiti oute ou terrtermi co cove ver r l; touch tou ches es the metal metal ba batte ttery ry holder, holder, the battery battery deplet depletes es very very qu quick ickly ly and the Proflo Proflo displ display ays s LOW
Page 2 16 of 19
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For models models JGC:D:F JGC:D:F
Section Sectio n 2 - Instr Instrum umen entatio tation n
BATT. It is poss BATT. possib ible le for for one one batt battery ery to co comp mple lete tely ly depl deplet ete e an and d th the e ot othe herr to revers reverse e po pola larit rity. y. Repla Replace ce with new unscratc unscratche hed d ba batte tterie ries s if thi this s oc occu curs. rs. 6. Slide Slide the pl plas astic tic protec protectiv tive e sl slee eeve ves s onto onto the ne new w ba batte tterie ries s and in inse sert rt ne new w batteri batteries es into into the ba batte ttery ry hold holder. er. Th The e pl plas asti tic c sl slee eeve ves s and and the the gask gasket et on the the bott bottom om of th the e co cove verr en ensu sure re a tigh tightt ba batt ttery ery fit. fit. Compres Comp resso sorr vibrati vibration on can can caus cause e prema premature ture fai failur lure e in ba batte tteries ries not instal installe led d tig tightl htly. y. Verify Verify the batteri bat teries es are instal installed led with correc correctt neg negati ative ve/po /posit sitiv ive e orient orientati ation on.. Do not sc scratc ratch h or da damag mage e ne new w battery batte ry outer outer covers covers during during installa installation. tion. 7. only Re-ass Re-a ssem embl ble etion; co cove ver, r, gask ga et, , and antdinstal sc screws rews. . The Th e co cove ver r gho hole les scove alig alver ign nr upside with withide th the edo six siwn x moni mo nito torts r bo body hole les sd in onl y one di direc rectio n; verify ve rifysket correc co rrect ins tallat lation ion. . Instal Ins tallin ling the co ups down resul res ults indy strippe striho pped screw screw th threa reads ds an and d comp compromi romise ses s the battery battery compa compartme rtment nt seal. seal. Do no nott ov over-ti er-tight ghten en the screws. screws. Repla Rep lace ce lo lost st co cove verr sc screws rews with with 4-40 4-40 x 3/16 3/16 in. in. pan pan head head ma mach chin ine e sc screws rews.. 8. Press Press SET once once,, then then press press MODE MODE unti untill the the LCD disp displa lays ysBATTERY BATTERY.. If st stor ored ed en ener ergy gy was was dissi dis sipa pated ted (see (see step step 4), the monito monitorr chec checks ks ba batte ttery ry volta voltage, ge, resets resets,, an and d displ display ays s remaini remaining ng battery battery power. powe r. The monit monitor or automa automatic ticall ally y searc searches hes for ba batte ttery ry volta voltage ge at the next next 30 minute minute read/wri read/write te interv interval al an and d update updates s to the ne new w battery battery power power pe perce rcenta ntage. ge. All tre trendi nding ng and confi configu gurati ration on da data ta store store in th the e Profl Proflo o EEPROM. EEPROM. Batt Battery ery fail failure ure or rep repla lace ceme ment nt ca caus uses es no memo memory ry lo loss ss..
Proflo Jr. No-Flow Switch CAUTION: See arc welding caution on on page page 2-1. 2-1.
Proflo Jr. Installation CAUTION: Explosion hazard - no user serviceable parts. Do not disconnect wiring while circuit is live. Complete all field wiring in accordance with local codes pertaining to potentially explosive atmospheres. Do not open battery compartment in areas known to contain explosive gases. 1. L Loo oose sen n th the e two Allen Allen head head se sett sc screws rews on to top p of Profl Proflo o Jr. cas ase e an and d remo remove ve magne mag nett ho hous using ing.. Do no nott remov remove e magne mag net, t, sprin spring, g, and spac spacer er from magnet housing. magnet housing. 2. Remove Remove piston piston en end d plug plug from de desi sired red di divi vide derr va valv lve. e. Th The e Pro Profl flo o Jr. inst instal alls ls on ei eith ther er si side de of any any divi divide derr va valv lve, e, but but require req uires s the correc correctt magne magnett ho hous using ing for each eac h divider divider valve valve manufac manufacturer. turer. NOTE: Do not install the Proflo Jr. on any divider valves with cycle indicator indica tor pins. 3. Ve Verif rify y O-rin O-ring g is in plac place e on magn magnet et housi hou sing. ng. Thread Thread magne magnett ho hous using ing into into end of divide dividerr valv valve. e. Torque Torque magne magnett housi hou sing ng to 15 foot-p foot-poun ounds ds maxi maximum mum..
1. Magnet Magnet Housing 5. 6. 2. O-Ring 7. 3. Allen Head Set 8. Screw (2) 4. Prof Proflo lo Jr. Case 9.
LED 10. Battery Plug Red Wire Leads (2) 11. Grounding Lug Orange W Wire ire Leads (2) (2) 12. Battery Yellow Wir Wire e Leads (2) 13. Divider Valve Green Wire Lead (1) 14. End Plug
FIGURE 2-15 Typical Proflo Jr. Installation
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Section 2 - Instrumentation
For models JGC:D:F
4. Sli Slide de Profl Proflo o Jr Jr.. al alll th the e way onto onto magn magnet et hous housin ing. g. Torqu Torque e Allen Allen he head ad se sett sc screws rews to 15 in inch ch-po -poun unds ds maximum. DO NOT NOT over-tighte over-tighten n set screws screws.. 5. Th The e LED on on th the e Profl Proflo o Jr. Jr. indi indica cate tes s one one co comp mple lete te cy cycl cle e of th the e divi divide derr va valv lve e sy syst stem em.. Verif Verify y co corre rrect ct op opera eratio tion n by pumpin pumping g oil throug through h the divide dividerr valv valve e as asse semb mbly. ly. The force force feed feed lubric lubricato atorr data data plate plate on the lu lubric bricato atorr box indic indicate ates s either either no norma rmall and break break-in -in cycl cycle e times times at maxi maximum mum rated rated spee speed, d, or norma normall cy cycl cle e time time fo forr appl applie ied d sp spee eed. d. Use break break-in -in cy cycl cle e time times s on only ly fo forr th the e firs firstt 20 200 0 ho hours urs of op opera erati tion on befo before re ch chan angi ging ng to the the norma normall cy cycl cle e time time.. If unab unable le to dete determi rmine ne cy cycl cle e time time,, co cont ntac actt th the e Ariel Ariel Response Respo nse Center. 6. Linco Lincoln ln di divi vide derr va valv lves es may may requi require re adju adjust stme ment nt to the the Profl Proflo o Jr. by slid slidin ing g it ba back ck ab abou outt 1/ 1/8” 8” on th the e magne ma gnett housi housing ng until until the LED fla flash shes es.. All cond conduit uit an and d conn connec ectio tions ns shou should ld be approp appropriat riate e for area area clas cl assi sific ficati ation. on. Use fle flexi xible ble condu conduit it to ease ease instal installa latio tion. n. Suppo Support rt condu conduit it and fittin fittings gs to minimi minimize ze vibration. 7. After After Proflo Proflo Jr. instal installa latio tion n or perform performan ance ce of an any y mainte maintena nanc nce e on the lube lube sy syste stem, m, compre compress ssor or cylinde cyl inders, rs, or packing packing,, pre-lube the complete system with a purge gun to purge air from the divider valves and all components BEFORE COMPRESSOR START-UP.
Proflo Jr. Battery Replacement
1. Proflo Jr. 2. Prof Proflo lo Jr. Batt Battery ery W Wires ires
3. Replacement Batt Battery ery Wires 4. Heat Shrink Sleeve Sleeves s
5. Replacement Battery Battery 6. Pipe Plug
FIGURE 2-16 Proflo Jr. Battery Replacement If ba batte ttery ry volta voltage ge drops drops be below low normal normal operati operating ng levels levels,, the Proflo Proflo Jr. shuts shuts down and the comp compres resso sor r cann cannot ot be re-start re-started ed until until the ba batte ttery ry is replac replaced ed.. The Bat Battery tery Replac Replaceme ement nt Kit conta contains ins one battery battery as asse semb mbly ly with heat heat shrin shrink. k. CAUTION: Do not open the Proflo Jr. in an explosive gas atmosphere. 1. Remov Remove e th the e la larg rge e si silv lver er pipe pipe plug plug.. A larg large e flat flat bit bit is requi required red to break break th the e pi pipe pe pl plug ug free. free. 2. Pl Plug ug remov removal al expo expose ses s the the old old batt battery ery.. Grab Grab the the heat heatsh shrin rink k on th the e batte battery ry with with ne need edle le no nose se pl plie iers rs an and d pull pull th the e batte battery ry out out of the the hous housin ing. g. Untwis Untwistt the the red and and blac black k Profl Proflo o Jr. wires. wires. 3. Cut Cut th the e Profl Proflo o Jr Jr.. wi wire res s free free from from the the old old ba batt tter ery y as cl clos ose e to th the e ba batt tter ery y as po pos ssi sibl ble. e. 4. Remov Remove e abou aboutt 3/ 3/8 8 in. in. of insu insula lati tion on from from the the ends ends of the the Pro Profl flo o Jr. wires. wires. 5. Remov Remove e abou aboutt 3/ 3/8 8 in. in. of insu insula lati tion on from from the the ends ends of the the rep repla lace ceme ment nt ba batte ttery ry wires. wires. 6. Sli Slide de he heat at shrink shrink sl sleev eeves es ov over er the replac replacem ement ent battery battery wires. wires. 7. Sold Solder er th the e bare bare ends ends of the the repla replace ceme ment nt batt battery ery wires wires to th the e ba bare re en ends ds of th the e Profl Proflo o Jr Jr.. wires. wires. Matc Match h red red to re red d an and d bl blac ack k to blac black k. 8. Slide Slide heat heat sh shrin rink k sl slee eeve ves s over over the the so sold ldere ered d wire ends ends and and sh shrin rink k us usin ing g a he heat at gun. gun. 9. Twist Twist batt battery ery wires wires 4 – 5 turns turns and and sl slid ide e the the batt battery ery into into th the e Profl Proflo o Jr Jr.. co comp mpart artme ment nt.. 10. Th Thre read ad th the e pi pipe pe pl plug ug ba bac ck into into the the Profl Proflo o Jr. Jr. un unti till the the plug plug to top p is flus flush h with with th the e case case..
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For models models JGC:D:F JGC:D:F
Section Sectio n 2 - Instr Instrum umen entatio tation n
Main Bearing Temperature Alarms and Shutdown Main Mai n bearin bearing g thermo thermoco coup uples les or RTD tempe temperatu rature re sens sensors ors are op optio tional nal for JGC:D:F JGC:D:F fram frames es..
Thermocouples - J (Iron-Constantan) or K (Chromel-Alumel) A thermocou thermocouple ple is two dissimila dissimilarr conduc conductors tors joined joined together together at one end to form a sensor sensor that produces produces a thermoele thermo electri ctric c volta voltage ge as an ac accu curate rate fun functi ction on of tempe temperatu rature. re. Approp Appropria riate te contro controls ls interp interpret ret the thermocou thermo couple ple voltage voltage as temperature temperature..
Resistance Temperature Devices (RTD’s) An RTD is a sensor sensor that produces produces electrica electricall resistanc resistance e as an accurate accurate functi fun ction on of tempe temperatu rature. re. Approp Appropria riate te contro controls ls interp interpret ret the electr electrica icall resis res istan tance ce as tempera temperature ture.. A typica typicall measu measurem remen entt techni technique que sends sends a small small cons constan tantt curren currentt throug through h the sens sensor or an and d meas measure ures s volta voltage ge ac acros ross s the sens sensor or with a di digit gital al voltm voltmete eterr to indica indicate te resis resistan tance ce by a comp compute uterr an and d wave-fit wave-fittin ting g equations. For main main be beari aring ng temper temperatu ature re sens sensing ing,, Ariel Ariel suppl supplies ies dual dual ele elemen ment, t, si six-wir x-wire, e, 100 100 Ohm (a (att 0°C) 0°C) RTD’s. RTD’s. Dual Dual elem elemen entt RTD’s RTD’s allo allow w rewiri rewiring ng inst instea ead d of sens sensor or replac replaceme ement nt if an elemen elementt fai fails ls.. Insul Insulate ate unuse unused d wire en ends ds fro from m each each other oth er and cond conduit uit ground ground.. To si simp mpli lify fy wirin wiring, g, RTD's RTD's come come with with tw two o blac black k wires wires an and d on one e gr gree een n fo forr on one e el elem emen ent, t, an and d two re red d wi wire res s an and d one one wh whit ite e for for the the othe other. r. See See FIG FIGURE URE 2-1 2-17 7. A Zone 1 environm environment ent may require require the installa installation tion of proper, proper, intrinsic intrinsically ally safe or equivale equivalent nt protectio protection n to fulfi fulfillll electrical electrical requiremen requirements. ts.
FIGURE 2-17 Typical Dual Element RTD Wiring Diagram
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Page 2-19 of 19
Section 3 - Maintenance Ariel compress compressors, ors, like all industria industriall equipmen equipment, t, require require main maintena tenance. nce. The severity severity of compress compressor or service service direc directly tly influe influenc nces es the freque frequenc ncy y and amoun amountt of mainte maintenan nance ce neede needed. d. Below Below are recomm recommen ended ded interv intervals als for inspec inspectio tions ns an and d replac replacem ement ents s to he help lp de determ termin ine e approp appropria riate te interv interval als s for a given given comp compres resso sorr ap appli plica catio tion. n. Careful Careful do docu cumen mentat tatio ion n of inspec inspectio tion n result results s is cri critic tical al to es estab tablis lish h whethe whether r recomm rec ommend ended ed interv intervals als are adequ adequate ate or requir require e mor more e or less less frequen frequency cy.. NOTE: For intermittent duty service, see ER-8.2.2 see ER-8.2.2.. As part of your your maintena maintenance nce progra program, m, Ariel recommend recommends: s: • Consis Consisten tentt ad adher herenc ence e to safet safety y po polic licies ies,, proce procedur dures es,, an and d eq equip uipmen mentt warning warning labels labels.. • Daily operation operational al checks checks.. • Routin Routine e trendin trending g and review review of op operat eratio ional nal pa parame rameters ters.. • Routin Routine e oil analy analysi sis s an and d trendin trending. g. • Detaile Detailed d record records s of al alll mainte maintenan nance ce.. • To avoi avoid d co cont ntam amin inat atio ion, n, ke keep ep all all co cove vers rs in plac place e where where ac acce cess ss is no nott requi required red.. Use lint lint free free clot cloths hs or paperr towels during pape during internal internal maintena maintenance nce.. CAUTION: Gas compressors are complicated and dangerous pieces of equipment. Only trained operators and mechanics familiar with unit should attempt any wear maintenance. Read and thoroughly understand theoperation appropriate manual and always appropriate personal protection equipment during maintenance. Never adjust any fastener torques while the unit is operating or pressurized. To reduce the risk of serious personal injury or death, verify driver or compressor cylinder gas pressure cannot turn compressor crankshaft during maintenance. For engine-driven compressors, either remove the center coupling or lock the flywheel; for electric motor-driven compressors, either detach the driver from the compressor or lock out the driver switch gear. Before any maintenance or component removal, relieve all pressure from compressor cylinders. See packager information to completely vent the system or call the packager for assistance. After maintenance, purge the entire system with gas prior to operation to avoid a potentially explosive air/gas mixture.
Initial Ini tial Maintenance Comply Compl y with with Ariel Ariel Packa Package gerr Stand Standard ards s and and the the co comp mpres resso sorr Start Start Up Check Check List List.. Adhe Adhere re to all all item items s be before fore and aft after er start-up start-up.. After After runnin running g a new, reloca relocated ted,, recon reconfig figure ured, d, or ov overh erhaul auled ed compr compres esso sorr for 24 ho hours urs,, shut shut down, down, vent vent the gas syst system, em, an and d pe perform rform the fol followi lowing ng maint maintena enanc nce: e:
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Page 3-1 of 32
Section 3 - Maintenance
For models JGC:D:F
1. Perf Perform orm a hot coupl coupling ing alignm alignment ent ch chec eck k withi within n 30 minu minute tes s of sh shut utdo down; wn; bar bar dr driv iver er sh shaf aftt to packager packag er recommendations. recommendations. To ensure ensure pa parall rallel el an and d conc concen entric tric drive train alignmen alignment, t, position position connec con nected ted equipmen equipmentt so total in indi dica cato torr re read adin ing g (TIR) (TIR) is as cl clos ose e to ze zero ro as poss possib ible le on the the co coup upliling ng hu hub b faces faces and ou outsi tside de diamet diameters ers at normal normal operati operating ng temper temperatu ature. re. Do not not exce exceed ed 0. 0.00 005 5 inch inches es (0.13 (0.13 mm)) on th mm the e fa face ce and and outs outsid ide e di diame ameter, ter, ex exce cept pt for ou outsi tside de di diam amet eters ers abov above e 17 in. in. (43 cm) cm) where whe re th the e angu angula larr face face TIR limi limitt is 0° 1’ (0.01 (0.0167 67°). °). See FIGURE FIGURE 33-1 1
FIGURE 3-1 Angular Coupling-Hub Face Alignment TIR Limits
• Hub O.D. O.D. > 17 17 in in.. x 0.00 0.0002 029 9 = ang angul ular ar co coup upliling ng-hu -hub b fa face ce TIR, in in.. max. max. • Hub O.D. O.D. > 43 cm x 0.00 0.0029 29 = angu angula larr co coup upliling ng-hu -hub b face face TIR, mm max. max.)) Cente Cen terr th the e co coup upliling ng betwe between en the the drive driverr and and co comp mpres resso sorag r so itst does doeithe esher not no thrus thrust ore. forc force e the the crank cra nksh shaft aft again ainst eit r tthrust thru st tface. fac For cold cold alignm alignment ent,, ac acco count unt for the di diffe fferen rence ce in therma thermall growth growth height height between between the comp compres resso sorr an and d dri drive ver. r. The compre compress ssor or cente centerlin rline e he heigh ightt chan change ge for JG JGC:D:F C:D:F co comp mpres resso sors rs is 0. 0.01 014 4 in. in. (0.36 (0.36 mm mm)) base based d -6 -6 on 6.5 x 10 /°F /°F (1 (11 1.7 x 10 /° /°C) C) and and a di diffe fferen rentia tiall tempe temperatu rature re of 10 100°F 0°F (55.6° (55.6°C). C). Obtai Ob tain n driver driver thermal thermal growth growth pred predic ictio tions ns from the dri drive verr manufa manufactu cturer. rer. 2. At ho hott al align ignmen mentt chec check, k, adjus adjustt di disc scha harge rge bo bottl ttle e supp supports orts and head head en end d supp supports orts,, if FIGURE 3-2 Thermal Growth applicable. NOTE: To avoid cylinder distortion, lift discharge bottles only 0.003 to 0.005 inch using the supports. 3. Check Check fasten fastener er torque torque on ga gas s no nozz zzle le fla flang nges es,, valv valve e caps caps,, cylin cylinde derr he heads ads,, piston piston rod packin packing g fla flange nges, s, TABLE E A-3 in cross cro sshe head ad gu guide ide ho hold ld do down, wn, an and d cross crosshea head d guide guide to frame frame boltin bolting, g, if ap appli plica cable ble.. See TABL Appendix Appen dix A for correc correctt torque torques. s. 4. Re Repe peat at torque torque chec check k aft after er 75 750 0 hou hours. rs. If loose looseni ning ng persist persists, s, cons consult ult your your pa pack ckage ager. r. Rechec Recheck k fasten fasteners ers found fou nd loose loose in an any y of these these interv intervals als aft after er an ad addit dition ional al 75 750 0 ho hours urs.. If loose loosenin ning g conti continu nues es,, conta contact ct your your packag pac kage e supplie supplierr immediat immediately. ely.
Page 3-2 of 32
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For models models JGC:D:F JGC:D:F
Secti Section on 3 - Mai Mainte ntena nance nce
Daily Maintenance Log and and trend trend th the e foll followi owing ng:: 1. Log • Opera Operati ting ng RPM, gas gas press pressure ure and and temp tempera eratu tures res - de dete termi rmine ne if th the e un unit it is op oper erat atin ing g withi within n de desi sign gn parameters param eters and expecta expectation tions. s. NOTE: Verify high and low pressure shutdowns are set as close as practical to normal operating conditions. Set points must protect the machine from exceeding compressor limits. • Bearing Bearing tempe temperatu ratures res - if the unit unit is eq equip uipped ped with main main be bearin aring g temper temperatu ature re sens sensors ors.. • Frame Frame oi oill press pressur ure e - at opera operati ting ng temp tempera eratu ture re (190°F (190°F (88°C) (88°C) max. max. in inle lett oil oil te temp mpera eratu ture) re),, it sh shou ould ld be 50 to 60 ps psig ig (3.5 (3.5 to 4.2 4.2 barg barg)) at the the fi filt lter er ga gaug uges es.. If pr pres ess sur ure e fa fall lls s be belo low w 50 ps psig ig,, shut shut down down th the e compre compress ssor or then then de determ termin ine e and correc correctt the caus cause. e. • Frame inlet inlet oil temper temperatu ature. re. • Oil Oil fil filter ter differe differenti ntial al press pressure ure - differe differenti ntial al press pressure ure ex exce ceed eding ing the filter filter chan change ge value value indic indicate ates sa need need fo forr a filt filter er ch chan ange ge.. See filt filter er info informa rmati tion on plat plate e on to top p co cove verr or “O or “Oilil Fil Filte ter” r” on pa page ge 3-1 3-16 6 for procedure. Check frame frame oi oill leve level. l. It sh shou ould ld be abou aboutt mid-l mid-lev evel el in th the e sigh sightt glas glass s an and d free free of fo foam am when when runni running ng.. If 2. Check not, not, dete determi rmine ne and and co corre rrect ct the the ca caus use. e. Do not not overf overfilill. l. Check Check oil oil make makeup up ta tank nk fo forr su suffi ffici cien entt oil oil supp supply ly.. Fo Forr dry su sump mp frame frames, s, ch chec eck k the the pack packag age e su sump mp oil oil leve level. l. Do no nott ad add d oil oil to th the e cra crank nkca case se th thro roug ugh h th the e breath bre ather er hole hole while while the un unit it runs. runs. This This caus causes es oil foamin foaming g an and d un unnec neces essa sary ry no-flo no-flow w shutd shutdowns owns in the force feed lubricati lubrication on system. system. 3. Check Check fo forc rce e fe feed ed lubri lubrica cato torr box box oil oil leve level. l. It sh shou ould ld be fu fullll to th the e ov overf erflo low w line line.. 4. Log and trend trend pa pack cking ing vent vent tempera temperature ture and chec check k cross crosshe head ad guide guide vents vents for leaka leakage. ge. 5. If ap appli plica cabl ble, e, chec check k sucti suction on valv valve e un unloa loader der ac actua tuator tor vents vents for leaka leakage ge.. 6. If ap appli plica cabl ble, e, chec check k cleara clearanc nce e po pock cket et vents vents for lea leaka kage. ge. 7. Verify Verify th the e hi high gh di disc scha harge rge gas gas temp tempera eratu ture re sh shut utdo down wn is se sett to withi within n 10 10% % or as clos close e as pract practic ical al above abo ve the normal normal operati operating ng disch discharg arge e tem temper peratu ature. re. Do no nott ex exce ceed ed the maximu maximum m disch discharg arge e tempe tem peratu rature re shutd shutdown own setti setting ng for the applic applicati ation on.. 8. Log Log and trend trend valve valve cap cap tempe temperatu ratures res.. 9. Check Check lubric lubricato atorr block block cycle cycle time. time. See lubric lubricato atorr box da data ta plate plate for correc correctt cy cycl cle e time. time. Contami Contaminat nated ed gas gas may may re requ quire ire a sh shor orte terr cy cycl cle e time time.. Check Check lube lube sh shee eett fo forr un unit its s no nott runni running ng at rated rated sp spee eed. d. 10. Check 10. Check fo forr gas, gas, oi oil, l, and and co cool olan antt leak leaks. s. CAUTION: Do not attempt to repair leaks while the unit is operating or pressurized. 11. Che 11. Check ck for un unus usual ual no nois ises es or vibrati vibrations ons.. 12. See packa packager ger docume documenta ntatio tion n for ad addit dition ional al recomm recommen ended ded chec checks ks,, i.e i.e.. sc scrub rubber ber liq liquid uid level levels, s, du dump mp valv valve e operati operation, on, coole coolerr louv louver er po posi sitio tions ns,, etc. etc.
Monthly Maintenance Maintenance 1. Perform Perform all Daily Daily mainte maintenan nance ce.. 2. Verify Verify safety safety shutdown shutdown function functionality ality.. forr a lis list of wha what 3. Sampl Sample e frame frame oi oill and and se send nd it to a reput reputab able le lubri lubrica cant nt la lab b fo forr an anal alys ysis is.. See See ER-56.06 fo an oil analy analysi sis s shoul should d provid provide. e. If ana analy lysis sis resul results ts indic indicate ate increa increasi sing ng levels levels of lead, lead, tin tin,, or coppe copper r parti particl cles es in th the e oi oil, l, sh shut ut down down unit unit.. Remov Remove e frame frame top top co cove verr an and d cross crosshe head ad gu guid ide e side side co cove vers rs..
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Page 3-3 of 32
Section 3 - Maintenance
For models JGC:D:F
Visually Visual ly inspec inspectt for de debris bris.. Do no nott disas disasse sembl mble e further further without without good good reaso reason. n. If de debris bris indic indicate ates, s, repl replac ace e af affe fect cted ed parts parts,, then then ch chan ange ge oil, oil, oil oil filt filter, er, and and cl clea ean n th the e st strai raine nerr with with a su suit itab able le so solv lven ent. t. 4. Check Check an and d log cylin cylinder der clear clearanc ance e device devices s in us use e and their their setti settings ngs..
Six-Month (4,000-Hour) Maintenance 1. Perform al alll Daily Daily an and d Monthl Monthly y mainte maintena nanc nce. e. 2. Shut do down wn un unit it an and d allow allow suffi suffici cien entt time time for compo compone nents nts to cool. cool. 3. Drain Drain and and repla replace ce forc force e feed feed lubri lubrica cato torr box box oil. oil. 4. Clean Clean si sint ntere ered d el elem emen entt in the the smal smalll oil oil filt filter er on the the forc force e fe feed ed lubri lubrica cati tion on sy syst stem em no now w or at ev every ery main main oi oill filter filter chang change. e. Use a suita suitable ble solv solvent ent.. Filt lter” er” on pa page ge 3-1 3-16 6 for procedure procedure). ). 5. Chang Change e oi oill filt filter. er. See See top top co cove verr filt filter er info informa rmati tion on plat plate e or ““Oil Oil Fi NOTE: On replaceable element style filters, drain the canister completely before removing the element. element. NOTE: Replaceable filter elements have a finite shelf life. Check the "Install by" date on the filter element before installation. Inspect elements for cleanliness and damage. Do not install dirty or damaged elements. 6. Chan Change ge oil. oil. Extrem Extremely ely dirty dirty environ environmen ments, ts, oil suppl supplier ier rec recom ommen menda datio tions ns,, or oil analy analysi sis s may may di dicta ctate te a di diffe fferen rentt oi oill chang change e interv interval. al. Fol Follow low these these steps steps:: a. Drain oi oill from frame, frame, as asso socia ciated ted piping piping,, an and d oil coole cooler. r. b. Clean Clean oi oill st strai raine nerr with with a su suit itab able le so solv lven ent. t. In dry su sump mp ap appl plic icat atio ions ns,, th the e st strai raine nerr is lo loca cate ted d at th the e oil oil reservoir. c. Remov Remove e frame frame top top co cove verr and and cros crossh shea ead d guid guide e si side de co cove vers rs.. Visu Visual ally ly insp inspec ectt fo forr de debri bris. s. Do no nott di disa sass ssem emble ble furthe furtherr without without good good reaso reason. n. If debris debris indic indicate ates, s, replac replace e aff affec ected ted pa parts rts,, then then chang change e th the e oi oill filt filter er and and cl clea ean n the the st strai raine nerr wit with h a su suit itab able le so solv lven ent. t. d. Refil Refilll frame frame with with fresh fresh,, cl clea ean n oil. oil. 7. Check cylinde cylinderr lubricati lubrication. on. See“Cyli See “Cylind nder er Lu Lubri brica catio tion n Pap Paper er Tes Test” t” on pag page e 3-3 3-31 1 for procedure. procedure. 8. Re-ti Re-tigh ghte ten n hold hold down down fast fasten eners ers to prope properr torqu torque. e. Insp Inspec ectt fo forr frame frame twist twist or be bend ndin ing g to ve verif rify y main main flatne tness ss and soft soft foot foot require requiremen ments. ts. be beari aring ng bore align alignmen ment. t. See Ariel Ariel do docu cumen mentt ER-82 for fla 9. Perform Perform a coupl coupling ing alignm alignmen entt (see (see "Initial Maintenan Maintenance" ce" above).
One-Year (8,000-Hour) Maintenance Perform al alll Daily, Daily, Monthl Monthly, y, and Six-Mo Six-Month nth mainte maintena nanc nce. e. 1. Perform 2. Grease rease VVCP st stem em threa threads ds at greas grease e fitt fittin ing, g, with with 2 to 3 pu pump mps s of mult multi-p i-purp urpos ose e gr grea ease se us usin ing ga sta tand ndar ard d ha hand nd pu pump mp grea grease se gu gun. n. Turn Turn VVCP VVCP ad adju jus stm tmen entt ha hand ndle le all all th the e way way in an and d all all th the e wa way y ou outt to lu lubri brica cate te th the e th threa reads ds.. Meas Measure ure or co coun untt turn turns s to retu return rn th the e hand handle le to its its origi origina nall po posi siti tion on.. 3. Open pen fo forc rce e fe feed ed lu lubri brica cato torr box box and and vi visu sual ally ly insp inspec ectt pump pump fo follllowe owers, rs, ca cams ms,, an and d ge gears ars fo forr wear. wear. 4. Pressu Pressure re test test distrib distributi ution on block blocks. s. See“Div See “Divid ider er Val Valve ve By Bypa pass ss Pre Press ssure ure Te Test st”” on pa page ge 3-2 3-23 3 for procedure. 5. Meas Measure ure,, log, log, and trend trend the fol followi lowing ng:: ge 4-3 4-37 7 • and Mainpag Main be bearin aring, g,2conn connec ectin ting g rod bea bearing ring,, and crank cranksh shaft aft jack jack an and d thrust thrust cleara clearanc nces es.. Seepa See page page e 4-42 4-4 NOTE: Clearance trends along with oil analysis and crankcase visual inspection can indicate the need for bearing replacement. Contact Ariel for original assembly clearances.
Page 3-4 of 32
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For models models JGC:D:F JGC:D:F
Secti Section on 3 - Mai Mainte ntena nance nce
• Crosshead Crosshead to guide guide clearanc clearances. es. • Pist Piston on ro rod d ru run n out. out. See See “Pist “Piston on Rod Run Runou out” t” on pa page ge 4-1 4-18 8 If any any of th the e abov above e item items s are outs outsid ide e limi limits ts list listed ed in Appe in Appendix ndix B, replac replace e the aff affec ected ted pa parts rts.. 6. Remove Remove valv valves es an and d valv valve e ga gask skets ets:: a. Visua Visually lly in insp spec ectt valv valve e po pock ckets ets for da damag mage. e. Verify Verify all old valve valve seat seat gaske gaskets ts are remov removed. ed. b. Have a qualif qualified ied valv valve e repair repair shop shop disas disasse sembl mble, e, visu visuall ally y inspe inspect, ct, and refurbi refurbish sh the valv valves es where where need needed ed.. Provi Provide de the the va valv lve e repa repair ir sh shop op an Ari Ariel el torqu torque e ch char artt an and d va valv lve e se servi rvice ce gu guid ide. e. c. Visua Visually lly in insp spec ectt cylin cylinde derr gas pa pass ssag ages es an and d cl clean ean them them of all de debris bris.. 7. If ap appli plica cabl ble, e, visual visually ly inspe inspect ct sucti suction on valv valve e un unloa loader der ac actua tuator tor stems stems for da damag mage e or wear. Visual Visually ly in insp spec ectt st stem em se seal als s for for dama damage ge or wear wear and and co conf nfirm irm th that at th the e ac actu tuat ator or move moves s freel freely. y. 8. If ap appli plica cabl ble, e, visual visually ly inspe inspect ct pneuma pneumatic tic cl clear earanc ance e po pock ckets ets for da damag mage e or wear (seati (seating ng surfac surface e an and d stems ste ms/st /stem em seals seals). ). Confirm Confirm that that ac actua tuator tor mo move ves s freely. freely. 9. In Insp spec ectt cy cylilind nder er bores bores for for dama damage ge or wear. wear. Repla Replace ce th the e cy cylilind nder er bo body dy or resto restore re th the e bo bore re if an any y of th the e following follo wing conditio conditions ns exis exist: t: • Bore surfac surface e bl blemi emish shes es or gouges gouges.. • Bore Bore out out of round round more more than than 0.00 0.001 1 inch inch per per inch inch of bo bore re diam diamet eter er (0.00 (0.001 1 mm/m mm/mm) m) or ta tape pered red.. 10. Insp 10. Inspec ectt piston piston rin rings gs and wearban wearband: d: a. Measu Measure re and log piston piston rin ring g cond conditi ition on,, en end d ga gap, p, and side side cl clea earan rance ce.. Appendix dix B . b. Repla Replace ce rin rings gs that that are dama damage ged d or outs outsid ide e limi limits ts list listed ed in Appen c. When When repla replaci cing ng rings rings,, rere-me meas asure ure and and log log ring ring si side de clea cleara ranc nce e to ch chec eck k fo forr gr groo oove ve wear. wear. d. Meas Measur ure e and and log log radia radiall pro proje ject ctio ion n of wear wear band band.. 11. In Insp spec ectt pi pist ston on ro rods ds for for dama damage ge and and exce excess ssiv ive e wea wear. r. Repla Replace ce rod if an any y of th thes ese e co cond ndit itio ions ns ex exis ist: t: • Goug Gouges es or sc scrat ratch ches es on the the rod. rod. • Unde Underr si size ze more more than than 0.00 0.005 5 inch inch (0. (0.13 13 mm mm). ). • Out of ro roun und d more more than than 0.00 0.001 1 inc inch (0.0 (0.03 3 mm) mm) per per in inc ch of ro rod d diam diamet eter er.. • Ta Tape pered red more more than than 0.00 0.002 2 inch inch (0.0 (0.05 5 mm) mm) per per inch inch of rod diam diamet eter er.. ston on Rod Pa Pack ckin ing” g” on pa page ge 4-2 4-20 0 for procedure. procedure. 12. Reb 12. Rebuil uild d pi pisto ston n rod press pressure ure pa pack cking ing case cases. s. See“Pi See “Pist 13. Re-ins 13. Re-instal talll valve valves, s, retaine retainers, rs, and valve valve caps caps us using ing new v valv alve e gaske gaskets ts an and d valv valve e cap cap o-rings o-rings/s /seal eals. s. Use proper pro per instal installat lation ion techn techniqu iques es an and d torque torque proce procedur dures es for valv valve e caps caps.. 14. Check 14. Check and re-cali re-calibra brate te all req require uired d instru instrumen mentat tation ion.. 15. Clean 15. Clean crank crankca case se breath breather er fil filter ter with suita suitabl ble e solv solvent ent.. 16. Check 16. Check and, and, if need needed ed,, adju adjust st drive drive ch chai ains ns.. See See “Chain “Chain Adj Adjus ustme tment” nt” on pag page e 4-4 4-48 8 for procedure. procedure. 17. If 17. If the compr compres esso sorr is eq equip uipped ped with crank crankca case se ov over-p er-pres ressu sure re relief relief valv valves es,, vi visu suall ally y ins inspec pectt an and d exercise exe rcise valves valves to manufact manufacturer urer recommen recommendatio dations. ns. 18. Check 18. Check fasten fastener er torques torques of ga gas s no nozz zzle le fla flang nge, e, valv valve e cap, cap, piston piston rod packin packing, g, cross crosshe head ad pin throug through h bolt, bol t, cross crosshe head ad guide guide to frame, frame, cross crosshea head d gu guide ide to cylin cylinder, der, cy cylin linde derr mount mounting ing fla flange nge to forged forged steel steel cylin cylinde der, r, di dista stanc nce e piece piece to cylin cylinder der,, dis distan tance ce pi piec ece e to cross crosshe head ad guide, guide, and tandem tandem cy cylin linder der to cylinder.
Two-Year (16,000-Hour) Maintenance 1. Perform Perform all Daily, Daily, Month Monthly ly,, Six-Mo Six-Month nth,, an and d One-Ye One-Year ar maint maintena enanc nce. e. 2. Rebui Rebuild ld oi oill wiper wiper case cases. s.
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Page 3-5 of 32
Section 3 - Maintenance
For models JGC:D:F
3. If applic applicab able, le, us use e new piston piston an and d stem stem seals seals to reb rebuil uild d ac actua tuators tors on sucti suction on valv valve e unload unloaders ers an and d fix fixed ed volum volume e pneuma pneumatic tic po pock ckets ets.. Repl Replac ace e piston piston stem stem as asse sembl mblies ies where stem stem is da damag maged ed or worn. 4. Check Check au auxi xilia liary ry en end d chain chain driv drive e for un under dercu cutt sproc sprocke kett tee teeth th and chai chain n for ex exce cess ssiv ive e str stretc etchin hing. g. Replac Repl ace e as requi required. red.
Three-Year (24,000-Hour) Maintenance 1. Perform Perform al alll Daily, Daily, Monthl Monthly, y, Six-Mo Six-Month nth,, an and d One-Ye One-Year ar mainte maintena nanc nce. e. 2. Replac Replace e non-ELP non-ELP conn connec ectin ting g rod bea bearin rings gs for JG JGE:T: E:T:C:D:F:U: C:D:F:U:Z:B: Z:B:V V an and d KBB:V model models. s. See “Con “Connec nectin ting g Rods Rods”” on pag page e 4-3 4-31 1 and “Cranks “Cranksha haft” ft” on pa page ge 4-4 4-40 0. NOTE: Main and connecting rod bearing wear and replacement intervals are heavily dependent on many factors including speed, load, oil temperature, oil cleanliness, and oil quality. Depending on the severity of service, the bearing maintenance interval may be longer or shorter.
Four-Year (32,000-Hour) Maintenance 1. Perform Perform al alll Daily, Daily, Monthl Monthly, y, Six-Mo Six-Month nth,, One-Ye One-Year, ar, an and d Two-Year Two-Year mainte maintenan nance ce.. 2. Remove Remove cross crosshe head ad pins. pins. Measu Measure re and log log cross crosshea head d pi pin n to cross crosshea head d pin bore bore an and d conne connecti cting ng rod bush bushin ing g bore bore cl clea earan rance ces. s. Check Check the the cros crossh shea ead d pin pin end end ca caps ps an and d th throu rough gh bo bolt lt fo forr wear. wear. Repla Replace ce if needed. 3. Check Check fo forr bush bushin ing g wear wear in the the auxi auxililiary ary end end drive drive ch chai ain n tigh tighte tene ner. r. 4. Check Check fo forr rin ring g gr groo oove ve wear wear in pist piston ons. s.
Six-Year (48,000-Hour) Maintenance 1. Perform Perform al alll Daily, Daily, Monthl Monthly, y, Six-Mo Six-Month nth,, One-Ye One-Year, ar, Two-Ye Two-Year, ar, and Three-Ye Three-Year ar mainte maintena nanc nce. e. 2. Replace Replace lubricato lubricatorr distribut distribution ion blocks. blocks. 3. Replac Replace e cross crosshe head ad and conn connec ectin ting g rod bus bushin hings gs.. See“Cros See “Crossh shead eads” s” on pa page ge 4-2 4-27 7 and “Connecting Rods” Rod s” on pa page ge 4-3 4-31 1. ectin ting g Rods Rods”” on pag page e 4-3 4-31 1. 4. Replac Replace e conn connec ectin ting g rod be bearin arings gs.. See“Conn See “Connec 5. Replace Replace main main be bearin arings gs.. See“Cran See “Cranks ksha haft” ft” on pa page ge 4-4 4-40 0.
Page 3-6 of 32
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For models models JGC:D:F JGC:D:F
Secti Section on 3 - Mai Mainte ntena nance nce
Frame Oil There are seve There several ral oi oill spec specifi ifica catio tions ns,, mainte maintena nanc nce e proce procedu dures res,, and op opera eratin ting g cond conditi itions ons which which aff affec ectt oil perform perf orman ance ce.. For op optim timal al pe perform rformanc ance, e, ens ensure ure the oil mee meets ts the spec specifi ifica catio tions ns be below low and and is suita suitable ble for the given given applicat application, ion, and diligen diligently tly complete complete maintena maintenance nce procedures procedures..
Viscosity
Fo Forr co cold ld ambi ambien entt te temp mpera eratu tures res,, desi design gn the the oil oil sy syst stem em so th the e un unit it may may sa safe fely ly st start art with with ad adeq equa uate te oi oill flow flow to the jo journ urnal al be bearin arings gs.. Succe Success ssful ful operati operation on may may require require temper temperatu ature re contro controlle lled d cool cooler er by by-pa -pass ss valv valves es,, oil heaters hea ters,, coole coolerr lo louv uvers ers,, and ev even en bu build ilding ings. s. Th The e mini minimu mum m al allo lowab wable le vi visc scos osit ity y of the the oil oil ente enterin ring g the the frame frame is 16 cS cSt. t. Ty Typi pica calllly, y, th this is is the the visc viscos osit ity y of ISO ISO 15 150 0 gr grad ade e oi oill at ab abou outt 190° 190°F F (88° (88°C). C). TABLE 3-1 Oil Viscosity Requirements, cSt Max. Viscosity to START
Max Viscosity to LOAD
JGH:E:K:T & smaller
3,300
1,000
JGC:D :F JGZ:U, KBZ:U:B:V
2,000 2,000
1,000 350
Frame
Max Viscosity into Compressor at Operating Temp.
Min Viscosity Viscosity into Compressor at Operating Temp.
60
16
Oil Pressure Th The e fa fact ctory ory se sets ts norma normall press pressure ure on the the disc discha harge rge si side de of th the e oil oil filt filter er at 60 ps psig ig (4.1 (4.1 ba barg) rg) fo for r compress comp ressors ors tested tested mechanic mechanically ally complete complete (inspecto (inspectorr tag display displayed). ed). If factory factory tested tested as mechani mechanicall cally y inco incomp mple lete te (no in insp spec ecto torr tag) tag),, the the pack packag ager er se sets ts norma normall oil oil pre press ssure ure at in init itia iall st start art-up -up to 60 ps psig ig (4.1 (4.1 barg) barg) at th the e lo lower wer of the the frame frame or cy cylilind nder er rated rated sp spee eed, d, or dr driv iver er sp spee eed d at norma normall op opera erati ting ng te temp mpera eratu ture. re. Ariel uses uses the pump safety safety relief relief or separate separate lube oil pressure pressure regulatin regulating g valve valve to regulate regulate pressure pressure into the compre compress ssor. or. If oi oill press pressure ure into into the compre compress ssor or at minimu minimum m op opera eratin ting g spee speed d an and d normal normal op opera eratin ting g temp tempera eratu ture re does does not not read read abou aboutt 60 psig psig (4.1 (4.1 barg) barg),, adju adjust st th the e pu pump mp sa safe fety ty relie relieff or se sepa parat rate e lube lube oil oil pressu pres sure re regul regulati ating ng valve valve.. With compr compres esso sorr runnin running g at minimu minimum m rated rated speed speed,, turn turn the adjus adjustme tment nt sc screw rew clockwise clock wise to increa increase se oil press pressure ure,, or coun counter-c ter-cloc lockwis kwise e to decreas decrease e it. Th The e co comp mpres resso sorr requi requires res a 45 psig psig (3.1 (3.1 barg barg)) low low oil oil press pressure ure sh shut utdo down wn fo forr prote protect ctio ion. n. NOTE: If oil pressure drops below 50 PSIG (3.4 barg) when crankshaft speed equals or exceeds minimum rated operating speed, find the cause and correct it.
Oil Temperature Mainta Main tain in frame frame in inle lett oil oil temp tempera eratu ture re as cl clos ose e to 170°F 170°F (77°C) (77°C) as po poss ssib ible le.. Mini Minimu mum m lube lube oi oill op opera erati ting ng temp tempera eratu ture re is 150°F 150°F (66°C) (66°C) to drive drive off off water water va vapo por. r. Maxi Maximu mum m allo allowab wable le oil oil te temp mpera eratu ture re in into to th the e co comp mpres resso sorr frame frame is 190° 190°F F (88°C) (88°C).. Highe Higherr temp tempera eratu ture res s incre increas ase e th the e ox oxid idat atio ion n rate rate of oi oil. l. Every Every 18 18°F °F (10°C) (10 °C) withi within n th the e opera operati ting ng range range doub double les s the the oxid oxidat atio ion n rate rate of oil. oil. For prope properr operati operation on of the thermo thermosta static tic contro controll valve valve,, the maxim maximum um differe differenti ntial al press pressure ure between between the ho hott oi oill sup uppl ply y li line ne an and d the the cool cooled ed oil oil retu return rn li line ne is 10 ps psid id (0 (0.7 .7 ba bard rd). ).
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Page 3-7 of 32
S e c t i o n 3 M a i n t e n a n c e
P a g e 3 8 o f 3 2
F o r m o d e l s J G C : D : F
FIGURE 3-3 Viscosity vs. Temperature Graph of Different Lubricants R E V : 1 0 / 1 4
For models models JGC:D:F JGC:D:F
Secti Section on 3 - Mai Mainte ntena nance nce
Oil Maintenance An oil analysi analysis s program program is the most most effective effective way to determine determine frame oil change change intervals intervals.. Consisten Consistentt oil anal analys ysis is ca can n id iden enti tify fy when when to ch chan ange ge oil oil on the the basi basis s of need need ra rath ther er th than an a sc sche hedu dule led d in inte terva rval. l. Depen Dependi ding ng on servi service ce,, oil an analy alysi sis s can can si signi gnific fican antly tly ex exten tend d oil chang change e in interv tervals als.. Inst Instal alll a sa samp mpliling ng poin pointt betwe between en the the oil oil pump pump and and filt filter er at an ea easi sily ly ac acce cess ssib ible le lo loca cati tion on.. Mini Minimi mize ze dirt dirt or debri debris s th that at ca can n co collllec ectt aroun around d it. it. Use a need needle le va valv lve e to bette betterr co cont ntrol rol press pressuri urize zed d oil oil flow. flow. Collec Coll ectt and analy analyze ze oil samp samples les to verify verify suita suitabi bilit lity y for conti continue nued d servi service ce.. Oil Oil an analy alysi sis s shou should ld includ include: e: • Visco Viscosi sity ty te test stin ing g at 104° 104°F F (40°C) (40°C) and and 212° 212°F F (100°C) (100°C).. Th This is ve verif rifie ies s th that at oil oil ha has s not not mixe mixed d with with cy cylilind nder er oi oils ls or proce process ss gas. gas. • Parti Particl cle e co coun unti ting ng to the the late latest st ve vers rsio ion n of ISO 4406 4406.. • Spectrosc Spectroscopy opy to determine determine wear metals, metals, contami contaminant nants, s, and additive additives. s. • FTIR (Fourie (Fourierr Transfo Transform rm Inf Infrare rared d Spectro Spectrosc scopy opy)) to chec check k for ox oxida idatio tion, n, water water or coola coolant nt co cont ntam amin inat atio ion, n, and and addi additi tive ve depl deplet etio ion. n. This This is more more impo importa rtant nt if th the e su sump mp oi oill is no nott co cons nsum umed ed by th the e force forc e feed feed syste system. m.
Dry Sump Compress Compre ssors ors su subj bjec ectt to trans transie ient nt moti motion on,, roll, roll, and and ya yaw w on bo board ard a sh ship ip or a floa floati ting ng plat platfo form rm ma may y requi require re a dry su sump mp (“dry (“dry”” crank crankca case se and and se sepa parat rate e oil oil rese reservo rvoir) ir).. With Wit h a dry su sump mp,, drain drains s are su supp pplilied ed at each each end end of the the co comp mpres resso sorr frame frame an and d an ad addi diti tion onal al oil oil pu pump mp ch chai ain n oi oile lerr is pr prov ovid ided ed by Ariel Ariel.. The The pack packag ager er mu must st provi provide de a lube lube oil oil reserv reservoi oirr size sized d an and d lo loca cate ted d so th that at the the oi oill pump pump has has oi oill su suct ctio ion n regard regardle less ss of the the tilt tilt of the the sh ship ip or floa floati ting ng plat platfo form. rm. An oi oill su sump mp st strai raine nerr must must be in inst stal alle led d in th the e pump pump su suct ctio ion n line line at the the outl outlet et of th the e se sepa parat rate e lube lube oi oill reserv reservoi oirr (unmo (unmoun unte ted d st strai raine nerr is provi pro vide ded d by Ariel Ariel with with a new new dry su sump mp co comp mpres resso sor). r).
Oil System Cleanliness Clean th Clean the e co comp mpres resso sorr frame frame oil oil pipi piping ng sy syst stem em and and co comp mpon onen ents ts of all all fo forei reign gn matte matterr su such ch as sa sand nd,, rust, rust, milll scale mil scale,, metal metal chips chips,, weld spatt spatter, er, greas grease, e, and pa paint int.. Use prope properr cl clea eanin ning g proce procedur dures es with proper proper cleaners, clea ners, acids, acids, and/or and/or mechani mechanical cal cleaning cleaning to meet cleanlin cleanliness ess requiremen requirements. ts. Ariel recommen recommends ds flu flush shing ing all oil-pip oil-piping ing syste systems ms with an electr electric ic or pneuma pneumatic tic drive driven n pu pump mp and filtere filtered, d, cl clean ean produ producti ction on oil. oil. Ariel thoroughly thoroughly cleans cleans all compress compressor or frame cavities cavities prior to assembl assembly y and test runs compress compressors ors with a filtere filtered d clos closed ed loop loop lube lube syste system. m. NOTE: Ariel recommends not disturbing lube oil piping downstream of the installed oil filter. Contaminants that enter this piping or open ports flush into the bearings causing catastrophic damage. To remove or alter piping, cover the inlets to the oil gallery, the ends of the piping, and the filter outlet so no contaminants enter. Before reinstallation, chemical and mechanical cleaning is required. Flush the pipe in accordance with Ariel cleanliness requirements (see TABLE (see TABLE 3-2). 3-2). Prior to start-up Prior start-up,, flu flush sh all compr compres esso sors rs instal installed led with an electri electric c or pn pneum eumati atic c powered powered pre-lub pre-lube e pu pump mp and and le less ss th than an 50 fe feet et (15 m) of oil oil pipi piping ng as outl outlin ined ed belo below. w. In Incl clud ude e co cool oler er oil oil pa pass ssag ages es in th the e flus flushi hing ng loop. loo p. While While oil syste systems ms for compre compress ssors ors withou withoutt an electri electric c or pn pneum eumati atic c powered powered pre-lub pre-lube e pu pump mp and less less th than an 50 fe feet et (15 m) of oil oil pipi piping ng must must be cl clea ean, n, oil oil flus flushi hing ng is de desi sirab rable le,, bu butt no nott requi require red. d. Fo Forr al alll co comp mpres resso sors rs with with oil oil pipi piping ng sy syst stem ems s great greater er than than 50 fe feet et (1 (15 5 m), clea cleani ning ng an and d flus flushi hing ng must must resul resultt in a cl clea eanl nlin ines ess s le leve vell to ISO-44 ISO-4406 06,, Grad Grade e 13/1 13/10/ 0/9 9 and/ and/or or NAS-1 NAS-163 638, 8, Class Class 5 (s (see ee TABLE TABLE 3-2 3-2), ), prior rior to start-up.
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Page 3-9 of 32
Section 3 - Maintenance
For models JGC:D:F
1. Prior Prior to asse assemb mbliling ng lube lube oil oil pipi piping ng,, remov remove e sc scal ale, e, weld weld slag slag,, rust rust an and d an any y ot othe herr matt matter er th that at co coul uld d conta contamin minate ate lube lube oil. oil. Confirm: Confirm: • Comp Complet lete e and close closed d lube lube oil syste system. m. • Crankca Crankcase se fil filled led to the correc correctt lev level el with ap appro propria priate te oil. oil. • Prope Properr an and d correc correctly tly instal installed led lube lube oil fil filters ters.. • Opera Operatio tiona nall and vi viewab ewable le oil press pressure ure transd transduc ucer er or ga gauge uge,, oil filter filter differe differenti ntial-p al-pres ressu sure re transd tran sduc ucers ers or gauges gauges,, an and d oil tempe temperatu rature re RTD or or indic indicato ator. r. 2. Start pre-lub pre-lube e pu pump. mp. Record Record oil press pressure, ure, oil fil filter ter differe differenti ntialal-pre press ssure ure,, an and d oil temper temperatu ature. re. Mini Minimu mum m oi oill press pressure ure is 30 psig psig (2.1 (2.1 barg) barg) for for effe effect ctiv ive e flus flushi hing ng.. Do no nott ex exce ceed ed 90 ps psig ig (6 (6.2 .2 ba barg) rg).. 3. Flush Flush conti continuo nuous usly ly for one ho hour. ur. Oi Oill fil filter ter differe differenti ntialal-pre press ssure ure must must not increa increase se more than than 10 10% % of meas me asure ured d oil press pressure ure into into the fil filter. ter. Record Record the oil pre press ssure ure,, oil filter filter differe differenti ntial al press pressure ure,, an and d oil temp tempera eratu ture re every every 15 minu minute tes. s. Oil Oil temp tempera eratu ture re incre increas ases es of more more th than an 10 10°F °F (5.5°C) (5.5°C) du durin ring g an ho hour ur of flu flush shing ing invali invalida date te the syst system em clean cleanlin lines ess s test, test, du due e to oil vi visc scos osity ity chang change. e. TABLE 3-2 Oil Flush Cleanliness Requirements 4. After After one one hour hour of pre pre-lu -lube be flus flushi hing ng,, if differentia diffe rentiall pressure pressure or temperature temperature increase increases s ISO-4406 GRADE 13/10/9
ex exce ceed ed the limits limits ab abov ove, e, conti continu nue e flu flush shing ing.. If the lu lube be oil fil filter ter differe differenti ntial al press pressure ure ex exce ceed eds s chang change e fil filter ter limits limits,, stop stop the pre-lub pre-lube e pu pump mp and ch chan ange ge th the e oi oill filt filter. er. To ensu ensure re sy syst stem em clea cl eanli nline ness ss,, re-set re-set time time an and d conti continue nue flu flush shing ing un until til the comp compres resso sorr ac achie hieve ves s a conti continu nuous ous ho hour ur of flu flush shing ing within within differe differenti ntial al press pressure ure and temperature temp erature increase increase limits. limits. See ISO-44 ISO-4406 06 "Intern "Internati ation onal al Standar Standard d - Hydra Hydrauli ulic c fl flui uid d po powe werr - Fl Flui uids ds - Meth Method od for for codi coding ng leve levell of conta contamin minati ation on by solid solid pa partic rticles les"" an and/o d/orr NAS-16 NAS-1638 38 "National "Nation al Aerospace Aerospace Standard, Standard, Aerosp Aerospace ace Indus Ind ustrie tries s Assoc Associat iation ion of Americ America, a, Inc. Inc. Cleanli Clea nlines ness s Require Requiremen ments ts for Part Parts s Used Used in Hydraul Hydr aulic ic System Systems" s" for comp complet lete e inform informati ation on.. Use a co comp mpet eten entt oi oill la lab b fo forr sa samp mple le test testin ing. g.
Grade Requirement
Particle Size um/ml Oil Sample
Particles Allowed
/13
Greater th than 4
40 to to 8 80 0
/10
Greater th than 6
5 tto o 10 10
/9
Greater th than 1 14 4
2.5 to to 5
NAS-1638 GRADE 5 Particle Size Range
Grade 5 Maximum
um/100ml Oil Sample 5 to 15
Particles Allowed 8,000
15 to 25
1,424
25 to 50
253
50 to 100
45
Over 100
8
Page 3-10 of 32
REV: 10/14
For models models JGC:D:F JGC:D:F
Frame Oil System Components
Secti Section on 3 - Mai Mainte ntena nance nce
Oil Conn Connections ections(see (see Ariel outline drawing for details) A1 Packager connection ffrom rom oil pump. A2 Packager connection to oil filt filter. er. A3 Oil connection fr from om compressor crankcase (oil sump). A4 Lube oil compress compressor or inlet connect connection ion to gallery tub tube. e. Oil flows to to crankshaf crankshaftt main bearings, connect connecting ing rod bearings,, cros bearings crosshead shead pins, and bushings bushings.. A5 Pressure regulating valve ret return urn connection to oil sump,, when applic sump applicable. able. A6 Fil Filter ter ve vent nt return return connect connection ion to oil sump, when applicable on some models. A7 Oil tubing connections from fframe rame gallery tube to top and bottom of crosshead guides to lubricat lubricate e crossheads. A8 Compressor crankc crankcase ase oil drain (oil sump drain).
System Components 1. Y-Strainer. 2. Compressor driven oil pump (wit (with h safet safety y relief valve for for pressure regulation, or in models with a separate regulating valve (6), for relief). relief). 3. Thermost Thermostatic atic control v valve, alve, 170°F (77°C) nominal rating - required (purchase separately from Ariel). 4. Pre-lube oil pump - rrequired equired (shown with oil heating circuit, circ uit, when applicable). applicable). 5. Opt Optional ional duplex oil filter. filter. 6. Oil filter. 7. Pressure regulating valve wit with h overflow return to to oil sump, when applica applicable. ble. 8. Oil cooler - required. 9. Check valve.
A9 Pre-lube/recirc Pre-lube/recirculation/heater ulation/heater connect connections ions (4).
10. (when applicable). 11. Heater Temperature Temperat ure indicator. 12. Pressure indicator. 13. Pressure indicator/shutdown indicator/shutdown connection.
FIGURE 3-4 Standard Frame Lube Oil Schematic
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Page 3-11 of 32
Section 3 - Maintenance
For models JGC:D:F
System Components 1. Separate lube oil reservoir (oil sump) - required. 2. Heater. 3. Y-St Y-Strainer rainer - required (supplied unmounted by A Ariel). riel). Oil Connectio Connections ns(see (see Ariel outline drawing for details) 4. Check valve. A1 Packager connection fr from om compressor-driven oil pump. 5. Compressor driven oil pump (with safet safety y relief valve A2 Packager connection to oil filt filter. er. for pressure regulation, regulation, or in models with a separate A3 Packager connection - oil from compr compressor essor crankcase. regulating valve (13), for relief). A4 Lube oil compressor-inlet-connection tto o gallery tube 6. Oil cooler - required. and bearings. 7. Thermost Thermostatic atic control valve, 170°F (77°C) nominal A5 Pressure regulating valve return connection tto o rating - required (available option from Ariel). crankcase, crank case, when applicable on some models models.. 8. Pre-lube oil pump - rrequired equired (with oil heating circuit circuit,, A6 Filter vent return connection tto o tthe he crankcase, when when applicable). applicable). applicable on some models. 9. Opt Optional ional duplex oil filter. filter. A7 Oil tubing connections from fframe rame gallery tube to top 10. Temperat Temperature ure indicator. and bottom of crosshead guides to lubricate cross crossheads. heads. 11. Pressure indicator. A8 Compressor crankcase oil drain. 12. Oil filter. 13. Pressure regulating valve with overflow return to for further details about dry NOTE: See ER-93 See ER-93 for crankcase, crank case, when applicable for some models. 14. Pressure indicator/shutdown indicator/shutdown connection. sump lubrication systems.
FIGURE 3-5 Optional Dry Sump Frame Lube Oil Schematic - Typical
Oil Strainer An oil strai strainer ner installe installed d upstream upstream of the pump prevents prevents debris debris from entering entering the pump and damaging damaging it. Ariel supplie supplies s a 40 mesh mesh (400 micro microns) ns) strainer strainer on all JGC:D:F JGC:D:F compress compressors. ors. It is located located on the auxilia auxiliary ry
Page 3-12 of 32
REV: 10/14
For models models JGC:D:F JGC:D:F
Secti Section on 3 - Mai Mainte ntena nance nce
end end of th the e cr cran ankc kcas ase e belo below w oil oil leve level. l. Remov Remove e the the st strai raine nerr ba bask sket et an and d wash wash it in an ap appro propri priat ate e so solv lven entt whenev when ever er lubric lubricati ating ng oil is chan changed ged..
Oil Pump & Regulating Valve The oil pump pump cons constan tantly tly supp supplie lies s oil to all journal journal be bearin arings gs,, bushin bushings gs,, an and d crosshead cross head sliding sliding surfaces surfaces.. The crank cra nksh shaf aftt drive drives s it by a ch chai ain n an and d sproc sprocke kett to provid provide e ad adequ equate ate oil flo flow w to bearing bea rings s when the compr compres esso sor r operate ope rates s at the mi minim nimum um spee speed d rating rating (typic (typ icall ally y ha half lf of maxi maximum mum rated rated spee speed). d). JGC:D:F JG C:D:F compr compres esso sors rs maint ma intain pres pressu sure re with a sprin sp ring-l g-load oaded edain safet saoil fety y relie relieff va valv lve e withi within n th the e pump pump head head.. To adju adjust st,, remov remove e th the e dust dust ca cap p to expo expose se
FIGURE 3-6 Typical Lube Oil Pump
the safet safety y relief relief valv valve e adjus adjustme tment nt screw. screw. When in When inst stal alliling ng a new new oil oil pump pump on a co comp mpres resso sorr or afte afterr main mainte tena nanc nce e on an ex exis isti ting ng oil oil pump pump,, Ariel Ariel recomm rec ommen ends ds pri primin ming g the pump pump (wetting (wetting the gears gears with oil) oil) be before fore start-up start-up to ensure ensure proper proper op opera eratio tion. n.
Oil Cooler An oil cooler cooler is required required to remove remove heat heat from the frame lube oil.When oil.When sizing sizing an oil cooler, cooler, consid consider er temper tem peratu ature re and flo flow w rate of both both cool cooling ing medium medium and lube lube oil. oil. Insuff Insuffic icien ientt cooli cooling ng water water flo flow w rate is the prima primary ry ca caus use e of hi high gh oil oil temp temper erat ature ures. s. Moun Mountt co cool oler er as clos close e to th the e co comp mpres resso sorr as po poss ssib ible le with with pipi piping ng of adeq adequa uate te si size ze to mini minimi mize ze pre press ssure ure dro drop p of both both lube lube oi oill an and d co cool olin ing g me medi dium um.. The Applic Applicati ation on Manua Manuall lists lists require required d cool cooling ing water water temper temperatu ature re and flo flow w rate to properl properly y cool cool oil with Ariel supplie supplied d coolers. coolers. The Ariel Performance Performance Program lists lists oil heat rejection rejection data for each each frame in the frame fram e de detai tails ls sect section ion (conta (contact ct Arie Ariell for de detai tails) ls)..
Flushing to Change to a PAG Lubricant Recommended Recom mended Flushing Oil Th The e prefe preferre rred d flus flushi hing ng oil oil is so solu lubl ble e in both both the the origi origina nall oil oil an and d PAG lu lubri brica cant nt.. A line linear ar di dies este terr is prefe preferre rred, d, su such ch as Shell Shell Coren Corena a DE 150 150 or Mobi Mobill Rarus Rarus 829. 829. If this this is un unav avai aila labl ble, e, us use e th the e de desi sired red PAG lu lubri brica cant nt fill fill oil oil as th the e in init itia iall flus flushi hing ng oil. oil.
Flushing Procedure
Below is a gene Below general ral flus flushi hing ng pro proce cedu dure re recom recomme mend nded ed to ch chan ange ge from from mine mineral ral or PAO oils oils to a sy synt nthe heti tic c PAG lubricant. lubricant. 1. Drain Drain ol old d oi oill fr from om fram frame e whil while e the the oil oil is sti till ll warm warm.. 2. Drain Drain al alll su supp pply ly and and return return liline nes s upst upstrea ream m of the the frame frame lube lube oil oil filt filter, er, filt filter er ho hous usin ing g (if ap appl plic icab able le), ), coole coolers, rs, an and d other other periph periphera erall eq equip uipmen mentt in the lubric lubrican antt supp supply ly loop. loop. 3. Remov Remove e st stan andi ding ng oil oil in the the frame frame and and guid guide e co comp mpart artme ment nt low low poi point nts. s. Remov Remove e as much much oi oill as poss possib ible le with with a va vacu cuum um hose hose.. If heav heavy y depo deposi sits ts are vi visi sibl ble, e, remov remove e th them em as be best st as po poss ssib ible le by ha hand nd us using ing clea clean, n, dry, dry, lint-fre lint-free e rags. rags. 4. Replac Replace e al alll oi oill fil filters ters..
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Page 3-13 of 32
Section 3 - Maintenance
For models JGC:D:F
5. Remove Remove an and d eithe eitherr cle clean an or replac replace e the Y-strain Y-strainer er eleme element. nt. 6. Recon Reconne nect ct oi oill pi pipi ping ng and and inst instal alll drain drain plug plug in frame frame.. 7. Conne Connect ct a di diap aphra hragm gm pump pump upst upstre ream am of the the frame frame moun mounte ted d oil oil filt filter. er. ed Flus Flushing hing Oil Oil"") fr from om a clean lean re rese serv rvoi oirr an and d 8. Feed Feed the di diaph aphrag ragm m pump pump flu flush shing ing oil (see (see "Recommend "Recommended pr prim ime e th the e lu lube be oi oill sy syst stem em.. Prime Prime unti untill old old oil oil is purge purged d from from oi oill pa pass ssag ages es an and d flus flushi hing ng oil oil st stea eadi dily ly flows flows from all bearing bearings s an and d cross crosshea head d bu bush shing ings. s. 9. Drain Drain frame frame.. Remov Remove e stan standi ding ng oil oil in the the frame frame and and guid guide e co comp mpart artme ment nt lo low w point points. s. Remov Remove e as much much oi oill as poss possib ible le with with a va vacu cuum um hose hose.. 10. Remove 10. Remove diaphragm diaphragm pump. pump. 11. Instal 11. Installl drain drain plug plug in frame. frame. 12. Refi 12. Refillll th the e frame frame with with flus flushi hing ng oil oil (see (see"Recom "Recommend mended ed Flus Flushing hing Oil Oil""). 13. Circul 13. Circulat ate e flus flushi hing ng oi oill for for at leas leastt four four hour hours, s, and and up to 24 ho hours urs if ne need eded ed,, to lo loos osen en al alll de debri bris s an and d ex exist isting ing depos deposits its.. Monito Monitorr lube lube oil fil filter ter di diffe fferen rentia tiall press pressure ure du during ring flu flush shing ing.. The filter filter may may need need to be take taken n of offf liline ne or ch chan ange ged d se seve vera rall time times s durin during g flus flushi hing ng,, as lo loos osen ened ed de depo posi sits ts te tend nd to plug plug th the e filt filter er
quickly. 14. Drain Drain th the e fi firs rstt fl flus ushi hing ng oil oil from from the the fram frame e whil while e the the oil oil is still till warm warm.. Take Take care care to also also dr drai ain n al alll supp supply ly an and d return return lin lines es,, fil filter ter hou housi sing, ng, and other other peri periphe pheral ral eq equip uipmen mentt in the lubric lubricant ant suppl supply y loop. loop. If standi standing ng oi oill re rema main ins s in th the e frame frame,, remov remove e as much much as poss possib ible le wit with h a va vacu cuum um ho hose se.. 15. Refil 15. Refilll th the e frame frame with with the the PAG lubri lubrica cant nt of the the reco recomm mmen ende ded d visc viscos osit ity y fo forr th the e ap appl plic icat atio ion. n. At th this is time time,, as muc much as 22-3% 3% of the the in init itia iall oil oil may may stil stilll rema remain in in the the syste ystem. m. Circ Circul ulat ate e th this is fill fill fo forr at leas leastt fo four ur ho hour urs s and and up to 24 hours hours if poss possib ible le.. Repla Replace ce filt filter ers s as need needed ed.. NOTE: If the PAG lubricant is clear and bright after circulating and no debris or emulsion is visible, it may be possible to skip the final steps and simply begin normal operation. However, a second flush is preferred (see steps 16 and 17). 16. Drain 16. Drain se seco cond nd flus flushi hing ng (PAG lubri lubrica cant nt)) oil oil from from the the frame frame while while th the e oi oill is st stililll warm warm.. 17. Refil 17. Refilll frame frame with with PAG lubri lubrica cant nt of the the rec recom omme mend nded ed vi visc scos osit ity y an and d circu circula late te fo forr at le leas astt fo four ur ho hours urs.. At this this poin point, t, th the e in init itia iall oil oil remai remaini ning ng in the the sy syst stem em sh shou ould ld be less less th than an 0. 0.5% 5%.. Samp Sample le th the e oi oill an and d ex exam amin ine e it fo forr any any emul emulsi sion on or debr debris is.. If the the oil oil is cl clea earr and and brigh brightt (a slig slight ht ha haze ze is ac acce cept ptab able le), ), th then en co cont ntin inue ue no norma rmall operati operation on an and d top off as neede needed. d. If si signi gnific fican antt emuls emulsion ion or de debris bris remain remains, s, then then cond conduc uctt on one e more mo re drain drain an and d flu flush sh.. If the the frame frame uses uses th the e sa same me oil oil as the the force force-fe -feed ed cy cylilind nder er lubri lubrica cati tion on sy syst stem em,, th the e ov over erfl flow ow line line on th the e lu lubri brica cato torr box box ca can n remai remain n atta attach ched ed to the the frame frame auxi auxililiary ary end end co cove ver. r. If th the e frame frame oil oil an and d cy cylilind nder er oil oil are incomp inc ompati atible ble or of differe different nt ISO grade grades, s, di disc scon onnec nectt ov overfl erflow ow lin line e on the lubric lubricato atorr bo box x (see (see "Independent Oil Suppl Supply" y"). ). Fill Fill th the e fo forc rce-f e-fee eed d lubri lubrica cato torr box box wit with h the the sa same me oi oill us used ed to lu lubri brica cate te th the e co comp mpres resso sor r cylin cylinde ders/p rs/pac acki king ngs. s. To chang change e the lubric lubricato atorr box lubric lubricant ant from a minera minerall oil or synth syntheti etic c PAO lubric lubrican antt to a PAG synth syntheti etic c lubric lubrican ant: t: Drain ol old d oi oill from from lu lubri brica cato torr box. box. 1. Drain 2. Rinse Rinse lu lubric bricato atorr box with flu flush shing ing oil (see (see "Recom "Recommend mended ed Flus Flushing hing Oil Oil""). 3. Fill lu lubri brica cato torr box box with with PAG lubri lubrica cant nt to be used used for for the the cyli cylind nders ers..
Flushing the Force Feed Lubrication System Common Comm on Oil Oil Supply Supply 1. If ins instal talled led,, drain drain the si sinte ntered red fil filter ter and cl clea ean n the elemen elementt with solv solvent ent.. 2. Drain Drain th the e lu lube be line line upst upstrea ream m of the the force force feed feed pump pump inle inlet. t.
Page 3-14 of 32
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For models models JGC:D:F JGC:D:F
Secti Section on 3 - Mai Mainte ntena nance nce
3. Drain tubin tubing/m g/mani anifol fold d feedin feeding g the force force feed feed pump(s pump(s). ). 4. Remov Remove e th the e purge purge/v /ven entt co conn nnec ecti tion on on the the outl outlet et of each each fo forc rce e fe feed ed pu pump mp.. 5. Use a purg purge e gun gun fill filled ed with with cl clea ean/ n/fi filt ltere ered d flus flushi hing ng oil oil (see (see Note) Note) to prime prime ea each ch fo forc rce e fe feed ed pu pump mp by forcing forc ing oil throug through h the pu pump mp inlet inlet an and d ou outt the purge/ purge/ve vent nt conne connecti ction on.. 6. Recon Reconne nect ct th the e purg purge e gun gun to the the forc force e feed feed pump pump purge purge/v /ven entt ou outl tlet et co conn nnec ecti tion on.. If pu pump mps s are pa paire ired d togeth tog ether er at their their ou outle tlets, ts, clos close e on one e of the pu purge rge/ve /vent nt conne connecti ctions ons.. 7. Fo Forr th the e zo zone ne fe fed d by the the force force feed feed pump pump bein being g prime primed, d, disc discon onne nect ct lu lube be line lines s at th the e inle inlett of th the e do doub uble le-ball check check valves. valves. 8. Pla Place ce pa paper per towels towels or suita suitable ble colle collecti ction on conta containe iners rs be benea neath th ea each ch disc discon onnec nected ted lu lube be lin line e to catch catch flu flush shing ing oi oill during during priming priming.. 9. Prime Prime flu flush shin ing g oil from the force force feed feed pu pump mp purge/ purge/ve vent nt conn connec ectio tion n to do downst wnstrea ream m tubing tubing,, divid divider er blocks, and check blocks, check valves. valves. 10. Pri 10. Prime me unti untill no ai airr bubb bubble les s appe appear ar in the the flus flushi hing ng oil oil at al alll disc discon onne nect cted ed lu lube be line lines s in th the e zo zone ne.. 11. Recon 11. Reconne nect ct lu lube be line lines s to doub double le ball ball ch chec eck k va valv lves es in th the e prime primed d zo zone ne..
12. Co 12. Cont ntin inue ue to prime prime 2 floz floz of oil oil per per thro throw w tthro hroug ugh h the the prime primed d zo zone ne.. 13. Repe 13. Repeat at st step eps s 6 thru thru 12 for for rem remai aini ning ng zo zone nes. s.
Independen Inde pendentt Oi Oill Supply Supply 1. If ins instal talled led,, drain drain the si sinte ntered red fil filter ter an and d cl clean ean the el eleme ement nt with solve solvent. nt. 2. Drai Drain n dayt daytan ank, k, oi oill filt filter er,, and and lube lube line lines s upst upstrea ream m of the the fo force rce fe feed ed pu pump mp inle inlet. t. Oil Oil tra trapp pped ed in pi pipi ping ng will will need need va vacu cuum umed ed out out or flus flushi hing ng oil oil ca can n be pump pumped ed throu through gh th thes ese e line lines s to disp displa lace ce th the e ol old d oi oil. l. 3. Drain tubin tubing/m g/mani anifol fold d feedin feeding g the force force feed feed pump(s pump(s). ). 4. Remov Remove e th the e purge purge/v /ven entt co conn nnec ecti tion on on the the outl outlet et of each each fo forc rce e fe feed ed pu pump mp.. purge e gun gun fill filled ed with with cl clea ean/ n/fi filt ltere ered d flus flushi hing ng oil oil (See (See Note# Note#1) 1) to prime prime ea each ch fo forc rce e fe feed ed pu pump mp by 5. Use a purg forcing forc ing oil throug through h the pu pump mp inlet inlet an and d ou outt the purge/ purge/ve vent nt conne connecti ction on.. 6. Recon Reconne nect ct th the e purg purge e gun gun to the the forc force e feed feed pump pump purge purge/v /ven entt ou outl tlet et co conn nnec ecti tion on.. If pu pump mps s are pa paire ired d togeth tog ether er at their their ou outle tlets, ts, clos close e on one e of the pu purge rge/ve /vent nt conne connecti ctions ons.. 7. Fo Forr th the e zo zone ne fe fed d by the the force force feed feed pump pump bein being g prime primed, d, disc discon onne nect ct lu lube be line lines s at th the e inle inlett of th the e do doub uble le-ball check check valves. valves. 8. Pla Place ce pa paper per towels towels or suita suitable ble colle collecti ction on conta containe iners rs be benea neath th ea each ch disc discon onnec nected ted lu lube be lin line e to catch catch flu flush shing ing oi oill during during priming priming.. 9. Prime Prime flu flush shin ing g oil from the force force feed feed pu pump mp purge/ purge/ve vent nt conn connec ectio tion n to do downst wnstrea ream m tubing tubing,, divid divider er blocks, bloc ks, and check check valves. valves. 10. Prime 10. Pri me unti untill no ai airr bubb bubble les s appe appear ar in the the flus flushi hing ng oil oil at al alll disc discon onne nect cted ed lu lube be line lines s in th the e zo zone ne.. 11. Recon 11. Reconne nect ct lu lube be line lines s to doub double le ball ball ch chec eck k va valv lves es in th the e prime primed d zo zone ne.. 12. Cont 12. Contin inue ue to prime prime 2 floz floz of flus flushi hing ng oil oil per per throw throw tthro hroug ugh h th the e prime primed d zo zone ne.. 13. Disc 13. Discon onnec nectt the purge purge gun an and d instal installl cap cap for pu purge rge/ve /vent nt conn connec ectio tion. n. 14. Repe 14. Repeat at st step eps s 6 thru thru 12 for for rem remai aini ning ng zo zone nes. s. 15. In 15. Insta stallll a ne new w oil oil fil filter. ter. 16. Reco 16. Reconne nnect ct lube lube lines lines be betwee tween n daytan daytank k and pump pump inlets inlets.. 17. Place 17. Place a colle collecti ction on conta contain iner er be benea neath th the disco disconne nnecte cted d lube lube lin line e ne near ar the force force feed feed pump pump inlet inlet connection.
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Page 3-15 of 32
Section 3 - Maintenance
For models JGC:D:F
18. Add 18. Add enou enough gh flus flushi hing ng oil oil to the the dayt daytan ank k to prime prime the the sy syst stem em up to th the e di disc scon onne nect cted ed line line in st step ep 17 17.. 19. Coll 19. Collec ectt oi oill unti untill no ai airr bubb bubble les s appe appear ar in the the flus flushi hing ng oil. oil. 20. Recon 20. Reconne nect ct fe feed ed liline ne to force force feed feed pump pump.. 21. Bleed 21. Bleed trappe trapped d air by loos looseni ening ng tube tube conn connec ectio tions ns nea neares restt each each pu pump mp inlet inlet..
Oi Oill Temperat Temperature ure Control Control Valve Valve Th The e lu lube be oi oill sy syst stem em requi require res s a therm thermos osta tati tic c va valv lve e to contro controll compr compres esso sorr oil tempe temperatu rature. re. A thermos thermostat tatic ic va valv lve e is a th three ree-way -way va valv lve e with with a temp tempera eratu ture re sens sensiti itive ve eleme element. nt. As the oil he heats ats,, the sens sensing ing el elem emen entt open opens s th the e th third ird port port in the the va valv lve. e. Ariel recommend recommends s a thermosta thermostatic tic valve valve with a 170°F 170°F (77°C) (77°C) el elem emen ent. t. Inst Instal alll the the va valv lve e in mixi mixing ng mode mo de to more directl directly y contro controll oil tem tempe peratu rature re into into the the frame frame (see (see FIGURE FIGURE 33-7 7).
Thermostatic control valve configuration may vary from Thermostatic this schematic schematic depending on valve size. Valve connections A-B-C are marked on the valve.
FIGURE 3 7 Thermostatic Valve in Mixing Mode
Oil Filter
All compress compressor or frames require require oil filte filters rs to remove remove particle particle contamin contaminatio ation n that can damage damage equipme equipment nt an and d oil. oil. Contam Contamina inants nts that that da damag mage e eq equip uipmen mentt includ include e wear pa partic rticles les from eq equip uipmen mentt , airborn airborne e pa partic rticles les such such as du dust st or sand sand,, and partic particula ulates tes in ne new w oi oil. l. Contami Contaminan nants ts that that damage damage oil includ include e ox oxidi idize zed d oi oill compone com ponents nts and air bubbles bubbles.. • Ariel Ariel filt filters ers ar are e not not desi design gned ed for for rever reverse se flow flow often often ca caus used ed by pu pump mpin ing g oi oill ou outt of th the e co comp mpres resso sorr th throu rough gh the the filt filter. er. Th This is ca can n in inve vert rt and and tear tear the the filt filter er medi media, a, se send ndin ing g dirty dirty oi oill to cr cran anks ksha haft ft be beari aring ngs. s. • With With ca cani nist ster er st styl yle e filt filters ers,, alway always s drain drain oil oil filt filter er hous housin ing g befo before re el elem emen entt remov removal al or dirty dirty oi oill wil willl be se sent nt to crankshaft bearings. • Arie Ariell ca cartr rtrid idge ge filt filter ers s have have a 24 mont month h sh shel elff life life from from the the date date of manu manufa fact cture ure,, an and d an in inst stal all-b l-by y da date te is stam st ampe ped d on th the e to top p of each each filt filter. er. Disca Discard rd any any filt filter er exce exceed edin ing g th the e inst instal all-b l-by y da date te.. JGC:D:F/2 compress JGC:D:F/2 compressors ors ship ship with simplex, simplex, spin-on, spin-on, non non-bypa -bypassi ssing, ng, resin-impre resin-impregnat gnated ed filters filters as stan st anda dard rd.. Spin-o Spin-on n filt filters ers ca carry rry a 5 micro micron n nomi nomina nall and and 17 micr micron on ab abso solu lute te ratin rating. g. Th The e Beta Beta ratin ratings gs are ß5 = 2 and and ß1 ß17 7 = 75. 75. Many Many sp spin in-on -on filt filters ers fit fit an Ari Ariel el co comp mpres resso sor, r, bu butt ve very ry fe few w meet meet filt filtrat ratio ion n ratin ratings gs of Ariel Ariel filters filters.. Do not us use e aft after-m er-mark arket et fil filters ters.. JGC:D:F/4/6 JGC:D:F/4 /6 compr compres esso sors rs ship ship with si simp mplex lex or du duple plex x cartrid cartridge ge st style yle pl pleat eated ed sy synth ntheti etic c filters filters as stand standard. ard. Cartrid Cart ridge ge filt filter ers s ar are e rat rated ed as 1 micro micron n nomi nomina nall and and 12 micr micron on ab abso solu lute te filt filter ers. s. Th The e Beta Beta ratin ratings gs are ß1 = 2, ß5 = 10 and ß12 ß12 = 75. 75. Pressure Pressu re gauge gauges s monito monitorr press pressure ure dro drop p ac acros ross s the fil filter. ter. High differe differenti ntial al press pressure ure indic indicate ates s a plugg plugged ed filt filter. er. Ariel Ariel recom recomme mend nds s lube lube oil oil filt filter er repl replac acem emen entt every every 6 mont months hs,, or 40 4000 00 ho hours urs,, or when when oi oill filt filter er differe differenti ntial al press pressure ure at normal normal op operat erating ing tem tempe peratu rature re reach reaches es 10 ps psid id (0.7 bard) bard) for spin-o spin-on n filters filters or 15 ps psid id (1.0 ba bard) rd) for cartrid cartridge ge fil filters ters,, whiche whicheve verr comes comes first. first. On st start-u art-up, p, differe differenti ntial al press pressure ure may may ex exce ceed ed the filter filter replac replaceme ement nt limit limit un until til the oil rea reach ches es op opera eratin ting g tempe temperatu rature. re. On the same same sc sche hedul dule, e, or with every every main main oi oill filt filter er ch chan ange ge,, cl clea ean n the the si sint ntere ered d elem elemen entt in the the smal smalll oil oil filt filter er of th the e fo force rce fe feed ed lu lubri brica cato tor. r.
Simplex Spin-on Filter Replacement NOTE: Replace oil filters only with Ariel approved filters. 1. Remove Remove ol old d fil filter, ter, cl clean ean fil filter ter bas base e surfac surfaces es,, and verify verify old ga gask sket et is remove removed. d. 2. Insp Inspec ectt new new filt filter er fo forr dama damage ge or debri debris. s. Do not not inst instal alll dama damage ged d or di dirty rty filt filters ers.. Never operate a unit with a damaged or leaking oil filter. 3. Appl Apply y cl clea ean n oi oill to th the e filt filter er gask gasket et and and threa thread d the the filt filter er with with ga gask sket et on onto to th the e ba base se.. Page 3-16 of 32
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For models models JGC:D:F JGC:D:F
Secti Section on 3 - Mai Mainte ntena nance nce
4. Tigh Tighte ten n th the e filt filter er one one turn turn afte afterr the the filt filter er gask gasket et co cont ntac acts ts th the e ba base se.. 5. Use th the e co comp mpres resso sorr pre-l pre-lub ube e pump pump to fill fill the the oil oil filt filter er wit with h oil oil an and d pu purge rge ai airr from from th the e oil oil sy syst stem em.. Manu Ma nual ally ly fill fillin ing g the the filt filter er with with oil oil ca can n intro introdu duce ce debri debris s on th the e clea clean n side side of th the e filt filter. er. Th This is de debri bris s ca can n damag dam age e the compr compres esso sorr to the point point of catas catastrop trophic hic bearin bearing g fai failure lure.. 6. After After startin starting g the unit, unit, chec check k for lea leaks ks,, an and d retigh retighten ten if ne nece cess ssary ary..
Simplex Filter Cartridge Replacement NOTE: Replaceable filter elements are delicate and require proper storage to prevent material degradation, flash rust inside, contamination, etc. Inspect elements for cleanliness and damage. Do not install dirty or damaged elements. 1. Remov Remove e 3/ 3/4” 4” NPT drain drain plug plug and and drain drain oil oil co comp mple lete tely ly.. 2. While While th the e oi oill drain drains, s, open open 3/4” 3/4” NPT ve vent nt,,
1. 3/4" NPT Vent 2. Top Cover 3. Top Cover O-Ring O-Ring 4. Spring Plate Assembly 5. Filt Filter er Element Element 6. 7. Filter Drain Vessel Plug
3. After After the oil drains drains compl complete etely ly,, remov remove e top cove cover, r, sprin spring g plate plate as asse sembl mbly, y, and fil filter ter ele eleme ments nts.. 4. In Insp spec ectt in inte terio riorr of filt filter er ve vess ssel el for for debri debris. s. Clean Clean if needed. 5. Place ne new w elemen element(s) t(s) ov over er seat seat in bottom bottom of vess vessel. el. 6. Re-install Re-install spring spring plate ass assembl embly. y. 7. In Insp spec ectt co cove verr o-rin o-ring g for for wear. wear. Repla Replace ce if need needed ed.. 8. Clos C lose e drain. drain. 9. In Inst stal alll co cove ver. r. To Torqu rque e nuts nuts to 70-80 70-80 Lb x Ft (95-11 (95-110 0 N•m). 10. Use 10. Use co comp mpres resso sorr pre-lu pre-lube be pump pump to fill fill the the oil oil filt filter er wit with h oi oill and and purge purge ai airr from from the the oil oil sy syst stem em.. Manu Manual ally ly fill fillin ing g th the e filt filter er with with oi oill ca can n intro introdu duce ce debri debris s on the the cl clea ean n si side de of th the e filt filter er.. Debris Debris ca can n dama damage ge the the co comp mpres resso sorr to the the point poi nt of catas catastrop trophic hic bearin bearing g fai failur lure. e.
FIGURE 3-8 Typical Oil Filter Vessel
11. Releas 11. Release e trappe trapped d air through through vent. vent. Check Check for lea leaks ks..
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Section 3 - Maintenance
Duplex Filter Filter Cartridge Cartridge Replacement NOTE: Replaceable filter elements are delicate and require proper storage to prevent material degradation, flash rust inside,, contamination, inside contamination, etc. Inspect elements elements for cleanliness and damage. Do not install dirty or damaged elements. 1. Open Open eq equa ualiz lizati ation on valv valve e to equali equalize ze pre press ssure ure be betwee tween n the fil filters ters.. 2. Th The e tri trian angl gle e in indi dica cato torr on top top of the the trans transfe fer r valve va lve ha hand ndle lerpo point ints toward towa rdunti the activ tive es filter. fil ter. Tu Turn rn trans tra nsfe fer va valv lve es hand ha ndle le un tillac it stop st ops to make make the in inac activ tive e fil filter ter the ac activ tive e fil filter. ter. 3. Close equaliz equalization ation valve. valve.
For models JGC:D:F
4. Verif Verify y no oi oill is flowi flowing ng throu through gh the the inac inacti tive ve filt filter er.. Ventt trapped Ven trapped air, if ne nece cess ssary ary.. 5. Follow Follow steps steps of "Simpl "Simplex ex Fil Filter ter Cartri Cartridge dge Replacement" for the inacti inactive ve fil filter. ter.
Compressor Pre-lube System Ariel compress compressors ors must must be pre-lubed pre-lubed anytime anytime the cr cran anks ksha haft ft is tu turne rned d and and prio priorr to start startin ing. g. Ariel Ariel strongly recommend strongly recommends s an automate automated d pre-lube pre-lube syste system m to ex exten tend d drivel driveline ine comp compone onent nt life. life.
FIGURE 3-9 Typical Duplex Oil Filter
Ariel requires requires automate automated d pre-lube pre-lube systems systems for compress compressors ors that meet any of the following following criteria: criteria: • Electric Electric motor motor driven driven compress compressors. ors. • Unattended-s Unattended-start tart compress compressors, ors, regardles regardless s of driver driver type. type. • Compres Compresso sorr models models JGC:D:F: JGC:D:F:Z:U:B: Z:U:B:V V and KBZ:U:B:V. KBZ:U:B:V. pre-lube e ci circu rcuit it design design.. See FIGURE FIGURE 3-4 for pre-lub NOTE: The pre-lube return into the frame must be upstream of the oil filter. For on-dem on-deman and d compr compres esso sorr applic applicati ation ons, s, the pre-lu pre-lube be pump pump can can circu circulat late e oil conti continu nuous ously ly through through the be bearin arings gs while while on standb standby. y. Ariel requiremen requirements ts are based based on a pre-lube pre-lube pump sized sized for 25% of frame oil pump pump flow to ens ensure ure oil flow to be bearin arings gs,, bushi bushings ngs,, and oil-fil oil-filled led cleara clearanc nces es prior prior to turning turning or start-up start-up (see (see the Ariel Ariel Perf Perform ormanc ance e Progra Pro gram m fo forr frame frame oi oill pump pump flow flow rat rates es). ). Pre-lube Pre-lu be press pressure ure sh shal alll be 30 psig psig (2.1 (2.1 barg) barg) at the the oil oil gall galler ery y fo forr a mini minimu mum m of 2 minu minute tes s prior prior to tu turni rning ng or sta startin rting. g. NOTE: A 10 to 15 minute pre-lube is required after: major dri drive ve lin line e maint maintena enanc nce e • Any major • The main main lu lube be oi oill sy syst stem em is drain drained ed • Oil filter filter replaceme replacement nt
Page 3-18 of 32
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For models models JGC:D:F JGC:D:F
Secti Section on 3 - Mai Mainte ntena nance nce
Instrumentation: Autom Instrumentation: Automated ated pre-lube pre-lube systems systems require require a start permissi permissive ve logic logic and instrumen instrumentatio tation n to satis satisfy fy the minimu minimum m require required d press pressure ure an and d durati duration on at the oil gal gallery lery inlet. inlet. It is highly highly recom recommen mended ded that that the comp compres resso sorr low oil pre press ssure ure shutd shutdown own be Class Class B. Inhibi Inhibited ted time time shall shall be no lo long nger er th than an 10 se seco cond nds s afte afterr idle idle sp spee eed d is achi achiev eved ed on ga gas s en engi gine nes s or st star artt init initia iati tion on for for elec electri tric c motors. If th the e co comp mpres resso sorr fa failils s to achi achiev eve e 45 psig psig (3.1 (3.1 barg) barg) oil oil press pressur ure e withi within n 10 se seco cond nds s af afte terr re reac achi hing ng en engi gine ne idle idle spee speed d or electri electric c motor motor start start initia initiatio tion, n, en ensu sure re shutd shutdown own an and d correc correctt the caus cause. e. Repeat Repeat pre-lub pre-lube e before bef ore ea each ch start start att attemp empt. t. NOTE: If a compressor fails to start or shuts down at start-up due to low oil pressure, DO NOT re-start until the cause is corrected.
Oil Heaters TABLE 3-3 Heat Required to Maintain Minimum Th The e co comp mpres resso sorr may may need need a frame frame oil oil heat heater er to meett allowab mee allowable le oil vi visc scos osity ity requi requireme rements nts at startstart- JGC:D:F Frame Temperature: kW = C h x ∆T up (see (see TAB TABLE LE 3-1 3-1). ). One One possib possible le heatin heating g mode mode
maintains mainta ins the compr compres esso sorr frame frame at a minimu minimum m temper tem peratu ature re so the comp compres resso sorr can can st start art TABLE LE 3-3 3-3). ). Mul Multip tiply ly immed imm ediat iately ely if neede needed d (see (see TAB the coeff coeffic icien ients ts lis listed ted in TABLE TABLE 3-3 by the the differe differenti ntial al be betwee tween n target target oil tem temper peratu ature re and ambien amb ientt tempe temperatu rature re to obtain obtain the ki kilowa lowatt tt rating rating for for a heat heater er.. Another mode heats Another heats oil from ambient ambient to a minimu min imum m temper temperatu ature re prior prior to startin starting g (see (see TABL TABLE E 3-4 3-4). ). Multip Multiply ly the coeff coeffic icien ients ts lis listed ted in TABLE E 3-4 by th the e ris rise e in oil oil temp tempera eratu ture re and and TABL divi divide de by ta targe rgett hour hours s to obta obtain in the the ki kilo lowat wattt ratin rating g for for a heat heater er..
Heater Coefficient (Ch), kW/ F (kW/ C) 2 Throw
4 Throw
6 Throw
0.039 0.0 392 2 (0.07 (0.0706 06))
0.072 0.0722 2 (0.13 (0.1300 00))
0.104 0.1044 4 (0.1 (0.188 880) 0)
TABLE 3-4 Heat Required to Warm Cold JGC:D:F Frame and Oil: kW = C h x ∆T / ∆ t Heater Coefficient (Ch), kW-h/°F (kW-h/°C) 2 Throw
4 Throw
6 Throw
0.149 0.1 494 4 (0.26 (0.2689 89))
0.302 0.3024 4 (0.58 (0.5832 32))
0.452 0.4526 6 (0.8 (0.814 147) 7)
Ariel recommend recommends s circulat circulation ion heaters heaters for all units. units. Heated oil should should circulate circulate through through the filter, filter, bearings bearings,, and and cr cros ossh shea eads ds as wel welll as the the su sump mp.. All Ariel compress compressors ors have have at least least one heater heater connec connection tion;; four and six throw frames frames have have two. 2 2 Maxi Ma ximu mum m al allo lowab wable le watt watt dens densit ity y for for an imme immers rsio ion n heat heater er is 15 W/i W/in n (2. (2.3 3 W/cm W/cm ). Th This is limi limitt preve prevent nts s oil oil cokin coking g on the he heate aterr elemen element, t, which which reduc reduces es heater heater eff effic icien iency cy an and d conta contamin minate ates s remain remaining ing oil. oil.
Force Feed Lubrication System Components The cy der r lu lubric syste sy mrce injec inj lub ricati ation on int cylin cy,linde der r bores bor an and packin pac kings gs. The sy syste stem meck cons coknsis ists ts of ancylin oi oillinde l su supp pply ly,bricati , anation oi oilon l filt filter, er,stem a forc fo eects feed fets edlubric lubri lubrica cato torr into pump puomp, di divi vide der r bloc bles ocks ks, ,dpress pre ssure ure indi in. dica cato tors rs, , ch chec valve valves, s, and flo flow w monit monitorin oring g shutd shutdown own de devic vices es.. The syste system m is progre progress ssive ive;; each each piston piston in the divide divider r block blo ck mus mustt compl complete ete a cycl cycle e be before fore the syste system m cycl cycles es again. again. Thi This s type type of sy syst stem em off offers ers be bette tterr lubric lubricati ation on precisio preci sion n and eases eases monitoring monitoring..
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Page 3-19 of 32
Section 3 - Maintenance
For models JGC:D:F
Force Feed Lubricator
1. Inlet Header Header 2. Priming Stem 3. Pump P Plunger lunger Str Stroke oke Adjustment Screw 4. Lock Nut 5. Lubricator Oil Fill Fill Connection 6. Sight Glas Glass s 7. Mounting Flange Capscrews (4) 8. Drain Plug 9. Pum Pump p IInlet nlet fr from om Header 10. Priming Pump Connection
The force force feed feed lubric lubricati ation on syst system em oi oils ls the compr compres esso sorr cylin cylinde ders rs and piston piston rod pack packin ings gs.. Oil Oil flows flows to th the e 150 150 micr micron on sinte si ntered red bronz bronze e fil filter ter on the sucti suction on side side of the force force feed feed lubric lubricato atorr pum pump p direc directly tly from fro m th the e press pressure ure si side de of the the frame frame lubric lub ricati ation on syste system, m, or from an ov overh erhead ead ta tank nk.. Fi Filt lter ered ed oi oill fl flow ows s to a head header er an and d to pu pumps mps on the force force feed feed lubric lubricato ator. r. A self-con self-contain tained ed oil reservoir reservoir oils the force force fe feed ed lu lubr bric icat ator or worm gear gear and and cam. cam. The force force feed feed lubric lubricato atorr si sight ght glass gla ss shows shows the reserv reservoir oir oil level. level.
11. Pump Outlet Outlet to Distribution Distribut ion Block 12. Rupture Disk Assembly 13. Lubricator Overflow Overflow
FIGURE 3-10 Typical Force Feed Lubricator
Priming the Pump Use filt filter ered ed oi oill when when primi priming ng the the pump pump and and forc force e feed feed sy syst stem em (mini (minimu mum m 5 micr micron on nomi nomina nall filt filter) er).. Refer Refer to Figu Figure re 2 durin during g prim primin ing. g. 1. Remov Remove e and and di disc scard ard the the plas plasti tic c plug plugs s in the the pump pump inle inlett an and d ou outl tlet et.. 2. Apply Apply thread thread seala sealant nt (user (user supp supplie lied) d) to inlet inlet and ou outle tlett lin line e fittin fittings gs.. 3. Inst Instal alll th the e in inle lett and and outl outlet et fi fitt ttin ings gs on the the pump pump.. 4. Conne Connect ct th the e in inle lett line line to the the inle inlett fitt fittin ing. g. 5. Intro Introdu duce ce oi oill in into to th the e inle inlett liline ne.. If inst instal alle led, d, open open oil oil su supp pply ly va valv lve e (lo (loca cated ted up upstre stream am from pump). pump). 6. Wipe Wipe th the e pump pump primi priming ng st stem em cl clea ean n and and lubri lubrica cate te with with oil. oil. 7. Manua Manually lly prim prime e pu pump mp by de depre press ssing ing the pump pump pri primin ming g stem stem repea rep eated tedly ly until until clea clean, n, air-free air-free oil flo flows ws from the outle outlett fit fittin ting. g. 8. Connec Connectt ou outle tlett lin line e to ou outle tlett fit fittin ting. g.
FIGURE 3-11 Pump Priming and Adjustment
9. Manu Manual ally ly prime prime pump pump usin using g pump pump primi priming ng st stem em unti untill cl clea ean, n, air-fr air-free ee oil oil flows flows from from th the e ou outl tlet et line line.. 10. Con 10. Conne nect ct th the e outl outlet et line line to the the lube lube poin point. t. 11. Aft 11. After er startu startup, p, adjus adjustt indiv individu idual al pu pumps mps to meet meet require required d flo flow w rates rates.. See "Pump "Pump Adjus Adjustme tment" nt"..
Pump Adjustment Adjustment The flo flow w adju adjustm stment ent screw screw contro controls ls pu pump mp flo flow w rate; rate; turning turning it chan changes ges the length length of the piston piston st strok roke e which whic h chan changes ges the pump pump disch discharg arge e volum volume. e. Refer Refer to Figure Figure 2 during during ad adjus justme tment. nt. Loosen the flow adjustme adjustment nt screw screw locknut. locknut. 1. Loosen 2. Lu Lubri brica cate te the A-9065 A-9065 o-ring o-ring be benea neath th the ad adjus justme tment nt screw screw lockn locknut ut with oi oil. l.
Page 3-20 of 32
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For models models JGC:D:F JGC:D:F
Secti Section on 3 - Mai Mainte ntena nance nce
3. Turn the flo flow w adjustm adjustment ent screw. screw. Counterc Countercloc lockwis kwise e increa increase ses s flo flow w and decrea decrease ses s cy cycl cle e time; time; clockwise cloc kwise decrease decreases s flow and increase increases s cycle cycle time. time. 4. Check Check fo forc rce e fe feed ed lubri lubrica cato torr data data plat plate e or Ariel Ariel lube lube sh shee eets ts fo forr co corre rrect ct cy cycl cle e time time.. Adjus Adjustt flow flow unti untill desired des ired cycl cycle e time time is ac achie hieve ved d with the force force feed feed syste system m op opera eratin ting. g. 5. Repe Repeat at St Step eps s 2 and and 3 as ne need eded ed.. 6. After After ad adjus justme tment nt to the prope properr cycl cycle e time, time, tig tighte hten n the ad adjus justme tment nt sc screw rew lockn locknut. ut. NOTE: Inconsistent flow can occur if pump stroke is set below 20% of maximum stroke. NOTE: A dust seal inside the flow adjustment screw holds the priming stem stationary during operation.
Force Feed Lube Blow-Out Fittings, Rupture Disks, and Tubing TABLE 3-5 Blow-Out Fittings, Replacement Rupture Disks, & Tubing Fo Force rce fe feed ed lu lube be pump pump discharge disc harge lines lines require require Rep plac lacemen ment Ru Rup pture Di Dis sk St Sta andard Tubing ing blow-out blo w-out fit fittin tings gs and the Blow-out Re
properly properl y rated rated rupture rupture disk dis k instal installe led. d. The disk disk color color shoul should d show show at the fittin fitting g blow-out blow-out ho hole. le. A system sys tem blockage blockage causes causes pressure press ure build-up build-up that rupture rupt ures s the disk. disk. Ventin Ven ting g the syste system m throug thro ugh h the blow-out blow-out disk dis k caus causes es the no no-flo -flow w shutd sh utdown own switch swit ch tosor. shut sh down the comp co mpres resso r.ut
Fitting Rating Ariel P/N psig (barg)
Ariel Color P/N
A-0080 A-00 80
325 3250 0 (224) (224)
A-01 A-0124 24
Purp Purple le
A-3531 A-35 31
370 3700 0 (255) (255)
A-35 A-3536 36
Yellow Yellow
A-3532 A-35 32
460 4600 0 (317) (317)
A-35 A-3537 37
Red
A-3533 A-35 33
550 5500 0 (379) (379)
A-35 A-3538 38
Ora Orange nge
A-3534 A-35 34
640 6400 0 (441) (441)
A-35 A-3539 39
Pink
A-3535 A-35 35
730 7300 0 (503) (503)
A-35 A-3540 40
Blue
Size in. (mm)
Rating Ariel P/N psig (barg)
1/4 x 0.035 0.035 (6.4 (6.4 x 0.9 0.9)) wall
5100 510 0 (35 (352) 2)
1/4 x 0.065 0.065 (6.4 (6.4 x 1.7 1.7))
10,200
PT0201CD
wall
(703)
(316 (316 SS)
PT0200CB (304 (304 SS)
Ariel force feed lube blow-out blo w-out fit fittin ting g rupture rupture disks disks are colorcolor-co coded ded to identi identify fy rupture rupture press pressure ure ratings ratings.. Some Some di disk sks s come come with half half th the e fini finish shed ed fa face ce co coat ated ed.. If the the disk disk co colo lorr co coat atin ing g is less less th than an ha half lf th the e fa face ce su surfa rface ce,, th the e co colo lorr may may no nott show show through through the small small cente centered red bl blow-ou ow-outt hole hole when instal installed led in the blow-out blow-out fittin fitting. g. When When thi this s happe happens ns,, a visual visual inspec inspectio tion n for colo colorr codin coding g may not indica indicate te the correc correctt disk disk is instal installe led, d, and fittin fitting g disas disasse sembl mbly y is requi req uired red to co conf nfirm irm the the prope properr disk disk inst instal alla lati tion on.. To co corre rrect ct th this is is issu sue e in th the e fu futu ture, re, th the e fini finish shed ed fa face ce of ruptu rup ture re di disk sks s su supp pplilied ed to Ariel Ariel afte afterr March March 2005 2005 are co comp mple lete tely ly co coat ated ed with with co colo lor. r. Disks Disks ne need ed no nott be replac repl aced ed be beca caus use e of thi this s chang change e and ex exis istin ting g di disk sk stock stock may be us useded-up. up. CAUTION: Use a mirror to inspect rupture disk color if force feed lube system is pressurized. A rupturing disk or high pressure oil can potentially cause personal injury. Use a ru rupt pture ure di disk sk th that at matc matche hes s the the blow-o blow-out ut fitt fittin ing g type type an and d ap appl plic icat atio ion n press pressure ure.. Gene General rally ly,, us use ea ruptu rup ture re di disk sk rated rated abou aboutt 1000 1000 psig psig (70 barg) barg) great greater er than than th the e hi high ghes estt MAWP MAWP cy cylilind nder. er. When When in inst stal alliling ng a rupt ruptur ure e di disk sk,, tigh tighte ten n the the blow blow-o -out ut hex hex fi fitt ttin ing g cap cap to 40 lb lb.. x in. in. (4 (4.5 .5 N•m) N•m) to torq rque ue.. Do no nott ov over er tigh tighte ten n cap cap or blow-out blo w-out press pressure ure may de decre creas ase, e, which which may may incre increas ase e nu nuis isanc ance e shutd shutdowns owns.. For al For alll tu tubi bing ng do down wnst stre ream am from from a forc force e feed feed pu pump mp on a pu pump mp ci circ rcui uitt ra rate ted d 55 5500 00 ps psig ig (3 (380 80 barg barg)) or great gre ater er (oran (orange ge,, pi pink nk,, and and blue blue disk disks) s),, that that ci circu rcuit its s with with any any cy cylilind nders ers great greater er th than an 36 3600 00 ps psig ig MAWP MAWP (248 (248 barg) barg),, use use ¼-inc ¼-inch h x 0.06 0.065 5 (6.4 (6.4 x 1.7 1.7 mm) mm) heav heavy y wall wall st stai ainl nles ess s st stee eell hi high gh-pr -pres essu sure re tu tubi bing ng.. Rated Rated tu tubi bing ng pressu pres sures res are calc calcula ulated ted from eq equat uation ions s in ASME/ANSI ASME/ANSI B31.3 B31.3 code code for press pressure ure piping piping,, ba base sed d on maximu max imum m ou outsi tside de di diame ameter ter an and d minimu minimum m wall thi thick cknes ness. s. When When grade grade 316 stainl stainles ess s steel steel tubing tubing is spec specifi ified ed on ne new w compr compres esso sors, rs, Ariel Ariel provid provides es ¼-inch ¼-inch x 0.0 0.065 65 (6.4 x 1.7 mm) tubing tubing regardl regardles ess s of rupture rupture disk dis k or cylin cylinder der rating ratings. s.
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Section 3 - Maintenance
Distribution Blocks Distributio Distribu tion n block blocks s cons consis istt of three three to seve seven n divide div iderr valv valves es and an op optio tiona nall by bypas pass s block block fasten fas tened ed to a segme segmente nted d basepl baseplate ate.. Viton Viton Orin rings gs (90 Durome Duromete ter) r) se seal al betwe between en the the divide div iderr valv valves es and ba base sepla plate te an and d be betwee tween n ba base sepla plate te segme segments nts.. Check Check valv valves es are instal ins talled led at all lube lube po port rt outlet outlets. s. Divide Divi derr valv valves es conta contain in meteri metering ng piston pistons s that that discharg disch arge e a predet predeterm ermine ined d amoun amountt of oil with ea each ch cycle cycle in a single single lin line, e, progre progress ssive ive lubrication system. NOTE: Pistons are matched to a specific divider valve. Do not try to place a
For models JGC:D:F
different piston into a divider valve. Single Singl e or twin twin va valv lves es may may be exte externa rnalllly y singl si ngled ed or cross cross-po -ported rted.. Plug unuse unused d ou outle tlets ts when si singl ngling ing or cross cross-po -portin rting. g. Bypass Bypas s block blocks s can can replac replace e a divide dividerr valve valve secti section on to elimi eliminat nate e the lubric lubricati ation on po point ints. s. Plug Plu g bo both th outle outlets ts be below low the by bypas pass s block block.. A by bypa pass ss block block can can mount mount in an any y ba base sepla plate te lo loca cati tion on,, but but it requi requires res at leas leastt three three workin working g divide div iderr valv valves es in the block block as asse semb mbly ly (i.e. (i.e. by bypa pass ss block blocks s cann cannot ot be us used ed on 3-sec 3-sectio tion n baseplates).
6. Check Valve 1. Piston Intermed iate Blocks 2. Crossport Plat Plate e 7. Intermediate 8. Outlet Outlet Port (correct (correct 3. I Inlet nlet Port position i s off-center 4. IInlet nlet Block toward towar d inlet block) 5. O-Rings
9. End Block 10. Tie Rod Nut 11. Tie Rod 12. Divider Valve 13. Valve Screw
The ba base sepla plate te conta contains ins the di divid vider er valv valve e inlet inlet FIGURE 3-12 Typical Distribution Block and outlet outlet connec connections tions,, interrelate interrelated d pa pass ssag ageway eways, s, and bu built ilt-in -in chec check k valve valves. s. All lubric lubricant ant piping piping to an and d from the distrib distributi ution on block block conn connec ects ts to the ba base sepla plate. te. The basepl baseplate ate cons consist ists s of on one e inlet inlet block block,, thre three e to seve seven n interm intermed ediat iate e block blocks, s, on one e en end d block blo ck,, an and d three three tie rods. rods. The nu numbe mberr of basepl baseplate ate interme intermedia diate te bl bloc ocks ks determ determine ines s the number number of divide divider r valv valves es al allowe lowed. d. Each Each distrib distributi ution on block block req require uires s a minimu minimum m of three three divide dividerr valve valves. s.
Distribution Block Assembly NOTE: See specific frame Parts Book for available divider valve assembly drawings, parts lists, and repair kits. 1. Th Thre read ad th three ree tie tie rods rods into into inle inlett bloc block k unti untill the the en ends ds flus flush h with with th the e to top p su surfa rface ce of th the e bloc block. k. 2. Sl Slid ide e In Inte terme rmedi diat ate e bloc blocks ks onto onto tie tie rods. rods. Verif Verify y all all o-rin o-rings gs are inst instal alle led d an and d di disc scha harge rge po ports rts are of off f cente centerr toward toward the inlet inlet block block.. 3. Slide Slide end end bl bloc ock k onto onto tie tie rod rods. s. 4. La Lay y base base pl plat ate e asse assemb mbly ly on a flat flat su surfa rface ce.. Use"Recom Use "Recommend mendation ations s for Torque Accu Accuracy racy"" to tig tighte hten n th the e ti tie e ro rod d nu nuts ts to th the e corre orrect ct torq torque ue li lis sted ted in TABLE TABLE A-3 A-3.. mendation ations s for Torque 5. Moun Mountt th the e di divi vide derr va valv lves es with with o-rin o-rings gs onto onto the the base base plat plate. e. Use"Recom Use "Recommend Accuracy" Accu racy" to tigh tighte ten n the the ti tie e rod rod nuts nuts to the the corre correc ct torq torque ue list listed ed in TABLE TABLE A-3 A-3..
Page 3-22 of 32
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For models models JGC:D:F JGC:D:F
Secti Section on 3 - Mai Mainte ntena nance nce
Divider Valve Bypass Pressure Test Lubricant Lubric ant can can leak leak (by-pa (by-pass ss)) from a divide dividerr valv valve e when the divide dividerr valve valve piston piston become becomes s worn. Pressu Pressure re test test or re repl plac ace e al alll di divi vide derr va valv lves es every every twelv twelve e mont months hs.. Test Testin ing g ve verif rifie ies s th the e pist piston on fits fits tigh tightl tly y en enou ough gh in th the e divi divide derr va valv lve e bore bore fo forr adeq adequa uate te press pressure ure to forc force e oil oil into into th the e in inje ject ctio ion n po poin int. t. The supplier pressure tests all new Ariel divider valves. To te test st di dist strib ribut utio ion n bl bloc ocks ks for for va valv lve e by-pa by-pass ssin ing g requi requires res a manu manual al pu purge rge gu gun n with with a press pressure ure ga gaug uge e capab capable le of develo developin ping g 5000 5000 ps psig ig (350 (350 ba barg). rg). Ariel Ariel off offers ers an op optio tional nal force force feed feed lu lubric bricati ation on hand hand pu purge rge n 1). Pre Press ssure ure test test ea each ch divi divide derr va valv lve e on one e at a time time,, co comp mple lete te with with gun gun with with a press pressure ure gaug gauge e (see (see Sectio Section pin indicato indicators rs installe installed. d. Distribution Distributi on Blo Block ck A ll Outl Outlets ets Open
Testi Testing ng "T" Divid Divider er Valve Block Block
Testing Testing "S" Divider Divider Valve Block Block
FIGURE 3-13 Pressure Testing Divider Valves 1. For new divid divider er valv valves es,, verify verify working working piston piston sect section ion fasten fastener er torque torque is 75 lblb-in. in. Lo Loos osen en the secti section on fa fast sten eners ers,, th then en st step ep-to -torqu rque e them them first first to 40 lb-in lb-in,, and and th then en to 75 lb lb-in -in.. Used Used di divi vide derr va valv lves es ca can n be tested tes ted “as is”, is”, with approx approxima imate te secti section on fasten fastener er torq torque ue verifi verified ed aft after er testin testing. g. 2. Place Place th the e di dist strib ribut utio ion n bloc block k in an open open co cont ntai aine nerr with with all all ba base se ou outl tlet ets s op open en.. Conne Connect ct pu purge rge gu gun n fill filled ed with wit h room room te temp mpera eratu ture re (65°F) (65°F) 10 wt. (ISO (ISO 32) 32) mine mineral ral oi oill to th the e di divi vide derr bloc block k in inle let. t. Pump Pump th the e pu purge rge gun gun to purge purge ai airr from from the the divi divide derr bloc block k asse assemb mbly ly.. Verif Verify y th that at oi oill flows flows freel freely y from from al alll ou outl tlet ets s (s (see ee FIG FIGURE URE 3-1 3-13 3 “Divi “Divider der Block Block All Outle Outlets ts Open” Open”). ). Te Test stin ing g with with 10 wt. mine mineral ral oil oil at 65°F 65°F si simu mula late tes s divi divide derr bloc block k op opera erati tion on at 12 120° 0°F F with with 40 wt. (ISO 150) 150) mine mineral ral oi oil. l. If 10 wt. mine mineral ral oil oil is unav unavai aila labl ble, e, use use 40 wt. (IS (ISO O 15 150); 0); ho howev wever, er, th the e press pressur ure e te test st will be less less sens sensiti itive ve in de detec tectin ting g a by bypa pass ssin ing g divid divider er valv valve. e. 3. The di divi vide derr bl bloc ock k asse assemb mbly ly sh shou ould ld cy cycl cle e at less less than than 30 300 0 ps psii while while pu purg rgin ing g at a st stea eady dy rate. rate. Cycle Cycle press pre ssure ures s ab abov ove e 30 300 0 ps psii indica indicate te inhibi inhibited ted piston piston move movemen ment, t, po poss ssib ibly ly caus caused ed by the piston piston rubbin rubbing g the bore, bore, oil conta contamin minati ation on,, pa part rt geomet geometry, ry, or bore bore distort distortion ion due to ov over-ti er-tight ghten ening ing the secti section on fastne fas tners. rs. If re-torqu re-torquing ing the valv valve e secti section on fai fails ls to imp improv rove e cycl cycle e press pressure ure,, replac replace e the di divid vider er valv valve e secti section. on. Do not att attem empt pt to alter alter the piston piston/bo /bore re fit by polish polishing ing compo componen nents. ts. 4. For For di divi vide derr valv valves es stamp tamped ed with with a “T” (for (for “twi “twin” n”), ), us use e a 1/ 1/8 8 inc inch pipe pipe or tu tubi bing ng pl plug ug to plug plug on only ly one one base base outl outlet et when when test testin ing g that that si side de of the the pist piston on,, and and le leav ave e al alll ot othe herr ou outl tlet ets s op open en.. Plug Plug an and d te test st ea each ch ba bas se ou outl tlet et of di div vider ider valve alves s stam stampe ped d wi with th a “T “T”” on one e side ide at a time time.. See See FIGURE FIGURE 3-1 3-13 3 “Tes “Testin ting g ‘T’ Divide Divi derr Valve Valve”. ”. Indivi Individua duall tes testin ting g of ea each ch outlet outlet ens ensure ures s bo both th sides sides of the piston piston bu build ild adequ adequate ate press pre ssur ure. e. Fo Forr al alll divi divide derr va valv lves es st stam ampe ped d with with an “S” on th the e front front (for (for “s “sin ingl gle”) e”),, leav leave e th the e on one e side side pl plug ugge ged d and and pl plug ug the the othe otherr outl outlet et as well well to test test both both side sides s of th the e pi pist ston on fo forr by by-pa -pass ssin ing g 3-13 3 “Tes “Testin ting g ‘S’ Divider Divider Valve Valve”. ”. simultaneously. simultane ously. See FIGURE FIGURE 3-1
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Page 3-23 of 32
Section 3 - Maintenance
For models JGC:D:F
5. Pump Pump th the e purge purge gun gun unti untill the the press pressure ure gaug gauge e indi indica cate tes s 30 3000 00 ps psi. i. Hold Hold th this is press pressur ure e fo forr 5 se seco cond nds, s, then then in incr crea ease se it to 3500 3500 psi. psi. Stop Stop pump pumpin ing g at 3500 3500 psi. psi. 6. Start Start time timerr and and moni monito torr the the press pressur ure e drop drop from from 3500 3500 psi psi fo forr 30 se seco cond nds. s. Check Check disc discha harge rge ou outl tlet et(s (s)) pl plug( ug(s) s) to confi confirm rm no ex exter ternal nal leaks leaks.. Als Also o chec check k o-ring o-rings s for ex extern ternal al leaka leakage. ge. If the valv valve e by bypas passe ses s rapi rapidl dly, y, repea repeatt th the e test test to ensu ensure re the the bypa bypass ss wasn’ wasn’tt due due to trapp trapped ed ai air. r. New va valv lves es sh shou ould ld no nott ex exce ceed ed a 400 400 psi psi press pressure ure drop drop in 30 se seco cond nds. s. Used Used va valv lves es sh shou ould ld no nott ex exce ceed ed 10 1000 00 ps psii press pressure ure drop drop in 30 seco seconds nds.. If press pressure ure drops drops ex exce ceed ed these these lim limits its,, the divid divider er valv valve e fai fails ls the test. test. 7. Repea Repeatt Steps Steps 4 th thru ru 6 for for the the rem remai aini ning ng outl outlet ets s on the the divi divide derr bloc block k as asse semb mbly ly.. NOTE: Test distribution blocks at higher pressures if the application dictates higher system operating pressure pr essure.. If a di divi vide derr va valv lve e fa failils, s, repla replace ce it. it. Disca Discard rd worn divi divide derr va valv lves es.. If th the e te test sted ed va valv lve e pa pass sses es th the e te test st,, relie relieve ve the the press pressur ure, e, move move th the e plug plug to the the next next outl outlet et,, and and rep repea eatt the the te test st fo forr all all di divi vide derr valv valves es.. When When all all divi divide der r va valv lves es ei eith ther er pass pass th this is press pressure ure test test or are repl replac aced ed,, reass reassem embl ble e th the e dist distrib ribut utio ion n bl bloc ock, k, purge purge it with with th the e prope pro perr fo forc rce e fe feed ed lu lubri brica cant nt,, and and put put it into into se serv rvic ice. e. This Thi s distrib distributi ution on bl bloc ock k press pressure ure test test procedu procedure re is not infall infallib ible. le. Arie Ariell recomm recommend ends s pe period riodic ic tests tests for prope proper r
cylin cylinde derr bore bore lubric lubricati ation on rates rates and/or and/or aft afterm ermark arket et de devi vice ces s that that meas measure ure flo flow. w.
Balance Valves Installl ba Instal balan lance ce valv valves es on low-pres low-pressu sure re lube lube lines lines to artific artificial ially ly in incre creas ase e lu lube be lin line e press pressure ure an and d reduc reduce e differe differenti ntial al press pressure ure between between lube lube po point ints s downstr downstream eam of a divide dividerr block block.. Importa Important nt cons consid iderat eratio ions ns:: • Set and and main mainta tain in bala balanc nce e va valv lves es downs downstre tream am of a divi divide derr bl bloc ock k wit withi hin n 50 500 0 ps psii (3400 (3400kP kPa) a) of ea each ch ot othe her r or le less ss.. Th The e cl clos oser er th the e bala balanc nce e va valv lve e se sett pres pressu sures res,, the the more more relia reliabl ble e th the e sy syst stem em.. • Avoi Avoid d si situ tuat atio ions ns in which which the the bala balanc nce e va valv lve e se sett press pressur ure e is th the e great greates estt co cont ntrib ribut utor or of press pressure ure to th the e divider divi der block block immediate immediately ly upstream upstream.. • With a ba balan lance ced d divid divider er block block,, the up upstre stream am divid divider er block block pre press ssure ure ga gauge uge shou should ld ex exhib hibit it no erratic erratic needle nee dle movem movement ent as the divide dividerr bl bloc ock k cycl cycles es.. To mai mainta ntain in the force force feed feed lube lube syst system, em, record record the maxim maximum um injec injectio tion n press pressure ure indica indicated ted at ea each ch di divid vider er bl bloc ock k gaug gauge, e, bala balanc nce e va valv lve e se sett press pressur ures es,, and and divi divide derr bloc block k cy cycl cle e time time at le leas astt on once ce a da day y fo forr ea each ch zo zone ne in the the sy syst stem em.. See See Appendix Appendix E. Do not not adju adjust st bala balanc nce e va valv lves es prior prior to opera operati ting ng the the unit unit.. Verif Verify y th the e tigh tightn tnes ess s of al alll fitt fittin ings gs an and d fix fix an any y kn known own le leak aks. s. To remov remove e any any trapp trapped ed air air or gas gas in the the force force fe feed ed lu lube be sy syst stem em,, us use e a high high-p -pres ressu sure re ha hand nd purge purge pump pump and and th the e sa same me oil oil recom recomme mend nded ed for for the the cy cylilind nder er ap appl plic icat atio ion n to pu purge rge it. it. DO NOT USE ANY OTHER OT HER FL FLUIDS UIDS FOR FOR PURGING PURGING!! Call Call the the Ariel Ariel Respo Respons nse e Cente Centerr fo forr de deta tailils s ab abou outt pu purch rchas asin ing g a ha hand nd pu purge rge pu pump. mp. To prepar prepare e for ba balan lance ce valv valve e ad adjus justme tment: nt: 1. Start Start the comp compres resso sorr an and d bri bring ng the cylin cylinder ders s up to no norma rmall operati operating ng pressu pressure. re. 2. Allow operating operating pressures pressures to stab stabiliz ilize. e. 3. See See th the e cy cylilind nder er lu lube be sh shee eets ts for for bala balanc nce e va valv lve e loca locati tion ons s an and d pro prope perr sp sprin ring g ty type pe fo forr ea each ch de devi vice ce..
Page 3-24 of 32
REV: 10/14
For models models JGC:D:F JGC:D:F
Secti Section on 3 - Mai Mainte ntena nance nce
Adjustment of Balance Valves Fed by a Divider Block 1. Se Sele lect ct one one di divi vide derr bloc block k that that feed feeds s one one or mo more re balance bala nce valves valves nearest nearest the compress compressor or cylinder/packing. 2. Fo Forr each each bala balanc nce e va valv lve e downs downstre tream am of the the selec selected ted di divid vider er block block,, loo loose sen n the balanc balance e valv valve e lock loc k nu nutt an and d rotate rotate the adjus adjustme tment nt cap cap count counterercl cloc ockwis kwise e un until til the cap cap is loose loose.. Some Some resid residual ual press pre ssure ure may remain remain on the ba balan lance ce valv valve e ga gauge uge.. 3. Monito Monitorr the selec selected ted di divid vider er blo block ck gau gauge ge for one minute min ute and record record the minimu minimum m an and d maxim maximum um pressures in pressures in Appen Appendix dix E. 4. Calcula Calculate te the balanc balance e valve valve set set press pressure ure by multip mul tiply lying ing the maximu maximum m record recorded ed press pressure ure by
1. Balance Valve
4. Lock Nut
2. Balance Valve Pressure Gauge 3. Adjustment Adjustment Cap
5. Pressure Divider Block Gauge 6. Divider Block
0.85.
FIGURE 3 14 Balance Valves Fed by Divider Block
5. Se Sett balanc balance e valv valve(s e(s)) down downst stream ream of the selec selected ted di divi vide derr bl bloc ock k to the the press pressure ure ca calc lcul ulat ated ed in st step ep 4 by rotat rotatin ing g th the e ad adju just stme ment nt ca cap p cloc clockwi kwise se to incre increas ase e press pre ssure ure.. Set pressu pressure re within within ±50 ps psii of the calc calcula ulated ted value value.. 6. Moni Monito torr th the e di divi vide derr bloc block k gaug gauge e for for one one minu minute te and and record record th the e mini minimu mum m an and d maxi maximu mum m pr pres essu sures res in Appen Appendix dix E. Th The e diff differe erenc nce e betwe between en the the mini minimu mum m and and maxi maximu mum m sh shou ould ld no nott ex exce ceed ed 12 1200 00 ps psig ig.. If it does does,, repea repeatt st step eps s 2 throu through gh 6. 7. Tigh Tighte ten n th the e bala balanc nce e va valv lve e lock lock nut. nut. DO NOT lock lockwire wire th the e ad adju just stme ment nt ca cap. p. 8. Repeat Repeat st step eps s 2 throu through gh 7 for for any any remai remaini ning ng divi divide derr bloc block k th that at fe feed eds s on one e or more more ba bala lanc nce e va valv lves es nearest the compress nearest compressor or cylinde cylinder/pac r/packing king.. 9. After After se sett ttin ing g al alll bala balanc nce e va valv lves es in the the forc force e feed feed sy syst stem em,, op opera erate te th the e sy syst stem em fo forr 4 to 6 ho hours urs,, th then en repea rep eatt st step ep 6 fo forr each each divi divide derr bloc block. k.
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Page 3-25 of 32
Section 3 - Maintenance
For models JGC:D:F
Adjustment of Balance Valves Fed by Primary/Secondary Divider Blocks NOTE: Set secondary balance valves before setting primary balance valves. If the system contains no secondary balance valves downstream of a secondary divider block, proceed to step 4. 1. Sele Select ct one seco seconda ndary ry divide dividerr bl bloc ock k that that feeds fee ds on one e or more more seco seconda ndary ry ba balan lance ce valves val ves nearest nearest the compress compressor or cylinder/packing. 2. For the selec selected ted seco seconda ndary ry divide dividerr block block and seconda secondary ry balance balance valves, valves, perform perform nt of ste teps ps 2 th thro roug ugh h 7 in "Adjustme "Adjustment Bala Ba lanc nce e Va Valv lves es Fe Fed d by a Div Divid ider er Blo Block ck""
above. 3. Repea Repeatt st step eps s 1 and and 2 for for any any rem remai aini ning ng seco seconda ndary ry divide dividerr bl bloc ocks ks that that feed feed on one e or mor more e seco second ndary ary balanc balance e valv valves es nearest nea rest the compress compressor or cylinder/packing. 4. Selec Selectt one primary primary divide dividerr block block tha thatt feed feeds s one one or more more prima primary ry bala balanc nce e valve valves s locate located d pri prior or to a seco seconda ndary ry di divid vider er block block or lu lube be point. point. 5. For the selec selected ted primary primary divide dividerr block block an and d ba balan lance ce valv valves es,, perform perform steps steps 2 "Adjustme stment nt of Balan Balance ce throu through gh 7 in "Adju Valv Va lves es Fe Fed d by a Div Divid ider er Blo Block ck"" above.
1. Primary Balance 5. Primary Divider 8. Secondary Divider Block Block Pressure Valve Gauge 9. Secondary 2. Primary Balance Balance Valve 6. Primary Divider Valve Pressure Block 10. Secondary Gauge Balance Valve 3. Adjustment Adjustment Cap 7. Secondary Pressure 4. Lock Nut Divider Gauge Block Pressure Gauge
FIGURE 3-15 Primary/Secondary Divider Block System
6. Re Repe peat at st step eps s 4 and and 5 for for any any remai remaini ning ng prima primary ry divi divide derr bloc block k th that at fe feed eds s on one e or more more ba bala lanc nce e va valv lves es lo loca cate ted d prior prior to a se seco cond ndary ary divi divide derr bloc block k or lube lube poin point. t. 7. After After se setti tting ng al alll bala balanc nce e va valv lves es in the the forc force e feed feed sy syst stem em,, op opera erate te th the e sy syst stem em fo forr 4 to 6 ho hours urs,, th then en repe repeat at st step eps s 3 th throu rough gh 7 in "Adju "Adjust stme ment nt of Ba Bala lanc nce e Va Valv lves es Fe Fed d by a Div Divid ider er Blo Block ck"" ab abov ove e for ea each ch pri primar mary y or seco second ndary ary divide dividerr block block..
Subsequent Compressor C ompressor Start-Up Start-Up 1. Verif Verify y tigh tightn tnes ess s of al alll fitt fittin ings gs and and fix fix any any kn known own leak leaks. s. Purge Purge fo force rce fe feed ed lube lube sy syst stem em.. the e fo forc rce e fe feed ed lu lube be sy syst stem em has has been been disa disass ssem embl bled ed or pa parts rts repla replace ced d sinc since e th the e la last st st start artup up,, pu purge rge 2. If th the the fo forc rce e fe feed ed lu lube be sy syst stem em with with a high high-pr -pres essu sure re hand hand purge purge pu pump mp.. When When pu purgi rging ng th the e sy syst stem em,, us use e th the e sa same me oi oill th that at is re reco comm mmen ende ded d for for the the cy cylilind nder er appl applic icat atio ion, n, to remov remove e an any y trapp trapped ed air air or ga gas s in th the e sy syst stem em.. DO NOT USE ANY OTHER OTHER FLUIDS FLUIDS FOR FOR PURGING PURGING!! Call Call th the e Ariel Ariel Respo Respons nse e Cente Centerr fo for r de detai tails ls ab about out purch purchas asing ing a ha hand nd pu purge rge pump. pump. 3. Start Start the comp compres resso sorr an and d bri bring ng up to normal normal operati operating ng press pressure ure..
Page 3-26 of 32
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For models models JGC:D:F JGC:D:F 4. Ope pera rate te th the e un unit it for for 2 to 3 ho hour urs s to allo allow w the the operati ope rating ng press pressure ures s to stabil stabilize ize.. DO NOT adjust adju st the balancin balancing g valves valves immediat immediately ely after start st artup up.. It is poss possib ible le that that so some me lube lube poin pointt injec injectio tion n press pressure ures s will flu fluctu ctuate ate aft after er a short short perio period d of run time time and and the the sy syst stem em press pressure ures s will stabil stabiliz ize e as compo compone nents nts increa increase se in temperature. cylinder der lube lube shee sheets ts for ba balan lance ce valv valve e 5. See the cylin locati loc ation ons s and proper proper spring spring type type for ea each ch device.
Secti Section on 3 - Mai Mainte ntena nance nce
TABLE 3-6 Ariel Balance Valve Part Numbers Des De script iption ion
Ar Arie iell Part Numb Numbe er
Ba Bala lan nce Valv Valve e with witho out Spr Sprin ing g
CACA-8005
BalanceVa ceVallveSp veSprrings
See ER-5 R-57.1
Ba Bala lan nce Valv Valve e Sea Seal Rep RepairKit
A-8 A-8005-K
Balance V Va alve P Pllug
A-10330
Pressure G Ga auges
See E R R--57.1
6. Selec Selectt one one di divi vide derr bloc block k that that feed feeds s one one or more more bala balanc nce e va valv lves es.. 7. pressures Moni Monito tor r th the ein se sele lect cted ed divi divide block k gaug gauge e for for one one minu minute te an and d rec record ord th the e mini minimu mum m an and d maxi maximu mum m press ures in Appen Appendix dix Eder . r bloc 8. See"Bala See "Balance nce Valve Valves" s" if any of the cond conditi ition ons s below below oc occu cur: r:
a. The differe differenc nce e be betwee tween n the maximu maximum m an and d minimu minimum m record recorded ed di divid vider er block block press pressure ures s ex exce ceed eds s 1200 psig. psig. b. The maxim maximum um record recorded ed ba balan lance ce valv valve e press pressure ure ex exce ceed eds s 85% of the maximu maximum m record recorded ed divid divider er block bloc k pressure. pressure. c. The divide dividerr bl bloc ock k ga gaug uge e ex exhib hibits its erratic erratic ne needl edle e moveme movement nt as the divide dividerr block block cy cycl cles es.. DO NOT RUN UNIT WITH LEAKING BALANCE VALVES. Ariel VALVES. Ariel offers a balance balance valve valve seal seal repair repair kit - Part No. A-8005-K. A-8005-K . To mainta maintain in the force force feed feed lube lube syste system, m, record record max maximu imum m in injec jectio tion n press pressure ure in indic dicate ated d at the divide dividerr block block gaug gauge, e, bala balanc nce e va valv lve e se sett press pressure ure,, and and divi divide derr bloc block k cy cycl cle e time time at le leas astt on once ce a da day y fo forr ea each ch zo zone ne in th the e lube system. system.
Force For ce Feed System Design Design & Oper Operatin ating g Parameters Parameters To op optim timize ize force force-fee -feed d lubric lubricati ation on syst system em operati operation on,, Ariel Ariel us uses es these these ge genera nerall gu guide idelin lines es:: 1. M Main aintai tain n lube lube ratios ratios within within presc prescrib ribed ed limits limits and cycl cycle e times times as low as po poss ssib ible le (norma (normally lly 10 sec sec minimu min imum) m) to lubric lubricate ate ea each ch po point int as frequen frequently tly as possi possible ble.. 2. Multip Multiple le pu pumps mps with manifo manifoldi lding ng ensure ensure 15 150% 0% of the no normal rmal lubric lubricati ation on rate during during break break-in -in.. 3. Do not not opera operate te pump pumps s belo below w 20% 20% of full full st strok roke e or they they be beco come me in inco cons nsis iste tent nt.. Fu Fullll st strok roke e is 0. 0.43 438 8 in inch ch;; 20% 20% of fu fullll st strok roke e is 0.08 0.088 8 inch inch.. 4. In some some ap appli plica catio tions ns,, a si singl ngle e divid divider er secti section on deliv delivers ers lu lubric bricati ation on to both both a packi packing ng an and d a cy cylin linde derr to optimi opt imize lu lubric bricati ation sy m nt op opera eratio n.nInpoin some soint. me appli plica catio tions ns,, cross cross-po -ported rted divide dividerr valv valves es delive deliverr the pro prope perrze propo pro porti rtion onon ofsyste lubri lustem brica cant to a tion. give given po t. ap
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Page 3-27 of 32
Section 3 - Maintenance
For models JGC:D:F
5. During During op opera eratio tion, n, verify verify oi oill fil fills ls the lubric lubricato atorr res reserv ervoi oirr si sigh ghtt glass glass TABLE 3-7 Force Feed Lubricator Reservoir Oil at le leas astt half half way, way, but but does does not not exce exceed ed two-th two-third irds. s. Se See e sp spec ecif ific ic pa pack ckage agerr data data to determ determine ine no norma rmall op opera eratin ting g cond conditi itions ons,, cy cylin linde der r Capacity working work ing pressu pressures res,, and rated rated speed speed.. Reservo Reservoir ir oil lub lubric ricate ates s the Lubricator Type US Gallons worm wor m gear gear and and ca cam; m; it does does not not flow flow throu through gh the the sy syst stem em.. Th The e Ariel Designs (Liters) rese reservo rvoir ir al also so ca catc tche hes s lube lube pump pump over overfl flow. ow. Add Add oil oil only only if ne need eded ed to raise raise reserv reservoi oirr oi oill leve level. l. See TABLE TABLE 3-7 3-7.. Single Pump 0.25 (1) 6. Ariel Ariel fill fills s th the e fo forc rce e feed feed sy syst stem em with with mine mineral ral oil. oil. If tubi tubing ng is miss missin ing, g, or if th the e sy syst stem em is drai draine ned, d, fill fill and and prime prime the the sy syst stem em throu through gh a 1/ 1/8 8 in inch ch pl plug ug on the the disc discha harge rge end end of the the lubri lubrica cato tor r pump.
Dual Pump
0.5 (1.75)
Four Pu P ump
0.8 (3 (3)
7. Prime Prime th the e fo forc rce e fe feed ed lubri lubrica cati tion on sy syst stem em with with a prope properr primi priming ng pu pump mp ju just st prior prior to st start artin ing g th the e com compress pressor ored (see Sec Sectio tion n Do 1 for fono r pump pu mp ilillu lust rati tion on). ).uid Use cl clea ean fo forc rce e to fe feed ed lubri lue. brica cati ting ng oil oil of sa same me ty type pe an and d grad grade e as us used in serv se rvic ice. e. not t us use e an any ystra othe ot her r fl flui d ty type pe orngr grad ade e pr prim ime. 8. For recent recently ly ov overh erhau auled led un units its,, adjus adjustt lubric lubricato atorr for maximu maximum m delive delivery. ry. Lo Loos osen en adjus adjustin ting g sc screw rew
lock locknu nut. t. Turn plunge plungerr stroke stroke adjus adjustme tment nt screw screw to the ful fulll up po posi sitio tion. n. Tighte Tighten n ad adjus justin ting g sc screw rew locknut locknut.. Sett prope Se properr fe feed ed rate rate afte afterr the the mach machin ine e st start arts. s. 9. When When two or more more pump pumps s are are mani manifo fold lded ed to feed feed one one dist distrib ribut utio ion n bl bloc ock, k, ad adju just st th them em eq equa ualllly. y. Start Start with wit h pump pumps s wide wide open open,, and and adju adjust st them them toge togeth ther er so that that whe when n br brea eakk-in in cy cycl cle e time time is se set, t, th the e pu pump mps s strok st roke e abou aboutt th the e sa same me.. After After bre break ak-in -in perio period, d, adju adjust st the the pu pump mps s in th the e sa same me mann manner, er, provi provide ded d th the e fina finall pump pump st strok roke e is not not too too sh short ort.. Try to ke keep ep the the st strok roke e grea greate terr th than an 20 20% % of maxi maximu mum; m; a sh shor orte terr st strok roke e pr prod oduc uces es unrel unrelia iabl ble e pump pump outp output ut.. If need needed ed,, cl clos ose e one one pump pump to st stop op its its flow flow an and d op open en th the e ot othe her(s r(s)) to make ma ke th the e “norma “normal” l” cy cycl cle e time time,, and and main mainta tain in a st strok roke e great greater er th than an 20 20% % in th the e fu func ncti tion onin ing g pu pump mp(s (s). ).
Common Oil Supply FIGURE 3-16 6 sh shows ows th the e forc force e feed feed lube lube sy syst stem em inst instal alla lati tion on when when co comp mpres resso sorr frame frame lube lube oi oill is also also us used ed FIGURE 3-1 for cylin cylinder der an and d packin packing g lubric lubricati ation. on.
Page 3-28 of 32
REV: 10/14
For models models JGC:D:F JGC:D:F
1. Frame Oil G Gallery allery 2. Single Ball Check Valve 3. Sintered B Bronze ronze Filt Filter er 4. Force Feed Lubricat Lubricator or Pump 5. Rupture Disk 6. Pressure Gauge 7. Divider Valves/ Valves/Distribut Distribution ion Block 8. Fluid Flow M Monitor onitor No-F No-Flow low Timer Shutdown Switch 9. Double Ball Check Valve 10. Top Cylinder Injection Point 11. Bott Bottom om Cylin der Injection Injection Point 12. Packing Injection Point
Secti Section on 3 - Mai Mainte ntena nance nce
FIGURE 3-16 Force Feed Lubrication System Common Oil Supply
Independent Oil Supply
When cylin When cylinde ders rs and packi packing ng requir require e oil oil di diff ffere erent nt from from frame frame oil, oil, the the forc force e feed fee d lubric lubricato atorr syste system m requir requires es an indepe ind epende ndent nt oi oill supp supply ly syste system m (see (see FIGURE 3FIGURE 3-17 17). ). An el elev evat ated ed tank tank supplies supp lies pressurize pressurized d lubricato lubricatorr oil.
To preve prevent nt fo force rce fe feed ed oil oil from from contamin cont aminatin ating g compress compressor or frame oil, disconn disc onnect ect lubricato lubricatorr box ove overflow rflow tubing tub ing from the compre compress ssor or frame frame an and d direc directt it to an appro appropri priat ate e drain drain system.
1. Oil S Supply upply Tank 2. Oil Filter 3. Syst System em Inlet 1/4-inch NPT (female) (fem ale) custom customer er connection 4. Sintered Bronze F Filter ilter 5. Force F Feed eed Lubricator Pump 6. Blow-Out Blow-Out Disc 7. Pressure Gauge 8. Divider Valves Dist Distribution ribution Block 9. Fluid F Flow low Monitor No-F No-Flow low Timer Shutdown Switch
Independ Indep endent ent force force feed feed lube lube syste systems ms require requ ire oil with a visc viscos osity ity below below 11 1100 00 cS cStt at th the e lu lubri brica cato torr pump pump inle inlet. t. Possi Pos sible ble measu measures res to ensure ensure the force force feed feed pu pump mp is fe fed d with with oil oil du duri ring ng the the suction suc tion stroke: stroke: • Increa Increase se pipe pipe and fit fittin ting g si size ze from ta tank nk to fo forc rce e fe feed ed pump pump.. • Heat Heat th the e oi oil. l. • Pressu Pressuriz rize e the suppl supply y tank. tank.
FIGURE 3-17 Force Feed Lubrication System Independent Oil Supply
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1/4-inch NPT (femal 1/4-inch (female) e) overflow. overflow. Pip Pipe e or tubet o app approp ropria riate te isolatedc isolatedc ustomerc onn onnection ection.. Do not dra drain in to crank case.
Page 3-29 of 32
Section 3 - Maintenance
For models JGC:D:F
Force For ce Feed Lubrication Lubrication Conditi Conditions ons CAUTION: To prevent personal injury, verify driver or compressor cylinder gas pressure cannot turn compressor crankshaft during maintenance: on engine-driven compressors, either remove the center coupling or lock the flywheel; on electric motor-driven compressors, either detach the driver from the compressor or lock out the driver switch gear. Before any maintenance or component removal, relieve all pressure from compressor cylinders. See Packager’s instructions to completely vent the system. After maintenance, purge the entire system with gas prior to operation to avoid a potentially explosive air/gas mixture.
Lubricator Lubricat or Cycle Time T ime
Lu Lubric brican antt flo flow w rates rates are measu measured red in seco seconds nds per cycl cycle e of the distrib distributi ution on block block.. The calc calcula ulated ted break break-in -in and and norma normall cy cycl cle e time times s are st stam ampe ped d on the the lubri lubrica cato torr box box data data pl plat ate. e. Th Thes ese e cy cycl cle e time times s ar are e ca calc lcul ulat ated ed ba base sed d on the gas an analy alysi sis, s, operati operating ng cond conditi itions ons,, and applie applied d spee speed d spec specifi ified ed in the comp compres resso sorr order. order. If ga gas s cond conditi itions ons were not suppl supplied ied with the compre compress ssor or order, order, the data data pl plate ate/lu /lube be shee sheett rates rates defau default lt to clea cl ean, n, dr dry, y, 0. 0.65 65 sp spec ecif ific ic gravi gravity ty,, sweet sweet gas gas and and cy cylilind nder er MAW MAWP. P. If th the e ap appl plie ied d sp spee eed d is no nott sp spec ecif ifie ied, d, th the e cy cycl cle e time time is base based d on maxi maximu mum m rated rated sp spee eed d of the the fra frame me or cy cylilind nders ers,, which whichev ever er is less less.. Th The e lu lube be sh shee eets ts in the the Ariel Ariel Parts Parts Book Book st stat ate e gas gas co cond ndit itio ions ns and and lilist st the the base base rate rate mult multip iplilier er at ea each ch lu lube be po poin int. t. Break-in Rate - Set Set th the e break break-in -in lube lube rate rate abou aboutt twice twice the the recom recomme mend nded ed da dailily y rate rate (150% (150% mini minimu mum); m); i.e. i.e. se sett the the br brea eakk-in in cy cycl cle e time time abou aboutt half half the the norma normall cy cycl cle e time time (67% (67% max. max.)) to incr increa ease se lube lube rate. rate. Main Mainta tain in break bre ak-in -in rate for 200 hours hours of op opera eratio tion n for ne new w equipm equipment ent,, or when replac replacing ing pa pack cking ing and/or and/or pi pisto ston n rin rings gs.. Contac Contactt Ariel Ariel if ex exis istin ting g pu pump mp is incap incapabl able e of minimu minimum m flo flow w rate require required. d. Lube Rate and Speed - Rec Recom omme mend nded ed lube lube rat rates es for for break break-in -in or no norma rmall op opera erati tion on,, in se seco cond nds s pe per r cy cycl cle, e, are ca calc lcul ulat ated ed at the the frame frame rate rated d sp spee eed d (RPM) (RPM) st stam ampe ped d on th the e frame frame da data ta pl plat ate e or th the e cy cylilind nder er rated rat ed RPM st stam ampe ped d on the the cy cylilind nder er data data plat plate, e, which whichev ever er is lo lower wer.. Lu Lube be ra rate te reduc reduces es with with sp spee eed, d, (as comp compres resso sorr ac actua tuall runnin running g speed speed de decre creas ases es,, cycle cycle time time increa increase ses s to reduc reduce e lube lube rate): rate): (RPMmax ÷ RPM RPMactual) x cy cycl cle e time time se seco cond nds s from from lube lube plat plate e = cy cycl cle e time time se seco cond nds s at ac actu tual al runni running ng sp spee eed. d. Or se see e th the e Ariel Ariel Parts Parts Book Book Lubr Lubric icat atio ion n Shee Sheets ts for for the the Cycle Cycle Time Time (seco (second nds) s) vs vs.. RPM (comp (compres resso sor r spee speed) d) table table at variou various s runnin running g speed speeds s at stated stated gas op opera eratin ting g cond conditi ition ons s and lubric lubricant ant.. Adjusting the cycle Adjusting cycle time changes changes the lubricati lubrication on rate for all the compress compressor or cylinde cylinders rs and packin packings gs su supp pplilied ed by a parti particu cula larr pump pump.. To ch chan ange ge the the lubri lubrica cati tion on rate rate fo forr on only ly on one e cy cylilind nder er or pa pack ckin ing g requi requires res indiv ind ividu idual al di divid vider er valve valve chang changes es.. Contac Contactt your your pa pack ckag ager er or Ariel Ariel for inform informati ation. on. To se sett prope properr fo forc rce-f e-fee eed d lubri lubrica cato torr pump pump flow flow rate, rate, rea read d or me meas asure ure th the e cy cycl cle e time time from from th the e in inst stal alle led d de devic vice. e. For a magne magnetic tic cycl cycle e indic indicato atorr as asse semb mbly ly,, time time the cycle cycle from initia initiall ind indic icato atorr pin movem movement ent at the full fully y retrac retracte ted d posi positi tion on to the the time time when when the the pin pin return returns s to the the fu fulllly y retrac retracte ted d po posi siti tion on an and d just just be begi gins ns init initia iall move mo vemen mentt ou outt ag again ain.. Adjus Adjustt the lubric lubricato atorr pu pump mp to provi provide de the require required d cy cycle cle time. time. NOTE: Pump output can become inconsistent if the flow rate is set too low. Changes in operati Changes operating ng cond conditi itions ons (such (such as gas proper propertie ties s or press pressure ures, s, tempera temperature tures, s, flo flow w requi requireme rements nts,, or cyl cylinde inderr re-configura re-configuration) tion) require require lubri lubricati cation on rate re-calcul re-calculatio ation n and possibl possible e force-feed force-feed lubricati lubrication on syste system m altera alteratio tion. n. Consult Consult the Ariel Ariel Packa Package gerr Standa Standards rds,, the Packa Package ger, r, an and/o d/orr Ariel. Ariel.
Page 3-30 of 32
REV: 10/14
For models models JGC:D:F JGC:D:F
Secti Section on 3 - Mai Mainte ntena nance nce
Under/Over Lube Under lubric Under lubricati ation on caus causes es ex extrem tremely ely rapid rapid break breakdo down wn of piston piston and pa pack ckin ing g ring materi materials als.. Black Black,, gu gummy mmy depos dep osits its in the distan distance ce pie piece ce,, pa pack cking ing case case,, cylin cylinder der,, an and d valv valves es indic indicate ate under under lubric lubricati ation. on. When When symptom sym ptoms s indicate indicate under under lubri lubricati cation: on: • Verify Verify prope properr op opera eratio tion n of force force feed feed lubric lubricato atorr pum pumps ps.. • Confirm Confirm distrib distributi ution on block block cycl cycle e time time match matches es the lube lube sheet sheet or force force feed feed lu lubric bricato atorr data data pl plate ate.. • Verif Verify y all tubing tubing an and d fit fittin ting g tig tightn htnes ess; s; chec check k for lea leaka kage ge.. Check Check fittin fittings gs inside inside cy cylin linder der ga gas s pa pass ssage ages. s. • Press Pressure ure te test st or repla replace ce divi divide derr va valv lves es to ensu ensure re they they do no nott by bypa pass ss.. Over lu Over lubri brica cati tion on ca can n resul resultt in exce excess ssiv ive e oil oil ca carry rryov over er into into th the e ga gas s st strea ream, m, an and d in incr crea ease sed d va valv lve e an and d ga gas s passa pas sage ge depos deposits its.. Valve Valve plate plate break breakag age e an and d pa pack cking ing fai failure lure may may also also in indic dicate ate ov over-l er-lub ubric ricati ation. on.
Cylinder Lubrication Paper Test
1. Remov Remove e head head end end head head and and posi positi tion on pist piston on for for the the desi desired red cy cylilind nder er at in inne nerr de dead ad ce cent nter. er. 2. Using Using ligh lightt press pressure ure,, wipe wipe the the cy cylilind nder er bore bore wit with h two laye layers rs of regul regular ar un unwax waxed ed ciga cigaret rette te pa pape per r to toge geth ther. er. Begi Begin n at the the top top and and wipe wipe downwa downward rd abou aboutt 20 20°° alon along g th the e bo bore re circu circumf mfere erenc nce. e. Th The e pa pape per r agai agains nstt th the e bore bore su surfa rface ce sh shou ould ld be st stai aine ned d (wette (wetted d with with oi oil), l), bu butt th the e se seco cond nd pa pape perr shou should ld no nott be soaked soa ked through. through. 3. Repe Repeat at th the e te test st at both both sides ides of the the bo bore re at ab abou outt 90° 90° fr from om th the e to top, p, us usin ing g two cl clea ean n pa pape pers rs fo forr ea eac ch si side. de. Paper Paper ag again ainst st the bo bore re surfac surface e no nott staine stained d throug through h may indic indicate ate under-l under-lub ubric ricati ation; on; both both pa paper pers s staine sta ined d through through may indic indicate ate ov over-lu er-lubri brica catio tion. n. In eithe eitherr case case,, Arie Ariell no norma rmally lly recomm recommend ends s chan changin ging g lubric lub ricati ation on rate ac acco cordi rding ngly ly and repeati repeating ng al alll pa pape perr tests tests until until passe passed. d. 4. Repea Repeatt th this is pr proc oced edure ure for for all all cy cylilind nders ers.. If the the test test indi indica cate tes s a lubri lubrica cati tion on rate rate reduc reducti tion on or in incr crea ease se fo for r a cy cylilind nder, er, ch chan ange ge in 5% incr increm emen ents ts by adju adjust stin ing g cy cycl cle e time time at th the e fo forc rce e fe feed ed lube lube pu pump mp (s (see ee “Pump Adjustmen Adjus tment” t” on page 3-20 3-20). ). Rep Repea eatt oil oil film film test testin ing, g, for for af affe fect cted ed cy cylilind nder ers, s, af afte terr 24 ho hours urs of op oper erat atio ion. n. NOTE: The paper test indicates only oil film quantity. Aftermarket devices exist that measure flow. Neither method indicates viscosity quality. Oils diluted with water, hydrocarbons, or other constituents may ostensibly produce an adequate film or flow, but dilution may reduce load-carrying load-ca rrying capability capability below requirements.
REV: 10/14
Page 3-31 of 32
Section 3 - Maintenance
For models JGC:D:F
Coolant System Requirements Coola Coo lant nt flow flow = numb number er of pack packin ing g ca case ses s x 1 US gall gallon on per per minu minute te (gpm), (gpm), mini minimu mum m for for each each inch inch of pi pist ston on ro rod d di diam amet eter er (No. ca case ses s x 0.14 0.149 9 l/mi l/min n for for each each mm of pi pist ston on ro rod d di diam amet eter) er).. Based Based on usin using ga solut solution ion of 50/50 50/50 treated treated water/gl water/glyc ycol ol solu solutio tion. n. See FIGURE 3-1 FIGURE 3-18 8. Exam Exampl ple: e: JGK/2 JGK/2 with with 2. 2.0 0 inch inch (50.8 (50.8 mm mm)) diam diamet eter er piston pis ton rod. 2 pa pack ckin ing g case cases s x 1 gp gpm m pe perr inch inch of rod rod diam diamet eter er x 2. 2.0 0 inch inch rod di diam amet eter er = 4 gpm gpm (2 pa pac cki king ng cas ases es x 0. 0.14 149 9 l/ l/mi min n per per mm of rod rod di diam amet eter er x 50.8 50.8 mm rod diam diamet eter er = 15. 15.2 2 l/mi l/min) n)
1. Packing Case 2. Throt Throttling tling Valve Valve 3. Isolat Isolation ion Valve 4. Surge Tank 5. Strainer
Coolerr si Coole size ze numb number er of ca case ses s x 70 6. Water Pump Pressure essure Indicat Indicator or BTU/minu BTU/m inute/ te/inc inch h of rod diamet diameter er (numb (number er of case cases s PI = Pr 7. Cooler TI = Temperature Temperature Indicator x 0. 0.05 05 kW/m kW/mm m of rod di diam amet eter) er).. The The press pressur ure e drop drop FI = Flow Flow Indicator 8. Thermostatic acros across s each each ca case se must must exce exceed ed 30 psi psi (2.1 (2.1 bar). bar). LG = Level Gauge Valve Coola Coo lant nt in into to th the e pack packin ing g must must not not exce exceed ed 130°F 130°F FIGURE 3-18 Typical Packing Cooling System maxim ma ximum um (54°C (54°C max.). max.). Lower Lower coola coolant nt tempe temperatu rature re increas inc reases es he heat at transfe transferr to the coola coolant nt and is better better in hig high-p h-pres ressu sure re ap appli plica catio tions ns..
Page 3-32 of 32
REV: 10/14
Section 4 Part Replacement Major frame Major frame as asse sembl mbly y comp compone onents nts includ include e the crank crankca case se,, crank cranksh shaft aft and bearing bearings, s, conn connec ectin ting g rods, rods, chain chain drive drive syste system, m, cross crosshe heads ads an and d gu guide ides, s, an and d distan distance ce pi piec eces es.. Remova Removable ble en end d cove covers, rs, an alumin aluminum um top cove cover, r, and cross crosshea head d gu guide ide si side de cove covers rs provi provide de easy easy ac acce cess ss to intern internal al compo componen nents. ts. Part replac replaceme ement nt requir requires es ab abso solut lute e cl clean eanlin lines ess; s; us use e lint-fre lint-free e wiping wiping cloths cloths.. When When not working working on a frame frame with ac acce cess ss cove covers rs rem remov oved ed,, cove coverr it to protec protectt the interi interior or from du dust. st. Protec Protectt remove removed d compo componen nents ts from corros corrosion ion an and d fal fallin ling g ob objec jects ts that that might might mar or chip chip runnin running g surfac surfaces es.. When di When dism smant antlin ling g the machin machine, e, carefu carefully lly inspec inspectt gaske gaskets ts at non-pre non-press ssure ure locati locations ons.. If da damag maged ed,, replac replace e them. the m. Replac Replace e ga gask skets ets at press pressure ure loc locati ation ons. s. Always Always apply apply an an anti-s ti-seiz eize e lubric lubrican antt to bo both th si sides des of ga gask skets ets to ease ease fut future ure remov removal. al. For major major ov overha erhauls uls,, drain drain and flu flush sh the crank crankca case se.. If replac replacing ing a conn connec ectin ting g rod as asse sembl mbly, y, pi pisto ston, n, pis piston ton an and d rod as asse semb mbly ly,, cross crosshe headad-bal balan ance ce nuts, nuts, or cross cro sshe head, ad, weigh weigh comp compone onent nt pa parts rts and comp compare are to the Compres Compresso sorr Balanc Balancing ing Record Record inclu included ded in the pa parts rts manual manual with ea each ch comp compres resso sor. r. If the there re are weight weight chang changes es,, recalc recalcula ulate te oppos opposing ing throw throw reciprocat recip rocating ing weight differenti differential. al. See "Op "Oppos posed ed Throw - Recipro Reciprocati cating ng Weigh Weightt Balan Balancing cing"".
CAUTION: Gas compressors are complicated and dangerous pieces of equipment. Only trained operators and mechanics familiar with unit operation should attempt any maintenance. Read and thoroughly understand the appropriate manual and always wear appropriate personal protection equipment during maintenance. Never adjust any fastener torques while the unit is operating or pressurized. To reduce the risk of serious personal injury or death, verify driver or compressor cylinder gas pressure cannot turn compressor crankshaft during maintenance. For engine-driven compressors, either remove the center coupling or lock the flywheel; for electric motor-driven compressors, either detach the driver from the compressor or lock out the driver switch gear. Before any maintenance or component removal, relieve all pressure from compressor cylinders. See packager information to completely vent the system or call the packager for assistance. After maintenance, purge the entire system with gas prior to operation to avoid a potentially explosive air/gas mixture.
Positioning a Throw Componen Compon entt replac replacem ement ent oft often en requir requires es manua manually lly turning turning the crank cranksh shaft aft to positi position on a throw throw in on one e of two po posit sition ions: s: inner inner de dead ad cente centerr or out outer er dea dead d cente center. r. Durin During g no norma rmall operati operation on,, cross crosshe head ads s sl slide ide ba back ck an and d forth forth in th the e cross crosshe head ad guid guides es.. In the the inne innerr de dead ad ce cent nter er posi positi tion on,, th the e cr cros ossh shea eads ds slid slide e to toward ward th the e cr cran ankc kcas ase e as fa farr as poss possib ible le.. In the the oute outerr dead dead ce cent nter er posi positi tion on,, th the e cr cros ossh shea eads ds slid slide e away away from from th the e crank cra nkca case se as far as possib possible le (see (see fig figure ure bel below). ow). Some Some proce procedur dures es requir require e a dial dial indic indicato atorr with magne magnetic tic base base to lo loca cate te th the e pre preci cise se inne innerr or oute outerr dead dead ce cent nter. er. At ot othe herr time times, s, a proce procedu dure re may may requi require re tu turni rning ng th the e cr cran anks ksha haft ft so a th throw row o occ ccup upie ies s its its high highes estt or lowes lowestt posi positi tion on.. In th the e figu figure re be belo low, w, th the e th throw row on on th the e left left is in it its s hi high ghes estt posi positi tion on and and the the throw throw on the the rig right ht is in its its lowes lowestt po posi siti tion on..
Inner nner Dead Dead Cent Center er Posit ositio ion n
Outer uter Dead Dead Cent Center er Pos osit itio ion n
High Highes estt/Lo Lowe wes st Thr hrow ow Pos osit itio ion n
FIGURE 4-1 Throw Positioning REV: 10/14
Page 4-1 of 50
Section 4 Part Replacement
For models JGC:D:F
Variable Volume Clearance Pocket (VVCP) A VVCP changes changes the clearance clearance volume volume of the head end of a cylinde cylinder. r. The amount amount of clearanc clearance e depends depends on the po posit sition ion of the cleara clearanc nce e po pock cket et piston piston.. Users turn the pi pisto ston/s n/stem tem as asse semb mbly ly coun counterc tercloc lockwis kwise e to in incr crea ease se cl clea earan rance ce,, and and cl cloc ockwi kwise se to decr decrea ease se it it.. In the the even eventt th that at ga gas s be begi gins ns to le leak ak from from th the e VVCP ve vent nt,, repla replace ce th the e V-pac V-packi king ng or se seal al withi within n the the VVCP. VVCP.
VVCP Removal CAUTION: Completely vent the cylinder before VVCP removal. Attempting to remove the VVCP without venting results in possible equipment damage, personal injury, or death. 1. Aft After er venti venting ng the cylin cylinder der,, loo loose sen n the lockin locking g ha hand ndle le so the adjus adjustme tment nt ha handl ndle e can can turn
1. Cylinder 2. Eyebolt 3. Packing Vent
freely free ly.. Turn the adjus adjustme tment nt ha handl ndle. e.
4. Locking Handle 5. Adjustment Handle 6. Flange B Bolts olts 7. Bellows Thread Protector
CAUTION: A hard to turn adju adjustme stment nt handle indicates pressurized pressurized gas trapped within the VVCP. See VVCP Disassembly caution below. 2. Tighte Tighten n the lo lock cking ing handle handle.. 3. Disconne Disconnect ct the packin packing g vent. vent.
FIGURE 4-2 Typical VVCP
4. Remove Remove pl plas astic tic plug plug from ey eyeb ebolt olt ho hole le an and d thread thre ad an ey eyeb ebolt olt in into to the ey eyebo ebolt lt hole. hole. 5. Sl Slid ide e a cr cran ane e hook hook thro throug ugh h the the eyeb eyebol oltt and and rem remov ove e sl slac ack k from from th the e cr cran ane e ch chai ain. n.
6. Remove Remove al alll flan flange ge bolt bolts s and and sl slid ide e the the VVCP out out from from the the cy cylilind nder er.. Th The e Ariel Ariel Perfo Performa rmanc nce e Progra Program m contain con tains s approxim approximate ate VVCP weights. weights. 7. Disca Discard rd th the e head head gask gasket et and and tra trans nspo port rt the the VVCP to a su suit itab able le work area area fo forr di disa sass ssem embl bly. y.
VVCP Disassembly Th The e VVCP pi pist ston on rin ring g is not not gasgas-ti tigh ghtt to allo allow w a nearl nearly y bala balanc nced ed ga gas s pre press ssure ure,, which which ea ease ses s VVCP ad adjus justme tment nt with the cylin cylinde derr press pressuri urize zed. d. Gas Gas press pressure ure beh behind ind the VVCP piston piston normal normally ly vents vents when the cy cylilind nder er ve vent nts. s. Proce Process ss debri debris s or rus rustt aroun around d the the pist piston on rin ring g ca can n fo form rm a se seal al th that at traps traps ga gas s withi within n th the e VVCP as asse sembl mbly, y, somet sometime imes s at subs substan tantia tiall press pressure ure.. CAUTION: Trapped gas pressure can present a personal safety hazard when servicing the VVCP. Work in a well-ventilated, non-sparking area, particularly with sour gas applications. Do not breathe gas emission from VVCP when venting trapped gas.
Page 4-2 of 50
REV: 10/14
For models models JGC:D:F JGC:D:F
1. Pl Pla ace th the e VVCP VVCP on a table tab le,, adapte adapterr up up.. 2. The be bello llows ws thread thread prote pro tect ctor or grips grips a lip lip on the adjustme adjustment nt handle. handle. Use Us e pl plie iers rs to pu pull ll the the bellows bel lows from the adjustme adju stment nt handle handle lip. Do not not te tear ar th the e bell bellows ows.. 3. Remove locknut. locknut. 4. Remove Remove adjustme adjustment nt handle. hand le. The adjustme adjustment nt hand handle le is a ta tape pered red fit fit onto onto th the e pi pist ston on st stem em;; use use a ha hamm mmer er or pu pull ller er to
Section 4 Par Partt Replacemen Replacementt
NOTES: 1. Some adapters use a bolted retaining retaining plate (15) and others use a snap ring (16) and spring retainer (17). 2. The o-ring (14) ffits its into into a groove machined into either the head (11) face or adapter (7) base.
break bre ak th the e fit. fit. 5. Thread Thread the locki locking ng hand handle le of offf of th the e pist piston on stem. ste m. Leave Leave the bellows bellows thread protector protector att attac ached hed to the lock locking ing handle.
1. Locknut 2. Adjustment Adjustment Handle 3. Adjust Adjustment ment Handle Lip 4. Bellows Thread Protector 5. Locking Handle 6. Grease F Fitting itting
7. Adapter 8. Match Mark 9. Piston Stem 10. Sock Socket et Head Bolt 11. Head 12. Piston 13. Piston Ring
14. O-Ring 15. Retaining Plate 16. Snap Ring 17. Spring Retainer 18. Compression Spring 19. Backup Ring 20. V-Packing or Seal
6. Depen Dependi ding ng on si size ze,, a VVCP VV CP may may hav ave e two two to fourr sock fou socket et he head ad bolts bolts.. Use Us e a mark marker er to draw draw matc ma tch h mark marks s on the the si side de FIGURE 4-3 VVCP VVC P Disassembly Disassembly/Assem /Assembly bly of the the VVCP VVCP wher where e the the adap adapte terr and and head head join join at each eac h sock socket et head head bo bolt lt locati location on.. Lo Loos osen en the sock socket et he head ad bo bolts lts ev evenl enly y an and d increm increment entall ally y to relea release se an any y potentia pote ntially lly high-press high-pressure ure gas. Do not breathe gas emission from VVCP. 7. Remov Remove e so sock cket et head head bolt bolts s and and turn turn the the adap adapte terr co coun unte tercl rcloc ockwi kwise se to th threa read d it of offf of th the e pist piston on st stem em.. Place Pla ce adap adapte terr base base up next next to the the head head.. 8. Remov Remove e th the e pi pist ston on st stem em and and pist piston on asse assemb mbly ly from from th the e he head ad.. Th The e pist piston on st stem em an and d pi pist ston on are perman per manen ently tly joine joined; d; do no nott att attem empt pt to disas disasse sembl mble e them. them. 9. Remov Remove e th the e pi pist ston on ring ring from from the the pist piston on.. 10. Depen 10. Dependi ding ng on VVCP si size ze,, Ariel Ariel mach machin ines es a groov groove e fo forr th the e OO-rin ring g into into eith either er th the e fa face ce of th the e he head ad or th the e base base of th the e adap adapte ter. r. Remov Remove e and and disc discard ard the the O-rin O-ring. g. 11. Some 11. Some adap adapte ters rs use use a bolt bolted ed retai retaini ning ng plat plate e while while othe others rs us use e a sn snap ap rin ring g an and d sprin spring g re reta tain iner er:: a. Retaining Retaining Plate Plate - Remo Remove ve retaini retaining ng plate plate bol bolts ts an and d retaini retaining ng plate. plate.
REV: 10/14
Page 4-3 of 50
Section 4 Part Replacement
For models JGC:D:F
b. Snap Ring and and Spring Retainer Retainer • Thre Thread ad a nu nutt on onto to a thre thread aded ed rod rod that that is a fe few w in inch ches es lo long nger er than than the the heig height ht of the the adapter. • Slid Slide e a wash washer er wider wider than than the the main main bore bore of th the e adap adapte terr down down to the the nut. nut. • In Inse sert rt th the e th threa reade ded d rod end end with with no nut nut into into th the e main main bore bore of the the adap adapte terr unti untill it protru protrude des s from fro m th the e base base of the the adap adapte ter. r. • Slide Slide a washe washerr wide wide enou enough gh to over overla lap p the the sp sprin ring g retai retaine nerr but but less less wide wide than than the the sn snap ap rin ring g onto onto th the e th threa reade ded d rod pro protru trudi ding ng from from the ba base se.. • Th Threa read d a nut nut onto onto the the threa threade ded d rod protru pro trudi ding ng from from the the base base.. Tigh Tighte ten n the the nut nut
1. Washer 2. Snap Ring 3. Threaded Rod 4. Nut 5. Backup Ring 6. Spring Retainer 7. Compression Spring 8. V-Packing or Seal
until the compress until compression ion spring spring compress compresses es en enoug ough h to sepa separate rate the sprin spring g retaine retainerr from th the e sn snap ap rin ring. g.
FIGURE 4-4 Spring Compression for Snap Ring Removal
• Use Use sn snap ap rin ring g plie pliers rs to rem remov ove e sn snap ap rin ring. g. • Remov Remove e th the e nut nut from from the the threa threade ded d rod rod,, then then remov remove e th the e th threa reade ded d rod an and d washe washers rs from from th the e main ma in bore bore of th the e adap adapte ter. r. 12. Remo 12. Remove ve sprin spring g retaine retainer, r, compr compres essio sion n spring spring,, an and d ba back ckup up rin ring g from the ad adapt apter er count counterb erbore ore.. 13. Remov 13. Remove e V-pac V-packi king ng or se seal al from from adap adapte terr co coun unte terb rbore ore.. Find Find a st stron rong, g, fo foot ot-lo -long ng meta metall 3/ 3/16 16 in inch ch rod or pi pipe pe and and bend bend abou aboutt .75 .75 inch inch at 90°. 90°. Inse Insert rt the the rod into into th the e ad adap apte terr co coun unte terbo rbore re an and d slid slide e th the e .7 .75 5 inch inch be bene neat ath hcounterbo th the enterbore. V-pac V-pack k ing ing or seal seal.. Pull Pull up on the the rod rod or pipe pipe to pu pull ll the the V-pac V-packi king ng or seal seal fr from om th the e adapter ada pter cou re.
VVCP Reassembly Clean al Clean alll VVCP parts parts of all all debri debris, s, rust, rust, etc. etc. Repla Replace ce parts parts if ex exce cess ssiv ivel ely y worn or da dama mage ged. d. Repla Replace ce Vpack packin ing g or se seal al if exce excess ssiv ive e gas gas leak leakag age e occu occurs rs at the the pack packin ing g ve vent nt.. See FIGURE FIGURE 44-3 3 and FIGURE FIGURE 44-4 4. 1. With With fa face ce up, up, pl plac ace e the the head head on a tabl table. e. With With base base faci facing ng up up,, plac place e th the e ad adap apte terr be besi side de th the e he head ad.. 2. Depen Dependi ding ng on VVCP si size ze,, Ariel Ariel mach machin ines es a groov groove e for for th the e OO-rin ring g in into to eith either er th the e fa face ce of th the e he head ad or the the base base of adap adapte ter. r. Oil Oil and and inse insert rt a new new O-ri O-ring ng into into O-rin O-ring g gro groov ove. e. Installl the piston piston ring on onto to the piston piston.. 3. Instal 4. Oil th the e head head ca cavi vity ty wal walls ls,, then then inse insert rt pist piston on st stem em and and pist piston on as asse semb mbly ly in into to th the e he head ad ca cavi vity ty.. 5. Oil th the e adap adapte terr co coun unte terbo rbore re walls walls and and inse insert rt V-pac V-packi king ng or se seal al.. Th The e V-pac V-packi king ng or se seal al co cons nsis ists ts of five five pa partit rtition ions; s; insert insert V-pack V-packin ing g or seal seal into into the coun counterb terbore ore with the thi thick ckes estt partit partition ion do down wn an and d the th thin inne nest st pa part rtit itio ion n up up.. Use Use a soli solid d cyli cylind nder er of wood wood or meta metall as a ra ram m an and d ta tap p th the e V-pac V-packi king ng or seal seal two or th three ree time times s in into to the the co coun unte terbo rbore re to ensu ensure re prope properr se seat atin ing. g. 6. Insert Insert backu backup p rin ring g into into ad adapt apter er count counterb erbore ore.. 7. Insert Insert compress compression ion spring spring into adapter adapter counterb counterbore. ore. 8. Place Place sprin spring g retaine retainerr on top of the comp compres ressi sion on sprin spring. g. 9. Some Some adap adapte ters rs use use a bolt bolted ed ret retai aini ning ng plat plate e while while othe others rs us use e a sn snap ap rin ring g an and d sprin spring g retai retaine ner: r:
Page 4-4 of 50
REV: 10/14
For models models JGC:D:F JGC:D:F
Section 4 Par Partt Replacemen Replacementt
a. Retaining Retaining Plate Plate - Pl Plac ace e the the reta retain inin ing g plat plate e on to top p of th the e spri spring ng re reta tain iner er an and d pres press s do down wn to compr compres ess s the compre compress ssion ion sprin spring. g. thread thread retaini retaining ng plate plate bo bolts lts through through the retaini retaining ng plate plate and into into the Adapte Adapterr ba base se.. Tighte Tighten n the retaini retaining ng plate plate bolts bolts ha hand nd tig tight. ht. b. Snap Ring and Spring Spring Retainer Retainer • Compres Compress s the comp compres ressi sion on spring spring (see (see FIG FIGURE URE 4-4 4-4). ). • Use sn snap ap rin ring g plie pliers rs to inst instal alll the the sn snap ap rin ring g abov above e th the e sp sprin ring g retai retaine ner. r. • Remov Remove e th the e nut nut from from the the threa threade ded d rod rod,, then then remov remove e th the e th threa reade ded d rod an and d washe washers rs from from th the e main ma in bore bore of the the adap adapte ter. r. Grease se pi pist ston on st stem em threa threads ds and and threa thread d adap adapte terr cl cloc ockwi kwise se on onto to pist piston on st stem em.. Th Threa read d ad adap apte terr as fa farr as 10. Grea poss possib ible le on th the e pi pist ston on st stem em,, then then turn turn the the adap adapte terr co coun unte ter-c r-clo lock ckwis wise e to alig align n th the e so sock cket et he head ad bo bolt lt matc ma tch h mark marks s on the the adap adapte terr base base with with the the matc match h mark marks s on th the e he head ad.. 11. Instal 11. Installl the sock socket et head head bo bolts lts.. Tighte Tighten n sock socket et hea head d bo bolts lts hand hand tig tight. ht. 12. Th 12. Threa read d lo lock ckin ing g hand handle le onto onto the the pist piston on st stem em,, but but do not not lock lock it. it. Th Threa read d th the e lock lockin ing g ha hand ndle le with with th the e bellows bel lows thread thread protec protector tor fac facing ing up.
13. Slide 13. Slide th the e adju adjust stme ment nt hand handle le onto onto the the pist piston on st stem em and and us use e a ha hamm mmer er to po poun und d it do down wn ev even enly ly on onto to th the e tapered tape red fit. 14. Use th the e adju adjust stme ment nt hand handle le to turn turn the the pist piston on st stem em co coun unte ter-c r-clo lock ckwis wise e to tigh tighte ten n th the e se seal al be betwe tween en th the e adapte ada pterr an and d he head, ad, then then lock lock the locki locking ng handle handle.. 15. Thre 15. Thread ad th the e lo lock cknu nutt onto onto the the pist piston on st stem em.. While While the the torqu torque e fo forr th the e lo lock cknu nutt is no nott cri criti tica cal, l, tigh tighte ten n it enoug eno ugh h to preve prevent nt ad adjus justme tment nt handle handle from loose loosenin ning. g. 16. Slide 16. Slide thread thread protec protector tor bel bellows lows onto onto the ad adjus justme tment nt handle handle lip and verify verify that that it grips grips secu securely rely.. 17. Torque 17. Torque sock socket et head head bo bolts lts.. See Appendix Appendix A for pro prope perr torque torque value value and torque torque proce procedu dure. re. 18. Apply 18. Apply 3-4 pump pumps s of all-p all-purp urpos ose e petro petrole leum um greas grease e with with a gr grea ease se gu gun n at th the e gr grea ease se fitt fittin ing. g.
VVCP Installation 1. Slide Slide a crane crane hook hook throu through gh the the VVCP eyeb eyebol oltt and and move move th the e VVCP to th the e cy cylilind nder. er. 2. Apply an an anti-s ti-siez ieze e lubric lubricant ant to bot both h the ne new w he head ad ga gask sket et and the cylin cylinder der seati seating ng surfac surface. e. Stick Stick the new he head ad gaske gas kett to the cylin cylinde derr seati seating ng surfac surface. e. 3. Sl Slid ide e th the e VVCP into into the the cy cylilind nder er and and alig align n the the adap adapte ter r fla flang nge e bolt bolt ho holes les with the cylin cylinde derr bolt bolt ho holes les.. 4. Lu Lubri brica cate te fla flang nge e bo bolt lt thread threads s and seati seating ng surfac surfaces es with petrol pet roleum eum type type lubric lubricant ant and instal installl bo bolti lting ng.. See 1. Head Cylinder 3. 4. Eyebolt Packing Vent 2. 5. Flange Bolts Gasket
Appendix dix A fo forr prope properr torqu torque e va valu lue e and and torqu torque e Appen procedure.
Reconne nnect ct pa pack cking ing vent. vent. To instal installl a new VVCP, re-set re-set 5. Reco FIGURE 4-5 VVCP Installation crank cra nk end/he end/head ad end feeler feeler cl clear earanc ances es with VVCP dix B in Appen in Appendix dix B . compl complete etely ly cl clos osed ed an and d chec check k tot total al piston piston end cl clea earan rance ce.. See Appen See Appendix
VVCP Adjustment Users may chan change ge VVCP cleara clearanc nce e volu volume me with the comp compres resso sorr runnin running g or stoppe stopped. d. The ex expe pecte cted d chang change e in compr compres esso sorr flo flow w an and d ab abso sorbe rbed d po power wer de depen pends ds on compr compres essio sion n ratio ratio an and d proper propertie ties s of the co comp mpres resse sed d gas. gas. Consu Consult lt pack packag ager er inst instruc ructi tion ons s rega regardi rding ng where where to se sett th the e VVCP. VVCP. Also Also se see e th the e VVCP
REV: 10/14
Page 4-5 of 50
Section 4 Part Replacement
For models JGC:D:F
data data sh shee eett in th the e Ariel Ariel Main Mainte tena nanc nce e and and Rep Repai airr Ma Manu nual al Parts Parts Book Book.. To op open en VVCP to a de desi sired red percentage: 1. Lo Loos osen en the locki locking ng ha handl ndle e so the ad adjus justme tment nt handle handle can can turn freely freely.. 2. Find Find the VVCP dimens dimensio ion n plate. plate. 3. Subtrac Subtractt the ful fully ly close closed d di dimen mensio sion n from the ful fully ly op open en dimens dimension ion.. The Ariel Ariel Perform Performan ance ce progra program m al also so lis lists ts these these dim dimens ension ions s if the VVCP dimens dimension ion pl plate ate is missi missing. ng.
FIGURE 4-6 VVCP Dimension Plate
4. Mult Multip iply ly th the e st step ep 3 resul resultt by the the desi desire red d perc percen enta tage ge ex expres presse sed d as a decima decimal. l. 5. Add th the e st step ep 4 re resu sult lt to the the full fully y cl clos osed ed dime dimens nsio ion. n. 6. Tu Turn rn th the e adju adjust stme ment nt hand handle le unti untill the the me meas asure ureme ment nt from from th the e ba base se of th the e lo lock ckin ing g ha hand ndle le,, when when lo lock cked ed,, to th the e to top p of th the e adju adjust stme ment nt hand handle le equa equals ls the the st step ep 5 res resul ult. t.
Compressor Valves - Removal and Installation Most comp Most compres resso sorr valv valves es us use e non-me non-metal tallic lic plates plates.. Before Before servi servicin cing g any valv valve, e, see see the correc correctt valv valve e asse assemb mbly ly drawin drawing, g, parts parts list list,, and and se serv rvic ice e lite literat rature ure in the the Parts Parts Book. Book. Th The e cy cylilind nder er co cove verr sh shee eett in th the e Parts Part s Book Book lis lists ts the valv valve e ori origin ginall ally y supp supplie lied d with ea each ch cylin cylinder der.. Changes Changes in op opera eratin ting g press pressure ures, s, tempe tem peratu ratures res,, RPM, or ga gas s comp compos ositi ition on may require require altern alternate ate valve valve confi configur gurati ation on includ including ing spring springing ing and and lift. lift. Conta Contact ct yo your ur Packa Package gerr and/ and/or or Ariel Ariel for for help help in va valv lve e se sele lect ctio ion. n. CAUTION: Gas compressors are complicated and dangerous pieces of equipment. Only trained operators and mechanics familiar with unit operation should attempt any maintenance. Read and thoroughly understand the appropriate manual and always wear appropriate personal protection equipment during maintenance. Never adjust any fastener torques while the unit is operating or pressurized. To reduce the risk of serious personal injury or death, verify driver or compressor cylinder gas pressure cannot turn compressor crankshaft during maintenance. For engine-driven compressors, either remove the center coupling or lock the flywheel; for electric motor-driven compressors, either detach the driver from the compressor or lock out the driver switch gear. Before any maintenance or component removal, relieve all pressure from compressor cylinders. See packager information to completely vent the system or call the packager for assistance. After maintenance, purge the entire system with gas prior to operation to avoid a potentially explosive air/gas mixture.
Required Tools and Materials • Approp Appropriat riate e Ariel Ariel parts parts lis listt • Approp Appropriat riate e Ariel Ariel Mainte Maintena nanc nce e an and d Repair Repair manual manual • Calibrat Calibrated ed torque torque wrench wrench with the ap appro propria priate te range range for targ target et value values s • Regul Regular ar grade grade Never Never Seez Seez (for (for forge forged d st stee eell cy cylilind nders ers)) or ISO 15 150 0 mine mineral ral oil oil (for (for ca cast st iro iron n cy cylilind nders ers)) • Appropriate Appropriate personal personal protectio protection n equipme equipment nt • Bottle brush brush • Pressurized Pressurized liquid liquid solven solventt • Valve Valve Tool Tool
Page 4-6 of 50
REV: 10/14
For models models JGC:D:F JGC:D:F
Valve Cap Removal Valve Caps on Cast Iron Cylinders or HighPressure Caps without Spring Energized Seals 1. Sligh Slightl tly y lo loos osen en al alll ca cap p sc screw rews s in st step eps s and and even evenly ly on a va valv lve e ca cap; p; the the ca cap p sh shou ould ld st stay ay in its its origi origina nall positi pos ition on.. If it pu push shes es out outward, ward, STOP! Completely vent vent the cylin cylinde der. r. See Caution above. 2. After After th the e abov above e sa safe fety ty ch chec ecks ks and and with with ca cap p sc screws rews stililll in pl st plac ace e but but loos loosen ened ed,, pry the the va valv lve e ca cap p out out unti untill th the e o-rin o-ring g cl clea ears rs the the cy cylilind nder er to co conf nfirm irm prope proper r cyli cylind nder er ven enti ting ng.. Use Use a pa pair ir of pry pry bars bars or scre screwd wdri riv ver ers, s, on one e on ea each ch sid ide e of the the cap, cap, to pry pry it
Section 4 Par Partt Replacemen Replacementt
out. 3. Remov Remove e ca cap p sc screws rews and and va valv lve e ca cap. p. Take Take ca care re to preve pre vent nt da damag mage e to fasten fastener er thre threads ads..
1. Cap Screw 2. Valve Cap 3. O-Ring
4. Valve Retainer 5. Valve Assembly 6. Valve Seat Gas Gasket ket
FIGURE 4-7 Valve Cap Assembly for Cast Iron Cylinder
CAUTION: Valve cap, retainer, and valve may fall out of bottom pockets if not supported. Support them after cap screw removal to prevent personal injury.
1. Valve Cap 2. Valve Retainer 3. Valve Assembly
4. Valve Seat Gas Gasket ket 5. Metallic W Wire ire G Gasket asket
FIGURE 4-8 High-Pressure Valve Cap Assembly without Spring Energized Seal
REV: 10/14
Page 4-7 of 50
Section 4 Part Replacement
For models JGC:D:F
Valve Cap with Spring Energized Seal 1. Remov Remove e ca cap p nuts nuts fro from m long long st stud uds. s. 2. S Sliligh ghtl tly y lo loos osen en al alll hex hex nuts nuts on each each va valv lve e ca cap p in step st eps s and and even evenly ly.. With With all all the the nuts nuts loos loose, e, the the ca cap p sh shou ould ld st stay ay in its its origi origina nall posi positi tion on.. If it push pushes es out out of it its s own acco accord, rd, STOP! STOP! Compl Complet etel ely y ve vent nt the the cylinde cyl inder. r. See Caution above. 3. Afte Afterr th the e abov above e sa safe fety ty ch chec ecks ks and and with with hex hex nuts nuts stil stilll in pl plac ace e but but lo loos osen ened ed,, remov remove e hex hex nuts nuts from from sh short ort studs. 4. th Eve Evenl yve back bacck off fom hex hexthe nu ts lind on long lo ng stud steuds while whi le pull pu ing g the e vnly al alve apof fr from thnuts e cyli cy nder er. . Use Us aspa pair ir of pry pryllin ba bars rs or scre screwd wdri rive vers rs,, on one e on ea each ch si side de of the the cap, cap, to
6. Valve 1. Hex Nut 7. Valve 2. Cap Nut Gasket 3. Valve Cap 8. Keeper 4. Seal Keeper Bolt 5. Retainer
9. 2-Piece Wedge Lock Washer 10. Spring Energized Seal
pr pry y it out. out. Ensure Ensure th the e sp sprin ring g energ energiz ized ed se seal al compl complete etely ly diseng disengage ages s from the cylin cylinde derr bef before ore remo removi ving ng th the e hex hex nuts nuts fro from m long long st stud uds. s.
FIGURE 4-9 High-Pressure Valve Cap Assembly with Spring Energized Seal
NOTE: Long studs are assembled with thread locker to eliminate the possibility of the studs backing out of the cylinder while the hex nut is removed. 5. Remove Remove lo long ng st stud ud hex hex nuts nuts and and va valv lve e ca cap. p. 6. Inspe Inspect ct seal seal for damag damage. e. If undam undamage aged, d, the sprin spring g energi energize zed d seal seal is re-usa re-usabl ble. e. CAUTION: Valve cap, retainer, and/or valve may fall out of bottom pockets if not supported. Support them carefully after removing hex nuts to prevent personal injury.
Valve Removal 1. With With th the e va valv lve e ca cap p remov removed ed and and the the va valv lve e reta retain iner er stil stilll in plac place, e, th threa read d a va valv lve e to tool ol ov over er th the e va valv lve e n1. cente centerr bolt. bolt. See Sectio Section 2. It ma may y be nece necess ssary ary to loos loosen en the the plas plasti tic c thum thumb b sc screws rews in th the e va valv lve e retai retaine ners rs.. In so some me cy cylilind nder er clas cl asse ses, s, th the e di disc scha harge rge va valv lve e retai retaine nerr is held held in plac place e wit with h an oo-rin ring g - simp simply ly pu pullll th the e retai retaine nerr ou outt to remov rem ove e it. 3. Fo Forr hi high gh pr pres essu sure re appl applic icat atio ions ns that that use use a meta metallllic ic wire gask gasket et se seal al un unde derr th the e va valv lve e cap, cap, th the e cy cylilind nder er ve vent nts s upon upon lo loos osen enin ing g the the ca cap p sc screws rews.. Use the the va valv lve e tool tool to un unse seat at th the e meta metallllic ic wire ga gask sket et.. 4. Pull Pull out out th the e va valv lve e and and retai retaine nerr toge togeth ther. er. 5. Head en end d tandem tandem cylin cylinders ders may may requi require re rem remov oval al of sucti suction on an and d disch discharg arge e piping piping an and d the cy cylin linde der r he head ad to ac acce cess ss the conc concen entric tric valv valve. e. A conc concent entric ric valve valve combi combines nes sucti suction on and di disc scha harge rge valv valves es in on one e assembly. 6. In most most ca case ses, s, th the e flat flat meta metall gask gasket et remai remains ns in the the pock pocket et.. It is di diff ffic icul ultt to se see. e. A flas flashl hlig ight ht an and d a smal smalll mirro mirrorr on an adju adjust stab able le rod are the the best best tool tools s to se see e the the ga gask sket et clea clearly rly.. On cy cylilind nders ers with with ho horiz rizon onta tall va valv lves es,, th the e gask gasket et may may fall fall into into the the gas gas pass passag age. e. Use a smal smalll ma magn gnet et on a flex flexib ible le ex exte tens nsio ion n rod to remov rem ove e gaske gaskett from cylin cylinde der. r. For op optim timum um seali sealing ng,, replac replace e valv valve e seat seat ga gask skets ets anytim anytime e a valv valve e is remo remove ved d from from a cy cylilind nder er of a unit unit that that has has been been in se serv rvic ice. e.
Page 4-8 of 50
REV: 10/14
For models models JGC:D:F JGC:D:F
Valve Installation 1. Coat Coat a new new va valv lve e se seat at gaske gas kett with Never Never Seez. See z. Eithe Eitherr in inse sert rt it in into to th the e va valv lve e pock pocket et or stic st ick k it on th the e valv valve. e. In ei eith ther er ca case se,, do not not allow allow the gaske gaskett to fal falll into into the ga gas s pa pass ssage age.. For optimu optimum m seali sealing, ng, replac rep lace e valve valve seat seat gaske gas kets tsremov an anyti ytime me valv valve e is rem oved edafrom a cy cylilind nder, er, if th the e unit unit
Section 4 Par Partt Replacemen Replacementt
has be been en in servi service ce.. 2. Ins Install tall suction suction valves valves only onl y in suct suction ion pocke pockets ts and discharge discharge valves valves only onl y in disch discharg arge e pocke poc kets. ts. The valve valve pockets poc kets have have identification identificati on plates. 13. Discharge Valve Spring 7. Suction Valve Instal Ins talll all valv valves es with 1. 12-Point Capscr Capscrew ew Spring 14. Discharge Valve Plate (Center Bolt) valve valv e fastener(s fastener(s)) 8. Cushion P Plate late 15. Plastic Retainer-Keeper 2. Threaded Washer positi pos ition oned ed away from 9. Waf Wafer er Spring Spring 3. Valve Retainer th the e cy cylilind nder er bore. bore. If a 10. Cylinder Bore 16. (Thumbscrew) Valve Cap O-Ring 4. Seat 11. Guide Ring 17. Valve Cap va valv lve e is not not mark marked ed for for 5. Guard 12. Valve Seat Gasket Gas ket suction suc tion or discha discharge, rge, 6. Suct Suction ion Valve Plat Plate e manually manu ally depress depress the FIGURE 4-10 Typical Valve Assemblies Assemblies va valv lve e pl plat ate e to ve verif rify y the the type. typ e. Prefera Preferably bly,, us use ea to tool ol so soft fter er th than an the the va valv lve e plat plate e mate materia riall or exer exerci cise se ca care re to preve prevent nt da dama mage ge to th the e pl plat ate. e. A su suct ctio ion n va valv lve e pl plat ate e may may be depre depress ssed ed only only from from the the va valv lve e fast fasten ener er (bo (bolt ltin ing) g) side side of th the e va valv lve; e; a disc discha harge rge va valv lve e pl plat ate e may may be depre depress ssed ed only only from from the the si side de of the the va valv lve e th that at fa face ces s th the e cy cylilind nder er bo bore. re. 3. Us Use e th the e va valv lve e to tool ol to inse insert rt the the va valv lve e and and retai retaine nerr into into th the e po pock cket et to toge geth ther er (s (see eeSec Sectio tion n 1 ). Veri Verify fy th the e valv valve e seats seats prope properly rly in the po pock cket. et. When When instal installed led correc correctly tly,, the valv valve e rotates rotates freely freely by ha hand. nd. 4. Plasti Plastic c thumbs thumbscre crews ws hold hold valv valve e retaine retainers rs in pos positi ition on in bottom bottom valv valve e po pock ckets ets.. Tighte Tighten n these these screws screws just enough enough to provide provide friction friction so retainers retainers and valves valves in bottom bottom pockets pockets will not fall out during during valve valve cap installation. installation. 5. Lubric Lubricat ate e a new new o-rin o-ring g wit with h oil oil and and inst instal alll it in the the groov groove e on th the e va valv lve e ca cap p no nose se.. Some Some hi high gh press pressure ure cy cylilind nders ers use use a so soft ft meta metallllic ic wire gask gasket et or sp sprin ringg-en energ ergiz ized ed se seal al in lieu lieu of th the e o-rin o-ring. g. Conti Continu nue e to "Valve "Valv e Cap Installa Installation tion". ".
Valve Cap Installation Installation Depending Depend ing on the applic applicati ation on,, Ariel Ariel compre compress ssor or cylin cylinder ders s uti utiliz lize e differe different nt style styles s of valv valve e caps caps.. Cast iron cy cylilind nders ers ut utililiz ize e va valv lve e ca caps ps in which which an O-rin O-ring g on the the va valv lve e ca cap p seal seals s ga gas s withi within n th the e cy cylilind nder. er. Fo Forge rged d st stee eell cy cylilind nders ers ut utililiz ize e a va valv lve e ca cap p with with eith either er a sp sprin ringg-en energ ergiz ized ed se seal al or a round round meta metallllic ic ga gask sket et to se seal al ga gas s withi wit hin n th the e cy cylilind nder. er. Th The e va valv lve e ca cap p pres presse ses s the the round round gask gasket et into into a trian triangu gula larr cros cross s se sect ctio ion n du durin ring g th the e torque procedure procedure.. REV: 10/14
Page 4-9 of 50
Section 4 Part Replacement
For models JGC:D:F
It is cr crit itic ical al to to torqu rque e th the e va valv lve e ca cap p foll followi owing ng the the torqu torque e proc proced edure ure be belo low. w. Valve Valve ca cap p bo bolt lt fa faililur ures es ca can n oc occu cur r if the the ca cap p is to torqu rqued ed impro imprope perly rly.. Draw bolt boltin ing g to full full torqu torque e in ev even en,, gr grad adua uall st step eps, s, witho without ut bias bias on on one e bo bolt lt or co cock ckin ing g th the e va valv lve e ca cap p in the the bore. bore. Suc Such h bias bias or co cock ckin ing g ca can n un unev even enly ly crush crush th the e ga gask sket et,, which which may may caus cause e le leak akage age and/or and/or bo bolt lt fai failure lure.. Ensure Ensu re al alll th threa reads ds ar are e cl clea ean n and and fre free e of debri debris s or burrs burrs.. Use a bo bott ttle le brush brush an and d press pressur uriz ized ed liqu liquid id so solv lven entt to cl clean ean thread threaded ed ho holes les thorou thoroughl ghly. y. Avoid Avoid send sending ing de debris bris into into cy cylin linde derr gas pa pass ssag age. e. Bolts Bolts shoul should d thread thread into into ho hole le an and d bo bott ttom om ou outt on the the valve alve cap by ha hand nd wit witho hout ut resi resist stan anc ce or us use e of a wrenc wrench. h. If bo bolt lts s do no nott thread thre ad into into ho hole le freely freely conta contact ct ARC for thre thread ad repair repair ins instruc tructio tions ns..
Torque See Appendix See Appen dix A for inform informati ation on on torque torque ac accu curac racy. y. For fasten fas teners ers in a ci circu rcula larr arrange arrangemen ment, t, torque torque in a criss crisscro cross ss order. ord er. ng Forpatte 3-bolt 3-b olt va lve e caps ca make ma multi ple e passe pas us using ing foll fo llowi owing pa ttern: rn:valv 123, 12 3, 231, 23ps, 1,,312 31 2 ke (see (semu e figu filtipl gure re to the thses e srig right ht). ). the Init Initia ialllly y to torqu rque e fa fast sten eners ers to 25% 25% of fina finall torqu torque, e, then then torqu torque e
them them up to 100% 100% in 25% 25% incre increme ment nts. s. Fastener Fasten er jo joint ints s with wire ga gask skets ets (press (pressure ure pa pack ckin ing, g, and some some forged forged steel steel valve valve caps caps)) requi require re mu multi ltipl ple e rounds rounds of torqu torque e af afte terr reach reachin ing g 100% 100% of fina finall torqu torque e to prope properly rly se seat at and and cr crus ush h th the e gask gasket et.. Conti Continu nue e in a criss crisscr cros oss s patte pattern rn unti untill no turns turns on th the e bolt bolts s are obse observ rved ed.. Proper Prop er tensio tensionin ning g of gas conta contain inmen mentt fasten fasteners ers is critic critical al to en ensu sure re safe safe and reliab reliable le op opera eratio tion. n. CAUTION: Severe personal injury and property damage may result from improperly torqued valve cap bolts. See Appendix See Appendix A for A for correct torque and detailed recommendations.
Valve Caps on Cast Iron Cylinders or High-Pressure Caps without Spring Energized Seals 1. Instal Installl valv valve e as asse sembl mbly y (and (and hi high gh cleara clearanc nce e spac spacer, er, if applic applicab able), le), with the valv valve e seat seat ga gask sket et and valve valve Instal talla latio tion” n” on pa page ge 4-9 4-9.. reta retain iner er in th the e va valv lve e pock pocket et.. See “Valve “Valve Ins 2. For high-pressure high-pressure valve valve caps caps only: Pla Place ce a new, new, round round,, meta metallllic ic wire ga gask sket et.. Alway Always s us use e a ne new w wire gaske gaskett when instal installin ling g a high-p high-pres ressu sure re valve valve cap; cap; gaske gaskets ts are not re-use re-useab able. le. 3. Oil and and in inst stal alll a new new o-r o-rin ing g on the the va valv lve e ca cap. p. Inst Instal alll the the va valv lve e ca cap. p. 4. For stand standard ard fasten fasteners ers,, lubric lubricate ate thread threads s an and d bo bolt lt seati seating ng surfac surfaces es with minera minerall oil. oil. For stainl stainles ess s steel steel fasten fasteners ers,, lubric lubricate ate threads threads and bolt bo lt se seat ing gzsu surfa s with wit Never Nev erers. Seez Se. ez regu re Appendix gula larr grade gra Docorrec not t us use Never Nev er atin Seez See onrface stand stces andard ardhfasten fas teners See Appen See dixde. A.for cono rrect te va valv lve e ca cap p bolt bolt to torqu rque. e. See "Torque" above. NOTE: For high-pressure applications, the valve cap joint design requires pressing a round metallic wire gasket into a triangular cross section. This requires multiple passes in a crisscross pattern with the torque wrench. See "Torque" See "Torque" above.
Page 4-10 of 50
1. Cylinder 3. Metallic Wire Gasket 2. Valve Cap 4. Valve Retainer
FIGURE 4-11 Gasket Crush
REV: 10/14
For models models JGC:D:F JGC:D:F
Valve Caps with Spring Energized Seals 1. Instal Installl valv valve e as asse sembl mbly y with valv valve e seat seat gaske gaskett and valve valve Installa allation tion”” on retai ret aine nerr in th the e va valv lve e pock pocket et.. See See “Valve Inst page pag e 4-9 4-9.. 2. Inspec Inspectt an and d lig lightl htly y lubric lubricate ate sprin spring g en energ ergize ized d seal seal with petroleum petrol eum oil. 3. In Inst stal alll th the e va valv lve e ca cap. p. Align Align valv valve e ca cap p roll roll pins pins so they they are para parallllel el with with th the e main main bore bore of the the cy cylilind nder. er. This This alig aligns ns th the e retaine reta inerr op open ening ings s with the cylin cylinde derr gas passa passage. ge. Be ca caref reful ul not not to goug gouge e the the bore bore,, or dist distort ort or dama damage ge the the gaske gas ket. t. Tighte Tighten n thumb thumb screws screws,, if applic applicab able. le. 4. Li Libe beral rally ly co coat at th the e va valv lve e ca cap p st stud ud threa threads ds and and hex hex nut nut se seat atin ing g su surfa rface ce or ca cap p sc screw rew threa threads ds and and unde underr the the he head ad
Section 4 Par Partt Replacemen Replacementt
with Never Seez. Seez. 5. In Inst stal alll va valv lve e ca cap p so the the roll roll pins pins enga engage ge the the cl clea earan rance ce slot slots s in the retaine retainer. r. for co corre rrect ct va valv lve e ca cap p fast fasten ener er torqu torque. e. See See 6. See Appendix Appendix A for "Torque" abo above ve for torq torque ue proce procedur dure. e. 7. Con Conti tinu nue e to to torqu rque e the the va valv lve e ca cap p at 100% 100% torqu torque e va valu lue e un unti till no bolt bolt move movemen mentt is ob obse serve rved. d. Even Even minute minute bo bolt lt moveme mov ement nt warrants warrants anothe anotherr pas pass s aroun around d the valv valve e cap cap in a crisscros crisscross s pattern. pattern. NOTE: The valve cap joint design requires pressing a round metallic wire gasket into a triangular cross section (see FIGURE (see FIGURE 4-11). 4-11). This requires multiple passes in a crisscross pattern with the torque wrench. wrenc h. See "Torque" See "Torque" above. above. 8. Tigh Tighte ten n ca cap p nuts nuts on long long stud studs, s, hand hand wrench wrench tigh tight. t.
Gas Containment Containment Fastener Torque Checks
1. Valve Gasket
5. Roll Pins
2. Valve 3. Retainer (openings aligned with gas passage) 4. Thumb Screws
6. Keeper 7. Seal Spring Energized Seal 8. Valve Cap 9. Hex nut 10. Cap Nut
FIGURE 4-12 High-Pressure Valve Cap Assembly with SpringEnergized Seal
Per Ariel Ariel ER-10.4.x serie series s (start-up checklis checklists) ts) and ER-8.x serie series s (Recommende (Recommended d Maintena Maintenance nce Int Interv ervals als), ), Ariel Ariel recom recommen mends ds chec checkin king g al alll gas conta contain inmen mentt fasten fastener er torque torques s by the sc sche hedul dule e be below low an and d includ inc luding ing thi this s sched schedule ule in your your compu computeri terize zed d mai mainte ntena nanc nce e manag manageme ement nt sy syste stem m (CMMS): (CMMS): • Prior Prior to st start art-up -up • 24 ho hours urs aft after er start-up start-up • 75 750 0 ho hours urs aft after er start-up start-up • Every Every 8,000 8,000 hours hours aft after er start-u start-up p re-chec eck k any any fast fasten eners ers foun found d loos loose e in any any of th thes ese e inte interva rvals ls af afte terr an ad addi diti tion onal al 75 750 0 ho hours urs.. If Per ER-8.2,, re-ch Per ER-8.2 loosenin loos ening g continu continues, es, contact contact your your packag packager er immediat immediately. ely.
REV: 10/14
Page 4-11 of 50
Section 4 Part Replacement
For models JGC:D:F
Piston and Rod CAUTION: To prevent personal injury, verify neither driver nor compressor cylinder gas pressure can turn the crankshaft during maintenance: on engine-driven compressors, either remove the center coupling or lock the flywheel; on electric motor-driven compressors, either detach the driver from the compressor or lock out the driver switch gear. Before any maintenance or component removal, relieve all pressure from compressor cylinders. See packager information to completely vent the system or call the packager for assistance. Before removing a cylinder head, back off all cap screws 1/8 inch (3 mm). Verify the head is loose and the cylinder is completely vented.
Piston and Rod Removal NOTE: See Section See Section 1 for illustrations of tools mentioned below. For non-lube cylinde cylinders, rs, see 4-49 . “Component Cleaning & Thread Lube for Non-Lube Compressor Cylinders” on page 4-49. 1. Lo Loos osen en cylin cylinde derr head head bo bolts lts.. Remove Remove cylin cylinder der he head ad and all cro cross sshea head d gu guide ide si side de cove covers. rs. 2. Move Move cr cros ossh shea ead d to inne innerr dead dead ce cent nter. er. Back Back off, off, but but do not not rem remov ove, e, th the e cross crosshe head ad ba bala lanc nce e nu nutt se sett sc screws rews.. Loos Loosen en cross crosshe head ad bala balanc nce e nut nut with with the the sp spec ecia iall slug sluggi ging ng wrench wrench.. Use th the e op open en en end d wrench wrench for for hex hex nuts nuts,, th the e peg peg wren wrench ch for for round round nuts nuts,, or use use the the se sepa para rate tely ly pu purc rcha hase sed d hy hydra draul ulic ic cr cros ossh shea ead d ba balan lance ce nut torque torque tool. tool. 3. In ta tand ndem em cy cylilind nders ers where where the the outb outboa oard rd cy cylilind nder er bore bore is smal smalle lerr th than an th the e in inbo board ard bo bore re,, remov remove e th the e ou outbo cylin cy der. Support Sup port such suly chthat cy ders du during ring remov rem al an and d instal installat lation ion,, to av avoid oid ex exce cess ssiv ive e weight weight ontboard th the eard pi pist ston onlinde and an dr.ro rod d asse as semb mbly thcylin atlinder may ma y sbend be nd them them. . oval 4. Move Move cr cros ossh shea ead d to oute outerr dead dead ce cent nter er.. If the the pist piston on uses uses a wea wearr ba band nd,, meas measure ure pist piston on to cy cylilind nder er clea cl earan rance ce at bott bottom om of pist piston on with with a feel feeler er gaug gauge. e. See See Appen Appendix dix B for tol tolera eranc nces es.. If out of tol tolera eranc nce, e, repla rep lace ce the wearband wearband.. 5. Use th the e pi pist ston on nut nut sp span anne nerr to turn turn the the pist piston on and and rod asse assemb mbly ly ou outt of th the e cross crosshe head ad.. Th The e two do dowel wels s on th the e to tool ol fit fit th the e pi pist ston on nut nut hole holes. s. Remov Remove e the the cross crosshe head ad nu nutt from from th the e pi pist ston on rod. rod. 6. Us Use e th the e pi pist ston on ro rod d ente enterin ring g sl slee eeve ve to sl slid ide e the the pist piston on rod th throu rough gh th the e wiper wiper an and d pa pack ckin ing. g. With With extre extreme me ca care, re, sl slowl owly y sl slid ide e pist piston on rod rod thro throug ugh h pack packin ing g so as no nott to da dama mage ge wiper wiper or pa pack ckin ing g rin rings gs.. 7. For on one-p e-piec iece e pi pisto ston n rings, rings, sl slide ide the piston piston rod as asse sembl mbly y from the cy cylin linder der,, then then carefu carefully lly remov remove e the pi pisto ston n rings. rings. For two-piec two-piece e pi pisto ston n rings rings (in high high press pressure ure applic applicati ation ons), s), slide slide the piston piston rod as asse sembl mbly y out out of cy cylilind nder er unti untill a fra fract ctio ion n of the the firs firstt rin ring g cl clea ears rs the the cy cylilind nder. er. Hold Hold th the e firs firstt rin ring g in th the e pist piston on gro groov ove e by hand haTh nd,is , or use us e nts a sband ba for forglarge la rger size si zes, s, unti un till tthe th ring rin clea cl ears rs th the edcy cyli lind nder er, th then en ca caref lyeremov rem ove e th the eove rin ring. g. This preve pre vent the thnd e ring rin from fro mrpopp po ppin ing g out ou ofethe th eggroov gro ove e an and ca caus usin ing g, da dama mage gereful toully th the rin ring. g. Remov Rem e su succ ccee eedi ding ng two-pi two-piec ece e rings rings and and wea wearr band band in the the sa same me way. way. Handl Handle e al alll pist piston on rin rings gs ca care refu fulllly y with with clea cl ean n to tool ols s and and hand hands s to prote protect ct them them from from nick nicks, s, marri marring ng,, an and d be bend ndin ing. g. Despi Despite te th thei eirr to toug ughn hnes ess s in se servi rvice ce,, so some me rin rings gs made made of PEAK are fragi fragile le whe when n remov removed ed.. 8. Th The e weigh weightt of th the e pi pist ston on rod is st stam ampe ped d on it its s head head.. Suppo Support rt th the e pist piston on ei eith ther er manu manual ally ly or with with a cr cran ane e as appro appropri priat ate e as it sl slid ides es fro from m the the cy cylilind nder er bore. bore. Th The e pi pist ston on rod must must remai remain n pa paral ralle lell with with th the e bore bore unti untill it le leav aves es the the bore bore co comp mple lete tely ly.. Take Take ca care re not not to di ding ng any any su surfa rface ces. s.
Page 4-12 of 50
REV: 10/14
For models models JGC:D:F JGC:D:F
Section 4 Par Partt Replacemen Replacementt
Hydraulic Torque Tools 4-13 13)) as an Properr to Prope torq rque ue is esse essent ntia iall for for pi pist ston on nuts nuts.. Ariel Ariel offe offers rs a hydr hydrau aulilic c to torq rque ue to tool ol (s (see ee FIGURE FIGURE 4option opt ion.. It is us used ed to as asse sembl mble e an and d disas disasse sembl mble e JGC:D:F JGC:D:F piston piston rod as asse sembl mblies ies..
1. Pist Piston on Nut (with 2 set setscrews) screws) 2. Dowel Drive Pins (4 provided) 3. Adapter B Base ase Plate ((3 3 provided) 4. Bushing
5. 6. 7. 8.
Bevel Gear 9/16 inch Hex Pinion Gear Drive Piston Return S Springs prings Tool Piston
9. Puller-Bolt Puller-Bolt Nut 10. Puller Puller-Bolt -Bolt Stem Stem 11. Puller Puller-Bolt -Bolt Ins Insert ert (2 Provided)
FIGURE 4-13 Typical B-6911 Hydraulic Piston Nut Torque Tool for JGC:D:F Frames
Hydraulic Torque Tool Repair Kits Ariel offers repair repair kits for both hydraulic hydraulic torque tool tools. s. Contact Contact the Ariel Response Response Center for details details.. Also, the the B-691 B-6911 1 to tool ol has has had had desi design gn upda update tes. s. See See CTB-201 CTB-201 an and d ER-113 ER-113 fo forr de deta tailils. s.
Piston and Rod Disassembly with Hydraulic Torque Tool CAUTION: Trapped gas pressure can present a personal safety hazard when disassembing the piston and rod. Work in a well-ventilated, non-sparking area, particularly with sour gas applications. Do not breathe gas emission when venting trapped gas. 1. Remov Remove e th the e two Allen Allen se sett sc screws rews from from the the pist piston on nut nut an and d disc discard ard.. 2. Clean Clean and and lu lubri brica cate te threa threade ded d hole hole in rod. rod. 3. Set up to torq rque ue to tool ol with with prope properr adap adapte terr endp endpla late te,, dowel dowels, s, an and d pu pullllerer-bo bolt lt in inse sert rt requi require red d fo forr th the e parti particu cula larr pi pist ston on and and rod. rod. The The tool tool co come mes s with with two diffe differen rentt size size pu pullllerer-bo bolt lt in inse serts rts,, fo four ur do dowel wel drive drive
REV: 10/14
Page 4-13 of 50
Section 4 Part Replacement
For models JGC:D:F
pi pins ns (two pairs pairs of di diff ffere erent nt si size zes s to matc match h each each pull puller er bolt bolt), ), an and d th three ree ad adap apte terr ba base se pl plat ates es.. A ch chan ange ge in pull puller er-bo -bolt lt si size ze requi requires res a ch chan ange ge in dowel dowel driv drive e pins pins as well. well. Wre Wrenc nch h flat flats s on th the e pu pullllerer-bo bolt lts s an and d reces rec esse sed d All Allen en sock sockets ets in the do dowel wel drive drive pins pins facili facilitat tate e remova removall an and d instal installat lation ion..
Page 4-14 of 50
REV: 10/14
For models models JGC:D:F JGC:D:F
Section 4 Par Partt Replacemen Replacementt
CAUTION: The B-6911 tool uses interchangeable base plates to adapt to different piston and nut sizes. Verify the plate selected will not permit the piston to be drawn into the end of the tool when tensioned. The B-6911 tool is equipped with an integral safety collar to ensure the puller-bolt stem remains captive if the puller-bolt insert fails. Older A-6774 and A-6799 tools were equipped with a safety nut on the lower portion of the puller-bolt stem. Verify this safety nut is re-installed when the puller-bolt stems are re-installed in the tool. Replacement A-6774 and A-6799 puller-bolt stems are of the B-6911 integral design. 4. Posit Positio ion n to torqu rque e tool tool with with the the two dowel dowels s inse inserte rted d into into th the e pist piston on nu nut. t. Tigh Tighte ten n pu pullllerer-bo bolt lt un unti till to torqu rque e to tool ol is co comp mple lete tely ly tigh tightt agai agains nstt the the pist piston on rod asse assemb mbly ly,, a mini minimu mum m of 8 tu turns rns,, th then en ba back ck of offf 1/ 1/4 4 tu turn. rn. NOTE: The puller-bolt nut of the B-6911 torque tool comes with barring holes to insert a 3/8 inch (9.5 mm) rod to tighten or loosen the puller-bolt.
5. App Apply ly hydr hydrau aulilic c press pressure ure to the the torqu torque e tool tool to st stret retch ch pist piston on rod (s (see ee ). Use clea clean n hy hydra draul ulic ic flui fluid d in pump/tool system. CAUTION: Do not overpressure torque tool; it can cause tool failure and/or excessive piston rod pre-load. Excessive pre-load can cause piston rod failure, which may result in personal injury. Install puller-bolt into the piston rod a minimum of 8 turns for the 1"-8 puller-bolt insert or 7 turns for the 7/8-9 puller-bolt insert. This prevents piston rod to puller-bolt thread failure, which may result in personal injury. If the puller-bolt fails to turn the specified number of turns, STOP. Inspect the tool to find the cause. Correct the problem and try again. Configure tool properly. 6. Loos Loosen en pi pist ston on rod nut nut by turni turning ng the the hex hex pini pinion on driv drive e co coun unte terc rclo lock ckwis wise e with with a so sock cket et wrenc wrench. h. Releas Rele ase e hy hydra draul ulic ic press pressure ure,, remo remove ve torque torque tool, tool, and then then remov remove e the piston piston nut. nut.
Piston and Rod Reassembly with Hydraulic Tool 1. Clean Clean all pi pisto ston n and rod as asse sembl mbly y parts parts thorou thoroughl ghly. y. Verify Verify piston piston is intern internall ally y clean clean and dry. dry. NOTE: Any reassembly of used parts requires re-cleaning and re-lubrication of threads and seating seating surfaces. surfaces. 2. In Insp spec ectt co collllar ar (or co collllar ar area area on rod, rod, whe when n co collllar ar is inte integra grall an and d no nott se sepa parab rable le),p ),pis isto ton, n, an and d pist piston on nu nutt fo forr ni nick cks, s, burrs burrs or sc scrat ratch ches es.. Repla Replace ce if su surfa rface ces s are da dama mage ged, d, worn, worn, or ga galllled ed.. In Insp spec ectt pist piston on ring ring groov gro oves es.. If dama damage ged d or rin ring g groov groove e width width is out out of tole tolera ranc nce e repla replace ce th the e pist piston on (see (see Appe Appendix ndix B for to tole leran rance ces). s). Dress Dress su surfa rface ces s with with a fine fine grit grit st ston one e as requi required red.. Fit Fit co collllar ar an and d nu nutt into into pist piston on to ve verif rify y th the e outs outsid ide e di diam amet eter er fits fits and and turns turns freel freely y by hand hand in the the pist piston on.. 3. Inspec Inspectt piston piston rod threads threads an and d colla collarr shou shoulde lder. r. Clean, Clean, de-bur de-burr, r, an and d lubric lubricate ate threads threads.. Instal Installl colla collar r and and nut nut onto onto pi pist ston on rod to ve verif rify y insi inside de diam diamet eter er fits fits and and rotat rotates es freel freely. y. Tigh Tighte ten n pi pist ston on nu nutt un unti till pi pist ston on th threa reads ds protru protrude de to ve verif rify y freed freedom om of threa thread d enga engage geme ment nt.. Remov Remove e nu nutt an and d co collllar. ar. ee fo forr to torqu rque e to seatt studs. sea studs. 4. Apply Apply a th thin in co coat at of Never Never-Se -Seez ez Regul Regular ar Grad Grade e to pist piston on rod sh shou ould lder, er, rod co collllar ar lo loca cati ting ng ba band nd,, an and d co collllar ar fa face ce in co cont ntac actt wit with h pist piston on,, then then sl slid ide e co collllar ar onto onto ro rod. d. 5. Apply Apply a th thin in co coat at of Never Never-Se -Seez ez Regul Regular ar Grad Grade e to pist piston on rod th thre read ads s at th the e pist piston on en end, d, th then en slid slide e pi pist ston on onto onto rod and and co collllar. ar.
REV: 10/14
Page 4-15 of 50
Section 4 Part Replacement
For models JGC:D:F
NOTE: If one end of the piston is machined 0.002 inch (0.05 mm) undersize across a 3/4 inch (20 mm) wide band (for manufacturing purposes) and the piston has the same number of piston ring grooves on each side, assemble with the undersize band toward the head end. For pistons with a different number of piston ring grooves on each side, assemble with the side of fewer piston ring grooves toward the head end. See FIGURE See FIGURE 413 6. Appl Apply y a th thin in co coat at of NeverNever-Se Seez ez Reg Regul ular ar Grad Grade e to pist piston on nu nutt th thre read ads s an and d pi pist ston on mati mating ng fa face ce.. In Inst stal alll nut nut and and hand hand tigh tighte ten n to ma make ke up the the pist piston on rod asse assemb mbly ly.. 7. Mark Mark a liline ne acros across s pi pist ston on and and nut nut prior prior to torqu torquin ing g to ensu ensure re th the e nu nutt tu turns rns.. Verif Verify y th the e th threa reade ded d ho hole le in the the rod is cl clea ean n and and oile oiled. d. Posit Positio ion n the the torqu torque e tool tool with with the the two do dowel wels s plac placed ed in into to th the e pist piston on rod nu nut. t. Tighte Tig hten n puller-b puller-bolt olt head, head, un until til torque torque tool tool is comp complet letely ely tig tight ht ag again ainst st the piston piston rod as asse sembl mbly, y, then then back back of offf 1/ 1/4 4 tu turn. rn. NOTE: The puller head comes with barring holes to insert a rod to help tighten or loosen the puller, if necessary.
8. App Apply ly hydra hydraul ulic ic press pressure ure of 5400 5400 psig psig (3723 (37230 0 kP kPa) a) to torqu torque e to tool ol to st stret retch ch th the e pist piston on rod. rod. To tigh tighte ten n pi pist ston on rod nut, nut, use use a ca calilibr brat ated ed torqu torque e wren wrench ch to torq torque ue th the e he hex x pini pinion on drive drive to 10 100 0 lb-ft lb-ft (136 (136 N•m). N•m). CAUTION: Do not overpressure torque tool; it can cause tool failure and/or excessive piston rod pre-load. Excessive pre-load can cause piston rod failure, which may result in personal injury. Install puller-bolt into the piston rod a minimum of 8 turns for the 1"-8 puller-bolt insert or 7 turns for the 7/8-9 puller-bolt insert. This prevents piston rod to puller-bolt thread failure, which may result in personal injury. If the puller-bolt fails to turn the specified number of turns, STOP. Inspect the tool to find the cause. Correct the problem and try again. Configure tool properly. NOTE: Periodically calibrate hydraulic pressure gauges for the required pressure. Use optional Ariel hydraulic hand pump kit. 9. Release Release hydrauli hydraulic c pressure. pressure. Reapply Reapply hydraulic hydraulic pressure, pressure, loosen loosen piston piston nut without without disasse disassembli mbling, ng, an and d then then re-tight re-tighten en to the recomm recommend ended ed torque. torque. This This do doubl uble-t e-torqu orquing ing ensures ensures piston piston as asse sembl mbly y integrity. 10. Relea 10. Release se hydra hydraul ulic ic press pressure ure and and remov remove e torqu torque e tool tool.. Insp Inspec ectt th the e pist piston on rod at th the e en end d of th the e pi pist ston on;; it sh shou ould ld not not protru protrude de more more than than 0.01 0.010 0 inch inch (0.2 (0.25 5 mm mm)) past past th the e pist piston on fa face ce.. Th The e nu nutt sh shou ould ld be flus flush h or recessed. TABLE 4-1 Set Screw Torque, lb x in (N•m)
11. App 11. Apply ly a th thin in co coat at of NeverNever-Se Seez ez Reg Regul ular ar Grade rade to two new new Allen Allen se sett sc screws rews.. To inst instal alll a set set scre screw, w, ti tigh ghte ten n it 15 15°° pa pas st the the Al Alle len n wrench yi wrench yield eld po point int.. Discard Discard the deform deformed ed Allen wrench and use a new Allen wrench to tigh tighte ten n th the e ot othe herr se sett sc screw rew in the the sa same me way. way. If Allen wrenches wrenches are unavaila unavailable, ble, use the torque torq ues s in TABLE TABLE 4-1. 4-1. 12. Us 12. Use e a pu punc nch h wi with thin in 1/16 1/16 inch inch (1.5 (1.5 mm) mm) of set set screw screw threads threads to de deform form the thread threads s and stak st ake e se sett sc screws rews in plac place. e.
FIGURE 4-14 Staking a Set Screw
Si z e
Torque
#10-32
36 (4.07)
1/ 4 - 28
87 (9 ( 9.83)
5/1 /16 6 - 24
165 (18.6 .64 4)
3/ 8- 24
288 (32.54)
13. Use 13. Use a ca calilibra brate ted d sc scal ale e to weigh weigh pist piston on rod asse assemb mbly ly with with pi pist ston on rin rings gs an and d wear wear ba band nd.. Stamp Stamp weigh weightt on pi pist ston on head head end. end. Flat Flatte ten n any any raise raised d lilips ps to avoi avoid d cl clea earan rance ce meas measure ureme ment nt errors errors.. Record Record weigh weightt fo for r fut future ure referen reference ce.. See “Oppos “Opposed ed Thro Throw w - Reci Recipro proca catin ting g Wei Weight ght Bal Balanc ancing ing”” on pa page ge C-3
Page 4-16 of 50
REV: 10/14
For models models JGC:D:F JGC:D:F
Section 4 Par Partt Replacemen Replacementt
Piston and Rod Installation 1. Instal Installl piston piston rin rings gs in cylin cylinde derr mai main n bore bore with withou outt piston piston to meas measure ure en end d ga gaps ps.. Ariel Ariel rec recomm ommend ends s replac rep lacing ing piston piston rin rings gs when the en end d gap equals equals three three tim times es its origin original al spec specifi ifica catio tion. n. See Appen See Appendix dix B for specifi specificati cation. on. 2. Use cy cylilind nder er and and pack packin ing g oil oil to lubri lubrica cate te the the pist piston on rin rings gs an and d rin ring g groov grooves es.. In Inst stal alll rin rings gs on th the e pist piston on with ring ga gaps ps stagg staggere ered. d. a. Fo Forr cy cylilind nders ers requi requirin ring g two-p two-pie iece ce pist piston on rin rings gs,, ve verif rify y th that at th they ey are a se sett by th the e matc match h marks marks.. TwoTwopi piec ece e rin rings gs use use dots dots as matc match h marks marks -veri -verify fy the the dots dots fa face ce th the e press pressure ure side side of cy cylilind nder. er. Do no nott us use e two pi pis sto ton n ri ring ngs s of the the same same matc match h mark marks s on the the same ame bo bore re siz ize e on a un unit it.. b. For For al alll ot othe herr rin rings gs,, se see e "Piston "Piston Rings" below. 3. Use th the e pi pist ston on rod entry entry sl slee eeve ve to sl slid ide e pist piston on rod wit with h pi pist ston on rin rings gs an and d wear wear ba band nd into into cy cylilind nder er bo bore. re. Damage Damag e to th the e pack packin ing g rin rings gs is poss possib ible le if an entry entry sl slee eeve ve is no nott us used ed.. 4. Positi Position on the crank cranksh shaft aft so the cross crosshe head ad is levele leveled d in de dead ad cente centerr po posi sitio tion. n. For crank cranksh shaft afts s with
round rou nd webs, webs, use use a dial dial indi indica cato torr to dete determi rmine ne dead dead ce cent nter er po posi siti tion on.. 5. Lubric Lubricate ate the piston piston rod and cross crosshea head d thread threads s with Never-See Never-Seez z Regula Regularr Grade. Grade. Spin Spin the balanc balance e nut nut onto onto th the e pi pist ston on rod. rod. Tu Turn rn the the pist piston on rod into into the the cros crossh shea ead. d. Visua Visualllly y ce cent nter er th the e pa pack ckin ing g flan flange ge aroun aro und d th the e pi pist ston on rod and and torqu torque e pack packin ing g bolt bolts s per per Appendix Appendix A. 6. Set piston piston en end d cl clear earanc ance e (see (see Appendix Appendix B): a. Using Using th the e pi pist ston on turni turning ng tool tool,, turn turn the the pist piston on rod into into th the e cross crosshe head ad.. b. Pla Place ce a fe feel eler er gaug gauge e equa equall to th the e cran crank k end end cl clea earan rance ce requi required red in th the e crank crank en end d to top p va valv lve e po pock cket et betwe between en th the e pist piston on and and the the head head on cy cylilind nder. er. c. Snug Snug pi pist ston on agai agains nstt the the feel feeler er gaug gauge e so the the feel feeler er ga gaug uge e ca cann nnot ot be pu pulllled ed ou out. t. d. Snug Snug the cross crosshe head ad nut agains againstt the cross crosshea head. d. e. Tighte Tighten n the cross crosshea head d nut by the sl slugg ugging ing metho method d or by hy hydrau draulic lic torquin torquing g device device.. See Mainte Mai ntena nanc nce e an and d Repair Repair manual manual for hy hydra drauli ulic c torquin torquing g de devic vice. e. shead ead Ins Instal tallat lation ion”” on pa page ge 4-2 4-29 9 for det detail ails s to re-atta re-attach ch piston piston rod to cross crosshea head, d, chec check k 7. See“Cros See “Crossh piston pis ton en end d cl clear earanc ance, e, pis piston ton rod runou runoutt an and d cross crosshe head ad cleara clearanc nces es,, and re-ass re-assem emble ble to clos close e cy cylin linder der and crosshead crosshead guide. guide. CAUTION: Ariel recommends leaving distance piece covers off after any piston rod or rod packing ring maintenance. Verify no ignition sources exist in the area, pressurize the unit, and check for gas leaks before distance piece cover installation. This protects against crosshead guide over-pressure and possible ignition due to incorrect installation of packing case or components. When checking for leaks, take proper precautions in process gas applications, such as H 2S.
REV: 10/14
Page 4-17 of 50
Section 4 Part Replacement
For models JGC:D:F
3. Set Scr Screw ew 4. Pist Piston on Nut Spanner
1. Crosshead 2. Crosshead Nut
FIGURE 4-15 Typical Piston and Rod Installation
Piston Rod Runout Check pi Check pist ston on rod run out out afte afterr new new unit unit inst instal alla lati tion on,, unit unit reloc relocat atio ion, n, or main mainte tena nanc nce e th that at may may af affe fect ct rod run out. Verify proper Verify proper shimm shimming ing of cross crosshea head d gu guide ides s to level. level. Veri Verify fy the cross crosshea heads ds di direc rectly tly conta contact ct the bo botto ttom m of the the cr cros ossh shea ead d guid guide. e. A 0.00 0.0015 15 inch inch (0.04 (0.04 mm mm)) feel feeler er st stoc ock k sh shou ould ld no nott inse insert rt more more th than an 1/ 1/2 2 in inch ch (13 mm) mm) at al alll fo four ur co corne rners rs of th the e cross crosshe head ad.. Posi Po siti tion on th the e st stem em of a 0. 0.00 0001 01 inch inch (0.00 (0.001 1 mm mm)) incr increm emen entt ca calilibra brate ted d dial dial TABLE 4-2 Max. Piston indic ind icato atorr ag again ainst st the piston piston rod, clo close se to the packin packing g case case.. Set indica indicator tor Rod Runout Readings to ze zero ro with with pi pist ston on to toward ward the the cran crank k end. end. Take Take readi reading ngs s in both both ve verti rtica call Di Dirrection ion In Inc ch (mm) mm) an and d horizo horizonta ntall directi directions ons.. When When meas measurin uring g vertic vertical al rod move movemen ment, t, record rec ord upward upward moveme movement nt as positi positive ve and downward downward movem movement ent as Ver Verti tica call 0.00 .002 (0.05 .051) ne negat gativ ive. e. When When meas measurin uring g ho horiz rizon ontal tal rod mov movem ement ent,, record record move movemen mentt Horrizont Ho izontal al 0.0 .001 01 (0.02 0.025) 5) toward toward th the e auxi auxililiary ary end end of the the frame frame as posi positi tive ve and and move moveme ment nt to toward ward the the drive drive end end of th the e frame frame as nega negati tive ve.. Copy Copy TABL TABLE E 4-3 belo below w to record readin rea dings gs.. Rotate Rotate crank cranksh shaft aft manua manually lly an and d record record rea readin dings gs at mid-st mid-strok roke e an and d with piston piston at the he head ad end. end. Compare Comp are readin readings gs to TAB TABLE LE 4-2 4-2.. TABLE 4-3 Piston Rod Run Out @ 0°, Inches R un un Out Measurement Piston @ CE Vertical (0°)
Throw 1
Throw 2
Throw 3
Throw 4
Throw 5
Throw 6
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
Mid-Stroke Piston Pist on @ HE Piston @ CE
Horizontal (0°)
Mid-Stroke Piston Pist on @ HE
Page 4-18 of 50
REV: 10/14
For models models JGC:D:F JGC:D:F
Section 4 Par Partt Replacemen Replacementt
If a vertical reading is greater than the maximum acceptable, use this procedure to determine acceptability: Bre Break ak the the bala balanc nce e nut nut loos loose. e. Look Lookin ing g from from th the e he head ad en end, d, tu turn rn th the e pist piston on 90 90ºº to th the e left left,, and and re-to re-torq rque ue th the e bala balanc nce e nut. nut. Record Record both both ve verti rtica call and and ho horiz rizon onta tall (90 (90º) º) readi reading ngs s in th the e ta tabl ble e be belo low. w. If readi rea ding ngs s are 0. 0.00 0003 03 inch inch or less less than than the the origi origina nall (0º (0º)) run ou outt readi reading ngs s ab abov ove, e, th the e ro rod d is ac acce cept ptab able le break bre ak th the e bala balanc nce e nut nut loos loose. e. Re-se Re-sett C.E. cl clea eara ranc nce e and and rere-to torqu rque e th the e ba bala lanc nce e nu nut. t. If rod run ou outt is great gre ater er th than an 0. 0.00 0003 03 inch inch more more than than the the origi origina nall (0°) (0°) readi reading ng ab abov ove, e, co cont ntac actt Ariel Ariel.. TABLE 4-4 Alternate Piston Rod Run Out @ 90°, Inches Run Out Measurement Piston @ CE Vertical (90°)
Throw 1
Throw 2
Throw 3
Throw 4
Throw 5
Throw 6
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
Mid-Stroke Piston Pist on @ HE Piston @ CE
Horizontal (90°)
Mid-Stroke Piston Pist on @ HE
Vertical Ver tical Run Out Difference Differencea Horizontal Horizon tal Run Out Differe Difference ncea a. Pist Piston on @ H. H.E. E. 0° - 90°.
Piston Rings Rings Most cylin Most cylinder ders s us use e one-pi one-piec ece e an angle gle-cu -cutt fil filled led PTFE piston piston rin rings gs.. High-pre High-press ssure ure cylin cylinde ders rs us use e two-piec two-piece e thermoplas thermo plastic tic rings. rings. Ariel recommend recommends s replacin replacing g rings when the end gap increase increases s to three times times the new dimensi dimension. on. To measu mea sure re en end d ga gaps ps,, insert insert rin rings gs in the cylin cylinde ders rs without without piston pistons s (see (see Appendix Appendix B for ne new w and and maximu maximum m end gap dimensio dimensions). ns).
High-Pressure Face-Cut Piston Rings Fa Face ce-cu -cutt pi pist ston on rin rings gs are typi typica calllly y used used in cy cylilind nders ers with with 25 2500 00 ps psii MAWP MAWP or high higher, er, an and d ge gene neral rally ly with with notc notche hed d and and flut fluted ed wear wear band bands. s. The The rings rings inst instal alll wit with h the the fa face ce cu cuts ts to toward ward th the e high highes estt press pressure ure,, or towar toward d th the e neare nearest st head head.. Gas Gas press pressur ure e in the the wear wear band band ar area ea es esca cape pes s pa past st th the e pist piston on rin rings gs via via th the e fa face ce cu cuts ts durin during g th the e su suct ctio ion n st stro roke ke to preve prevent nt load loadin ing g the the wear wear ba band nd an and d in incr crea ease se se serv rvic ice e life life.. Also, Also, do no nott alig align n th the e rin ring g end end gaps gaps;; st stag agge gerr them them to mini minimi mize ze gas gas leak leakag age. e.
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Page 4-19 of 50
Section 4 Part Replacement
For models JGC:D:F
1. Piston Rod 2. Crank End
3. Piston 4. Pist Piston on Rings
5. Wear Band 6. Head End
7. Notches 8. Staggered E End nd Gaps
FIGURE 4-16 High-Pressure Face-Cut Piston Ring Orientation
Wear Bands Most piston Most pistons s us use e a si sing ngle, le, on one-p e-piec iece e an angle gle-cu -cutt fil fille led d Teflon Teflon wear band. band. High-pre High-press ssure ure cy cylin linder ders s us use e twopiece pie ce thermo thermopla plasti stic c wear bands bands (see (see FIGURE FIGURE 4-1 4-16 6). Since wear Since wear band bands s do not not work as se seal alin ing g rin rings gs,, end end gap gap is not not cri criti tica cal. l. Wear Wear ba band nd pr proj ojec ecti tion on be beyo yond nd th the e ou outer ter piston piston diame diameter ter is importa important. nt. To chec check k wear ba band nd projec projectio tion, n, meas measure ure piston piston to cy cylin linde derr bo bore re clea cl earan rance ce at th the e bott bottom om of the the bore. bore. There There is no need need to remov remove e th the e pist piston on from from th the e cy cylilind nder. er. Repla Replace ce wearr band wea band befo before re it wea wears rs enou enough gh to allo allow w the the pist piston on to touc touch h th the e cy cylilind nder er bo bore. re. In Inst stal alll wear wear ba band nds s in th the e sa same me way as pi pist ston on rin rings gs,, abov above. e.
Piston Rod Packing Th The e pi pist ston on rod pack packin ing g preve prevent nts s gas gas from from ente enterin ring g the the cros crossh shea ead d gu guid ide. e. Pisto Piston n rod rin rings gs withi within n th the e pa pack cking ing wear ov over er time time an and d need need repla replace cemen ment. t.
Piston Pist on Rod Packing Remov Removal al on an and d Rod Rem Remov oval al”” on pa page ge 4-1 4-12 2. 1. Remov Remove e pi pist ston on and and pist piston on rod rod.. Se See e “Pist “Piston 2. Remove Remove pa pack cking ing diaph diaphragm ragm (if applic applicab able) le) and oil wipe wiperr packi packing ng.. 3. Disconn Disconnec ectt al alll tubing tubing an and d instrum instrumen entat tatio ion n (if ap appli plica cable ble)) from pa pack ckin ing g fla flange nge.. Remove Remove the twelve twelve-poin pointt ca cap p sc scre rews ws th that at hold hold the the pres pressu sure re pack packin ing g glan gland d to th the e crank crank en end d of th the e cy cylilind nder/ er/he head ad.. 4. Do not not remov remove e th the e smal smalll nuts nuts from from the the st stud uds. s. They They hold hold th the e pa pack ckin ing g ca case se to toge geth ther er fo forr remov removal al as an assembly. 5. Pull Pull enti entire re press pressure ure pack packin ing g out out into into the the cros crossh shea ead d guid guide, e, th then en th throu rough gh th the e la large rge side side op open enin ing g of th the e gu guide ide.. Take Take press pressure ure packin packing g to a clean clean place place for dis disas asse sembl mbly. y. 6. Set Set press pressure ure pack packin ing g on a cl clea ean n su surfa rface ce on it its s nose nose cu cup p or cy cylilind nder er en end. d. Matc Match h mark mark th the e ou outs tsid ide e di diam amet eter er of th the e cu cups ps for for prop proper er reass reassem embl bly. y. Three Three long long tie tie st stud uds s ho hold ld th the e press pressure ure pa pack ckin ing g to toge geth ther. er. Th The e st stud ud hole holes s ar are e uneq unequa ualllly y sp spac aced ed to pre preve vent nt misa misalilign gnme ment nt of th the e st stac ack k of pa parts rts.. Remov Remove e th the e nu nuts ts an and d un unsta stack ck the press pressure ure pac packi king ng.. Replac Replace e these these nut nuts s each each time time the press pressure ure packin packing g is servi service ced. d.
Page 4-20 of 50
REV: 10/14
For models models JGC:D:F JGC:D:F
Section 4 Par Partt Replacemen Replacementt
7. To ch chec eck k rin ring g wear, wear, plac place e asse assemb mble led d rings rings (note (note matc match-m h-mark arks) s) on th the e pist piston on ro rod. d. Check Check en end d ga gap p clea cl earan rance ce.. If th the e ends ends butt butt,, or near nearly ly butt butt,, repl replac ace e the the rin rings gs.. See “Ty “Type pes s of Pis Pisto ton n Rod Pac Packi king ng Rings Rin gs”” on pa page ge 4-2 4-22 2 for correc correctt ring ori orient entati ation on.. 8. Carefu Carefulllly y file file any any fins fins or wire edge edges s on the the rin rings gs to sq squa uare re all all ma matc tchi hing ng ed edge ges. s. 9. Pry lo loos ose e th the e meta metall gask gasket et on the the en end d cup cup wi with th a sha harp rp awl. awl. Do no nott scra scratc tch h th the e si side des s of th the e ga gas sket ket groove. 10. Before 10. Before reass reassem embly bly,, clean clean all pa parts rts thorou thoroughl ghly. y.
Piston Rod Packing Reassembly 1. Refer Refer to th the e press pressure ure pack packin ing g asse assemb mbly ly in yo your ur parts parts bo book ok.. Ariel Ariel su supp pplilies es pa parts rts bo book oks s with with ea each ch un unit it.. Conta Con tact ct yo your ur di dist strib ribut utor or to obta obtain in a parts parts book book.. Each Each press pressure ure pa pack ckin ing g re-bu re-builild d kit kit incl includ udes es a pressure press ure packing packing assembl assembly y drawing. drawing. 2. Ta Take ke ca care re not not to sc scrat ratch ch mati mating ng su surfa rface ces s of the the cu cups ps.. Cup su surfa rface ces s must must be clea clean n an and d dry fo forr re-
assembly. 3. To in inst stal alll a new new se sett of rod rin rings gs in an exis existi ting ng pack packin ing g ca case se,, in insp spec ectt ca case se pa parts rts fo forr wear. wear. Cups Cups sh shou ould ld be smoo smooth th an and d fl flat at on the the ba back ck si side de wher where e the the rod rod ring rings s must must seal seal.. If cup ups s or gr groo oov ves ar are e conc concav ave e or tapere tap ered, d, regrin regrind d or relap relap them. them. Contac Contactt Ariel Ariel for ap appro propria priate te rework rework thi thick ckne ness ss dimens dimension ions. s. It is rarely rarely nece necess ssary ary to al alte terr the the cross crosshe head ad si side de of cu cups ps,, but but if nece necess ssary ary,, ta take ke ca care re no nott to de dest stroy roy th the e co corre rrect ct si side de cleara clearanc nce e for the renewal renewal rin rings gs.. NOTE: If premature wear is suspected, see “Force see “Force Feed Lubrication Conditions” on page 3-30.. 3-30 4. Before Before a packin packing g case case instal installat lation ion,, disas disasse sembl mble e and thorou thorough ghly ly clean clean it in an approp appropriat riate e solve solvent nt for the intended intended service. service. 5. Verif Verify y th the e prope properr posi positi tion on of each each FIGURE 4-17 Piston Rod rod rin ring g and and cu cup p and, and, unle unless ss nonnonPacking Case Lube Cups lu lube be,, co coat at rin rings gs lilibe beral rally ly wit with h new, new, clean clea n lubrican lubricantt before before reassembl reassembly. y. Use only only th the e sa same me lubr lubric ican antt in the the force forc e feed feed lube lube syste system. m. If no non-lu n-lube be,, see “Comp “Compon onent ent Clea Cleanin ning g& Thread Thre ad Lu Lube be for Non-L Non-Lub ube e Compres Comp resso sorr Cyli Cylind nders ers”” on pag page e 449.. Ensure 49 Ensure tie tie st stud uds s are co comp mple lete tely ly threade thre aded d into into the en end d cup. cup. Examin Examine e al alll parts parts fo forr unus unusua uall nick nicks s or burrs burrs which whi ch may may in inte terfe rfere re with with the the free free floa floati ting ng of th the e ro rod d ring ring in the the cups cups.. Ta Take ke parti particu cula larr ca care re with with rod rin rings gs made ma de of so soft ft mate materia rials ls,, su such ch as bronz bronze e or TFE. TFE. It is extre extreme mely ly impo importa rtant nt to ha hand ndle le an and d in inst stal alll wiper wiper rin rings gs to preve prevent nt dama damage ge to the the sc scrap rapin ing g edge edges. s. If pack packin ing g ca case se is “wa “wate ter”-c r”-coo oole led, d, se see e “Water-Cooled Pisto Pis ton n Rod Pa Pack ckin ing” g” on pa page ge 4-2 4-26 6. 6. Lay out out parts parts on a work benc bench h for for progre progress ssiv ive e inst instal alla lati tion on,, with with ea each ch pa part rt in its its co corre rrect ct po posi siti tion on an and d th the e rod rin rings gs with with thei theirr prope properr face faces s toward toward the the pres pressu sure. re. Th Three ree lo long ng tie tie st stud uds s ho hold ld th the e press pressur ure e packin pac king g togeth together. er. The stud stud ho holes les are un unequ equall ally y spac spaced ed to preve prevent nt misali misalignm gnmen entt of the stack stack of pa parts. rts. Note that that all rod rin ring g segme segments nts are carefu carefully lly lettere lettered; d; as asse sembl mble e them them ac acco cordin rdingly gly.. This This is most most impo importa rtant nt fo forr prope properr se seal alin ing. g. Cente Centerr si side de-lo -load aded ed WAT an and d AL rin rings gs prior prior to tigh tighte teni ning ng tie tie st stud ud nu nuts ts.. In Inst stal alll tie tie nuts nuts and and tigh tighte ten n to the the torqu torques es in Appen in Appendix dix A. Manual Manually ly verify verify all rings rings move move freely freely,, radia radially lly,, in their their groov grooves es.. Side-lo Side-loade aded d rin rings gs are snug snug,, but shoul should d still still mov move e manua manually lly.. Center Center these these rin rings gs..
REV: 10/14
Page 4-21 of 50
Section 4 Part Replacement
For models JGC:D:F
7. For ne new w in insta stalla llatio tions ns,, carefu carefully lly cl clea ean n all ac accu cumul mulate ated d dirt in the lin lines es an and d compr compres esso sor. r. Any foreign foreign materi ma terial al lodges lodges in the packin packing g an and d be beco comes mes de destru structi ctive vely ly abras abrasive ive.. 8. Prior Prior to pack packin ing g ca case se inst instal alla lati tion on,, insp inspec ectt end end cu cup p gask gasket et fo forr ni nick cks s an and d da dama mage ge th that at may may ca caus use e le leak akag age. e. If in doub doubt, t, repla replace ce the the gask gasket et.. Verif Verify y the the gask gasket et su surfa rface ce in th the e pa pack ckin ing g co coun unte terr bo bore re on th the e cr cran ank k end end of th the e cy cylilind nder/ er/he head ad is cl clea ean n and and not not sc scrat ratch ched ed.. 9. Reins Reinsta tallll co comp mple lete te pack packin ing g ca case se asse assemb mbly ly with with oil oil su supp pply ly po poin intt on to top. p. Use rod pa pack ckin ing g bo bolt lts s to pu pullll packin pac king g into place. place. 10. Reinsta 10. Reinstallll packin packing g di diaph aphrag ragm m (if ap appli plica cabl ble) e) an and d wipe wiperr pa pack cking ing.. 11. Reinsta 11. Reinstallll piston piston an and d rod. rod. See“Pi See “Pist ston on an and d Rod In Inst stal alla lati tion on”” on pa page ge 4-1 4-17 7. 12. After 12. After tig tighte htenin ning g the cross crosshe head ad nut, nut, tig tighte hten n rod pac packin king g bo bolts lts ev even enly ly to the recom recommen mended ded torque torque in Appendix Appendix A. Th This is pr proc oced edure ure sq squa uares res the the press pressure ure pack packin ing g on its its no nose se ga gask sket et.. To al alig ign n th the e pa pack ckin ing, g, use use fe feel elers ers to main mainta tain in a unif uniform orm cl clea earan rance ce all all aroun around d betwe between en th the e ca case se bo bore re an and d th the e rod. rod. Rod pa pack cking ing bo bolt lt tig tighte htenin ning g on high high press pressure ure cylin cylinde ders rs requir requires es a torque torque multi multipli plier. er.
NOTE: Repeat final torque for rod packing bolts until the bolts no longer turn. Re-check torque on these fasteners at the next service interval. 13. Retight 13. Retighten en tie stud stud nuts. nuts. Reinsta Reinstallll tubing tubing conn connec ectio tions ns and in instru strumen ments ts (if applic applicab able). le). Take Take care care no nott to cross cro ss-th -thread read tubing tubing nuts. nuts. Tubin Tubing g nuts nuts must must be tig tight. ht. NOTE: After pressure packing installation, see “Force see “Force Feed Lubricator” on page 3-20 to 3-20 to prime the force feed lube system and obtain recommended lubrication rates for new machine breakin. Repeat priming each time a compressor is started because oil lines may bleed during down time. Break-in lube rates are approximately twice the normal rates, or half the normal indicator pin cycle time.
CAUTION: Ariel distance piece covers offin after piston rod or the rod packing ringrecommends maintenance.leaving Verify no ignition sources exist the any area, pressurize unit, and check for gas leaks before distance piece cover installation. This protects against crosshead guide over-pressure and possible ignition due to incorrect installation of packing case or components. When checking for leaks, take proper precautions in process gas applications, such as H 2S.
Long Two-Compartment Intermediate Packing Compresso Compres sors rs supp supplie lied d with long long two-com two-compart partme ment nt distan distance ce pi piec eces es includ include e an interm intermedi ediate ate packin packing g as asse semb mbly ly that that seals seals around around the rod bet between ween the outbo outboard ard an and d inboa inboard rd distan distance ce piece pieces. s. This This packi packing ng as asse semb mbly ly inclu includes des a singl single e AL rin ring g set. set. Fo Forr lubri lubrica cate ted d se servi rvice ce,, the the force force feed feed lube lube oils oils the the top top of the the rin ring g se sett at a ve very ry low low rate rate be beca caus use e th this is rin ring g se sett is not not su subj bjec ectt to cy cylilind nder er pre press ssur ures es and and temp tempera eratu tures res.. The The en end-t d-to-e o-end nd se seal al in th the e cu cup p an and d th the e low low lu lube be rate rat e of AL rin ring g se sets ts,, ensu ensure res s newly newly inst instal alle led d rin rings gs run vi virtu rtual ally ly dry fo forr th the e firs firstt fe few w ho hours urs of op opera erati tion on.. To av avoid oid damage damage to the rings rings and rod, rod, copio copious usly ly oil the ring set set du during ring insta installa llatio tion, n, be before fore rod instal installat lation ion.. nt Clea Cleanin ning g& Use only only th the e sa same me lu lubri brica cant nt in the the force force feed feed lube lube sy syst stem em.. If no non-l n-lub ube, e, se see e “Compone “Component Threa Th read d Lu Lube be fo forr Non Non-Lu -Lube be Com Compre press ssor or Cyl Cylin inde ders rs”” on pa page ge 44-49 49..
Types of Piston Rod Packing Rings Th There ere ar are e se seve veral ral type types s of pist piston on rod pack packin ing g rings rings depe depend ndin ing g on the the ap appl plic icat atio ion. n. Belo Below w are th thos ose e us used ed in Ariel JGC:D:F JGC:D:F compress compressors. ors.
Page 4-22 of 50
REV: 10/14
For models models JGC:D:F JGC:D:F
Section 4 Par Partt Replacemen Replacementt
“P” Pressure Breaker Th This is si sing ngle le rin ring g is cu cutt radia radialllly y into into three three equa equall se segm gmen ents ts.. It break breaks s do down wn or slows slo ws ga gas s flo flow w withou withoutt seali sealing ng it compl complete etely ly.. Total Total end ga gap p instal installed led is 0. 0.04 040 0 to 0. 0.04 046" 6" (1 (1.0 .0 to 1.2 1.2 mm) mm) for for PEEK, PEEK, 0.02 0.020 0 to 0.02 0.026" 6" (0 (0.5 .5 to 0. 0.7 7 mm mm)) for for bronz bronze e and and ca cast st iro iron. n. To main mainta tain in end end gap, gap, adju adjust st rin ring g ga gap p or repla replace ce ring.
FIGURE 4-18 “P” Pressure Breake B reaker r
“UP” Pressure Breaker
Th This is si sing ngle le so solilid d rin ring g break breaks s down down or sl slows ows gas gas flow flow witho without ut se seal alin ing g it completely.
FIGURE 4-19 “UP” Pressure Breake B reaker r
“P1U” Pressure Breaker This two-ring This two-ring set set allows allows contro controlle lled d lea leaka kage ge in one directi direction on only only and and in inst stal alls ls in th the e first first or se seco cond nd pack packin ing g cu cup p (clo (close sest st to th the e pi pist ston on). ). Th The e first first ring ring (pres (pressu sure re si side de)) is one-p one-pie iece ce with wit h a sin ingl gle e ra radi dial al cut; ut; the the seco second nd ring ring is soli solid d an and d has has a bore bore la large rgerr th than an th the e rod diam diamet eter. er. Tota Totall end end gap gap inst instal alle led d is 0. 0.04 040 0 to 0. 0.04 046 6 in in.. (1 (1.0 .0 to 1.2 1.2 mm) mm) for for PEEK, PEEK, and and 0.02 0.020 0 to 0. 0.02 026 6 in in.. (0 (0.5 .5 to .0 .07 7 mm) mm) for for Bronz Bronze, e, and and Cast Cast Iron Iron.. Main Ma inta tain in end end gap gap by adju adjust stin ing g ring ring gap gap or repla replaci cing ng the the ring.
FIGURE 4-20 “P1U” Pressure Breaker
“BTR” Single-Act Single-Acting ing Seal Set Th This is th thre ree-r e-rin ing g se sett se seal als s in one one direc directi tion on only only.. The The firs firstt rin ring g (pres (pressu sure re si side de)) is radia radialllly y cu cut. t. The The se seco cond nd ring ring is tang tangen enti tial ally ly st step ep cu cutt and and made made of the the sa same me mate materia riall as the the first first rin ring. g. Th Thes ese e two rin rings gs are dowel doweled ed to st stag agge gerr the the cu cuts ts from from one one rin ring g to the the othe other. r. Tota Totall end end gap gap inst instal alle led d is 3/ 3/8 8 to 13 13/3 /32 2 in in.. (9 (9.5 .5 to 10 10.3 .3 mm) mm) for for PEEK, PEEK, Bronz Bronze, e, an and d Cast Ca st Iron Iron,, an and d 3/ 3/16 16 to 7/32 7/32 in. in. (4.8 (4.8 to 5.6 5.6 mm) mm) for for Tefl Teflon on.. Main Ma inta tain in end end gap gap by adju adjust stin ing g ring ring gap gap or repla replaci cing ng the the rin ring. g. Th The e th third ird rin ring g is ca calllled ed a back back-up -up rin ring. g. It is radia radialllly y cu cutt and and has has a bore bore la large rgerr than than the the rod rod diam diamet eter. er. This This allo allows ws the the ra radi dial al jo join ints ts to fo form rm a tigh tightt gas gas se seal al.. This This ring ring need needs s no dowel. dowel. REV: 10/14
FIGURE 4-21 “BTR” Single-Acting Seal Set
Page 4-23 of 50
Section 4 Part Replacement
For models JGC:D:F
“BD” Double-Acti Double-Acting ng Seal Set This two-ring This two-ring set set cons consis ists ts of tangen tangentia tially lly step step cut cut rin rings gs dowel doweled ed to st stag agge gerr th the e tang tangen enti tial al cu cuts ts from from one one rin ring g to the the othe other. r. Tota Totall en end d ga gap p in ins stall talled ed is 3/8 3/8 to 13 13/3 /32 2 in in.. (9.5 (9.5 to 10.3 10.3 mm)) fo mm forr PEEK, PEEK, Bronz Bronze, e, an and d Cast Cast Iron Iron,, an and d 3/16 3/16 to 7/32 7/32 in. in. (4.8 (4. 8 to 5. 5.6 6 mm) mm) fo forr Te Tefl flon on.. Main Mainta tain in end end gap gap by adju adjust stin ing g rin ring g gap gap or repla replaci cing ng th the e rin ring. g. This This doub double le acti acting ng se sett se seal als s in either either direc directio tion. n. In cylin cylinde ders rs op operat eratin ing g near near atm atmos osph pheric eric press pre ssure ure,, it preve prevents nts air from en enteri tering ng the cylin cylinde der. r. Ins Instal talll with wit h th the e matc match h mark mark le lett tters ers faci facing ng the the press pressure ure..
FIGURE 4-22 “BD” Double-Acting Seal Set
WAT Double-Acti Double-Acting ng Seal Set In this this th three ree-ri -ring ng Te Tefl flon on se set, t, the the first first two rin rings gs (pres (pressu sure re side si de)) are radia radialllly y cu cut; t; th the e third third is tang tangen enti tial ally ly st step ep cu cut. t. The The la last st two rin rings gs are dowel doweled ed to st stag agge gerr the the cu cuts ts from from one one ring ring to th the e ot othe her. r. Tota Totall end end ga gap p inst instal alle led d is 3/16 3/16 to 7/32 7/32 in. in. (4.8 (4. 8 to 5. 5.6 6 mm). mm). Main Mainta tain in end end gap gap by adju adjust stin ing g ring ring gap gap or repla rep laci cing ng th the e rin ring. g. Th The e firs firstt rin ring, g, alon along g with with the the ce cent nter er rin ring, g, fo forms rms a wedge wedge th that at overc overcom omes es rod rod frict frictio ion n and and hold holds s the the rin ring g se sett agai agains nstt both both groov groove e face faces s durin during g eith either er di direc recti tion on of rod trave travel. l. Use this this rin ring g se sett prima primaril rily y for for low low press pre ssure ure ap appli plica catio tions ns.. WAT rings rings must must be cente centered red when
FIGURE 4-23 “WAT” Double-Acting Seal Set
instal ins talled led in the packi packing ng case case..
“AL” Double-Act Double-Acting ing Seal Set This fiv This five-ri e-ring ng Teflon Teflon set set functi functions ons lik like ea doub double le-e -end nded ed “WAT” “WAT” rin ring g se set. t. To Tota tall end end gap gap ins insta tall lled ed is 3/ 3/16 16 to 7/ 7/32 32 in. in. (4.8 (4.8 to 5.6 5.6 mm). mm). Main Ma inta tain in end end gap gap by adju adjust stin ing g ring ring gap gap or repla rep laci cing ng th the e rin ring. g. It to tota talllly y bl bloc ocks ks leak leakag age e in a groov gro ove e supp supplie lied d with low-pres low-pressu sure re flu fluid. id. AL rin rings gs must must be ce cent ntere ered d when when inst instal alle led d in the the packing pac king case. case.
FIGURE 4-24 “AL” Double-Acting Seal Set
“BTU” Single-Ac Single-Acti ting ng Seal Set
Th This is th three ree-ri -ring ng se sett se seal als s in one one direc directi tion on only only.. The The firs firstt rin ring g (pres (pressu sure re si side de)) is radia radialllly y cu cut; t; the the se seco cond nd is tang tangen enti tial ally ly st step ep cu cut. t. Th Thes ese e fi first rst two rin rings gs are do dowe wele led d to stag stagge gerr th the e cuts cuts from from on one e ring ring to the the othe other. r. The The th thir ird d ri ring ng is call called ed a ba back ck-u -up p ring ring.. It is so solilid, d, with with a bore bore la large rgerr than than the the rod diam diamet eter, er, al allo lowin wing g radia radiall jo join ints ts to form form a tigh tightt gas gas se seal al.. Tota Totall en end d ga gap p in inst stal alle led d is 3/ 3/8 8 to 13/3 13/32 2 in. in. (9.5 (9.5 to 10 10.3 .3 mm) mm) fo forr PEE PEEK, K, Bronz Bronze, e, an and d Cast Cast Iron Iron,, an and d 3/16 3/16 to 7/32 7/32 in. in. FIGURE 4-25 “BTU” Single-Acting Seal Set (4.8 (4.8 to 5. 5.6 6 mm) mm) fo forr Tefl Teflon on.. Main Mainta tain in en end d ga gap p by ad adjus justin ting g rin ring g ga gap p or replac replacing ing rin ring. g.
Page 4-24 of 50
REV: 10/14
For models models JGC:D:F JGC:D:F
Section 4 Par Partt Replacemen Replacementt
“BTUU” Single-Ac Single-Acti ting ng Seal Set Th This is fo four ur-ri -ring ng se sett se seal als s in one one direc directi tion on only only.. Th The e first first rin ring g (p (pres ressu sure re si side de)) is radiall radi ally y cut; cut; the seco second nd is tange tangenti ntiall ally y step step cu cut. t. Th Thes ese e rin rings gs are dowel doweled ed to st stag agge ger r the the cut uts s fr from om on one e ri ring ng to the the othe other. r. The The third third and and fo fourt urth h rin rings gs are so solilid d and and have have bores bores la large rgerr th than an th the e rod rod diam diamet eter, er, allo allowin wing g th the e ra radi dial al jo join ints ts of the the se seal alin ing g rin rings gs to fo form rm a ti tigh ghtt ga gas s sea eal. l. Tota Totall en end d ga gap p FIGURE 4-26 “BTUU” Single-Acting Seal Set in inst stal alle led d is 3/ 3/8 8 to 13 13/3 /32 2 in. in. (9.5 (9.5 to 10 10.3 .3 mm) mm) for for PEEK, PEEK, an and d 3/ 3/16 16 to 7/32 7/32 in in.. (4.8 (4.8 to 5.6 5.6 mm) mm) for for Tefl Teflon on.. Ma Main inta tain in en end d ga gap p by ad adju just stin ing g ring ring ga gap p or replac repl acing ing the rin ring. g.
“CU” Single-Act Single-Acting ing Seal Set Th This is th thre ree-r e-rin ing g se sett se seal als s in one one direc directi tion on only only.. The The firs firstt rin ring g (pres (pressu sure re si side de)) is radia radialllly y cu cut. t. The The se seco cond nd rin ring g is ta tang ngen enti tial ally ly cu cut. t. The The first first two rings rings are do dowe wele led d to st stag agge gerr the the cuts cuts from from on one e ring ring to the the ot othe her. r. The The th thir ird d ri ring ng is calle alled d a ba back ck-u -up p ring ring.. It is so solilid d and and has has a bore bore large largerr than than the the rod diam diamet eter. er. Tota To tall en end d ga gap p in inst stal alle led d is 3/8 3/8 to 13 13/3 /32 2 in. in. (9.5 (9.5 to 10 10.3 .3 mm) mm) fo forr PEEK, PEEK, Bronz Bronze, e, an and d Cast Cast Iron Iron,, an and d 3/ 3/16 16 to 7/ 7/32 32 in in.. (4 (4.8 .8 to 5.6 5.6 mm) mm) for for Tefl Teflon on.. Main Mainta tain in end end gap gap by adju adjust stin ing g rin ring g gap gap or repla replaci cing ng the the rin ring. g.
FIGURE 4-27 “CU” Single-Acting Seal Set
“STU” Single-Ac Single-Acti ting ng Seal Set Th This is th thre ree-r e-rin ing g se sett se seal als s in one one direc directi tion on only only.. The The firs firstt rin ring g (pres (pressu sure re si side de)) is so solilid, d, wit with h radia radiall grove groves s on th the e pr pres essu sure re si side de.. The The se seco cond nd rin ring g is tange tan genti ntiall ally y cut. cut. The thi third rd rin ring g is solid solid..
FIGURE 4-28 “STU” Single-Acting Seal Set
“CR” Single-Act Single-Acting ing Seal Set Th This is th thre ree-r e-rin ing g se sett se seal als s in one one direc directi tion on only only.. The The firs firstt rin ring g (pres (pressu sure re si side de)) is radia radialllly y cu cut. t. The The se seco cond nd rin ring g is ta tang ngen enti tial ally ly cu cut. t. The The first first two rings rings are do dowe wele led d to st stag agge gerr the the cuts cuts from from on one e ring ring to the the ot othe her. r. The The th thir ird d ri ring ng is calle alled d a ba back ck-u -up p ring ring.. It is radi radial ally ly cut an and d ha has s a bo bore re larg larger er than than the the rod rod diam diamet eter er to al allo low w the the radi radial al join joints ts to form form a tigh tightt gas gas seal seal.. Tota Totall en end d ga gap p ins install talled ed is 3/8 3/8 to 13/3 13/32 2 in. in. (9.5 (9.5 to 10 10.3 .3 mm) mm) fo forr PEEK, PEEK, Bronz Bronze e an and d Cast Cast Iron Iron,, and and 3/16 3/16 to 7/ 7/32 32 in in.. (4 (4.8 .8 to 5. 5.6 6 mm mm)) for for Tefl Teflon on.. Main Mainta tain in en end d gap gap by adju adjust stin ing g rin ring g gap gap or repla replaci cing ng the the rin ring. g.
FIGURE 4-29 “CR” Single-Acting Seal Set
REV: 10/14
Page 4-25 of 50
Section 4 Part Replacement
For models JGC:D:F
“3RWS” Oil Oil Wiper Wiper Set Th The e th three ree ca cast st iro iron n rin rings gs in this this se sett are radia radialllly y cu cutt and and dowel doweled ed to st stag agge gerr the the cu cuts ts from from one one rin ring g to th the e ot othe her. r. Th They ey ke keep ep cran crankc kcas ase e oil oil out out of the the pack packin ing g and and cy cylilind nder er.. Asse Assemb mble le with with the the bl blan ank k fa face ce to towar wards ds th the e oil oil (cran (crankc kcas ase) e) and and the the slott sl otted ed si side de towards towards the pressu pressure re pa pack cking ing.. To Tota tall end end gap gap in inst stal alle led d is 3/16 3/16 to 7/32 7/32 in. in. (4.8 (4.8 to 5. 5.6 6 mm). mm). Main Mainta tain in end end gap gap by adju adjust stin ing g ring ring gap gap or re repl plac acin ing g th the e rin ring. g.
FIGURE 4-30 “3RWS” Oil Wiper Set
Arrangement of Piston Rod Packing Rings
Ariel supplie supplies s packin packings gs in five pressure pressure range ranges. s. The figu figure re to the right
sh shows ows th the e gene general ral arran arrange geme ment nt of the the oil oil su supp pply ly,, se seal al ring, ring, an and d ve vent nt locati loc ations ons.. The type type of rin rings gs us used ed dep depend ends s on the press pressure ure app applic licati ation on.. A separate separate diaphragm diaphragm in the crosshe crosshead ad guid guide e carries carries the oil wiper rin rings gs and and one one se seal al rin ring g se set. t.
Piston Rod Packing Ring Material FIGURE 4-31 Piston Rod Some ye Some years ars ago, ago, bronz bronze e was the the st stan anda dard rd mate materia riall for for all all Ari Ariel el Packing Ring Arrangement pa pack cking ings. s. Bronze Bronze,, ho howeve wever, r, is tot totall ally y un unsa satis tisfac factory tory for sour sour gas servi service ce,, (hydro (hydroge gen n sulfi sulfide de in the ga gas). s). PEEK, cast cast iron an and d Teflon Teflon provide provide ou outst tstand anding ing servi service ce with sour sour gas, gas, and and si sinc nce e th they ey perfo perform rm equa equalllly y wel welll with with sweet sweet gas, gas, they they are no now w st stan anda dard rd ma mate teria rials ls.. A typical typical packing packing consis consists ts of a PEEK pressure pressure breaker, breaker, Teflon/ca Teflon/cast st iron single-a single-actin cting g rings, rings, all Teflon Teflon do doubl uble-a e-acti cting ng rin rings gs,, an and d a cast cast iron wiper wiper set. set. The Tef Teflon lon is glass glass-rei -reinfo nforce rced d an and d impreg impregnat nated ed with molyb mo lybde denum num disulf disulfide ide to provi provide de a strong strong,, sl slic ick k materi material al to reduc reduce e frictio friction n and wear.
Water-Cooled Piston Rod Packing When an When any y disas disasse semb mbly ly of (optio (optiona nal) l) water-co water-cool oled ed rod pa pack cking ing case cases s is requir req uired ed from the manufa manufactu cturer rer as suppl supplied ied/as /as receiv received ed cond conditi ition, on, prope pro perr re-ass re-assem embly bly and leak leak testin testing g is require required. d.
Reassembly See “Piston “Piston Rod Pac Packi king ng Reas Reasse semb mbly ly”” on pa page ge 4-2 4-21 1 and “Types “Types of Pisto Pis ton n Rod Pac Packi king ng Rin Rings gs”” on pa page ge 4-2 4-22 2. Refer to th Refer the e press pressure ure pack packin ing g asse assemb mbly ly in the the parts parts book book su supp pplilied ed with with yo your ur unit unit.. Conta Contact ct yo your ur dist distrib ribut utor or if yo you u do not not have have a parts parts bo book ok.. A press pre ssure ure pa pack cking ing as asse sembl mbly y drawing drawing also also comes comes with each each press pressure ure packing pac king re-build re-build kit. Water-coole Water-co oled d case cases s are lappe lapped. d. Take Take spec special ial care care not to scratc scratch h cup cup matin ma ting g surfac surfaces es;; it can can caus cause e signi signific fican antt proble problems ms.. Cup surfac surfaces es must must be cl clea ean n and and dry fo forr re-as re-asse semb mbly ly..
FIGURE 4-32 Water-Cooled Packing Turnaround Cups
1. The cups cups are number numbered ed on the outsi outside de diamet diameter; er; as asse sembl mble e them them in cons consec ecuti utive ve order, order, st starti arting ng with 4-32 2. The The st stud uds s ar are e the the end end cu cup. p. See See th the e press pressur ure e pack packin ing g asse assemb mbly ly in yo your ur pa parts rts bo book ok an and d FIGURE FIGURE 4-3 offs offset et so th the e cups cups fi fitt on only ly on one e way. way.
Page 4-26 of 50
REV: 10/14
For models models JGC:D:F JGC:D:F
Section 4 Par Partt Replacemen Replacementt
2. Veri Verify fy th the e ti tie e stu tuds ds thre thread ad comp comple lete tely ly in into to the the en end d cup. cup. Put Put th the e pr prop oper er ring ring in th the e gr groo oov ve an and d fa face ce it in th the e prope properr di direc recti tion on.. Th Three ree long long tie tie st stud uds s hold hold the the press pressure ure pa pack ckin ing g to toge geth ther. er. Th The e st stud ud ho hole les s ar are e no nott equa equalllly y sp spac aced ed.. This This preve prevent nts s misa misalilign gnme ment nt of the the st stac ack k of pa parts rts.. When When slid slidin ing g pa parts rts on onto to th the e tie tie stud st uds, s, ta take ke ca care re not not to sc scrat ratch ch the the lapp lapped ed face faces. s. Unles Unless s no non-l n-lub ube, e, co coat at rin rings gs libe liberal rally ly with with clea clean n lubric lub ricant ant before before reass reassem embly bly.. Use on only ly the same same lubric lubricant ant us used ed in the force force feed feed lube lube syst system. em. 3. Insta Installll th the e se seco cond nd cu cup, p, posi positi tion on the the rings rings,, and and ve verif rify y th the e two smal smalll O-rin O-rings gs are in pl plac ace e aroun around d th the e coola coolant nt ho holes les.. Repeat Repeat thi this s step step to as asse semb mble le the remain remaining ing parts parts cons consec ecuti utive vely ly in the confi configu gurati ration on detai det ailed led in the pa pack cking ing case case dra drawing wing.. 4. Tigh Tighte ten n tie tie st stud ud nuts nuts to the the torqu torque e list listed ed in Appendix Appendix A. Manua Manually lly verify verify all rin rings gs move move freely freely,, radial radially, ly, in th thei eirr groov grooves es.. Side-l Side-loa oade ded d WAT and and AL rin rings gs are sn snug ug,, bu butt sh shou ould ld st stililll move move manu manual ally ly.. Cente Center r these thes e rings. rings.
Testing All internal internal passag passages es must must function function with 100% 100% verificat verification. ion. To check check passag passages, es, blow dry compress compressed ed air
throu through gh th the e co conn nnec ecti tion on taps taps on the the flan flange ge and and ve verif rify y that that air air ex exit its s at th the e prope properr ho hole les. s. Air ap appl plie ied d to th the e conne connecti ction on tap stamp stamped ed “Coolan “Coolantt In” shoul should d ex exit it the conne connecti ction on tap stampe stamped d “Coolant “Coolant Out”; Out”; or air applie applied d to th the e ta tap p st stam ampe ped d “Lube “Lube”” sh shou ould ld exit exit at the the appro appropri priat ate e cu cup p on th the e insi inside de diam diamet eter er of th the e ca case se.. Pressu Pres sure re le leak ak test test pa pack cking ing case cases s as fol follows lows:: 1. Appl Apply y 60 to 10 100 0 ps psii (4 to 7 ba bar) r) dry, dry, compr ompres ess sed air air to th the e “Cool “Coolan antt In In”” conn connec ecti tion on;; it sho houl uld d ex exit it at conn connec ectio tion n tap “Coolan “Coolantt Out”. Out”. For water-co water-coole oled d rod pac packin king g case cases s in non-lu non-lube be servi service ce,, us use e oil-fre oil-free e co comp mpre ress ssed ed ai air. r. Air appl applie ied d to the the tap tap st stam ampe ped d “Lub “Lube” e” sh shou ould ld ex exit it at th the e appr approp opria riate te cu cup p on th the e insi inside de diamet dia meter er of the case case.. 2. Plug Plug th the e “Cool “Coolan antt Out” ut” conn connec ecti tion on an and d ap appl ply y 60 to 10 100 0 ps psii (4 to 7 ba bar) r) dr dry, y, compr ompres ess sed air air to th the e “Coolan “Cool antt In” conne connecti ction on through through a ball ball valve valve with a calib calibrate rated d press pressure ure ga gauge uge loca located ted between between the ball ball va valv lve e and and pack packin ing g ca case se.. Close Close the the ball ball va valv lve e and and disc discon onne nect ct th the e air air su supp pply ly.. Press Pressure ure sh shou ould ld no nott drop dro p for fiv five e minute minutes, s, minimu minimum. m. Disass Disassem emble ble,, inspec inspect, t, repair, repair, re-ass re-assem emble ble,, an and d re-test re-test any case cases s th that at fa failil th this is te test st.. Packi Packing ng ca case ses s may may be bolt bolted ed into into plac place e in a cy cylilind nder er he head ad to aid aid se seal alin ing, g, with with prope proper r bolting bolt ing and torques. torques.
Crossheads CAUTION: Before removing a cylinder head, back off all cap screws 1/8 inch (3 mm). Verify the head is loose and the cylinder is completely vented. Crossheads are heavy. Handle with care to avoid personal injury. The balance sheet that comes in the manual with each compressor lists each crosshead weight.
REV: 10/14
Page 4-27 of 50
Section 4 Part Replacement
Crosshead Removal NOTE: See Section See Section 1 for illustrations of tools mentioned below. 1. Remo Remove ve crosshe crosshead ad guide guide side si de co cove vers rs and and (head (head end) end) cylin cylinder der he head ad or un unloa loader der.. 2. Move Move cro cross sshe head ad to its inner inner de dead ad cente centerr po posi sitio tion. n. Back Back off, off, bu butt do no nott re remo move ve,, the the cross cro sshe head ad nu nutt set set screws screws.. 3. Loo Loose sen n cross crosshe head ad nut with
For models JGC:D:F
the spec specia iall slugg slugging ing pe peg g or op open en en end d wrench, wrench, de depen pendin ding g on nu nutt ty type pe.. Or us use e separately purchased hydrauli hyd raulic c crosshea crosshead d nut torque torqu e tool. tool.
4. End Plate 1. Shoe Area 5. Thru Bolt 2. Bushing Lock Nut 3. Crosshead Pin
6. Crosshead Nut 9. Set Scr Screw ew (loosen before 7. Roll Pin turning nut) 8. Thru Bolt
FIGURE 4-33 Typical Crosshead
4. Use Use th the e pi pis sto ton n nu nutt spann panner er to thre thread ad the the pis piston ton rod rod ou outt of th the e cr cros oss she head ad.. The The tw two o do dowe wels ls on th the e sp span anne nerr fit fit hole holes s in the the pist piston on nut. nut. Threa Thread d the the cros crossh shea ead d nu nutt of offf th the e pi pist ston on rod. rod. Push Push th the e rod en end d forwar forward d to th the e edge edge of the the pack packin ing g to provi provide de cl clea earan rance ce fo forr cr cros ossh shea ead d remov removal al.. 5. With cross crosshea head d in its outer outer dea dead d cente centerr pos positi ition on,, remov remove e cross crosshe head ad pin thru-bo thru-bolt, lt, lock lock nu nut, t, end-pl end-plate ates s and and pi pin. n. Disca Discard rd ol old d lock lock nut. nut. 6. Turn crank cranksh shaft aft to its inner inner de dead ad cente centerr po posi sitio tion. n. Move Move cross crosshea head d to its outer outer dead dead cente centerr po posi sitio tion, n, free fre e of th the e co conn nnec ecti ting ng rod. rod. Sup Suppo port rt co conn nnec ecti ting ng rod so it do does es no nott drop drop an and d da dama mage ge th the e cr cros ossh shea ead d guide guid e surface. surface. 7. Remove Remove oi oill wiper wiper pa pack cking ing from cross crosshe head ad guide guide diaphr diaphragm agm.. 8. Install Install cros crosshe shead ad installa installation tion/remov /removal al tool. tool. 9. Push Push cross crosshea head d on onto to cross crosshea head d insta installa llatio tion/re n/remov moval al tool tool and rotate rotate cross crosshea head d 90 90°. °. 10. Sl 10. Slid ide e a 3/ 3/16 16 in inch ch (5 mm) mm) thic thick k plat plate e into into the the gap gap betwe between en th the e cross crosshe head ad an and d cr cros ossh shea ead d gu guid ide e (see (see FIGURE 4-3 FIGURE 4-35 5). 11. Remove 11. Remove di diaph aphrag ragm m from cross crosshe head ad guide guide and slide slide cross crosshea head d ou outt of cross crosshe head ad guide guide onto onto the pl plate ate.. in Appendix dix B ). Dete Determ rmin ine e pin pin wear wear by 12. Che 12. Check ck cross crosshe head ad pin to bu bush shing ing cl clea earan rance ce (see (see Appendix Appendix B in Appen inspection. 13. Replac 13. Replace e pin, pin, if ne nece cess ssary ary.. To rep repla lace ce bu bush shing ings, s, ha hack cksa saw w or file file to with within in 1/3 1/32 2 in inch ches es (1 mm mm)) of th thei eirr th thic ickn knes ess, s, then then drift drift them them out. out.
Page 4-28 of 50
REV: 10/14
For models models JGC:D:F JGC:D:F
14. New bushi 14. bushing ng instal installat lation ion req require uires s a press press.. To ins instal talll a bushin bushing g in th the e cross crosshe head ad,, co cool ol the the bush bushin ing g in 95% 95% alco alcoho holl with with dry ic ice e solut solution ion.. Le Leav ave e the bu bush shing ing in the solut solution ion long long en enou ough gh to reach reach the same same tempe temperatu rature re as the solut solution ion,, ab about out -110°F -110°F (-80 (-80°C). °C). CAUTION: Do not touch cold surfaces without proper protection. Alcohol is flammable; use it only in open air or well-ventilated buildings. Avoid sparks and open flame. Avoid alcohol vapors which may cause injury to nose and eye tissue. Do not return solution to a closed container until it reaches room temperature or container may explode. NOTE: Directly support the crosshead side receiving the new bushing to prevent the press from possibly crushing
Section 4 Par Partt Replacemen Replacementt
the crosshead (see FIGURE (see FIGURE 4-34). 4-34). Thoroughly clean bushing and crosshead to prevent dirt accumulation between bushing and crosshead bore.
FIGURE 4-34 Crosshead Bushing Replace Replacement ment
15. Inspec 15. Inspectt shoe shoe surfac surfaces es;; there there shou should ld be no wear whatso whatsoev ever. er.
Crosshead Installation NOTE: Return crossheads to their original throw location. Use frame oil for lubrication where needed. 1. La Lay y a 3/ 3/16 16 in inc ch (5 mm) mm) thic thick k plat plate e in the the bott bottom om of the the cr cros ossh shea ead d guid guide e and and lay lay cros crossh shea ead d on it its s si side de (see (see FIG FIGURE URE 435). 35 ). Oi Oill cross crosshea head d an and d gu guide ide surfac surfaces es.. 2. Mount Mount Crossh Crosshead ead Instal Installat lation ion Tool Tool on onto to cross crosshea head d gu guide ide FIGURE URE 4-3 4-35 5). diaphr dia phragm agm an and d oil tool tool bea bearing ring surfac surfaces es (see (see FIG With tool tool mount mounted ed on diaph diaphrag ragm, m, instal installl diaph diaphrag ragm m into into cross cro sshea head d guide. guide. Sli Slide de cross crosshe head ad onto onto tool. tool. NOTE: Long two-compartment crosshead guides supplied prior to 11/08 require a crosshead installation tool with a smaller pilot diameter. Contact Ariel for the proper tool.
FIGURE 4-35 Crosshead Installation
3. Remov Remove e 3/ 3/16 16 in inch ch (5 mm mm)) thic thick k plat plate. e. Rotat Rotate e cross crosshe head ad 90 90°. °. Slide Slide cro cross sshe head ad into into gu guid ide e an and d of offf of th the e in inst stal alla lati tion on to tool ol.. Verif Verify y it does does not not beco become me co cock cked ed.. If cr cros ossh shea ead d be beco come mes s wedge wedged, d, do no nott fo force rce it. it. Ease Eas e it of offf and and st start art agai again. n. Be ca caref reful ul not not to dama damage ge cross crosshe head ad sh shoe oe su surfa rface ce du durin ring g in inst stal alla lati tion on.. 4. Remove Remove cross crosshea head d instal installat lation ion too tooll and reinsta reinstallll wiper wiper pa pack ckin ing. g.
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Page 4-29 of 50
Section 4 Part Replacement
For models JGC:D:F
5. Li Lift ft cr cros ossh shea ead d end end of co conn nnec ecti ting ng rod rod and and turn turn crank cra nksh shaft aft to its ou outer ter de dead ad cente centerr po posit sition ion to loca locate te the conne connecti cting ng rod in pos positi ition on an and d insert insert cross cro sshe head ad pin. pin. Use cross crosshe head ad pin alignm alignmen entt tool tool on th the e oppo opposi site te si side de of the the cros crossh shea ead d to as assis sistt pin inserti insertion on.. Oi Oill cross crosshea head d pin and al align ignmen mentt tool tool pri prior or to instal installat latio ion. n. Instal Installl cross cro sshe head ad pin en end-p d-plat lates es,, thru-bo thru-bolt, lt, and a new lo lock ck nut. nut. Tigh Tighte ten n th thruru-bo bolt lt and and lock lock nut nut to the the torque torq ue listed listed in in Appen Appendix dix A . (TIP: (TIP: If pin pin inse inserti rtion on is diffic difficult ult,, chill chill it first.) first.) 6. Lu Lubri brica cate te piston piston rod thread threads s with Never-Se Never-Seez ez regular regul ar grade. grade. Re-thread crosshe crosshead-ba ad-balanc lance e nu nutt on onto to piston piston rod; rod; allow allow enoug enough h cleara clearanc nce e to att attac ach h rod to cross crosshea head. d. Positi Position on setsc setscrew rew cup cup
FIGURE 4-36 Typical Crosshead Alignment Tool
poin points ts on cross crosshe head ad si side de of nut. nut. 7. Posi Positi tion on cr cran anks ksha haft ft at inne innerr dead dead ce cent nter er posi positi tion on of throw. throw. Use a dial dial indi indica cato torr with with a magn magnet etic ic ba base se to indic indicate ate cross crosshe head ad locati location on when fin findi ding ng ex exac actt inner inner and ou outer ter de dead ad cente centerr po posi sitio tions ns.. NOTE: At this point, set piston end clearance or serious damage may occur. See required piston crank end clearance on cylinder data plate or Appendix or Appendix B . B . 8. Inse Insert rt a fe feel eler er gage gage,, equa equall to the the requi required red cran crank k end end cl clea eara ranc nce, e, th thro roug ugh h an op open en va valv lve e po pock cket et.. Fo Forr 13 in in.. (330 (330 mm) mm) and and la large rgerr cy cylilind nders ers,, inse insert rt feel feeler er gage gage throu through gh a bo bott ttom om va valv lve e po pock cket et.. Tigh Tighte ten n th the e pi pist ston on rod in into to th the e cr cros ossh shea ead d unti untill pist piston on is tigh tightt agai agains nstt th the e fe feel eler er ga gage ge,, an and d th the e fe feel eler er ga gage ge ca cann nnot ot be removed removed manuall manually. y. 9. Tighte Tighten n cross crosshea head-b d-bala alanc nce e nu nutt in one of two ways: ways: a. Strik Strike e th the e sp spec ecia iall sl slug uggi ging ng peg peg or open open end end wrench wrench with with a de dead ad blow blow semi semi-so -soft ft fa face ced d ha hamm mmer er un unti till an audi audibl ble e di diff ffere erenc nce e ca can n be heard heard or the the wrenc wrench h “bo “boun unce ces” s” in indi dica cati ting ng a tigh tightt nu nut. t. Some Some mech me chan anic ics s obta obtain in desi desired red tigh tightn tnes ess s in 3 to 4 st strik rikes es;; ot othe hers rs may may requi require re more more..
Page 4-30 of 50
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For models models JGC:D:F JGC:D:F b. Use a separ separate ately ly purchased crossheadcrossheadbalance bala nce nut hydraulic hydraulic to torqu rque e to tool ol and and hand hand pump pump ki kit. t. See See Appen Appendix dix A for for the hy hydra drauli ulic c press pre ssur ure e to appl apply y to the the torque torq ue tool. tool. When When initia initially lly installi inst alling ng the tool, tool, positio position n the spann spanner er wrench wrench adapte ada pterr op open en area area toward towa rd the span spanner ner wrench wren ch as sh shown own in FIGURE FIGURE 4-3 4-37 7. Apply Apply hy hydra drauli ulic c press pressure ure to the
Section 4 Par Partt Replacemen Replacementt
ram to tigh tighte ten n the the crosshead-balance crosshead -balance nut. When Wh en th the e ra ram m en ends ds it its s travel, trave l, release release pressure pressure an and d in inde dex x th the e ram ram to the the span spanner ner wrench wrench slot slot and/or and /or spann spanner er wrench wrench to FIGURE 4-37 Typical Crosshead Balance Nut Hydraulic adapte ada pter, r, un until til the nu nutt Torque Tool - Tightening Position stop st ops s movi moving ng at the the spec specifi ified ed hy hydra drauli ulic c press pressure ure.. Durin During g tig tighte htenin ning, g, if the ad adapt apter er open open area area turns turns 90° before before the nu nutt is tigh tight, t, remov remove e the the sp span anne nerr wren wrench ch.. Remov Remove e the the bo bolt ltin ing g in th the e sp span anne nerr wrenc wrench h ad adap apte terr to th the e cross cro sshea head-b d-bala alanc nce e nut an and d repos repositi ition on the adapte adapterr so the open open area area again again faces faces the spann spanner er wrench. CAUTION: Do not allow open areas of spanner wrench and adapter to overlap, as the spanner wrench can be sprung. If the wrench becomes sprung, destroy and replace it. When Whe n nut nut is tigh tight, t, remo remove ve feel feeler er gage gage.. Ve Verif rify y remov removal al of al alll to tool ols s from from cy cylilind nder er an and d cr cros ossh shea ead. d. 10. With the head 10. head en end d he head ad or un unloa loader der prope properly rly instal installed led (cl (clos osed ed po posi sitio tion) n) an and d fasten fasteners ers tig tighte htene ned, d, rotat rot ate e crank cranksh shaf aftt 180° 180° to oute outerr dead dead ce cent nter er posi positi tion on of th thro row. w. Rem Remov ove e a to top p he head ad en end d va valv lve. e. Determin Dete rmine e require required d piston piston head head en end d cl clear earanc ance e limits limits from cy cylin linder der da data ta plate plate or Appendix Appendix B . Meas Me asur ure e head head end end cl clea eara ranc nce e at the the top top of the the head head end. end. Using Using fe feel eler er ga gage ges s th throu rough gh th the e op open en va valv lve e pocke poc ket, t, chec check k he head ad end clea clearan rance ce.. Determin Determine e if measu measured red cleara clearanc nce e is within within tol tolera eranc nce. e. Tighte Tighten n the cross cro sshea head-b d-bala alanc nce e nut set set screws screws.. Re-insta Re-installll valv valve e as asse semb mblie lies s an and d prope properly rly tig tighte hten n fasten fasteners ers.. See “Val “Valve ve Ins Instal tallat lation ion”” on pag page e 4-9 4-9.. 11. Check Check pi pist ston on rod runo runout ut and and cros crossh shea ead d cl clea earan rance ces s up upon on re-as re-asse semb mbly ly,, an any y time time a pist piston on rod is on Rod Run Runou out” t” on pa page ge 4-1 4-18 8 for crosshe crosshead ad clearanc clearances. es. removed. remov ed. See “Pist “Piston 12. Replac 12. Replace e cross crosshe head ad gu guide ide si side de cove covers rs an and d gaske gaskets, ts, tig tighte hten n all cap cap sc screws rews ha hand nd wrench wrench tig tight. ht. Lubric Lub ricate ate bo both th si sides des of cove coverr ga gask skets ets with an anti-s ti-seiz eize e lubric lubricant ant or multi multi-pu -purpo rpose se greas grease e to ea ease se fut future ure removal.
Connecting Rods A connect connecting ing rod assemb assembly ly consis consists ts of a rod with bushing bushing,, a rod cap, cap, rod cap bolts bolts (4), and two half bearing bea ring shell shells. s. The be bearin aring g shel shells ls join join togeth together er to form the conn connec ectin ting g rod bearin bearing. g.
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Page 4-31 of 50
Section 4 Part Replacement
For models JGC:D:F
Connecting Rod Removal 1. Remove Remove top cove coverr from crank crankca case se and si side de cove covers rs from cross crosshea head d gu guide ides. s. 2. Remov Remove e th the e midd middle le frame frame sp spac acer er bar bar of the the three three over over th the e de desi sire red d pa pair ir of th throw rows. s. Spac Spacer er ba bars rs fit fit sn snug ugly ly,, but but sh shou ould ld remov remove e manu manual ally ly witho without ut hamm hammeri ering ng.. Th They ey sh shou ould ld no nott fa fallll ou out. t. If fit fit is to too o lo loos ose e or tig tight ht conta contact ct your your pa pack ckage agerr or Arie Ariell before before proce proceed eding ing.. 3. Move Move thro throw w to ou outer ter de dead ad cente centerr pos positi ition on.. 4. Remov Remove e lo lock ck nut, nut, bolt bolt,, end end plat plates es,, and and cros crossh shea ead d pin pin fro from m cross crosshe head ad.. Disca Discard rd old old lo lock ck nu nut. t. Remove cross crosshe head ad as descri describe bed d in“Cros in “Crossh shea ead d Remo Remova val” l” on pag page e 4-2 4-28 8. 5. Remove 6. Suppo Support rt co conn nnec ecti ting ng rod so it does does not not dro drop p and and dama damage ge th the e cr cros ossh shea ead d gu guid ide, e, th then en turn turn th the e cr cran anks ksha haft ft unti untill th the e throw throw is at its its high highes estt poin point. t. Loos Loosen en all all th the e rod ca cap p bo bolt lts s pa part rt way. way. Using Using th the e n 1), jac jack ag agai ains nstt th the e bo bolt lt he head ads s to pu pull ll th the e ro rod d cap cap fr free ee conne connecti cting ng rod cap cap remov removal al tool tool (see (see Sectio Section
from from th the e do dowe wels ls.. Remo Remov ve the the top top two rod rod cap bo bolt lts s an and d th the e ro rod d be bear arin ing g cap ap.. The The bo bott ttom om two bo bolt lts s rema remain in in th the e ca cap p durin during g ca cap p remov removal al.. NOTE: Do not pry or chisel to separate cap from rod; it damages the connecting rod. 7. Half Half of th the e be bear arin ing g shell hell comes omes ou outt with with the the cap. cap. Sl Slid ide e ou outt th the e ot othe herr ha half lf fr from om th the e ro rod. d. 8. Turn crank cranksh shaft aft until until rod can can be remov removed ed through through the cross crosshe head ad gu guide ide si side de cove coverr openin openings gs.. 9. After After removi removing ng conne connecti cting ng rod(s), rod(s), protec protectt crank crank pi pins ns from nicks nicks or sc scratc ratche hes. s. NOTE: To remove all connecting rods, remove the crankshaft before rod removal. Detach all connecting rods from the crankshaft and retract them into the crosshead guides before crankshaft removal. To prevent personal injury, verify neither driver nor compressor cylinder gas pressure can turn the compressor crankshaft during maintenance. Follow appropriate lock out procedures. Before any maintenance or component removal, relieve all pressure from compressor cylinders. See packager information to completely vent the system or call the packager for assistance. After maintenance, purge the entire system with gas prior to operation to avoid a potentially explosive air/gas mixture.
Connecting Rod Bearing Removal NOTE: See Customer Technical Bulletin 132 Bulletin 132,, and 208 and 208 for for important information regarding JGC:D:F connecting rods and connecting rod bearings. 1. Remove Remove frame frame top cove cover, r, all cro cross sshe head ad guide guide cove covers rs an and d app applic licab able le di dista stanc nce e piece piece cove covers rs to ac acce cess ss the wiper wiper pa pack ckin ing g gland gland bolts. bolts. 2. Remov Remove e al alll head head end end head heads. s. 3. Remov Remove e th the e midd middle le frame frame sp spac acer er bar bar of the the three three over over each each pa pair ir of th throws rows.. If repla replaci cing ng main main an and d rod beari bearing ngs, s, remov remove e al alll sp spac acer er bars bars.. If sp spac acer er bar bar bolt bolts s are di diffi fficu cult lt to lo loos osen en,, us use e a 12 12-po -poin intt slug sluggi ging ng wrenc wre nch h and and hamm hammer. er. Spac Spacer er bars bars fit fit sn snug ugly ly,, but but sh shou ould ld slid slide e ou outt by ha hand nd witho without ut ha hamm mmeri ering ng.. Th They ey sh shou ould ld not not fa fallll out. out. If fit fit is too too loos loose e or tigh tight, t, co cont ntac actt yo your ur pa pack ckag ager er or Ariel Ariel be befo fore re proce proceed edin ing. g.
Page 4-32 of 50
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For models models JGC:D:F JGC:D:F
Section 4 Par Partt Replacemen Replacementt
4. Tu Turn rn th the e cr cran anks ksha haft ft unti untill the the throw throw is at it its s high highes estt poin point. t. Loos Loosen en al alll four four bolt bolts, s, bu butt ke keep ep them them sn snug ug agai agains nstt th the e rod ca cap. p. 5. Tu Turn rn th the e cr cran anks ksha haft ft unti untill the the throw throw is at oute outerr dead dead center. 6. Loos Loosen en al alll th the e co conn nn rod bolt bolts s appro approxi xima mate tely ly 3/4 3/4 in. in. (19 mm). mm). 7. Use th the e co conn nnec ecti ting ng rod ca cap p remov removal al tool tool to jack jack agai agains nstt th the e bolt bolt head heads s and and pull pull the the rod ca cap p free free fro from m th the e dowel dowels s (see (see FIGURE FIGURE 4-4 4-40 0). If the the cap does oes not sepa separate rate easily easily from the rod, rod, STOP STOP;; the the rod rod cap may be in a bi bind nd,, whic which h can can brea break k the the dowe dowell pins pins.. If bindin bin ding g oc occu curs, rs, re-tigh re-tighten ten the conn conn rod bol bolts ts an and d repeat rep eat the proce procedure dure..
1. Top Face
3. Threaded Hole for Eyebolt
4. Rod Cap
NOTE: Do not pry or chisel to separate cap from rod; it damages the connecting rod and can break the alignment dowel pins.
5. Rod
2. Conn Rod Bolts
FIGURE 4-38 Rod/Rod Cap Separation
8. After After th the e ca cap p se sepa parat rates es from from the the rod, rod, remov remove e the the ca cap p remov rem oval al to tool ol and and back back out out the the co conn nn rod bolt bolts s co comp mple lete tely ly,, bu butt do no nott remov remove e th them em.. Do not remove the bolts and cap until step 11. 9. Suppo Support rt th the e ca cap p and and rod rod by hand hand or cran crane e while while anot anothe herr pe pers rson on pries pries th the e cr cran ank k end end of th the e cross crosshe head ad toward toward the the cy cylilind nder er unti untill it bo bott ttom oms s ou out. t. When When th the e co conn nnec ecti ting ng rod is cl clea earr of the the cran cranks ksha haft ft,, res restt it on th the e cr cros ossh shea ead d gu guid ide e slide. Do not allow the rod or cap to drop, as damage can occur. 10. Rotat 10. Rotate e th the e rod ca cap p aroun around d the the crank cranksh shaf aftt unti untill the the bolt bolts s are ve verti rtica cal. l. Remove Remo ve bolts, bolts, then then remov remove e cap. cap. Always remove the bolts before the cap to prevent damage to the crankshaft.
FIGURE 4-39 Connecting Rod Cap Removal Tool
Lift ft th the e ca cap p while while hold holdin ing g the the beari bearing ng in the the ca cap p beca becaus use e oi oill ca caus uses es th the e be beari aring ng to st stic ick k to th the e 11. Li 11. cranksha crank shaft ft pin. 12. Rotat 12. Rotate e th the e crank crank to inne innerr dead dead ce cent nter er and and remov remove e the the co conn nnec ecti ting ng rod be beari aring ng.. 13. After 13. After remov removin ing g beari bearing ngs, s, cl clea ean n any any co coki king ng or debr debris is from from bo both th th the e ro rod d an and d ro rod d ca cap p su surfa rface ces s with with a non-me non -metal tallic lic Scotch Scotch-Brite -Brite or si simil milar ar scouri scouring ng pad and solv solven ent. t. Check Check for raise raised d ed edges ges on machin machined ed su surfa rface ces. s. All su surfa rface ces s sh shou ould ld be as cl clea ean n and and dry as po poss ssib ible le.. 1. Remove Remove frame frame top cove coverr and all all cross crosshe head ad gu guide ide cove covers. rs. 2. If rep repla laci cing ng main main and and rod beari bearing ngs, s, remo remove ve all all sp spac acer er ba bars rs.. Space Spacerr ba bars rs fit fit sn snug ugly ly,, bu butt sh shou ould ld slid slide e out out by hand hand witho without ut hamm hammeri ering ng.. They They sh shou ould ld not not fall fall ou out. t. If fit fit is to too o loos loose e or tigh tight, t, co cont ntac actt yo your ur packa pac kager ger or Ariel Ariel before before pro proce ceedi eding. ng. 3. Rotate Rotate the crank cranksh shaft aft to ap appro proxim ximate ately ly 45º (see (see ). 4. Loos Loosen en al alll th the e co conn nn rod bolt bolts s appro approxi xima mate tely ly 1/8 1/8 in. in. (3.2 (3.2 mm). mm). 5. Pry th the e cr cros oss she head ad towa toward rd the the cyl ylin inde derr unti untill it bo bott ttom oms s ou out. t. Work Work th the e ro rod d cap away away fr from om th the e ro rod d as even evenly ly as poss possib ible le.. Se Sepa parat ratin ing g the the two parts parts unev uneven enly ly ma may y break break th the e rod ca cap p do dowel wels s or ca caus use e th them em to bi bind nd in th the e ro rod d do dowe well hole holes. s. If the the two pa part rts s of the the con con ro rod d do no nott sep epar arat ate e ea easi sily ly by ha hand nd,, loos loosen en all all bolt bolts s an addi additi tion onal al 1/8 1/8 in. in. (3. (3.2 2 mm mm)) and and pry the the cros crossh shea ead d ag agai ain. n. NOTE: Do not pry or chisel to separate cap from rod; it damages the connecting rod and can break the alignment dowel pins.
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Page 4-33 of 50
Section 4 Part Replacement
For models JGC:D:F
6. Remov Remove e al alll bolt bolts s from from the the ca cap p first first,, and and then then remov remove e the the ca cap. p. Lift Lift th the e ca cap p while while ho hold ldin ing g th the e be bear arin ing g in the the ca cap p beca becaus use e oi oill ca caus uses es the the beari bearing ng to st stic ick k to the the cran cranks ksha haft ft pin. pin. Do not remove the cap with bolts in place. 7. Supp Suppor ortt th the e rod by hand hand while while anot anothe herr pers person on rot rotat ates es th the e cr cran ank k away away from from th the e rod. rod. When When th the e co conn nnec ecti ting ng ro rod d is cl clea earr of the the cran cranks ksha haft ft,, rest rest it on the the cros crossh shea ead d gu guid ide e slid slide. e. 8. Rotat Rotate e th the e cr cran ank k to inne innerr dead dead ce cent nter er and and remo remove ve the the co conn nnec ecti ting ng ro rod d be beari aring ng.. 9. After After remov removin ing g bear bearin ings gs,, cl clea ean n any any co coki king ng or debri debris s fro from m bo both th th the e rod an and d rod ca cap p su surfa rface ces s with with a no non-m n-meta etalli llic c Scotch Scotch-Brit -Brite e or simila similarr scou scouring ring pa pad d an and d solv solvent ent.Che .Check ck for raise raised d ed edges ges on mach machine ined d su surfa rface ces. s. All su surfa rface ces s sh shou ould ld be as cl clea ean n and and dry as poss possib ible le..
Connecting Rod Bearing Installation 1. Check Check ne new w be beari aring ng shell shells s for ha hand ndlin ling g
1. Rod
5. Bearing Shell 6. Bearing Shell
2. Rod Tab Bushing 3. Rod Dowel 7. Rod Cap Dowels Holes 4. Rod Notch 8. Rod Cap Notch 9. Rod Cap
da damag mage, e, scratc scratche hes, s, burrs, burrs, an and d loose loose materi ma terial al at the tabs. tabs. DO NOT RUB BEARING SURFACE WITH FINGERNAIL. New be beari aring ng shell shells s an and d crank cra nksh shaft aft crank crank pin be beari aring ng surfac surfaces es must must be ab abso solu lute tely ly cl clea ean. n. Fit Fit the the tab tab of a ne new, w, dry dry half half beari bearing ng sh shel elll in into to the the rod notc notch. h. NOTE: Where bearings are identified with an ink pictograph, connecting rod bearings and main bearings are not interchangeable. DO NOT put main bearings in a connecting rod. Do not mix part numbers on an individual main or connecting rod. Both bearing half shells must have the same part number.
FIGURE 4-40 Connecting Rod Bearing 2. Thorou Thorough ghly ly inspe inspect ct the crank crank pi pin n for di dings ngs Installation an and d scratc scratche hes. s. If needed needed,, us use e an Arkans Arkansas as ston st one e to dress dress di ding ngs s and and sc scrat ratch ches es (Norto (Norton n Hard Trans Translu luce cent nt Arkan Arkansa sas s Stone Stone,, 3” x 1/ 1/2” 2” x 1/ 1/2”, 2”, pr prod oduc uctt numb number er HF-43). HF-43). Ligh Lightl tly y sl slid ide e the the st ston one e aroun around d th the e circ circum umfe feren rence ce of th the e crank crank pin pin su surfa rface ce to remo remove ve any any hi high gh sp spot ots; s; do not not sl slid ide e it back back and and forth forth over over th the e le leng ngth th of th the e cr cran ank k pin. pin. After After dr dres essi sing ng,, ensu ensure re th the e crank crank pi pin n is cl clea ean n and and dry dry.. If the the cran crank k is sc score ored d aroun around d th the e circ circum umfe feren rence ce,, us use e 60 600 0 grit grit emery em ery cloth cloth to remov remove e high high spots spots.. 3. Appl Apply y cl clea ean, n, new new lub lube e oil oil libe liberal rally ly to the the crank crank pin. pin. 4. Fit Fit th the e ta tab b of th the e ot othe herr be bear arin ing g she hell ll into into the the rod rod cap cap notc notch. h. 5. At Atta tach ch th the e ro rod d cap to the the rod: rod: a. Rotate Rotate crank cranksh shaft aft to approx approxima imatel tely y ou outer ter de dead ad cente center. r. b. Careful Carefully ly lower lower the conne connecti cting ng rod cap cap (WITHOUT BOLTS!) on onto to th the e cr cran ank k pin. pin. Verif Verify y rod bo bolt lts s are unda undama mage ged d and and free free of dirt. dirt. Lubri Lubrica cate te them them per per , then then pl plac ace e al alll fo four ur bo bolt lts s into into th the e ro rod d ca cap. p. NOTE: Ariel stamps throw numbers on all rod caps and rods. Install a rod cap in the correct throw location with the stamped numbers facing up. c. Rot Rotat ate e ca cap p so th the e bolt bolts s alig align n with with the the co conn nnec ecti ting ng rod bo bolt lt ho hole les. s. Suppo Support rt th the e rod ca cap p while while an anot othe her r pers person on ca caref reful ully ly pries pries the the co conn nnec ecti ting ng rod towar towards ds the the cr cran anks ksha haft ft un unti till it bo botto ttoms ms ou out. t. Align Align th the e rod cap do dowe wels ls wi with th the the rod rod dowe dowell hole holes s an and d push push the the rod rod cap on onto to th the e ro rod d with with ev even en pr pres essu sure re.. The The ro rod d cap cap fi fits ts on onto to the the rod rod on only ly one one way way. Do not not forc force e th the e ro rod d cap cap on onto to th the e rod; rod; th the e do dowe wels ls shou should ld Page 4-34 of 50
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For models models JGC:D:F JGC:D:F
Section 4 Par Partt Replacemen Replacementt
slide slid e in into to th the e rod hole holes s witho without ut diff diffic icul ulty ty.. After After ensu ensurin ring g th the e rod ca cap p se seat ats s prope properly rly on th the e rod, rod, sn snug ug al alll fo four ur bolt bolts s and and pre-to pre-torqu rque e acco accordi rding ng to . d. Rotat Rotate e th the e crank cranksh shaf aftt unti untill the the thro throw w is at its its high highes estt po poin intt an and d tigh tighte ten n al alll co conn nn ro rod d bo bolt lts s to th the e torque torq ue listed listed in Appen in Appendix dix A . 6. Repeat Repeat steps steps 1-5 for all remain remaining ing conn connec ectin ting g rods. rods. 7. Measu Measure re each each conn connec ectin ting g rod be bearin aring g jack jack and thrust thrust cl clear earanc ance e as de detai tailed led in thi this s docume document. nt. If Appendix dix B tolera toleranc nces es,, conta contact ct your your pa pack ckag ager er or Ariel Ariel be before fore cl clear earanc ance e readin readings gs are no nott within within Appen proceeding. NOTE: If replacing main bearings, continue to "Main to "Main Bearing Removal". Removal". If not replacing main bearings, continue to Step 8. 8. In Inst stal alll spac spacer er ba bars rs so the the matc match h mark mark is up an and d next next to th the e spac spacer er bar bar bo boss ss with with th the e same ame mark mark.. Ti Tigh ghte ten n al alll sp spac acerer-ba barr ca cap p sc screws rews to the the torqu torque e lilist sted ed in . 9. Accou Account nt for al alll tools tools,, equipm equipmen ent, t, supp supplie lies, s, and parts parts to en ensu sure re no none ne are le left ft inside inside the crank crankca case se..
10. Exam Examin ine e to top p co cove verr and and si side de co cove verr gask gasket ets. s. If ther there e is do doub ubtt ab abou outt th thei eirr co cond ndit itio ion, n, repla replace ce th them em.. Apply Never-seez Never-seez Regular Regular Grade Grade to both sides sides of the gasket gasket to ease ease future removal. removal. Replace Replace top cove coverr and cross crosshea head d gu guide ide cove covers. rs. Tig Tighte hten n all cap cap sc screws rews hand hand wrench wrench tig tight. ht. 11. Reverse 11. Reverse lockout lockout procedures procedures.. 12. After 12. After replac replacin ing g bearin bearings gs,, thorou thoroughl ghly y pre-lu pre-lube be compr compres esso sorr to ensure ensure be bearin aring g lubric lubricati ation on an and d to he help lp remov rem ove e foreign foreign materi materials als from the lube lube syste system. m. 13. Run 13. Run th the e co comp mpre ress ssor or acco accordi rding ng to the the time time inte interva rvals ls list listed ed on th the e fo form rm in Appen Appendix dix D. Af Afte terr ea each ch ru run, n, sh shut ut down down and and remov remove e the the frame frame top top co cove ver. r. Meas Measure ure main main an and d co conn nnec ecti ting ng rod be beari aring ng ca cap p te temp mpera eratu tures res with with a hand hand held held therm thermoc ocou oupl ple e probe probe or in infra frare red d th therm ermom omet eter er an and d record record th them em on a dix D. Comp Comple lete te the the form form an and d emai emaill or fa fax x it to Ariel Ariel Fiel Field d Serv Servic ice. e. copy copy of th the e fo form rm in Appen in Appendix
Connecting Conn ecting Rod Bushing Bushing Remo Removal val and Install Installation ation 1. Che Check ck cross crosshea head d pi pin n to bushin bushing g cl clear earanc ance e (see (see Appen Appendix dix B in Appen in Appendix dix B ). Dete Determ rmin ine e pin pin wear wear by inspecti insp ection. on. Replace Replace pin, if necess necessary. ary. 2. To repla replace ce a bush bushin ing, g, file file or hack hacksa saw w the exis existi ting ng bush bushin ing g to reduc reduce e th the e tigh tightn tnes ess s of th the e sh shrin rink k fit. fit. From Fro m th the e in insi side de diam diamet eter er,, file file or sa saw w acros across s the the leng length th of th the e bu bush shin ing g to wit withi hin n 1/ 1/32 32 in inch ches es (1 mm) mm) of it its s radia radiall thic thickn knes ess. s. It ca can n then then be easi easily ly drift drifted ed ou out. t. DO NOT file or sa saw w into the connecting rod; any bore damage renders the rod useless and requires rod replacement. 3. Use a hydra hydraul ulic ic press press in a qual qualif ifie ied d mach machin ine e sh shop op to in inst stal alll th the e ne new w bus bushi hing ng.. Do no nott ha hamm mmer er bu bush shin ing g in into to pl plac ace; e; it will will dist distort ort the the bush bushin ing g bore. bore. 4. Be Before fore instal installat lation ion,, cool cool ne new w bushi bushing ng in a 95 95% % alc alcoh ohol ol an and d dry ic ice e solut solution ion.. Le Leav ave e bu bush shing ing in solut solution ion long lon g en enoug ough h to reach reach the solut solution ion tempera temperature ture,, ab abou outt -110°F -110°F (-80°C). (-80°C). 5. Posit Positio ion n co conn nnec ecti ting ng rod on the the press press tabl table e so the the ch cham amfe fered red ed edge ge of th the e rod bu bush shin ing g bo bore re is on to top. p. Align bushing bushing oil hole with connec connecting ting rod oil pas passag sage e (if applicab applicable) le) before before pressing pressing bushing bushing in. The bush bushin ing g has has an annu annula larr groo groove ve aroun around d its its outs outsid ide e diam diamet eter er al alig igne ned d with with th the e oi oill ho hole le;; if th the e bu bush shin ing g sh shif ifts ts in th the e co conn nnec ecti ting ng rod rod durin during g opera operati tion on,, oil oil st stililll trave travels ls to th the e bu bush shin ing g in insi side de diam diamet eter er an and d to th the e cr cros ossh shea ead d pi pin. n. Howeve However, r, a new new bush bushin ing g inst instal alla lati tion on sh shou ould ld co cove verr no more more th than an 1/ 1/3 3 of th the e rod oi oill pass passag age e hole hole.. Fo Forr ELP unit units s with with no drill drilled ed hole hole in the the co conn nnec ecti ting ng rod, rod, bu bush shin ing g ho hole le alig alignm nmen entt is no nott critical critic al (see CTB-208 CTB-208). ). CAUTION: Do not touch cold surfaces without proper protection. Alcohol is
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Section 4 Part Replacement
For models JGC:D:F
flammable; use it only in open air or well-ventilated buildings. Avoid sparks and open flame. Avoid alcohol vapors which may cause injury to nose and eye tissue. Do not return solution to a closed container until it reaches room temperature or container may explode. NOTE: Thoroughly clean bushing and connecting rod to prevent dirt accumulation between them. Immediately assemble them so the bushing does not warm and stick before it is in place. If the bushing sticks, remove it by notching as in step 2 above. 2 above.
Connecting Rod Installation 1. To instal installl a new conne connecti cting ng rod, rod, stamp stamp match match mar mark k nu numbe mbers rs match matching ing the throw throw lo loca catio tion n on the tops tops 4-41 1. of th the e co conn nnec ecti ting ng ro rod d and and beari bearing ng ca cap p (with (with notc notche hes s up). up). Se See e FIGURE FIGURE 4-4
2. Check ne new w be beari aring ng shell shells s for ha hand ndlin ling g da damag mage, e, scratc scratche hes, s, burrs, burrs, an and d loose loose materi material al at the tabs. tabs.DO DO NOT RUB BEARING SURFACE WITH FINGERNAIL. New be bearin aring g shel shells ls and crank cranksh shaft aft crank crank pi pin n bear bearin ing g su surfa rface ces s must must be abso absolu lute tely ly cl clea ean. n. Snap Snap a new, new, dry ha half lf be beari aring ng sh shel elll in into to th the e rod with with th the e beari bearing ng ta tab b pr prop operl erly y loca locate ted d in the the rod notc notch. h. With With the the cran crankc kcas ase e to top p co cove verr of off, f, tu turn rn th the e th throw row to in inne ner r dead dead ce cent nter er posi positi tion on and and sl slid ide e the the rod into into the the cros crossh shea ead d gu guid ide e sp spac ace. e. Oil Oil crank cranksh shaf aftt cr cran ank k pin pin be beari aring ng surfac surfaces es with ne new w clea clean n lubric lubricati ating ng oil, oil, the same same type type us used ed in the frame, frame, be before fore conn connec ectin ting g rod cap installa installation tion.. NOTE: Connecting rod bearings and main bearings are not interchangeable. Connecting rod bearings have a narrower groove or no groove at all. DO NOT put main bearings in connecting rod bearing locations. NOTE: Caps and rods are numbered by throw beginning with number one at the drive end. For throw numbering see FIGURE i-1. see FIGURE i-1. Always install rods with numbers up. Protect crank pin at allsequence, times. 3. Fit Fit co conn nnec ecti ting ng ro rod d to cran crank k pin pin and and turn turn to the the high highes estt posi positi tion on.. Posit Positio ion n ca cap, p, with with a ne new w ha half lf be beari aring ng sh shel elll prope properly rly lo loca cate ted d in the the notc notch, h, an and d the the bolt bolts. s. Snug Snug all all bo bolt lts; s; do no nott tigh tighte ten n th them em to fu fullll to torqu rque. e. 4. Reconn Reconnec ectt rod and cross crosshea head d with pin. pin. Instal Installl en end d plates plates,, thru-bo thru-bolt, lt, and ne new w lock lock nut. nut. Tighte Tighten n lock lock nu nutt A-3.. to th the e to torqu rque e list listed ed in TABLE TABLE A-3 5. Follow Follow the torqui torquing ng proce procedur dure e in "Recommen "Recommendati dations ons for Torque Accu Accuracy" racy" to tigh tighte ten n co conn nnec ecti ting ng rod ca cap p sc screws rews to the the recommen reco mmended ded torque torque in TABLE TABLE A-4 A-4.. 6. Pla Place ce a tu turn rn in indi dica cato torr onto onto the the wren wrench ch so sock cket et,, and and sl slid ide e th the e so sock cket et onto onto the the bolt bolt head head.. Tu Turn rn th the e in indi dica cato torr so the the vi vial al face faces s up with the bu bubbl bble e cente centered red,, the then n tig tighte hten n the indicato indi catorr thumbsc thumbscrew. rew. Turn the connec connecting ting rod rod ca cap p sc screws rews to th the e angl angle e rec recom omme mend nded ed in TAB TABLE LE A-4 A-4..
FIGURE 4-41 Typical Connecting Rod
7. Me Meas asure ure ea each ch conne connecti cting ng rod bea bearin ring g to "Connec nectin ting g Rod Bea Bearin ring g crank cra nksh shaft aft jack jack cl clea earanc rance e an and d conne connecti cting ng rod thrust thrust (side) (side) cl clear earanc ance e (see (see "Con Vertical Vertic al Jac Jack k Clearan Clearance ce Mea Measurem surement" ent" and "Connec "Connectin ting g Rod Thru Thrust st (Sid (Side) e) Clea Clearan rance ce Measurement" belo below). w). Record Record me meas asure ureme ment nts s on a co copy py of th the e fo form rm in in Appen Appendix dix D. If measu measurem rement ents s are out of tol tolera eranc nce e aft after er instal installin ling g new bearin bearings gs,, conta contact ct your your pa pack ckag ager er or Ariel Ariel be before fore proce proceedi eding ng 8. Reinsta Reinstallll spac spacer er bars. bars. All spac spacer er bars bars are match match-ma -marke rked d for prope properr locati location on;; reins reinstal talll them them in their their or orig igin inal al lo loca cati tion on.. Tigh Tighte ten n all all sp spac acer er bar bar bolt bolts s to the the torqu torque e list listed ed in TABLE TABLE A-3 A-3..
Page 4-36 of 50
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Section 4 Par Partt Replacemen Replacementt
9. Exam Examin ine e to top p co cove verr and and si side de co cove verr gask gasket ets. s. If ther there e is do doub ubtt ab abou outt th thei eirr co cond ndit itio ion, n, repla replace ce th them em.. Lubric Lub ricate ate bo both th si sides des of cove coverr ga gask skets ets with an anti-s ti-siez ieze e lubric lubricant ant or multi multi-pu -purpo rpose se greas grease e to ea ease se fut future ure remov rem oval. al. Replac Replace e top cove coverr and cross crosshe head ad gu guide ide cove cover. r. Tighte Tighten n all caps capscre crews ws hand hand wrench wrench tig tight. ht.
Connecting Rod Bearing Vertical Vertical Jack Clearance Measurement Measurement 1. Tu Turn rn the crank cranksh shaft aft pin of the de desi sired red throw throw to its highes highestt positi position on.. For JGH:E:K: JGH:E:K:T:C:D:F T:C:D:F:Z:U: :Z:U:B:V B:V 4-42 2). and and KBZ:U:B: KBZ:U:B:V V mode models ls,, threa thread d an eye eye bolt bolt into into the the co conn nnec ecti ting ng rod (s (see ee FIGURE FIGURE 4-4 2. Attac Attach h th the e magn magnet etic ic base base of a need needle le dial dial indi indica cato torr to th the e cr cran anks ksha haft ft web ad adja jace cent nt to th the e co conn nnec ecti ting ng rod.. Place rod Place th the e poin pointt of the the dial dial indi indica cato torr agai agains nstt the the top top of th the e co conn nnec ecti ting ng rod ne near ar th the e ce cent nter er of th the e cap seam. seam. 3. Zero Zero th the e di dial al in indi dica cato tor. r. Inse Insert rt a pry pry bar bar into into the the ey eye e bo bolt lt an and d pry pry ag agai ains nstt th the e fr fram ame e to fo forc rce e th the e conn connec ectin ting g rod up un until til the dial dial indica indicator tor nee needle dle stops stops moving moving.. For JG:A:M JG:A:M:N:P: :N:P:Q: Q:R:J: R:J:W W models models,, pry agains aga instt the top conn conn rod bo bolts lts.. While While maint maintain aining ing up upward ward press pressure ure,, no note te the readin reading. g.
4. Relea Release se upward upward press pressure ure and and push push downwa downward rd on th the e rod un unti till th the e indi indica cato torr reads reads ze zero ro ag agai ain. n. If a ze zero ro readi reading ng ca cann nnot ot be obta obtain ined ed,, ze zero ro the the indi indica cato torr agai again n an and d repea repeatt st step eps s 3 an and d 4. Repea Repeatt th the e measu mea surem remen entt proce process ss un until til the measu measurem rement ent returns returns to zero zero twice twice in a row to verify verify ac accu curac racy. y. 5. Repea Repeatt meas measure ureme ment nt proce process ss for for every every rod. rod. If a readi reading ng is ou outs tsid ide e Appendix Appendix B tolerances, contact your your packa package gerr or Ariel. Ariel. NOTE: Remove eye bolts, magnetic bases, dial indicators, and pry bars after measurement.
Dial indicator indicator magnet magnetic ic st stand and placement placement on top of crank crankshaf shaftt web, and pry bar inserted into eye bolt.
Use pry bar to check jack clearance.
FIGURE 4-42 Typical Connecting Rod Vertical Jack Clearance Measurement
Connecting Rod Thrust (Side) Clearance Measurement 1. Tu Turn rn th the e cr cran anks ksha haft ft pin pin of the the desi desired red throw throw to it its s high highes estt po posi siti tion on.. 2. Attac Attach h th the e magn magnet etic ic base base of a butt button on dial dial indi indica cato torr to th the e side side of th the e crank cranksh shaf aftt web ad adja jace cent nt to th the e co conn nnec ecti ting ng rod. rod. Place Place the the butt button on of the the dial dial indi indica cato torr ag agai ains nstt th the e th thrus rustt su surfa rface ce of th the e co conn nnec ecti ting ng rod FIGURE URE 44-43 43). ). (see FIG 3. Use a pry bar bar to pry agai agains nstt the the cran cranks ksha haft ft web and and th thrus rustt th the e co conn nnec ecti ting ng rod tigh tightt to towar ward d th the e dial dial in indi dica cato torr (do not not pry on rod ca cap) p).. Relea Release se press pressure ure and and ze zero ro th the e dial dial in indi dica cato tor. r. 4. Thrust Thrust the conne connecti cting ng rod tig tight ht in the oppos opposite ite directi direction on until until the dial dial indic indicato atorr ne needl edle e stops stops movin moving. g. Releas Rele ase e press pressure ure an and d no note te readin reading. g. Repe Repeat at steps steps 3 an and d 4 to verify verify measu measurem rement ent ac accu curac racy. y. 5. Repea Repeatt th the e meas measure ureme ment nt proc proces ess s for for every every rod. rod. If a readi reading ng is ou outs tsid ide e Appendix Appendix B tolerances, conta contact ct your your packa packager ger or Arie Ariel. l. NOTE: Remove magnetic bases, dial indicators, and pry bars after measurement.
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Section 4 Part Replacement
Dial indicator magnetic stand placement.
For models JGC:D:F
Dial indi indicat cator or but butto ton n plac placeme ement nt..
Th Thrus rustt rod tight towar oward d and away fr from om dial indicator.
FIGURE 4-43 Typical Connecting Rod Thrust (Side) Clearance Measurement
Measuring Head End Clearance for Forged Steel
Tandem Cylinders with Concentric Valves CAUTION: Completely vent compressor to relieve ALL gas pressure and remove coupling spacer prior to removing access covers for compressor internal maintenance. For electric drive motors, lock out the breaker. Failure to follow these steps can result in serious personal injury or death. 1. Set Set cr cran ank k end end pi pist ston on cl clea earan rance ce to the the prope properr feel feeler er gaug gauge e spec specifi ifica catio tion n stampe stamped d on the cylin cylinde derr dat data a pl plate ate or pri printe nted d in the Ariel Ariel Techni Technica call man manual ual.. 2. With head head en end d compo compone nents nts remov removed ed,, po posit sition ion the pi pisto ston n for the the desi desired red cy cylilind nder er at oute outerr dead dead ce cent nter. er. Posi Positi tion on a dial dial in indi dica cato torr to in inde dex x of offf of the the cros crossh shea ead d or cros crossh shea ead d nut nut oute outerr fa face ce,, with with th the e cy cylilind nder er near near to oute outerr de dead ad ce cent nter. er. Manu Ma nual ally ly tu turn rn cr cran anks ksha haft ft to find find the the 0.01 0.010 0 inch inch (0.25 (0.25 mm mm)) posi positi tion on,, befo before re and and afte afterr oute outerr dead dead ce cent nter. er. Then Then turn turn crank cra nksh shaft aft to po posit sitio ion n piston piston at ou outer ter de dead ad cente centerr (se (see e pi pict cture ure to th the e rig right ht). ). 3. Dimen Dimensi sion on A: Me Meas asure ure fro from m cy cylilind nder er head head end end to pist piston on head head end end to th the e neare nearest st thou thousa sand ndth th inch inch and and record record.. See See ill illus ustrat tration ion on the fol followi lowing ng page. page. 4. Dimen Dimensi sion on B: With gaske gaskett remov removed ed,, measu measure re from he head ad end end cy cylilind nder er fa face ce to the the gask gasket et se seat at and and record record..
Page 4-38 of 50
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For models models JGC:D:F JGC:D:F 5. Dimen Dimensi sion on C: Use 0.055 inch (1.40 mm) for nomina nominall 0.060 0.060 inch inch (1.52 (1. 52 mm) mm) th thic ick k st stee eell gask gasket et and and record. 6. Cal Calcu cula late te Head End Clearance: A - B + C = Head End Clearance A _______ ___________ ________ ____ - B _____ ________ _____ _____ _____ __ + C 0. 0.05 055 5 (1.40 (1.40 mm) mm)
Section 4 Par Partt Replacemen Replacementt
= _______________ 7. Com Compare pare calcu calculat lated ed he head ad end piston piston cl clear earanc ance e to cl clear earanc ance e tol tolera eranc nces es st stamp amped ed on the cy cylin linder der da data ta pl plat ate e or print printed ed in the the Ariel Ariel Tech Techni nica call manu manual al.. If tolerances are unavailable or if calculated clearance is outside tolerance, contact your packager or Ariel before proceeding. 8. Measure Measure head head en end d piston piston cleara clearanc nce e pri prior or to new start start up up,, as require required d by recom recommen mended ded mainte maintena nanc nce e intervals inte rvals in Sectio Section n 3 , or afte afterr inst instal alla lati tion on,, rem remov oval al,, or re repl plac acem emen entt of an any y on one e of th the e fo follllowi owing ng:: • Crankshaft • Connec Connecting ting Rod
• Crossh Crosshead ead Guide Guide • Pis Piston ton and/or and/or Pis Piston ton Rod
• Eith Either er Tande Tandem m Cylind Cylinder er Body Body • Cros Crossh shead ead and/or and/or Crossh Crosshea ead d Nut
9. Re Re-as -asse semb mble le all compo componen nents ts ac acco cordi rding ng to the Ariel Ariel Mainte Maintena nanc nce e an and d Repair Repair Manua Manuall supp supplie lied d with your your compre compress ssor. or. Verify Verify instal installat lation ion of al alll gaske gaskets ts an and d manua manually lly ba barr ov over er the comp compres resso sorr to confi confirm rm the crank cranksh shaft aft rotates rotates freely freely..
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Section 4 Part Replacement
For models JGC:D:F
Crankshaft Th The e cr cran anks ksha haft ft is th the e heart heart of the the co comp mpres resso sor. r. With With prope properr main mainte tena nanc nce, e, it sh shou ould ld provi provide de ye years ars of trouble-free troub le-free service. service.
Crankshaft Removal 1. Remove Remove coup couplin ling g dis disk k pa pack ck.. Remove Remove coupl coupling ing hu hub. b. It may may be ne nec ces essa sary ry to he heat at the the hub hub to remo remove ve it it;; wearr in wea insu sula late ted d gl glov oves es.. If the the hub hub is not not remov removed ed,, the the dr driv ive e end end co cove verr ca cann nnot ot be remov removed ed and and must must lift lift out out with the crank cranksh shaft aft.. 2. Remov Remove e to top p co cove ver, r, sp spac acer er bars bars,, an and d drive drive end end
co cove ver. r. TIP: TIP: If sp spac acer er bar bar bolt bolts s are are diff diffic icul ultt to loos loosen en,, us use e a 12-poi 12-point nt ha hamme mmerr wrench wrench.. 3. Do no nott da dama mage ge th the e shar sharp p corn corner ers s on ea each ch end end of the the cr cran ankc kcas ase e to top. p. Th They ey form form a junc juncti tion on betwe between en the the end end co cove vers rs,, to top p co cove ver, r, and and base base;; ke keep ep them them sh sharp arp and and unma unmarre rred d to preve prevent nt oil oil leak leaks. s. 4. Detac Detach h co conn nnec ecti ting ng rods rods and and move move them them to thei theirr full full outerr positio oute position. n. 5. Remove Remove chain chain eccentric eccentric adjustme adjustment nt capscrews capscrews.. Tu Turn rn th the e ecce eccent ntric ric to loos loosen en the the ch chai ain n and and sl slip ip it off off the cranksh crankshaft aft sprocket. sprocket. 6. Remove Remove caps capscre crews ws from main main be bearin aring g caps caps.. Pull Pull ca caps ps st strai raigh ghtt up to preve prevent nt dama damage ge to the the dowel dowel fit. fit. If ca cap p is tigh tight, t, use use a beari bearing ng ca cap p pull puller er as ilillu lust strat rated ed..
4. 11 in. (28 cm) cm) x 5/85/8-
1. 20.5 in. (52 cm) Steel Bar 2. 5/8-11 UNC Nut (turn to jack bearing cap st straight raight up) 3. 11/16 in. (18 mm) Hole (drill)
11 UNC Threaded Rod 5. 5/8-11 UNC Lock Nut 6. 5/8-11 UNC Puller Hole 7. Crankshaft
7. Before Before remov removing ing the crank cranksh shaft aft,, prepar prepare e wooden wooden sa sadd ddle les s with with si side des s hi high gh enou enough gh to preve prevent nt the the webs webs or oi oill sl slin inge gerr from from to touc uchi hing ng the the floo floorr to st store ore the the FIGURE 4-44 Main Bearing Cap Puller cr cran anks ksha haft ft durin during g main mainte tena nanc nce e - even even if for for only only a short short time. time. Also, Also, protec protectt the crank cranksh shaft aft from abo above ve so dro droppe pped d tools tools or equipm equipment ent canno cannott mar mar pin an and d journa journall surfac surfaces es.. 8. Tu Turn rn th the e cr cran anks ksha haft ft so that that sl slin ing g lilift ftin ing g poin points ts are are abov above e th the e sh shaf aftt ce cent nter er of gravi gravity ty to preve prevent nt rota ro tati tion on when whe nds lilift fted ed. .rallel Lift Lift strai ghtframe. t up wit with h the the crank cra nksh shaft aft en ends pa parall elst toraigh the fram e. The cr cran anks ksha haft ft weigh weightt requi require res s two men men and and a cran crane e or lift lift to sa safe fely ly remov remove e it. it. Use appro appropri priat ate e si size zed d ny nylon lon sling slings s to preve prevent nt marring marring the crank cranksh shaft aft running runni ng surface. surface. CAUTION: Lifting the crankcase may cause the shaft to bind and damage it.
1. Oil Slinger 2. Main B Bearing earing Journals 3. Chain Sprocket
NOTE: Lower half bearing shells sometimes stick to the shaft journals. After lifting the
4. Crank Pins 5. Counterweights
FIGURE 4-45 Typical Crankshaft
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Section 4 Par Partt Replacemen Replacementt
shaft about ¼ inch (6mm) clear of the saddles, verify the lower half bearing shells remain on the saddles. If not, tap them back onto the saddles before lifting the shaft further. 9. While While one one perso person n raise raises s the the crane crane ve very ry sl slowl owly, y, the the se seco cond nd pe perso rson n must must gr gras asp p th the e crank cranksh shaf aftt at th the e dr driv ive e en end d with with one one ha hand nd on the the coun counte terwe rweig ight ht or on one e of th the e th thro rows ws an and d th the e ot othe herr on th the e sha haft ft en end d to ke keep ep th the e cr cran anks ksha haft ft leve level. l. Wear Wear cl clea ean n glov gloves es for for a good good grip, grip, to av avoi oid d cu cuts ts from from th the e slin slinge ger, r, an and d to avoi avoid d marri marring ng th the e runni running ng su surfa rface ce.. As the the sh shaf aftt sl slowl owly y raise raises, s, lift lift th the e drive drive an and d auxi auxililiary ary en ends ds at th the e same same rate. rate. Carefull Carefully y gu guide ide the crank cranksh shaft aft to av avoid oid marrin marring g its surfac surfaces es..
Oil Slinger Slinger Replacement Replacement CAUTION: Do not touch hot surfaces without proper protection. Although Althou gh the slinger slinger should should last last indefinit indefinitely ely with proper proper care, care, it may become become nicked nicked.. To replace replace it:
1. Su Susp spen end d the crank cranksh shaft aft as de detai tailed led in"Cranks in "Crankshaft haft Remov Removal" al" an and d he heat at th the e slin slinge gerr un unti till it glows glows ye yellllow ow (abou (ab outt 400° 400°F F or 204°C) 204°C).. When When it expa expand nds, s, it sh shou ould ld fa fallll of offf by itse itself lf.. 2. Slide Slide a mini minimu mum m ½-inc ½-inch h (13mm (13mm)) diam diamet eter er rod throu through gh th the e ne new w sling slinger. er. Do no nott mar mar slin slinge gerr su surfa rface ces, s, an and d be care carefu full of it its s shar sharp p ou oute terr edge edge.. Su Susp spen end d the the slin slinge gerr an and d he heat at it with with a smal smalll to torc rch. h. When When it gl glows ows ye yellllow ow (abou (aboutt 400°F 400°F or 204° 204°C), C), sl slip ip it over over the the drive drive en end d of the the cr cran anks ksha haft ft.. Hold Hold th the e slin slinge gerr in pl plac ace e with with hi high gh temp temper erat ature ure glov gloves es or two piec pieces es of clea clean n wood. wood. Rotat Rotate e it slig slight htly ly to en ensu sure re squa squarene reness ss,, un until til it cools cools enoug enough h to shrin shrink k on onto to the crank cranksh shaft aft..
Main Bearing Bearing Remo Removal val 1. Remove Remove top cove coverr and spac spacer er bars bars.. If sp spac acer er bar bar bolt bolts s are are diffic difficult ult to loose loosen, n, us use e a 12-poi 12-point nt sl slugg ugging ing wrench wrench an and d hammer hammer.. Space Spa cerr bars bars fit fit sn snug ugly ly,, but but sh shou ould ld sl slid ide e out out by hand hand witho without ut hamme ham mering ring.. They They shoul should d no nott fal falll ou out. t. If fi fitt is to too o lo loos ose e or ti tigh ghtt conta contact ct your your packa packager ger or Arie Ariell before befo re proceedin proceeding. g. 2. Rem R emov ove e main main (journa (journal) l) be beari aring ng ca cap p sc screws rews.. Pull Pull ca caps ps st stra raig ight ht up to preve prevent nt dama damage ge to the the dowel dowel fit. fit. If cap cap is tigh tight, t, us use e a be bear arin ing g cap cap pu pulle llerr (see (see FIG FIGURE URE 4-4 4-46 6).
1. Puller Nut - tturn urn tto o pull bearing cap st straight raight up. 2. Steel Rectangular Bar Clearance Hole: 11/16 in. (18 mm mm)) Length:28 Lengt h:28 in. (70 mm) 3. Drill Hole 4. Threaded Rod Nominal Size: 5/ 5/8 8 in. - 11 Length:12 Lengt h:12 in. (30 mm) 5. Lock Nut 6. Puller Hole 7. Crankshaft
FIGURE 4-46 Main Bearing Cap Puller
Remove shell Remove shells s from main main bearing beari ng caps. caps. 3. Remov Remove e main main jo journ urnal al beari bearing ng sh shel ells ls from from unde underr the the cr cran anks ksha haft ft on one e at a time time.. If ne need eded ed,, at atta tach ch clea clean n nylo nylon n st strap raps s aroun around d the the cran cranks ksha haft ft and and lift lift it 0.00 0.003 3 - 0.00 0.005 5 inch inch to less lessen en weigh weightt on th the e be beari aring ngs s an and d al allo low w easi easier er remov removal al.. To remov remove, e, rotat rotate e sh shel elll unde underr th the e crank cranksh shaf aftt ta tab b side side ou outt firs first, t, by pu push shin ing g or ta tapp ppin ing g with with a non-m non-met etal allilic c tool tool on the the oppo opposi site te sp splilitt fa face ce side side.. Ariel Ariel op opti tion onal al to tool ol (B-334 (B-3340) 0) ca can n be used used on C:D:F C:D:F mode models ls to push push the the sh shel elll co comp mple lete tely ly out. out. Do no nott da dama mage ge cr cran anks ksha haft ft be beari aring ng su surfa rface ces. s. Replac Repl ace e with ne new w be bearin aring g shell shell,, be before fore rota rotatin ting g ou outt the ne next xt main main be beari aring ng shell shell.. 4. Cle Clean an any any co coki king ng or debri debris s fro from m both both the the sa sadd ddle le and and main main be beari aring ng ca cap p su surfa rface ces s an and d ch chec eck k fo forr raise raised d edge edges s on mach machin ined ed su surfa rface ces. s. Verif Verify y all all su surfa rface ces s are as clea clean n an and d dr dry y as po poss ssib ible le.. Ver Verif ify y no bo bolt ltin ing g is damaged.
REV: 10/14
Page 4-41 of 50
Section 4 Part Replacement
For models JGC:D:F
Main Bearing Installation 1. Che Check ck ne new w be beari aring ng shell shells s for da damag mage, e, scratc scratche hes, s, burrs, burrs, an and d loose loose materi material al at the tab. tab. DO NOT RUB BEARING SURFACE WITH FINGERNAIL. Kee Keep p the ba back cks s of shell shells s dry an and d cl clean ean;; instal installat lation ion requi req uires res pe perfec rfectly tly clea clean n bearin bearing g shell shells. s. Instal Installl be bearin aring g shell shells s in caps caps,, an and d frame frame journa journals, ls, properl properly y lo loca cate ted d in th the e ta tab b notc notch, h, (rota (rotate te in the the un-ta un-tabb bbed ed end end firs first). t). NOTE: Where bearings are identified with an ink pictograph, main and connecting rod bearings are not interchangeable. Do not put connecting rod bearings in main bearing locations. Do not mix part numbers on an individual main or connecting rod. Both bearing half shells must have the same part number. 2. Apply Apply a lib libera erall amoun amountt of clean clean,, ne new w lube lube oi oill to crank cranksh shaft aft be bearin aring g surfac surfaces es.. 3. Main Main bearing bearing caps caps ha have ve po posi sitio tion n mat match ch-ma -marks rks corres correspo pond nding ing with frame frame spac spacer er ba bars rs an and d spac spacer er bar
boss bosses es.. In Inst stal alll main main beari bearing ng ca caps ps wit with h new new beari bearing ng sh shel ells ls in th thei eirr co corre rrect ct lo loca cati tion ons. s. Seat Seat th the e ca cap p by ta tapp ppin ing g it with with th the e hand handle le of a ha hamm mmer er or scre screwd wdri rive ver. r. It is a mach machin ined ed fit, fit, no nott a pr pres ess s fit, fit, an and d th the e cap cap sho houl uld d no nott ro rock ck in th the e jaw jaw fit when when it sea eats ts.. Do not not us use e bo bolt ltin ing g to fo forc rce e th the e cap to seat seat.. Snug Snug th the e cap cap sc screws rews.. Starti Starting ng at the the thrus thrustt end, end, use use the the torqu torque e pro proce cedu dure re in th the e te tech chni nica call manu manual al to tigh tighte ten n th the e main ma in beari bearing ng ca cap p bolt bolts s to the the torqu torque e lilist sted ed in Appen in Appendix dix A . 4. Ve Verif rify y prope properr al alig ignm nmen entt of main main beari bearing ng ca cap p dowel dowels s with with th the e ho hole les s in th the e cr cran ankc kcas ase e base base.. A se sett sc screw rew on to top p of each each dowel dowel preve prevent nts s it from from back backin ing g out. out. 5. Check Check crank cranksh shaft aft journa journall bearin bearing g jack jack (at ea each ch bearing bearing)) an and d crank cranksh shaft aft thrust thrust clear clearanc ances es to value values s in Appendix dix B (see (see proce procedu dure re belo below). w). Record Record rea readi ding ngs s on a co copy py of th the e fo form rm in in Appe Appendix ndix D. If readi reading ngs s Appen are out of tol tolera eranc nce e aft after er ne new w be beari aring ng instal installat lation ion,, conta contact ct your your pa pack ckage agerr or Ariel Ariel be before fore proce proceed eding ing.. 6. In Inst stal alll spa pac cer ba bars rs so the the matc match h mark mark is up an and d next next to th the e spac spacer er bar bar bo bos ss with with th the e same same mark mark.. dix A . Tigh Tighte ten n al alll sp spac acerer-ba barr ca cap p sc screws rews to the the torqu torque e lilist sted ed in Appen in Appendix 7. Accoun Accountt for all tools tools,, eq equip uipmen ment, t, suppl supplies ies,, an and d pa parts rts to ensure ensure no none ne are left left in insid side e the crank crankca case se.. Reinsta Rein stallll gaske gaskets ts an and d top cove cover(s). r(s). Tighte Tighten n cove coverr bo bolts lts hand hand wrench wrench tig tight. ht. lockoutt procedures procedures.. 8. Reverse lockou 9. After After replac replacing ing be bearin arings gs,, pre-lub pre-lube e comp compres resso sorr for 10-1 10-15 5 mi minut nutes es at 30 ps psii to ensure ensure bearin bearing g lubric lubricati ation on and to he help lp remove remove foreign foreign materi materials als from the lube lube syste system. m. 10. Run 10. Run th the e co comp mpres resso sorr acco accordi rding ng to the the time time inte interv rval als s list listed ed on th the e fo form rm in Appendix Appendix D. Af Afte terr ea eac ch ru run, n, sh shut ut down down and and re remo move ve the the frame frame top top co cove ver. r. Meas Measure ure main main an and d co conn nnec ecti ting ng rod be beari aring ng ca cap p temp tempera eratu tures res with with a hand hand held held ther thermo moco coup uple le probe probe or in infra frared red th therm ermom omet eter er an and d re reco cord rd th them em on a cop opy y of th the e fo form rm in in Appen Appendix dix D. Comp Comple lete te the the form form and and em emai aill or fa fax x it to Ariel Ariel Fiel Field d Serv Servic ice. e.
Main Bearing Bearing Vertical Jack Clearance Measurement Measurement 1. Tu Turn rn th the e cr cran anks ksha haft ft unti untill the the web adja adjace cent nt to the the desi desired red main main be beari aring ng is ve verti rtica call (s (see eeFIG FIGURE URE 4-4 4-47 7). 2. Loop Loop a lilift ftin ing g stra strap p aro aroun und d the the cran cranks ksha haft ft web adja adjace cent nt to th the e main main be beari aring ng an and d at atta tach ch th the e st strap rap to a crane. NOTE: If the crane does not have a fine adjustment, attach a chain hoist to the crane lifting hook to prevent excessive force on the crankshaft and crane. 3. Attac Attach h th the e magn magnet etic ic base base of a need needle le dial dial indi indica cato torr to the the to top p of th the e main main be bear arin ing g ca cap. p. Place Place th the e po poin intt of th the e di dial al in indi dica cato torr agai agains nstt the the top top of the the adja adjace cent nt web and and ze zero ro it. it. 4. GENTLY lif liftt crank cranksh shaft aft.. The dia diall indic indicato atorr ne needl edle e move moves s st stead eadily ily until until the crane/ crane/ho hoist ist ov overc ercom omes es cr cran anks ksha haft ft oi oill st stic icti tion on,, at which which poin pointt the the need needle le jump jumps s a litt little le.. Stop Stop lift liftin ing g imme immedi diat atel ely y at th this is po poin int, t, an and d no note te the readin reading. g. 5. Releas Release e crane crane/ho /hois istt press pressure ure an and d repea repeatt step step 4 to verify verify the measu measurem rement ent.. Page 4-42 of 50
REV: 10/14
For models models JGC:D:F JGC:D:F
Section 4 Par Partt Replacemen Replacementt
6. Repea Repeatt th the e meas measure ureme ment nt proc proces ess s for for each each main main beari bearing ng.. If a readi reading ng is ou outs tsid ide e Appen Appendix dix B tol tolera eranc nces es,, conta contact ct your your pa pack ckag ager er or Ariel. Ariel. NOTE: Remove magnetic bases, dial indicators, and lifting strap after measurement.
Dial Indicator magnetic stand placement on top of a main be bearing aring ca cap. p.
Needle-type dial Indicator placement Place lifting strap around crankshaft on top of adjac adjacent ent cra cranks nkshaf haftt web. web - attach strap to a crane.
FIGURE 4-47 Typical Crankshaft Journal Bearing Vertical Jack Clearance Measurement
Crankshaft Thrust (End) Clearance Measurement 1. Attac Attach h th the e magn magnet etic ic base base of a butt button on dial dial indi indica cato torr to th the e to top p of a main main be beari aring ng ca cap. p. Place Place th the e bu butt tton on FIGURE URE 4-4 4-48 8). of th the e di dial al in indi dica cato torr agai agains nstt the the si side de of the the adja adjace cent nt cran cranks ksha haft ft web (s (see ee FIG 2. Use a pry bar bar to pry agai agains nstt the the co comp mpres resso sorr frame frame and and th thrus rustt th the e cr cran anks ksha haft ft tigh tightt to towar ward d th the e dial dial indic ind icato ator. r. Releas Release e press pressure ure an and d zero zero the dial dial indic indicato ator. r. 3. Thrust Thrust the crank cranksh shaft aft tig tight ht in the oppos opposite ite directi direction on until until the di dial al indic indicato atorr ne needl edle e stops stops moving moving,, then then releas rele ase e pressu pressure. re. Note readi reading. ng. Repeat Repeat steps steps 2 and 3 to verify verify meas measure uremen mentt ac accu curac racy. y. 4. If the measu measurem remen entt is ou outsi tside de Appendix Appendix B tolera toleranc nces es,, conta contact ct your your pa pack ckag ager er or Ariel. Ariel. NOTE: Remove magnetic bases, dial indicators, and pry bar after measurement.
Dial Indicator magnetic stand placement on top of a main be bearing aring ca cap. p.
Button-type dial Indicator placement Button-type against the side of crank crankshaf shaftt web.
Pry against compressor frame frame to thr thrust ust crankshaf crankshaftt back and for forth. th.
FIGURE 4-48 Typical Crankshaft Thrust Clearance Measurement
Crankshaft Installation 1. Verify Verify correc correctt ne new w main main be bearin aring g ha half lf shell shells s po posit sitio ioned ned in the frame frame saddl saddles es,, ab abso solut lute e cl clea eanne nness ss,, and bearin bea ring g surfac surfaces es lubric lubricate ated d with cl clea ean n crank crankca case se oil. oil. 2. Move Move co conn nnec ecti ting ng rod rods s to full full oute outerr posi positi tion on.. If th the e pist piston on rods rods are st stililll at atta tach ched ed to th the e cr cros ossh shea eads ds,, th the e head heads s and and wiper wiper pack packin ing g glan gland d may may need need repos reposit itio ione ned d so th the e rods rods clea clearr th the e cr cran anks ksha haft. ft. While While th the e cr cran anks ksha haft ft lo lowers wers ve very ry sl slowl owly y into into the the cran crankc kcas ase e (sus (suspe pend nded ed by a cr cran ane e with with a clea clean n ny nylo lon n slin sling), g), one one man man wearin wearing g cl clea ean n glov gloves es sh shou ould ld gras grasp p the the drive drive en end d an and d slowl slowly y mane maneuv uver er th the e drive drive en end d an and d auxili aux iliary ary end straigh straightt do down wn into into the crank crankca case se.. Both drive drive en end d an and d auxili auxiliary ary end journal journals s shoul should d touch touch th the e bott bottom om beari bearing ng sh shel ells ls at the the sa same me time time..
REV: 10/14
Page 4-43 of 50
Section 4 Part Replacement
For models JGC:D:F
3. When When the crank cranksh shaft aft rests rests on the bo botto ttom m bearing bearing shell shells, s, lubric lubricate ate up upper per crank cranksh shaft aft pin bearin bearing g surfac surfaces es with ne new w cl clea ean n crank crankca case se oil an and d ins instal talll be bearin aring g caps caps (with their their correc correctt be bearin aring g ha half lf shel shells ls in pl plac ace) e) with with th the e ca cap p sc screws rews ligh lightl tly y sn snug ugge ged. d. See "Recommen "Recommendati dations ons for Torque Accu Accuracy" racy" and TABLE TABLE A-3 in in Appen Appendix dix A to tigh tighte ten n the the bolt bolts s to the the co corre rrect ct to torqu rque. e. Bearin Bearing g ca caps ps are matc match-m h-mark arked ed to co corre rresp spon ond d with with the the sp spac acer er bar bar and and sp spac acer er bar bar boss bosses es on th the e frame frame.. 4. Verif Verify y beari bearing ng ca cap p dowel dowel alig alignm nmen entt with with crank crankca case se base base ho hole les. s. A se sett sc scre rew w on on to top p of ea each ch do dowel wel preve pre vents nts it from backin backing g ou out. t. 5. Befo Before re conn connec ectin ting g rod instal installat lation ion,, mea measu sure re each each crank cranksh shaft aft journa journall be bearin aring g jack jack clea clearan rance ce with a dial dial page ge 4-4 4-42 2 and allowab allowable le cl clea earan rance ces s in Appen in Appendix dix B in Appen in Appendix dix B ). indic indicato atorr (see (see proce procedu dure re on pa 6. Reattac Reattach h conn connec ectin ting g rods rods (See“Conn (See “Connec ectin ting g Rod Ins Instal tallat lation ion”” on pag page e 4-3 4-36 6), packin packing g diaphragm diaphragms, s, and unloaders unloaders/hea /head d end heads. heads. 7. Reinsta Reinstallll chain chain dri drive ve.. (See“Ch (See “Chai ain n Driv Drive e Sy Syst stem em”” on pa page ge 4-4 4-44 4).
8. Repla Replace ce sp spac acer er bars bars.. Loca Locate te sp spac acer er bar bar ma matc tch h mark mark.. Inst Instal alll sp spac acer er ba barr so th the e matc match h mark mark is up an and d next next to th the e sp spac acer er bar bar boss boss with with the the sa same me mark markin ing. g. 9. Lu Lubri brica cate te both both side sides s of cove coverr gas gaske kets ts with anti-s anti-sie ieze ze lubric lubrican antt or multi-p multi-purp urpos ose e greas grease e to ease ease fut future ure remo remova val. l. In Inst stal alll new new end end co cove verr gask gasket ets. s. With With a kn knif ife, e, trim trim ex exce cess ss from from ne new w en end d co cove verr ga gask sket ets s flus flush h to the ba base se aft after er re-bolt re-bolting ing en end d cove covers. rs. 10. Exam 10. Examin ine e to top p co cove verr gask gasket et.. If there there is doub doubtt abou aboutt it its s co cond ndit itio ion, n, in inst stal alll a ne new w ga gask sket et.. Reins Reinsta tallll to top p cove cover. r. Rein Reinst stall all coupl coupling ing hu hub b (if remov removed ed)) an and d the coup couplin ling g disk disk pack pack to coupl coupling ing manufa manufactu cturer rer instructions.
Chain Drive System Th The e ch chai ain n drive drive sy syst stem em is crank cranksh shaf aft-d t-driv riven en at the the auxi auxililiary ary en end d of th the e frame frame.. Fo Forr JGC:D: JGC:D:F/2 F/2/4 /4 co comp mpres resso sors rs,, a si sing ngle le ch chai ain n runs runs the the lube lube oil oil pump pump and and forc force e fe feed ed lubri lubrica cato tor. r. An id idle lerr sp spro rock cket et at atta tach ched ed to the ec ecce centri ntric c ad adjus justme tment nt cap cap contro controls ls chai chain n tig tightn htnes ess. s. The chai chain n dips dips in into to the crank crankca case se oil for cons constan tantt lubric lub ricati ation on.. In dry sump sump ap appli plica catio tions ns,, an oil spray sprayer er lub lubric ricate ates s the chain chain.. Fo Forr JGC:D: JGC:D:F/6 F/6 co comp mpre ress ssors ors,, one one ch chai ain n runs runs the the lube lube oil oil pump pump an and d an anot othe herr runs runs th the e fo forc rce e fe feed ed lu lubri brica cato tor. r. A separate separate idler idler sprocke sprockett for each each chain, chain, each each attached attached to its own eccentri eccentric c adjustme adjustment nt cap, cap, controls controls ch chai ain n tigh tightn tnes ess. s. Th The e lu lube be oil oil pump pump ch chai ain n dips dips into into the the cran crankc kcas ase e oi oill an and d sp spla lash sh ac acti tion on oi oils ls th the e fo forc rce e fe feed ed lubric lub ricato atorr chai chain n as well. well. In dry sump sump applic applicati ation ons, s, an oil spray sprayer er lu lubric bricate ates s the chain chains. s.
Page 4-44 of 50
REV: 10/14
For models models JGC:D:F JGC:D:F
Section 4 Par Partt Replacemen Replacementt
1. Force Feed Lubricator Sprocket 2. Crankshaft Sprocket 3. Chain 4. Oil Pump S Sprocket procket 5. Eccentric Ecce ntric Adjustment 6. Dust Plu Plug g 7. Force Feed Lubricat Lubricator or Chain Eccentric centric Adjust Adjustment ment 8. Oil Pump Ec 9. Force F Feed eed Lubricator Eccent Eccentric ric Adjustment 10. Oil Pump Chain 11. Cap Screw
FIGURE 4-49 JGC:D:F Chain Drive Systems
Chain and Sprocket Replacement Replace Replac e chain chain(s) (s) if el elong ongati ation on ex exce ceed eds s 0.0 0.084 84 inche inches s (2.13 (2. 13 mm) mm) over over a 10 pitc pitch h leng length th.. Meas Measur ure e the the se sect ctio ion n of ch chai ain n with with ve verni rnier er ca calilipe pers rs while while it is st stret retch ched ed tigh tightt in positi pos ition on in the compr compres esso sor. r. Add a meas measure uremen mentt outs outsid ide e th the e rolle rollers rs at 10 pitc pitche hes s (X) to a meas measure ureme ment nt betwe between en th the e in insi side de of the the sa same me rolle rollers rs (Y), and and then then divi divide de by two. two. Repla Replace ce the the ch chai ain n if the the res resul ultt exce exceed eds: s:
FIGURE 4-50 Measuring to Check Chain Elongation
• 3. 3.83 834 4 in inch ches es (9 (97. 7.4 4 mm) mm) for for 3/8" 3/8" (No. (No. 35) 35) ch chai ain n • 5. 5.08 084 4 in inch ches es (1 (129 29.1 .1 mm) mm) for for 1/2" 1/2" (No. 40) 40) ch chai ain n These The se numbe numbers rs apply apply to ei eithe therr one one-row, -row, two-ro two-row, w, or three-ro three-row w chain chains. s. Replac Repl ace e sproc sprocke kets ts showin showing g any un under dercu cutti tting ng or other other da damag mage. e.
REV: 10/14
Page 4-45 of 50
Section 4 Part Replacement
For models JGC:D:F
Chain Idler Sprocket Replacement (Eccentric Adjustment Caps) 1. Chain Chain idler idler sproc sprocke kett loca locatio tion n varie varies s for standa standard rd versus vers us reverse reverse rotation. rotation. 2. Remo Remove ve frame frame top cove cover. r. 3. Remov Remove e al alll dust dust pl plug ugs s from from the the ecce eccent ntric ric ca cap p and and all all cap cap screws screws ho holdi lding ng the ecce eccent ntric ric ca cap p to th the e end end cove cover. r. Rota Rotate te ec ecce centri ntric c cap cap to loose loosen n chain chain for remov removal. al. Drop Dro p th the e ch chai ain n of offf th the e idle idler r
1. Dust Plu Plug g
3. Stat-O-Seal
5. Washer
7. Thru Bolt
sproc sprocke kett an and d remov remove e en entire tire as asse sembl mbly y from the en end d cover.
4. Self-Lock Nut
2. Cap Screw
6. Sprocket
FIGURE 4-51 Typical Chain Idler Sprockets (Eccentrics)
Remove e and and di disc scard ard lock lock nut, nut, hex hex ca cap p sc screw, rew, st stat at-o-o-se seal al washe washer, r, an and d ca cap p OO-rin ring. g. 4. Remov 5. Rea Reass ssemb emble le new cap cap screw, screw, stat-o stat-o-se -seal al wash washer, er, sproc sprocke ket, t, an and d lock lock nu nut. t. Tighte Tighten n idler idler lock lock nu nutt to recommen reco mmended ded torque torque in Appen in Appendix dix A . 6. Apply oil and instal installl a ne new w O-ring. O-ring. Instal Installl as asse sembl mbly y an and d chai chain. n. 7. Ta Take ke ca care re when when meas measuri uring ng and and adju adjust stin ing g the the forc force e feed feed id idle lerr sp sproc rocke ket; t; it is th thin inne nerr th than an th the e fo forc rce e fe feed ed lu lubri brica cato torr and and drive drive sp sproc rocke kets ts.. To ce cent nter er the the idle idlerr sp sproc rocke kets ts in th the e ch chai ain, n, su subt btrac ractt th the e fo forc rce e fe feed ed idle idler r sp sproc rocke kett th thic ickn knes ess s from from the the drive drive sp sproc rocke kett thic thickn knes ess s and and di divi vide de th the e di diff ffere erenc nce e by 2. Add th this is va valu lue e to the thler e meas me ureme ment ntust from frotm the then e insi insproc side de face fa ce th e auxi au xili ary end enket d co cove verr surem to remen th the e ou outs tsid ide e fa face cedofwithin th the einfo forc rce e2fe feed edh idler id sproc spasure rocke ket. t. Adj Adjus driven driv sp rocke kets ts of to the the drive driv eliary sproc sprocke t measu mea ents, ts, aligne ali gned with 1/3 1/32 inch inc (1 mm) mm).. Non-alig Non-alignme nment nt may requir require e dis disas asse semb mbly ly an and d shimm shimming ing ec ecce centri ntrics cs.. 8. Adjust Adjust chain chain ac acco cordi rding ng to“Chai to “Chain n Adj Adjus ustme tment” nt” on pag page e 4-4 4-48 8.
Lube Oil Pump Sprocket Replacement 1. Re Remo move ve al alll pu pump mp piping piping.. Remove Remove fasten fas teners ers from pump pump mount mounting ing fla flange nge.. After chain chain removal, removal, the pump pump with sproc sprocke kett come comes s free through through the en end d cover cov er hole. hole. 2. To positi position on the ne new w sproc sprocke ket, t, us use ea ma mach chini inist rul rule e sproc to rocke meas meket asure theface ex exac di dista stanc nce estfrom sp ture dri drive ve fac eact tot pump pump moun mounti ting ng flan flange ge face face (X). Note Note thi this s meas measure uremen mentt for fut future ure refe referen rence ce.. 3. With With th the e oi oill pu pump mp on a benc bench, h, us use e an Allen wrench to remove remove the sprocket sprocket se sett sc scre rews, ws, th then en pull pull the the sp sproc rocke kett from from the shaft shaft..
1. Gaskets 2. Key 3. Set Scr Screws ews
4. Sprocket 5. Adapter 6. Pump
FIGURE 4-52 Typical Lube Oil Pump Chain Sprocket
4. Remov Remove e th the e ke key y from from the the sh shaf aftt and and file file the the sh shaf aftt to smoo smooth th bu burrs rrs raise raised d by th the e se sett sc screw rew cu cup p po poin int. t. 5. Inst Instal alll a new new key key (see (see buil build d book book for for type type and and dime dimens nsio ions ns). ). First First ve verif rify y it fits fits in into to th the e ne new w spro sprock cket et.. If too too th thic ick, k, poli polish sh th the e ke key y with with emery emery cl clot oth h on a flat flat su surfa rface ce un unti till it ea easi sily ly slid slides es in into to th the e no notc tch. h. Th The e to top p edge edge may may al also so requi require re a lilittl ttle e fili filing ng.. Page 4-46 of 50
REV: 10/14
For models models JGC:D:F JGC:D:F
Section 4 Par Partt Replacemen Replacementt
6. Ins Instal talll new sproc sprocke kett to the origina originall meas measure uremen mentt be betwee tween n the sproc sprocke kett drive drive face face and the pu pump mp mounti mou nting ng fla flang nge e face. face. When When in po posit sitio ion, n, tig tighte hten n set set sc screws rews.. 7. Lubric Lubricate ate bo both th si sides des of cove coverr ga gask skets ets with an anti-s ti-seiz eize e lubric lubricant ant or multi multi-pu -purpo rpose se greas grease e to ea ease se fut future ure remov rem oval. al. Instal Installl ne new w en end d cove coverr ga gask skets ets.. 8. Re Rein inst stal alll pump pump onto onto end end co cove ver. r. Using Using a st stra raig ight ht edge edge,, to wit withi hin n 1/ 1/32 32 inch inch (1 mm), mm), ch chec eck k alig alignm nmen entt to crank cra nksh shaft aft drive drive sproc sprocke kett with crank cranksh shaft aft cente centered red in en end d play. play. If misal misalign igned, ed, adjus adjustt sproc sprocke kett positi position on as needed. needed. 9. Adjust Adjust chai chain n ac acco cordin rding g to“Chai to “Chain n Adj Adjus ustme tment” nt” on pa page ge 4-4 4-48 8. 10. Reinsta 10. Reinstallll al alll pi pipin ping g to pump. pump.
Force Feed Lubricator Chain Sprocket Replacement 1. With a go good od machin machinis istt rule, rule, meas measure ure ex exac actt distan distance ce from
in insi side de fa face ce of auxi auxililiary ary end end co cove verr to near near face face of lubri lubrica cato tor r sproc sprocke ket. t. Note measu measurem rement ent for prope properr positi position oning ing of ne new w sprocket. sproc ket. Remove chain. chain. 2. Remove Remove sproc sprocke kett set set screw screw and sproc sprocke ket. t. Deta Detach ch al alll tubin tub ing g to lubric lubricato ator. r. 3. Remove Remove mounti mounting ng brack bracket et cap cap screws screws and lubric lubricato ator. r. 4. With th the e lu lubri brica cato torr on the the benc bench, h, remov remove e ke key y from from sh shaf aftt and and file file sh shaf aftt to remov remove e burrs burrs raise raised d by se sett sc screw rew cu cup p point. poi nt. Oi Oill an and d instal installl a new O-ring O-ring.. 5. Di Dig g ou outt th the e sha haft ft oil oil seal seal wi with th an aw awll and and inst instal alll a new new on one. e.
4. 5. Cap Screws (4) 2. Auxiliary End Cover 6. 7. 3. O-Ring 1. Mounting Bracket
Shaf Shaftt Oil Seal Key Set Scr Screw ew Sprocket
6. In Inst stal alll a new new key key.. Verif Verify y it fits fits into into the the new new spro sprock cket et (s (see ee buil build d book book fo forr ke key y type type and and dime dimens nsio ions ns). ). If too too thic thick, k, po polilish sh it with with emery emery cl clot oth h on a flat flat su surfa rface ce unti untill it easi easily ly sl slid ides es in into to th the e notc notch. h. Th The e to top p edge edge may may also also requi require re a lilitt ttle le fili filing ng.. FIGURE 4-53 Force Feed Lubricator Chain Sprocket 7. After After ne new w key key instal installat lation ion,, verify verify the ne new w sproc sprocke kett fit fits, s, oi oill th the e new new O-rin O-ring, g, and and remou remount nt lubri lubrica cato torr to the the end end co cove ver. r. 8. Slide Slide new new spro sprock cket et onto onto the the sh shaf aftt and and se sett to dime dimens nsio ion n meas measure ured d in st step ep 2. Tigh Tighte ten n se sett sc scre rew. w. 9. Using Using a st strai raigh ghtt edge edge,, to wit withi hin n 1/32 1/32 inch inch (1 mm), mm), ch chec eck k alig alignm nmen entt to cr cran anks ksha haft ft drive drive sp sproc rocke kett with with crank cra nksh shaft aft cente centered red in en end d play. play. When When align aligning ing thi this s sproc sprocke kett with the idler idler sproc sprocke ket, t, take take into into ac acco count unt thatt the idler tha idler sproc sprocke kett is thi thinne nnerr tha than n the other other sproc sprocke kets. ts. If misal misalign igned, ed, adjus adjustt sproc sprocke kett positi position on as needed. 10. In 10. Insta stallll chain chain an and d ad adjus justt ac acco cordin rding g to“Chai to “Chain n Adj Adjus ustme tment” nt” on pag page e 4-4 4-48 8. 11. Re-at 11. Re-attac tach h all tubing tubing to lubric lubricato ator. r.
REV: 10/14
Page 4-47 of 50
Section 4 Part Replacement
For models JGC:D:F
Crankshaft Chain Sprocket Replacement CAUTION: Do not touch hot surfaces without proper protection. Exam Examin ine e th the e sp sproc rocke kett ca caref reful ully ly for for wear; wear; sp sproc rocke kets ts opera operati ting ng fo forr five five ye years ars or more more may may requi require re replac rep lacem ement ent.. To replac replace e a worn sproc sprocke ket: t: 1. Drill Drill a hole hole in th the e sp sproc rocke kett hub hub paral paralle lell to the the sh shaf aftt ce cent nterl erlin ine e an and d bi big g enou enough gh to remov remove e most most of the the hub hub cross cross se sect ctio ion n (see (see figu figure re to th the e rig right ht). ). Multi Mu ltiple ple small smaller er ho holes les may be require required. d. DO NOT tou touch ch shaft shaft with drill. drill. Mark Ma rk th the e drill drill with with ta tape pe to avoi avoid d drill drillin ing g throu through gh the the sp sproc rocke kett an and d in into to th the e cr cran anks ksha haft face Th The eerhole ho ledrelie rel ieve ves most mo sts of thsp e sh shrin rink, k,t enou and anough d agh fe few wrradia rad ial st strik rikes es with witfthfa ace. hamm ha.mmer and an ch chis isel elsopen op ens the thethe sproc rocke ket en fo for ea easy syl
removal. 2. Susp Suspen end d th the e spro sprock cket et wit with h a wire wire an and d heat heat it wi with th a sm smal alll to torc rch h to ab abou outt 400° 400°F F (204° (204°C), C), th then en sl slip ip it over over the the auxi auxililiary ary end end of the the crank cranksh shaf aft. t. Hold Hold th the e sp sproc rocke kett in pl plac ace e and and rotat rotate e it sl slig ight htly ly to ensu ensure re sq squa uaren renes ess s un unti till it co cool ols s en enou ough gh to shrink shrink on onto to the crank cranksh shaft aft..
FIGURE 4-54 Chain Sprocket Remova R emovall
Chain Adjustment 1. Roll the crank cranksh shaft aft to the tig tighte htest st po posi sitio tion n of the chai chain. n. This This preve prevents nts snugg snugging ing the ch chai ain n at a sl slac ack k posi positi tion on and and bre break akin ing g rol roller lers, s, or ruining ruining the pu pump mp and lubric lubricato ator r beari bearing ngs s when when th the e ch chai ain n goes goes throu through gh its its tightest position. 2. Use a ta tape pe meas measure ure to meas measure ure the the longe longest st most most easily easily ac acce cess ssibl ible e span span from sproc sprocke kett cente centerr to sproc sprocke kett cente center, r, where the de defle flecti ction on will be ga gaug uged. ed. Determi Determine ne al allowa lowable ble de defle flecti ction on limits limits for the meas me asure ured d span span as define defined d by the shade shaded d ar area ea in FIGURE FIGURE 4-5 4-56 6. 3. Mea Measu sure re chai chain n deflec deflectio tion n from a straig straight ht edge edge held held on th the e ch chai ain n rolle rollers rs whe where re it wraps wra ps over over th the e two sp sproc rocke kets ts of the the sp span an.. FIGURE 4-55 Chain Deflection Measurement Use a mach machin inis ist’ t’s s sc scal ale e wit with h 0.01 0.01 inch inch or (0.5 (0.5 mm) mm) in incr crem emen ents ts to meas measure ure the the defl deflec ecti tion on dist distan ance ce from from th the e st strai raigh ghtt ed edge ge to a ch chai ain n rolle rollerr at th the e cent nte er of th the e span. App Applya forc force e of 2 to 10 lb (9 to 45N) fin finge gerr pre res ssur ure e to ta tak ke th the e slack ou outt of th the e ch chai ain. n. Do not not appl apply y exce excess ssiv ive e forc force e si sinc nce e a force force feed feed lube lube bo box x drive drive sh shaf aftt ca can n be bend nd an and d provi provide de an inaccurat inac curate e deflecti deflection on measurem measurement. ent. 4. If adju adjust stme ment nt is requi require red, d, remov remove e the the ca cap p sc screws rews and and plas plasti tic c plug plugs s from from th the e ec ecce cent ntric ric ca cap. p. Rotat Rotate e th the e ca cap p cl cloc ockwi kwise se to liline ne up the the firs firstt two new new ca cap p sc scre rew wh hol oles es.. If th this is tigh tighte tens ns th the e ch chai ain n to too o much much,, tu turn rn th the e cap cap count counterc ercloc lockwis kwise e for a di diffe fferen rentt ho hole le align alignmen ment. t. 5. Repla Replace ce and and tigh tighte ten n the the two ca cap p sc screws rews hand hand wrenc wrench h tigh tight. t.CAUTION: CAUTION: Over tightening may result in bent shafts. 6. Roll crank cranksh shaft aft to chec check k tig tightn htnes ess s in seve several ral positi position ons. s. At its tig tighte htest st positi position on,, the chain chain shoul should d deflec deflectt withi wit hin n th the e sh shad aded ed limi limits ts in the the figu figure re belo below. w. Repla Replace ce plas plasti tic c ca caps ps to ke keep ep ho hole les s clea clean. n.
Page 4-48 of 50
REV: 10/14
For models models JGC:D:F JGC:D:F
Section 4 Par Partt Replacemen Replacementt
FIGURE 4-56 Allowable Chain Deflection, Inches (mm)
Component Cleaning & Thread Lube for Non-Lube Compressor Cylinders Ariel cleans cleans and protects protects complete complete non-lube non-lube cylinde cylinders rs to non-lube non-lube service service requiremen requirements. ts. Clean all intern internal al pa parts rts shipp shipped ed loose loose,, conta contamin minate ated d intern internal al surfac surfaces es,, and repair repair parts parts prior prior to instal installat lation ion,, to ex exten tend d the lif life e of rin rings gs an and d no non-lu n-lube be compr compres esso sors. rs. Clean cylin Clean cylinde derr bore thorou thorough ghly ly with denatu denatured red alc alcoh ohol ol un until til a cl clea ean, n, alcoh alcohol-s ol-soak oaked, ed, white white paper paper towel towel remov rem oves es no more more debri debris. s. Th This is incl includ udes es all all surfa surface ces s of the the bo bore re,, co coun unte terr bo bore, re, va valv lve e po pock cket ets, s, et etc. c. Do no nott use use NeverNever-See Seez z on st stee eell gask gasket ets. s. Apply Apply only only a ve very ry ligh lightt film film of oil oil to cy cylilind nder er se seat atin ing g su surfa rface ces s to se seal al Orings. CAUTION: Denatured alcohol presents health and safety hazards. It contains methyl alcohol and is poisonous if ingested. Avoid eye and skin contact. Keep alcohol away from heat, sparks, flame and all other ignition sources. Use adequate ventilation, neoprene or butyl gloves, mono-goggles or face-mask and impermeable apron. Properly handle and dispose of materials resulting from clean-up. See manufacturer's material safety data sheets for more details. Do not not use use any any lu lubri brica cant nts s or anti anti-s -sei eize ze co comp mpou ound nds s on parts parts th that at may may co cont ntac actt th the e ga gas s st strea ream. m. Use ve very ry smal smalll amou amount nts s of NeverNever-See Seez z regul regular ar gra grade de on nu nutt an and d co collllar ar whe when n as asse semb mbliling ng pi pist ston on as asse sembl mbly. y. Thorou Thoroughl ghly y clean clean piston piston (espe (especia cially lly the ring groov grooves es)) with de denat nature ured d alcoho alcoholl until until a cl clean ean,, alcoh alc ohol-s ol-soak oaked ed towel towel remov removes es no more more de debris bris.. Disassemb Disass emble le packin packing g case case.. Wipe Wipe all surfac surfaces es cl clean ean with de denat nature ured d alcoho alcohol. l. Re-asse Re-assemb mble. le. Whe When n the ing” g” on pa page ge 44-27 27.. Handl Handle e clea cleane ned d pa parts rts with with pack packin ing g ca case se is water water co cool oled ed,, re-as re-asse semb mble le and and test test to “Test “Testin new or clea clean n "rubbe "rubber" r" or ne new w white white cotto cotton n glove gloves. s. Before pi Before pist ston on rod in inst stal alla lati tion on,, wipe wipe it with with dena denatu tured red alco alcoho hol. l. Be ca caref reful ul no nott to leav leave e fing fingerp erprin rints ts on th the e rod before before it conta contacts cts the packin packing g rin rings gs.. Wipe Wipe the rod with de denat nature ured d alcoh alcohol ol aft after er insta installa llatio tion. n.
REV: 10/14
Page 4-49 of 50
Section 4 Part Replacement
For models JGC:D:F
Clean th Clean the e head head end end head head or unlo unload ader er co comp mpon onen ents ts with with dena denatu tured red alco alcoho hol. l. Use mini minima mall am amou ount nts s of oil oil fo for r the the bolt bolt-ho -hole les s to ensu ensure re oil oil does does not not run into into the the cy cylilind nder. er. Also Also in inst stal alll th the e he head ad en end d st stee eell gask gasket et witho without ut Never-Seez. Disassem Disass emble ble an and d cl clean ean the valve valves s with denatu denatured red alc alcoh ohol, ol, then then re-ass re-assemb emble, le, wipe them them again, again, and in inst stal all. l. Clean Clean retai retaine ners rs and and high high cl clea earan rance ce asse assemb mblilies es with with de dena natu tured red alco alcoho hol. l. Use on only ly a th thin in film film of oil oil for the valve valve cap cap O-ring O-rings s an and d bo bolt-h lt-hole oles. s. Assemble cleaned Assemble cleaned parts immediat immediately ely to avoid avoid contamin contaminatio ation n and corrosion. corrosion. If cylinde cylinderr will not commenc commence e immedi imm ediate ate servi service ce,, conta contact ct Ariel Ariel for pre prese serva rvatio tion n instruc instructio tions ns to ER-34. ER-34.
Page 4-50 of 50
REV: 10/14
Section 5 - Start Up The chec checkl klis istt be below low conta contains ins all the chec checks ks,, verifi verifica catio tions ns,, an and d ins instruc tructio tions ns ne nece cess ssary ary to start start small smaller er Ariel Ariel recipro rec iproca catin ting g comp compres resso sorr model models. s. Use it as gu guide ide when restart restarting ing the compr compres esso sorr aft after er a shutd shutdown. own.
Warranty Notification - Installation List Data and Start Up Check Lists for Reciprocating Compressors JG:A:M:P:N:Q:R:J:H:E:K:T:C:D:F The fol follo lowing wing forms forms are de desig signe ned d to en ensu sure re a succ succes essfu sfull start-up start-up of small smaller er Ariel Ariel recipro reciproca catin ting g comp compres resso sorr models models.. Ariel Ariel warranty warranty cove coverag rage e requi requires res these these comp complet leted ed forms forms sent sent to: Administra Admin istrative tive Assistan Assistantt - Sales, Sales, Ariel Corporation Corporation
35 Black Blackja jack ck Road Road • Moun Mountt Verno Vernon, n, Ohio Ohio 4305 43050 0 USA Phone Pho ne:: 74 740-3 0-39797-031 0311 1 • FAX: 74 740-3 0-397-3 97-385 856 6
Warranty Notification - Installation List Data Date:_________________ Date:_________ _________ _ Name: _______________ _______________________ ________________ _______________ _______________ ______________ ______ Una Un assigned
Res Resale
Dire Direc ct Sal Sale
Lease-P -Pu urc rch hase
Ren Rental/Lease Uni Unit
Compressor Frame Frame Model:_____________________________________ Model:_____________________________________ Frame Serial #:_________________________________________ #:_______________________________________________ ______ Frame Lubricant Make and Grade:______________________ Grade:______________________________________ ________________________________ _________________________________ __________________________ _________ Package Startup Date:_______ Date:____________ _________ _________ __________ __________ ______ _
Distributor/Fabricator Company: _______________________________ _______________________________________________ _________________ _ Name: _______________ ________________________________ ______________________________ _____________ Address:_________ Addre ss:______________ __________ __________ _________ _________ __________ _________ _________ __________ __________ _________ _________ __________ __________ _________ _________ __________ _________ _________ ______ _ City :___________________________________ :___________________________________ State:________ Stat e:________ Zip:__________________ Country :___________________________ :___________________________ Fabricat or Unit Number: ________________ ________________________________ _______________________ _______
Application Air/Nitrogen
CNG/GNC
FPSO
Gathering Gathering
Fuel Gas Booster Booster
Ref rigerat ion
Pipeline
PRC
I nject ion
St orage/ Wit hdrawal
Mis c ellaneous
Elevation:_____________________________ H2S%:__________________ CO2%:__ %:_____ ______ ______ ______ ______ ____ _ Specific Specific Gravity:____ Gravity:_______ ______ ______ ______ ______Non-Lu ___Non-Lube: be:
Yes
No
REV: 10/14
Page 5-1 of 9
Section 5 - Start Up
For models JGC:D:F
Unit Location Cust omer Name:________________ Name: _________________________________ _________________________________ _________________________________ _________________________________ ____________________________ ____________ Project/ Lease Name: _______________ _______________________________ _________________________________ _________________________________ _________________________________ ___________________________ __________ Closest Close st Town:_ Town:____ ______ ______ ______ ______ ______ ______ ______ ______ ______ ____ _ State:__ State:_____ ______ ____ _ Coun Country:____ try:_______ ______ ______ ______ ______ ______Offshore: ___Offshore:
Yes
No
Direct ions to Location or GPS:__________________ GPS:__________________________________ ________________________________ _________________________________ _________________________________ _________________ _ _________ ____ _________ _________ __________ _________ _________ __________ __________ _________ _________ __________ __________ _________ _________ __________ _________ _________ __________ __________ _________ _________ _________ ____ _________ ____ _________ _________ __________ _________ _________ __________ __________ _________ _________ __________ __________ _________ _________ __________ _________ _________ __________ __________ _________ _________ _________ ____ _________ ____ _________ _________ __________ _________ _________ __________ __________ _________ _________ __________ __________ _________ _________ __________ _________ _________ __________ __________ _________ _________ _________ ____ Cust omer Contac t Person:____________________________________________ Person:____________________________________________ Contac t Phone:______________________________ Phone:______________________________ Contact Conta ct Email:___ Email:______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ _____ __ OKt o contact:
Yes
No
Driver Driver Manufac turer: _______________ _______________________________ _________________________________ ____________________ ___ Driver Model:____________________________ Driver Type:____________ Type:_________________ _________ _________ _________ ____ Appl Applied ied RPM:______ RPM:___________ __________ ________ ___ Name Plate HP (kW):_______ (kW):____________ _________ ________ ____ Coupling Manufac turer: _________________ _________________________________ ____________________________ ____________ Coupling Model:_____________________________ Model:______________________________ _
Compressor Cylinders and Operating Conditions Cylinder Class
Stage Number
Throw Number
Serial Number
Bore Dia. In. (mm)
Inlet Temp. °F (°C)
Inlet Pres. Pres. psig (barg)
Disc. Temp °F (°C)
Disc. Pres. psig (barg)
_________ _____ ____
____ _________ _____
_____ _________ ____
____ _________ _____
_____ _________ ____
_________ _________
_________ _________
_________ _________
_________ _________
_________ _____ ____
____ _________ _____
_____ _________ ____
____ _________ _____
_____ _________ ____
_________ _________
_________ _________
_________ _________
_________ _________
_________ _____ ____
____ _________ _____
_____ _________ ____
____ _________ _____
_____ _________ ____
_________ _________
_________ _________
_________ _________
_________ _________
_________ _____ ____
____ _________ _____
_____ _________ ____
____ _________ _____
_____ _________ ____
_________ _________
_________ _________
_________ _________
_________ _________
_________ _____ ____
____ _________ _____
_____ _________ ____
____ _________ _____
_____ _________ ____
_________ _________
_________ _________
_________ _________
_________ _________
_________ _____ ____
____ _________ _____
_____ _________ ____
____ _________ _____
_____ _________ ____
_________ _________
_________ _________
_________ _________
_________ _________
Cylinder Lubricant Make and Grade:_____________________ Grade:_____________________________________ ________________________________ _________________________________ _________________________ ________
Documentation and Access Accessories ories Check Chec k all ite items ms in inclu clude ded d in the shipm shipmen ent: t: Maintena Main tenance nce andRepairManual
Yes
No
Recommended Spares Spares List
Yes
No
Start-UpSpare Start-UpSpar e Parts Parts
Yes
No
Unit Start Start andSt op Procedures Procedures
Yes
No
Toolbox w/Ariel Tools
Yes
No
Toolbo Toolbox x with Hydraulic Tools (optiona (optional) l)
Yes
No
Unit Parts List
Yes
No
Toolbox with SAEH and Tools (optional) (optional)
Yes
No
Commissioning Commissi oning Agent Name: _______________ _______________________________ _________________________________C _________________C ompany: _______________ ________________________________ ______________________________ _____________ Address:________ Addre ss:_____________ _________ _________ __________ _________ _________ __________ __________ _________ _________ __________ _________ _________ __________ __________ _________ _________ __________ __________ _______ __ City :___________________________________ :___________________________________ State:________ Stat e:________ Zip:__________________ Country :___________________________ :___________________________ Phone:___________________________________ Phone:___________________ _____________________________ _____________ Email:____________________________ Email:____________________________________________ ____________________ ____
Page 5-2 of 9
REV: 10/14
For models models JGC:D:F JGC:D:F
Secti Section on 5 - Sta Starrt Up
START-UP CHECK LIST - ITEMS TO CHECK IN THE FIELD AT COMMISSIONING Description
Date Checked
Date Verified
1. Check Check an and d verify verify th the e top cover cover data data pl plate ate of the compr compresso essor r fra frame me for compre compressor ssor de design sign limitatio limitations ns such as ro rod d loa load, d, maximu ma ximum m and and min minimu imum m speed speed,, an and d maxi maximu mum m lub lube e oil temperature.
Commissioning Agent: Agent: ______________ _________ _________ ____
Distributor: _______________ __________ ________ ___
2. Check and and verify th the e availability availability o off correct correct start-up start-up spar spares, es, hand hand tools, special tools, tools, compre compressor ssor par parts ts list and dra drawings, wings, and technical manuals at installation.
Commissioning Agent: Agent: ______________ _________ _________ ____
Distributor: _______________ __________ ________ ___
Commissioning Agent: Agent: ______________ _________ _________ ____
Distributor: _______________ __________ ________ ___
3. Check and verify the Ariel lube sheet and Lub Lubrication rication Specification Specificati on matche matches s the recomm recommen ende ded d oil grad grade e an and d viscosity for the service service..
4. Check and and verify a allll lube lube oil pip piping ing clean cleanliness liness per per Ariel Ariel lu lubrica brication tion specifications specification s (see “O “Oilil System System Clea Cleanli nline ness” ss” on pa page ge 33-9 9).
Commissioning Agent: Agent: ______________ _________ _________ ____
Distributor: _______________ __________ ________ ___
Sy stem 5. Verify Verify lube oil storag storage e and supp supply ly line cleanline cleanliness ss p per er ““Oil Oil System Cleanli Clea nline ness” ss” on pa page ge 33-9 9). Verify Verify c cran rankcase kcase oil supp supply ly isolation valve is ope open. n.
Commissioning Agent: Agent: ______________ _________ _________ ____
Distributor: _______________ __________ ________ ___
6. Verify Verify pr pre-l e-lube ube pipin piping g cleanline cleanliness ss pe per r “Oil “Oil System Clea Cleanli nline ness” ss” on page pag e 3-9 3-9)) and corr correct ect circuit ope opera ration. tion.
Commissioning Agent: Agent: ______________ _________ _________ ____
Distributor: _______________ __________ ________ ___
7. Verify Verify there there is an oil cooler cooler an and d hig high h temper temperatu ature re shu shutdo tdown wn for the oil into into the compre compressor ssor frame. frame.
Commissioning Agent: Agent: ______________ _________ _________ ____
Distributor: _______________ __________ ________ ___
8. Verify Verify whe whethe therr the temper temperatu ature re con contro troll val valve ve insta installa llation tion is blending blendin g or diverting (blending (blending preferr preferred). ed). __________ _______________ _________ ____ _____ ___ __
Commissioning Agent: Agent: ______________ _________ _________ ____
Distributor: _______________ __________ ________ ___
9. Check compressor compressor crankcase crankcase oil level contro controller ller for pro proper per installation, operation, operation, levelne levelness ss,, an and d venting.
Commissioning Agent: Agent: ______________ _________ _________ ____
Distributor: _______________ __________ ________ ___
10. If applicable 10. applicable,, che check ck coolin cooling g water circuit cleanl cleanliness iness for the oil cooler coo ler an and d cooled cooled pa packing cking pe perr Mai Mainte ntena nance nce and and Rep Repair air Man Manua ual. l. Verify Ver ify c corr orrect ect routing routing and test pump rotation. rotation. Set pr pressure essure approp app ropriate riately ly per Main Maintena tenance nce and Repa Repair ir Manual Manual and leak te test. st.
Commissioning Agent: Agent: ______________ _________ _________ ____
Distributor: _______________ __________ ________ ___
11. Verify 11. Verify corre correct ct filter elem element ent in installation stallation.. Prime the oil filter eleme ele ment nt an and d all lu lube be oil p pipi iping ng with oil oil..
Commissioning Agent: Agent: ______________ _________ _________ ____
Distributor: _______________ __________ ________ ___
12. Verify prop 12. proper er compr compressor essor cran crankcase kcase oil level befo before re starting (a (abo bout ut 7/8 7/8 full in site gla glass). ss).
Commissioning Agent: Agent: ______________ _________ _________ ____
Distributor: _______________ __________ ________ ___
13. Verify 13. Verify corr correct ect installa installation tion of a low oi oill pressur pressure e shu shutdo tdown wn tub tubed ed to the downstr downstrea eam m side of the oil filter. filter.
Commissioning Agent: Agent: ______________ _________ _________ ____
Distributor: _______________ __________ ________ ___
Commissioning Agen Commissioning Agent: t: ______________ _________ _________ ____
Distributor: _______________ __________ ________ ___
14. Oper 14. Operate ate pr pre-lu e-lube be syst em.
15. OPTIO OPTIONAL NAL STEP: Record “ou “outt of plan plane” e” readin readings gs (pr (pre-g e-grou rout) t) - see see Appe Appendix ndix G - ER-82 ER-82.. ______ ___ ______ ___ ___ ______ ______ ___ ___ ______ ______ ___ ___ ______ ______ ___ ___ ______ ______ ___ ___ ______ ______ ___ Drive End ___ End ______ ______ ___ ___ ______ ______ ___ ___ ______ ______ ___ ___ ______ ______ ___ ___ ______ ______ ___ ___ ______ ______ ___ Auxiliary Auxiliary End Commissioning Agent: Agent: ______________ _________ _________ ____
Distributor: _______________ __________ ________ ___
REV: 10/14
Page 5-3 of 9
Section 5 - Start Up
For models JGC:D:F
START-UP CHECK LIST - ITEMS TO CHECK IN THE FIELD AT COMMISSIONING D escription
D ate Checked
Date Verified
16. Record 16. Record soft foot reading readings. s. Over 0.00 0.002 2 inches inches (0.05 (0.05 mm) pull-down pull-down on any frame foot rrequ equire ires s corr correction. ection. ______ ___ ______ ___ ___ ______ ______ ___ ___ ______ ______ ___ ___ ______ ______ ___ ___ ______ ______ ___ ___ ______ ______ ___ Drive End ___ End ______ ______ ___ ___ ______ ______ ___ ___ ______ ______ ___ ___ ______ ______ ___ ___ ______ ______ ___ ___ ______ ______ ___ Auxiliary Auxiliary End
17. Check 17. Check crosshe crosshead ad gu guide ide shim shimmin ming g for corre correct ct pre pre-l -loa oad d an and d hold hold down bolt torq torque. ue.
Commissioning Agent: ______________ __________ ________ ____
Distributor: ______________ _________ _________ ____
Commissioning Agent: ______________ __________ ________ ____
Distributor: ______________ _________ _________ ____
18. Record 18. Record piston piston en end d cleara clearance nces s with feeler feeler ga gage ges s (se (see e Ma Mainte intena nance nce an and d Rep Repair air Ma Manu nual, al, Appe Append ndix ix B).
Throw
1
2
3
4
5
6
______ ______ ___ ___ ______ ______ ___ ___ ______ ______ ___ ___ ______ ______ ___ ___ ______ ______ ___ ___ ______ ______ ___ Head End ___ ______ ______ ___ ___ ______ ______ ___ ___ ______ ______ ___ ___ ______ ______ ___ ___ ______ ______ ___ ___ ______ ______ ___ Crank End ___ NOTE: Pre-lube compressor before turning crankshaft.
Commissioning Agent: Commissioning ______________ __________ ________ ____
Distributor: ______________ _________ _________ ____
19. Measur 19. Measure e an and d recor record d ro rod d run run ou outt (see Mai Mainte ntena nance nce an and d Rep Repair air Man Manua uall for maxi maximu mum m accep acceptab table le read reading ings). s). 2 3 4 5 6 Throw 1 Vertical: ______ ______ ___ ___ ______ ______ ___ ___ ______ ______ ___ ___ ______ ______ ___ ___ ______ ______ ___ ___ ______ ______ ___ Piston @ CE ___ Mid-Stroke ___ ______ ______ ___ ___ ______ ______ ___ ___ ______ ______ ___ ___ ______ ______ ___ ___ ______ ______ ___ ___ ______ ______ ___ ______ ______ ___ ___ ______ ______ ___ ___ ______ ______ ___ ___ ______ ______ ___ ___ ______ ______ ___ ___ ______ ______ ___ Piston @ HE ___ Horizontal: ______ ______ ___ ___ ______ ______ ___ ___ ______ ______ ___ ___ ______ ______ ___ ___ ______ ______ ___ ___ ______ ______ ___ Piston @ CE ___ ______ ______ ___ ___ ______ ______ ___ ___ ______ ______ ___ ___ ______ ______ ___ ___ ______ ______ ___ ___ ______ ______ ___ Mid-Stroke ___ ______ ______ ___ ___ ______ ______ ___ ___ ______ ______ ___ ___ ______ ______ ___ ___ ______ ______ ___ ___ ______ ______ ___ Piston @ HE ___ NOTE: Pre-lube compressor before turning crankshaft.
Commissioning Agent: Commissioning ______________ __________ ________ ____
Page 5-4 of 9
Distributor: ______________ _________ _________ ____
REV: 10/14
For models models JGC:D:F JGC:D:F
Secti Section on 5 - Sta Starrt Up
START-UP CHECK LIST - ITEMS TO CHECK IN THE FIELD AT COMMISSIONING Descri ption
Date Checked
Date Verified
Commissioning Agent: Agent: _____________ _________ _________ _____
Distributor: _________ ____ __________ _________ ____
20. Measure 20. Measure crosshea crosshead d clear clearance ances s with cylinders cylinders mo mounte unted. d. To check top,, insert top insert 0.5 inch (12.7 (12.7 mm) wide fee feeler lers s fr from om on one e side ed edge ge across acr oss to the op oppo posite site side side,, at bo both th en ends. ds. Se See e Mai Mainte ntena nance nce an and d Repair Repa ir Manual, Manual, Appen Appendix dix B for limits. To check bottom bottom,, inser insertt a 0.001 0.0 015 5 inch (0.03 (0.038 8 mm) feeler feeler at th the e four four corne corners; rs; fee feeler ler should should insert inse rt no more more tha than n 0.5 0.50 0 (13 (13 mm) mm).. Re Recor cord d valu values: es: Top Max. Bottom Max. (Corners) Throw Top Min. 1
______ ___ ______ ___
______ ___ ______ ___
______ ___ ______ ___
2
______ ___ ______ ___
______ ___ ______ ___
______ ___ ______ ___
3
______ ___ ______ ___
______ ___ ______ ___
______ ___ ______ ___
4
______ ___ ______ ___
______ ___ ______ ___
______ ___ ______ ___
5
______ ___ ______ ___
______ ___ ______ ___
______ ___ ______ ___
6
______ ___ ______ ___
______ ___ ______ ___
______ ___ ______ ___
21. For ele 21. electric ctric motor motor driver drivers, s, check and and ver verify ify the moto motorr sha shaft ft is set at its magne magnetic tic center before before position positioning ing axial clear clearance. ance. With the coupling coup ling disconnected, disconnected, check a and nd verify driver driver rotation rotation matche matches s the compre compressor ssor rotatio rotation n arro arrow. w.
Commissioning Agent: Agent: _____________ _________ _________ _____
Distributor: _________ ____ __________ _________ ____
22. Check coupli 22. coupling ng bolt torq torque ue to coupl coupling ing man manufactur ufacturer er recommendations.
Commissioning Agent: Agent: _____________ _________ _________ _____
Distributor: _________ ____ __________ _________ ____
Commissioning Agent: Agent: _____________ _________ _________ _____
Distributor: _________ ____ __________ _________ ____
Commissioning Agent: Agent: _____________ _________ _________ _____
Distributor: _________ ____ __________ _________ ____
23. Check 23. Check an and d verify verify compr compressor essor to driver driver ali align gnme ment nt (in (installe stalled d on site, cold). cold). Record Record dial indicator indicator rea reading dings s in inches (mm) at the 3, 6, 9 an and d 12 o’cl o’clock ock positio positions ns or atta attach ch ali align gnmen mentt too tooll prin print-o t-out. ut.
If using using a lase laserr align alignme ment nt too tool, l, m make ake a print print out out a and nd atta attach ch it to this document. 24. Check and verify compr 24. compressor essor cran crankshaft kshaft thrust clearance. clearance. Th The e shaft sha ft sho should uld rema remain in stationa stationary ry after after thr thrustin usting g ea each ch directio direction n (se (see e Appe Appendi ndix x B). B ). ______ ___ ______ ______ ______ ______ ______ ______ ___ ___ ______ ______ ______ ______ ______ ______ ______ ____ _
REV: 10/14
Page 5-5 of 9
Section 5 - Start Up
For models JGC:D:F
START-UP CHECK LIST - PROCESS PIPING VENTS AND DRAINS D escri ption Verify th the e bo bottle ttle an and d proce process ss pipe pipe insta installa llation tion con contain tains s no no bo bolt lt 1. Verify bound bou nd flang flanges es or elevation elevation differe differences nces that ma may y stress the compressor compr essor cylinders cylinders
2. Verify Verify cold adjustment adjustment of any bottle or cylinder suppo supports. rts. 3. Verify Verify correct correct in inlet let screen orienta orientation tion in process process pip piping ing..
and verify ve vents nts and and dra drains ins o off the prim primar ary y an and d second secondary ary 4. Check and pa packing cking-ca -case se and and the crosshe crosshead ad dista distance nce pie piece ce are are op open en and and
Date Checked
D ate Verified
Commissioning Agent: Agent: _____________ _________ _________ _____
Distributor: _________ ____ __________ _________ ____
Commissioning Agent: Commissioning Agent: _____________ _________ _________ _____
Distributor: _________ ____ __________ _________ ____
Commissioning Agent: Commissioning Agent: _____________ _________ _________ _____
Distributor: _________ ____ __________ _________ ____
Commissioning Agent: Agent:
Distributor:
_________ ____ _________ _________ _____
_________ ____ __________ _________ ____
tubed tub ed to a safe atm atmosp osphe here re.. 5. Check Check an and d ver verify ify safe safety ty re relie lieff valve insta installa llation tion to prote protect ct cylinder cylind ers, s, piping piping,, and and coo cooler ler for ea each ch comp compre ression ssion stag stage. e.
Commissioning Agent: Agent: _____________ _________ _________ _____
Distributor: _________ ____ __________ _________ ____
6. Record Record metho method d of suctio suction n pressur pressure e con contro troll an and d valve size. ______ ___ ______ ______ ______ ______ ______ ______ ____ _ ______ _________ ______ ______ ______ ______ ______ ____ _
Commissioning Agent: Agent: _____________ _________ _________ _____
Distributor: _________ ____ __________ _________ ____
7. Check Check an and d ver verify ify cra crankcase nkcase brea breathe therr elemen elementt is open open to atmosphere atmosph ere and clean.
Commissioning Agent: Agent: _____________ _________ _________ _____
Distributor: _________ ____ __________ _________ ____
Commissioning Agent: Agent: _____________ _________ _________ _____
Distributor: _________ ____ __________ _________ ____
8. Check Check and verify verify tor torqu que e to spec spec on all g gas as contain containmen mentt and other other fastene faste ners rs where where loosen loosening ing ma may y result result in a safe safety ty hazar hazard d or equipme equ ipment nt failur failure e including: including: ga gas s nozzle flang flanges, es, valve caps, cylinder hea heads, ds, compressor compressor rod packing, packing, and crosshea crosshead d guid guide e support. See Appe See Appendix ndix A . A .
START-UP CHECK LIST - INSTRUMENTATION D escri ption 1. Check Check a and nd verify verify the set point point for the high high compre compressor ssor oil temperatu tempe rature re shutdo shutdown wn at 190 190°F °F (88°C) (88°C) maximu maximum. m.
Date Checked
D ate Verified
Commissioning Agent: Agent: _____________ _________ _________ _____
Distributor: _________ ____ __________ _________ ____
Commissioning Agent: Agent: _____________ _________ _________ _____
Distributor: _________ ____ __________ _________ ____
Commissioning Agent: Agent: _____________ _________ _________ _____
Distributor: _________ ____ __________ _________ ____
Commissioning Agent: Commissioning Agent: _____________ _________ _________ _____
Distributor: _________ ____ __________ _________ ____
2. Check Check an and d ver verify ify pr prop oper er vibr vibratio ation n shutdo shutdown wn insta installa llation tion and and op oper eratio ation. n. Record Record alarm alarm an and d shu shutt down down settin settings. gs. ______ ___ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ____ _ ______ ___ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ____ _ ______ ___ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ____ _ 3. Verify Verify operatio operation n of suction, suction, inter-stag inter-stage, e, and and dischar discharge ge pre pressure ssure shutdo shu tdowns. wns. Record Record alarm alarm an and d shu shutdo tdown wn settin settings. gs. ______ ___ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ____ _ ______ ___ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ____ _ ______ ___ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ____ _ 4. Check, verify, and reco record rd the over speed setting: ___ ______ ______ ______ ____ _
Page 5-6 of 9
REV: 10/14
For models models JGC:D:F JGC:D:F
Secti Section on 5 - Sta Starrt Up
START-UP CHECK LIST - FORCE FEED LUBRICATION SYSTEM Descri ption
D ate C hecked
Date Verified
Commissioning Agent: Commissioning Agent: ______________ _________ _________ ____
Distributor: _________ ____ __________ _________ ____
2. Pri Prime me the for force ce feed feed lub lubrica rication tion system thr throu ough gh the purg purge e port port at the for force ce fee feed d pu pump mp dischar discharge ge ma manifo nifold. ld. Check Check and ver verify ify each tube tub e conn connectio ection n for tightne tightness. ss.
Commissioning Agent: Agent: ______________ _________ _________ ____
Distributor: _________ ____ __________ _________ ____
3. Check Check a and nd verify verify op oper eratio ation n of force force fee feed d lub lubrica rication tion system no flow shutdowns. shutdowns.
Commissioning Agent: Agent: ______________ _________ _________ ____
Distributor: _________ ____ __________ _________ ____
4. Record Record colo colorr of for force ce fee feed d blo blow w out out discs (se (see e TABLE 3-5 for di disc sc
Commissioning Agent: Agent:
Distributor:
_________ _____ _________ _________ ____
_________ ____ __________ _________ ____
Check an and d verify verify fo force rce feed feed lub lubrica ricator tor bo box x for prop proper er oil leve level. l. 1. Check
ratings): ______________________________
5. Check, Check, veri verify, fy, an and d recor record d recomm recommen ende ded d lub lube e feed feed rates rates fr from om lubri lub ricato catorr data data pla plate te or “Pa “Parts rts Boo Book” k” Cylind Cylinder er Lu Lubr bricatio ication n sheet. sheet.
Commissioning Agent: Agent: ______________ _________ _________ ____
Distributor: _________ ____ __________ _________ ____
______ ___ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ____ _
FINAL PRE-START PRE-START CHECK LIST Descri ption
D ate C hecked
Date Verified
Commissioning Agent: Commissioning Agent: ______________ _________ _________ ____
Distributor: _________ ____ __________ _________ ____
Commissioning Agent: Agent: ______________ _________ _________ ____
Distributor: _________ ____ __________ _________ ____
3. For ele electric ctric moto motors, rs, ba barr the compre compressor ssor ove overr man manua ually lly to check and verify it rolls fre freely. ely.
Commissioning Agent: Agent: ______________ _________ _________ ____
Distributor: _________ ____ __________ _________ ____
4. For mach machine ines s comp compre ressing ssing a combustib combustible le ga gas, s, pur purge ge the en entire tire system incl includ uding ing the piping piping,, byby-pa pass, ss, recycle recycle line, line, and compressor compr essor cylinders cylinders of all air air..
Commissioning Agent: Agent: ______________ _________ _________ ____
Distributor: _________ ____ __________ _________ ____
Commissioning Agent: Commissioning Agent: ______________ _________ _________ ____
Distributor: _________ ____ __________ _________ ____
Commissioning Agent: Agent: ______________ _________ _________ ____
Distributor: _________ ____ __________ _________ ____
1. Operate Operate pr pre-lu e-lube be syst em. Record pre pre-lu -lube be pre pressure:_ ssure:____ ______ ______ ____ _ engin gine e driven driven un units, its, disable disable ign ignitio ition n an and d roll roll the en engin gine e with the 2. For en starter star ter to check check and verify verify the comp compre ressor ssor rolls rolls fre freely. ely. Check Check and
verify oil pr pressure essure incre increases ases noticea noticeably bly while rolling rolling on the starter. starter.
5. Review start-up start-up instruction instructions s for all othe otherr packag package e compo componen nents. ts.
6. Comple Complete te the requ require ired d review review of the Start-Up Start-Up an and d Oper Operatin ating g Instructio Instr uctions ns for the un unit it with the un unit it opera operator tor..
INITIAL POST START-UP START-UP CHECK LIST Descri ption D ate C hecked
Date Verified
1. Check and verify immediate immediate oil pre pressure ssure incre increase. ase. Enab Enable le oil pressure pre ssure shutdown shutdown and bea bearing ring tempe temperatu rature re shutdo shutdowns. wns. Record initial pressure press ure at operating speed._________ speed._____________ _________ __________ _______ __ __
Commissioning Agent: Agent: ______________ _________ _________ ____
Distributor: _________ ____ __________ _________ ____
2. Check and verify oil filter pressure pressure gau gauges. ges. Record initial differential: ____________________________________________ _
Commissioning Agent: Agent: ______________ _________ _________ ____
Distributor: _________ ____ __________ _________ ____
3. Check Check a and nd verify verify the low oil pressur pressure e shu shutdo tdown wn is active an and d set at 45 psig (3.1 (3.1 ba barg rg). ).
Commissioning Agent: Agent: ______________ _________ _________ ____
Distributor: _________ ____ __________ _________ ____
REV: 10/14
Page 5-7 of 9
Section 5 - Start Up
For models JGC:D:F
INITIAL POST START-UP START-UP CHECK LIST D escri ption
D ate C hecked
Date Verified
4. Check Check a and nd ver verify ify lube lube oi oill pre pressur ssure e set at 50 to 60 psi psig g (3.5 (3.5 to 4.2 barg) bar g) at opera operating ting speed and tempe tempera rature ture (see “Oi “Oill Pressure” on page pag e 33-7 7). Record final setting:_______ setting:____________ _______ __
Commissioning Agent: Agent: ______________ _________ _________ ____
Distributor: _______________ __________ ________ ___
5. Record Record oil filte filterr maxi maximu mum m diffe differe rentia ntiall refer referen ence ce value value listed on the compressor compr essor top cover filter data plate plate:: ___ ______ ______ ______ ______ ______ ______ ____ _
Commissioning Agent: Agent: ______________ _________ _________ ____
Distributor: _______________ __________ ________ ___
Commissioning Agent: Agent: ______________ _________ _________ ____
Distributor: _______________ __________ ________ ___
6. Listen Listen an and d feel feel for an any y strang strange e no noises ises or vibr vibratio ation n in the compressor compr essor or piping. piping. Record Record any o occurre ccurrences. nces. ______ ___ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ____ _
______ ___ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ____ _ ______ ___ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ____ _ 7. Check and verify high discharge discharge gas tempe temperatu rature re shutdo shutdowns wns a are re set about about 10% abo above ve normal normal op oper erating ating tempera temperature ture (350 (350 °F (17 (177 7 °C) ma maximu ximum) m) an and d fun function ctioning ing..
Commissioning Agent: Agent: ______________ _________ _________ ____
Distributor: _______________ __________ ________ ___
8. Check Check and and ver verify ify distribu distribution tion blo block ck cycle time ind indicato icatorr an and d set lubrica lub ricator tor pu pump mp for prop proper er brea break-in k-in rate. rate.
Commissioning Agent: Agent: ______________ _________ _________ ____
Distributor: _______________ __________ ________ ___
Commissioning Agent: Agent: ______________ _________ _________ ____
Distributor: _______________ __________ ________ ___
10. C 10. Check heck and and verify scru scrubbe bberr high level shutdo shutdowns wns op opera eration tion and check scrubber scrubber dum dumps ps operatio operation n and freq frequen uency. cy.
Commissioning Agent: Agent: ______________ _________ _________ ____
Distributor: _______________ __________ ________ ___
11. C 11. Check, heck, verify, verify, and record record tank levels th that at in indicate dicate the amount amount of liquids removed removed from the gas. ______ ___________ __________ __________ __________ _______ __
Commissioning Agent: Agent: ______________ _________ _________ ____
Distributor: _______________ __________ ________ ___
12. Check 12. Check and and ver verify ify piston rod rod pa packing ckings s sea s eall pro prope perly rly in the prima primary ry pa packing cking ven vents. ts.
Commissioning Agent: Agent: ______________ _________ _________ ____
Distributor: _______________ __________ ________ ___
13. C 13. Check heck and and verify o oper peration ation of all all safety safety function functions s to ensu ensure re unit shutdown shutdo wn upo upon n indication. indication.
Commissioning Agent: Agent: ______________ _________ _________ ____
Distributor: _______________ __________ ________ ___
14. If applicable, 14. applicable, check and verify main bearin bearing g temperatu temperatures res an and d record. reco rd. Watch for even bearing bearing tempe temperatu rature re incre increase. ase.
Commissioning Agent: Agent: ______________ _________ _________ ____
Distributor: _______________ __________ ________ ___
15. During 15. During various various oper operation ational al conditio conditions, ns, use the Ariel Ariel performa performance nce progr pro gram am to check and verify operatio operational nal characteristics characteristics of v vario arious us load loa d steps.
Commissioning Agent: Agent: ______________ _________ _________ ____
Distributor: _______________ __________ ________ ___
9. Check Check a and nd ver verify ify th the e un unit it and and pip piping ing is fr free ee fro from m an any yg gas as or flui fluid d leaks. Record any occurr occurrence ences. s. ______ ___ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ____ _ ______ ___ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ____ _ ______ ___ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ____ _ ______ ___ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ____ _
Page 5-8 of 9
REV: 10/14
For models models JGC:D:F JGC:D:F
Secti Section on 5 - Sta Starrt Up
24-HOUR POST START-UP CHECK LIST Descri ption
D ate C hecked
Date Verified
Commissioning Agent: Agent: ______________ _________ _________ ____
Distributor: _________ ____ __________ _________ ____
1. Record "hot" alignmen alignmentt reading readings s after reaching reaching nor normal mal op opera erating ting temperatures tempera tures an and d components become become heat soaked. Shutdown an and d ven ventt gas system. Within Within 30 min minute utes s and whil while e compon componen ents ts are are still hot, hot, record record dia diall indicato indicatorr read reading ings s in inch inches es (mm (mm)) at the 3, 6, 9 an and d 12 o’cl o’clock ock posi position tions s on lines lines pr provid ovided ed be below: low:
If using using a laser laser align alignmen mentt tool, tool, ma make ke a print print ou outt and and attach attach it to this document. 2. If using using a disch dischar arge ge bo bottle ttle or he head ad end end cylind cylinder er sup suppo ports, rts, ad adjust just when whe n comp compon onen ents ts a are re he heat at soake soaked d to en ensur sure e no exce excessive ssive for forces ces exist to cause detr detrimen imental tal cylinder defle deflection. ction.
Commissioning Agent: Agent: ______________ _________ _________ ____
Distributor: _________ ____ __________ _________ ____
3. Check Check an and d verify verify tor torqu que e on ga gas s no nozzle zzle flange flange,, val valve ve cap, cap, cylinde cylinder r he head ad,, comp compre ressor ssor rod rod pa packing cking flan flange ge,, an and d gu guide ide to fra frame me bo boltin lting. g.
Commissioning Agent: Agent: ______________ _________ _________ ____
Distributor: _________ ____ __________ _________ ____
4. Complete Complete Arie Ariel’s l’s “Compressor “Compressor Warr Warranty anty Notification - Installation Installation List Data” Data” (pages (pages 5-1 and 5-2). 5-2).
Commissioning Agent: Agent: ______________ _________ _________ ____
Distributor: _________ ____ __________ _________ ____
750-HOUR POST START-UP CHECK LIST Descri ption
D ate C hecked
Date Verified
Check an and d verify verify tor torqu que e on ga gas s no nozzle zzle flange flange,, val valve ve cap, cap, cylinde cylinder r 1. Check head, hea d, and compr compressor essor rod packing flang flange e boltin bolting. g. Re-che Re-check ck fastene faste ners rs foun found d loose loose in an any y of the these se inte interva rvals ls after an ad additi dition onal al 750 hou hours. rs. If loosenin loosening g continues, continues, conta contact ct your package suppl supplier ier immediately.
Commissioning Agent: Agent: ______________ _________ _________ ____
Distributor: _________ ____ __________ _________ ____
2. Send Send complete completed d for form m an and d check check lists (pag (pages es 5-1 5-1 to 5-12 5-12)) to Ari Ariel el as noted noted on page page 5-1. 5-1.
Commissioning Agent: Agent: ______________ _________ _________ ____
Distributor: _________ ____ __________ _________ ____
REV: 10/14
Page 5-9 of 9
Section 6 - Compressor Troubleshooting Expectt minor Expec minor proble problems ms du during ring routin routine e operati operation on of an Ariel Ariel compr compres esso sor. r. These These trouble troubles s most most oft often en trace trace to liq liquid uid,, dirt, dirt, improp improper er ad adjus justme tment, nt, or op opera erators tors unfami unfamilia liarr with Ariel Ariel comp compres resso sors. rs. These These diffic difficult ultie ies s can can us usua ually lly be correc corrected ted by clean cleaning ing,, proper proper ad adjus justme tment, nt, elimin eliminati ation on of an ad adve verse rse cond conditi ition on,, pa part rt replac rep lacem ement ent,, or prope properr trainin training. g. Major problem Major problems s us usual ually ly trace trace to long long period periods s of operati operation on with un unsu suita itable ble lubric lubricati ation on,, carel careles ess s operati operation, on, lack lac k of routin routine e mainte maintenan nance ce,, or us usin ing g the compr compres esso sorr for pu purpo rpose ses s no nott inten intended ded.. Recording Recordi ng inter-s inter-stag tage e press pressure ures s and temper temperatu atures res on multis multistag tage e un units its is valua valuable ble.. Any variat variation ion when opera operati ting ng at a gi give ven n load load poin pointt indi indica cate tes s troub trouble le in one one of th the e st stag ages es.. Normal Normally ly,, a de decre creas ase e in inte inter-s r-sta tage ge press pre ssure ure indic indicate ates s trouble trouble in the lower lower press pressure ure cylin cylinder der.. An increa increase se us usua ually lly indic indicate ates s trouble trouble in the highe hig herr press pressure ure cylin cylinder. der. Below Below is a lis listt of commo common n probl problems ems and possi possible ble caus causes es..
Problem
Low Oil Pressure
Possible Causes • Oil pu pump mp pressur pressure e regu regulati lating ng valve set too too low or sticking. sticking. • Oil pu pump mp or oil pu pump mp drive drive failur failure. e. • Oil foaming foaming from counterweig counterweights hts striking oil surface (oil (oil le level vel in sight glass too high) high),, or from from vor vortex tex at strain strainer er inlet inlet (oi (oill level in sight sight glass too low), low), or from from le leaks aks in pump pump suctio suction n line. line. Cold oil oil.. • Cold • Dirty oil filter. • Interi Interior or fra frame me oil leaks. leaks. • Excessive Excessiv e leakage leakage at bea bearin rings. gs. • Improp Improper er low oil oil pr pressur essure e switch setting. setting. • Oil pu pump mp relie relieff valve set too too low. • Defective pre pressure ssure gau gauge. ge. • Plugged Plugged oil sump straine strainer. r. • Improp Improper er en end d clea cleara rance nce in oil pump pump..
High/Low High/Lo w Suction Pressure Pressure
• Suction control control valve malfun malfunction. ction. • Faulty Faulty pressure pressure gau gauges. ges. • Frozen/plugged inlet line. • Plugg Plugged ed inta intake ke screen screen or filte filter. r. • Scrubb Scrubber er dump dump valve stuck o ope pen. n. • Recycle malfun malfunction. ction. • Site pro production duction equ equipme ipment nt pr proble oblems. ms.
• Faulty Faulty valves or or rin rings. gs. • Gas leak. • Fr Froze ozen n coole coolerr sect sectio ion n or tub tubin ing g to pane panel. l. High/Low High/Lo w Inter-Stage Inter-Stage Pressure Pressure • Faulty Faulty pressure pressure gau gauges. ges. • Scrubb Scrubber er dump dump valve stuck o ope pen. n. • Load change. change.
Noise Noi se in Cyli Cylind nder er
Frame Frame Kno Knocks cks
• Loose Loose piston. • Piston Piston hitting hitting cylind cylinder er he head ad en end d he head ad or cra crank nk en end d head head.. • Loose cro crosshe sshead ad balan balance ce nu nut. t. • Broken Broken or lea leaking king valve(s) valve(s).. • Worn Worn or broke broken n piston piston ri ring ngs s or wear wear ba band nds. s. • Valve impr imprope operly rly seated or dam damage aged d seat gasket. • Liquids Liquids in cylinder. cylinder. • Loose Loose cro crosshe sshead ad pi pin n or pi pin n cap caps. s. • Loose Loose or wor worn n ma main, in, cra crankp nkpin, in, or crosshe crosshead ad be bear aring ings. s. • Low oil pressure. pressure. • Cold Cold oil oil.. • Incorrect oil.
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Page 6-1 of 3
Section 6 - Co C ompressor Tr Troubleshooting
Problem
For mo models J JG GC:D:F
Possible Causes • Knock is actua actually lly fro from m cylinder end end.. • Low fluid fluid level in damper damper..
Excessive Carbo Carbon n on Valves Valves
Relief Valve Valve Popp Popping ing
• Exce Excessive ssive lu lube be oi oil. l. • Impr Improp oper er lub lube e oil. oil. • Oil ca carr rry-o y-over ver from from inl inlet et system or previo previous us stag stage. e. • Bro Broken ken or lea leaking king valves valves causing causing high high temper temperatu ature re.. • Excessive tem tempe pera ratur ture e du due e to hig high h pressur pressure e ratio ratio across across cylinder cylinders. s. • Faulty relief valve. • Le Leakin aking g suctio suction n valve valves s or rin rings gs o on n ne next xt hig highe herr stage. stage. • Ob Obstru struction ction,, clo closed sed or fau faulty lty va valve lve in dischar discharge ge line. line. • Excessive ratio ratio across across cylind cylinder er du due e to lea leaking king inl inlet et valves valves or or rin rings gs on ne next xt
High Discha Discharg rge e Temperature
High Fr High Fram ame e Oil Oil Temperature
higher high er stage. • Foul Fouled ed inter inter-cool -cooler er pipi piping. ng. • Le Leakin aking g disch dischar arge ge valve valves s or pisto piston n ri ring ngs. s. • High inle inlett temper temperatur ature. e. • Impr Improp oper er lub lube e oil and and/or /or lub lube e rate. rate. • Faulty temperature temperature gauge. gauge. • Dirty oil filters. • High oil leve level. l. • Faulty thermostatic element. • Faulty thermostatic control valve. • Clog Clogge ged d or blo blocked cked oil coo cooler ler.. • Bin Bindin ding g or tigh tightne tness ss in the compre compressor ssor..
Packing Packin g Over Over Heating Heating
• Lub Lubrication rication failur failure. e. • Improper Improper lube oil and/or and/or insufficient lube rate. rate. • Worn pa packing cking rin rings. gs. • Dirt in packing packing.. • Impr Improp oper er ri ring ng side or en end d ga gap p clea cleara rance nce.. • Scor Sc ored, ed, tapered tapered or out of round round piston rod rod.. • Excessive piston piston rod rod runo runout. ut.
Excessive Packing Packing Le Leaka akage ge
• Worn pa packing cking rin rings. gs. • Impr Improp oper er lub lube e oil an and d or insu insufficien fficientt lube lube rate. rate. • Dirt in packing packing.. • Packing rings rings assemble assembled d incorrectly. incorrectly. • Impr Improp oper er ri ring ng side or en end d ga gap p clea cleara rance nce.. • Plu Plugg gged ed packing packing ven ventt system. • Scor Sc ored, ed, tapered tapered or out of round round piston rod rod.. • Excessive piston piston rod rod runo runout. ut. • Packin Packing g not not sea seated ted or prop proper erly ly ru run n in.
Drive End of Cra Cranksh nkshaft aft Oil Leaks
• Clogg Clogged ed vent or vent pipi piping. ng. • Excessive cylind cylinder er pa packing cking lea leakag kage. e.
Piston Rod Oil Wiper Wiper Le Leaks aks
• Worn Worn wipe wiperr rings. rings. • Wipers incorrectly assembled. • Worn/scored Worn/scored rod rod.. • Impro Improper per fit of ring rings s to rod rod/side /side clearance clearance..
Force For ce Fee Feed d Lub Lubricatio rication n Shutdown
• For Force ce fee feed d pu pump mp or lub lubri ricato catorr blo block ck failur failure. e. • Lo Loss ss of oi oill sup supply ply to for force ce fee feed d pu pump. mp. • Lubr Lubricator icator drive drive failure. failure. • Proflo not progra programmed mmed correctly. correctly. • Pro Proflo flo batter battery y failu failure re or po power wer loss. • Loose or groun grounded ded contro controll wiring wiring..
Page 6-2 of 3
REV: 10/14
For models models JGC:D:F JGC:D:F
Problem
Sectio Section n 6 - Compre Compressor ssor Trou Trouble blesho shootin oting g
Possible C auses • Pin assem assembly bly no nott comp complete letely ly pushed pushed into the Proflo Proflo ho housin using. g.
Oil Leaks Leaks at Pipe Thread Threaded ed Connections
Vibration Vibr ation Shutdown Shutdown
• Joint not tight. • Pipe sealant sealant was omitted. omitted. Defective or da dama mage ged d pip pipe e thr threa eads. ds. • Defective • NPTF Dryseal thre threads ads not being being used. • Pre Pressur ssure e too high high for pipe pipe thr threa eade ded d con conne nection ction use. use. • Pip Pipe e thr threa ead d sealan sealantt incompa incompatibl tible e with the synthetic synthetic oi oill used. used. • Cra Cracked cked pip pipe e or fittin fittings. gs. • Short Short in wire to pa pane nel. l. • Incorrectly Incorrectly positioned positioned vibration vibration switc switch. h. • Lo Loose ose mo moun unting ting bo bolts. lts. • High scrubb scrubber er level (liq (liquid uid carr carry-over y-over). ).
• Bro Broken ken valve valve,, piston, piston, or or pisto piston n rod. rod. • Ma Main in drivedrive-lin line e or coupli coupling ng failur failure. e.
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Page 6-3 of 3
Appendix A - Ariel Fasteners and Torques This do This docu cumen mentt lis lists ts fasten fastener er lub lubric ricati ation on an and d torque torque require requireme ments nts for proper proper as asse semb mbly ly of curren currentt produ pro ducti ction on JGC:D:F JGC:D:F recipr reciproc ocati ating ng compr compres esso sors. rs. For older older un units its with lower lower spec specifi ified ed torque torque valu values es,, do no nott as assu sume me highe higherr valu values es withou withoutt cons consult ulting ing the packa packager ger an and/o d/orr Ariel. Ariel. only ly Ariel Ariel spec specifi ified ed • Use on fasten fas teners ers tig tighte htened ned to the correctt torque. correc torque. C onnec ectin ting g rod, rod, valv valve e cap, cap, • Conn and suction/discharge suction/discharge nozzle noz zle (Ariel supplie supplied d fla flange nge)) fasten fasteners ers are
TABLE A-1 Fastener Thread & Seating Surface Lubrication NOTE: Lubricate all fasteners both under the head and on the threads. Application
Lubricant
• Fra Frame: me: tie ba bars, rs, jack screws • Stee Steell Cylinders: Cylinders: valve cap cap,, cylinder cylinder mo moun unting ting flange flan ge to cylinder cylinder bo body, dy, packing, packing, cran crank k end end an and d Never-Seez
modified modifi ed to preve prevent nt fat fatig igue; ue; do not not repla replace ce th them em with with standa sta ndard rd cap cap screws. screws. For question ques tions s about about replacing replacing other oth er fasten fasteners ers with stanstandard dar d cap cap screws, screws, conta contact ct your your pa pack ckage agerr or Ariel. Ariel.
head hea d end hea head, d, gas passage passage • Pisto Pistons: ns: pisto piston n nu nuts, ts, set screws, pisto piston n collar collar,, crosshead crosshea d thre threads ads • All stainless steel fasteners fasteners Fastene Faste ners rs specifi specified ed with Loctite Loctite on threa threads ds
Regular Regul ar Grade Grade
Connecting ro r od f a as steners
• Clean Clean and and de-b de-burr urr all all threads.
All other fasteners fasteners
Use Loctite Loctite only only with no add additiona itionall lube Lubriplate 63 6 30
Mineral oil (ISO 100 100-15 -150) 0)
• Do no nott us use e Molyb Molybde denum num disulfide lubricants. • Do no nott us use e Never-Se Never-Seez ez for fas fasten tener er lub lubric ricati ation on unles unless s spec specifi ified ed or ex exce cess ssiv ive e stress stresses es may may result result with specifi spe cified ed torques. torques. See TAB TABLE LE A-1 A-1.. • Use an anti-s ti-seiz eize e lubric lubricant ants s spari sparingl ngly; y; ex exce cess ssiv ive e amoun amounts ts caus cause e oil analy analysi sis s to indica indicate te conta contamin minati ation on and may unneces unnecessaril sarily y increase increase maintena maintenance nce costs. costs. • Re-prese Re-preserve rve an any y fasten fasteners ers subje subject ct to corros corrosio ion n aft after er instal installa latio tion. n.
FIGURE A-1 Bolt Head Grade and Material Identification CAUTION: To replace a fastener, see parts list for fastener grade and part number. Do not use a lesser or greater material grade. Use Ariel parts to replace special fasteners and fasteners with reduced body diameter for fatigue resistance. Do not torque fasteners with compressor running or pressurized. Read technical manual safety warnings.
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Page A-1 of 5
Appendix Appen dix A - Ariel Fasteners Fasteners and Torques Torques
For models models JGC:D:F JGC:D:F
Recommendations for Torque Accuracy 1. Qual Qualifi ified ed pe perso rsonn nnel el must must us use e a prope properly rly calib calibrate rated d torque torque wrench wrench to correc correctly tly torque torque fasten fasteners ers.. 2. Determin Determine e torque torque wrench wrench ac accu curac racy y range range.. Most Most torque torque wrenches wrenches are no nott ac accu curate rate ov over er their their entire entire range. 3. Clean Clean and de-burr de-burr all thread threads s be before fore as asse semb mbly ly.. 4. Tigh Tighte ten n al alll mult multi-b i-bol oltt asse assemb mblilies es in st step eps s (opti (option onal al for for Grade rade 5 ca cap p sc screws rews). ). Snug Snug op oppo posi sing ng pa pairs irs of ca cap p sc screw rews s unti untill al alll are sn snug ug.. Next, Next, tigh tighte ten n each each ca cap p sc screw rew to 25 25% % of fu fullll to torq rque ue in th the e sa same me pa patte ttern. rn. Repea Rep eatt th this is st step ep fo forr 50%, 50%, 75%, 75%, and and 100% 100% of full full torqu torque. e. Fo Forr main main be beari aring ng st stud ud nu nuts ts an and d co conn nnec ecti ting ng rod rod bolt bolts, s, repea repeatt th the e 100% 100% st step ep to ve verif rify y prope properr pre-to pre-torqu rque e of fa fast sten eners ers prior prior to th the e fina finall pa parti rtial al tu turn. rn. 5. Al Alway ways s appl apply y a st stea eady dy sl slow ow forc force e to a torqu torque e wrenc wrench, h, and and st stop op imme immedi diat atel ely y when when th the e wrench wrench clic clicks ks;; do no nott je jerk rk it it.. Jer erki king ng a torq torque ue wrenc wrench h may may ap appl ply y up to on one e an and d a ha half lf time times s th the e to torq rque ue sett settin ing. g.
do no nott je jerk rk it it.. Jer erki king ng a torq torque ue wrenc wrench h may may ap appl ply y up to on one e an and d a ha half lf time times s th the e to torq rque ue sett settin ing. g. 6. Perfo Perform rm fina finall tigh tighte teni ning ng with with a torqu torque e wren wrench ch.. Do not not tigh tighte ten n fa fast sten eners ers with with a ra ratc tche hett or impa impact ct wrenc wre nch, h, and and th then en "che "check ck"" the the torqu torque e wit with h a torqu torque e wre wrenc nch. h. not doub double le ta tap p a torqu torque e wrenc wrench; h; it incr increa ease ses s the the se sett to torqu rque e sign signif ific ican antl tly. y. 7. Do not 8. When When ch chec ecki king ng th the e torqu torque e of a tigh tighte tene ned d fast fasten ener er,, se sett to torqu rque e wrenc wrench h to requi required red to torqu rque, e, th then en ap appl ply ya slow sl ow steady steady force force un until til the wrench wrench click clicks. s. 9. When When fini finish shed ed,, reset reset torqu torque e wren wrench ch to its its lowes lowestt se sett ttin ing g to relax relax th the e sp sprin ring g an and d he help lp re reta tain in ac accu curac racy. y. A torque wrench left in a high setting setting stresses stresses the spring spring and decrease decreases s accuracy accuracy with time. 10. Do 10. Do not not break break fa fast sten eners ers loos loose e with with a torqu torque e wren wrench ch;; it may may ov overl erloa oad d th the e wrench wrench an and/ d/or or de dest stroy roy calibration. 11. To dete determi rmine ne th the e to torqu rque e wrenc wrench h se sett ttin ing g when when usin using g a to torqu rque e mult multip iplilier er on la large rgerr fa fast sten ener ers, s, divi divide de th the e de desi sired red fasten fastener er torque torque by the multi multipl plier ier ac actua tuall mech mechani anica call adv advan antag tage, e, not the de desi sign gn mecha mechanic nical al ad adva vanta ntage. ge. Examp Example: le: An X4 torque torque multip multiplie lier, r, model model TD-1000 TD-1000 ha has s a de desig sign n mech mechani anica call advant advantag age e of 4.0,, bu 4.0 butt an ac actua tuall mech mechan anica icall ad adva vanta ntage ge of 3.6. 3.6. 12. Fo 12. Forr hard hard to acce access ss fast fasten eners ers requi requirin ring g a boxe boxed d end end or cr crow's ow's fo foot ot adap adapte terr wit with h a torqu torque e wrench wrench,, the the torqu torque e se sett ttin ing g is not not the the actu actual al torqu torque e appl applie ied d to the the fast fasten ener, er, unle unless ss th the e adap adapte terr is 90° 90° to the the torqu torque e wrenc wre nch. h. Th The e ratio ratio of actu actual al fast fasten ener er torqu torque e (Ta (Ta)) wit with h the the to torqu rque e se sett ttin ing g (Tw) is a func functi tion on of the the leng length th the the adap adapte terr adds adds to th the e torqu torque e wren wrench ch (A), and and the the loca locatio tion n of the ap appli plied ed force. force. Tw = Ta Ta x [L ÷ (L + A) A)]
FIGURE A-2 Torque Wrench with Angled Adapter
Tw = Torq Torque ue wrenc wrench h sett settin ing, g, lb x ft or N·m. N·m. Ta = Torq Torque ue re requ quir ired ed at fast fasten ener er,, lb x ft or N·m. N·m. L = Le Leng ngth th of wrenc wrench, h, ft or m (fro (from m squa square re driv drive e en end d to cen ente terr po poin intt of fo forc rce e on ha hand ndle le). ). A = Wrenc Wrench h le leng ngth th adde added d by adap adapte ter, r, ft or m (me (meas asure ured d th throu rough gh en end d of ad adap apte terr on a line line pa paral ralle lell to the the ce cent nter er line line of th the e wrenc wrench). h). NOTE: Lb x In ÷ 12 = Lb x Ft 13. When When st stud uds s are sp spec ecif ifie ied d for for cy cylilind nder er appl applic icat atio ions ns,, tigh tighte ten n nu nuts ts to th the e same same va valu lues es as ca cap p sc screws rews in similar applications. applications. 14. Instal 14. Installl pi pipe pe thread threads s and main main cap cap plugs plugs us usin ing g Loctit Loctite e 57 577 7 thread thread seala sealant. nt. Synthe Synthetic tic oils oils may may require require Loctite Loc tite 545 and Loctite Loctite Activator Activator 7649 7649 (N). Th Thes ese e ar are e gene general ral guid guidel elin ines es for for pro prope perr torqu torque e wrench wrench use. use. Call Call a to torqu rque e wrenc wrench h de deal aler er fo forr de deta tailils. s.
Page A-2 of 5
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For models models JGC:D:F JGC:D:F
Appe Appendix ndix A - Arie Ariell Fasteners Fasteners and Tor Torque ques s
TABLE A-2 Hoerbiger Valve Assembly Fastener Torques Fastener
Nomin Nominal al Size Inch - TPI
Type
5/16 /16 - 24 Center Cen ter Cap Screw Screwa
3/8 - 24
12 (16) (16) 12 Point Point - Steel Steel Gra Grade de 5 Material Mater ial Parts: Parts: SPL3 & 4
7/ 16 - 20
21 (28) 30 (41)
5/16 /16 - 24 3/8 - 24
Torque LB x FT (N·m), unless specified
18 (24) (24) 12 Point Point - Steel Steel Gra Grade de 5 Mater Ma terial ial Parts: Parts: SPL or SPL SPL5 5
7/ 16 - 20
32 (43) 50 (68)
5/16 /16 - 24
12 Point - Stainle Stainless ss Steel Gr Grade ade
12 120 0 lb x in. in. (14) (14)
3/8 - 24
B8M
16 (22)
Material Parts: SPL6
7/ 16 - 20 #10 - 32
25 lb x in in.. ((3) 3)
#12 - 28
43 lb x in. (5)
1/4 - 20
Periphe Peri pheral ral Cap Screw
Single-piece Single-p iece Lock Nuts (Microlok, JL-Nut,
24 (33)
110 lb x in. (12)
Hex Socket Head
5/ 16 - 18
176 lb x in. (20)
3/8 - 16
21 (28)
5/16 /16 - 24
10 109 9 lb x in. in. (12) (12)
3/8 - 24
17 (23)
7/ 16 - 20
26 (36)
1/2 - 20
41 (55)
Lock Nut
®
Spiralock , Greer)
Center Cen ter Stud Dra Drake ke 2-Pie 2-Piece ce Beam Bea m Lock Lock Nut
5/8 - 18 3/4 - 16
82 (110) 145 (195)
7/8 - 14
230 (310) Bottom Half Torque
Top Half Torque
LB x FT (N·m), unless specified
LB x FT (N·m), unless specified
1/4 - 28
103 llb b x in. (12)
66 lb lb x in. (8)
5/ 16 - 24
120 llb b x in. (14)
66 llb b x in. (8)
3/8 - 24
16 (22)
96 lb x in. (11)
1/2 - 20
36 (49)b
20 (27) (27)
5/8 - 18
73 (99)
40 (54)
3/4 - 16
130 (176)
70 (95)
210 (285)
115 (155)
Inch - TPI
Top Half
7/8 - 14
Bottom Half
a. Center cap scr screw ew valve assemblies have Spiralock (SP (SPL) L) thr threads eads to prevent loosening. See bottom bottom of valve assembly assem bly for SPL mat material erial part parts s number (3, 4, 5 or 6) and select proper tor torque que from the the table. Lubricate Lubricate both threads threads and seating surfaces surfaces with a petroleum ttype ype lubricant ONLY ONLY.. If using older valve assembli assemblies es not cover covered ed in the tab table, le, ® see the original torque chart provided in the compress compressor or tool box, or contact Ariel Ariel for inst instruct ructions. ions. Spiralock Spiralock threads cannot be dressed with a st standard andard tap. Clean center cap screws in valve assemblies not marked SPL wit with h Loctite safety safety sol solvent vent and lock them wit with h one or two drops of Loct Loctite ite #272 thr thread ead locking compound. DO NOT u use se petrol petroleum eum lubricants. ®
b. Use 29 (39) ffor or 1/2 - 20 bott bottom om half Drake lock nut with non-met non-metallic allic valve plates in lif liftwasher twasher valves.
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Page A-3 of 5
Appendix Appen dix A - Ariel Fasteners Fasteners and Torques Torques
For models models JGC:D:F JGC:D:F
TABLE A-3 JGC:D:F Fastener Torques Fastener
Nominal Size Inch - tpi
Type
Torque LB x FT (N·m), unless specified
Main Be B earing Ca C ap - Ca C ap S Sc crew
1-1/8 - 7
12 P Po oint - G Grrade 8
540 (7 (732)
C onnecting R Ro od - Cap S Sc crew
1-1/8 - 12
12 P Po oint - Gr Grade 8
See TABLE A-4
Torsional Vibration D e ettuner - Cap Screw
1" - 14 14
12 P oi oint - Gr G rade 8
530 (715)
Flywheel - C Ca ap Sc Screw
1-1/8 - 1 12 2
Hex - G Grrade 8
740 (1 (1010)
Crosshead Pin Through Cap Screw - Lock Nut
5/8 - 1 8
Hex - Prevailing
125 (165)
Spacer Ba Bar - Ca C ap Sc S crew
1-3/8 - 12 12
12 P Po oint - G Grrade 8
1060 (1 (1430)
Crosshead Gu Guide tto o Fr Frame - Cap Sc S crew
1” - 8
12 P Po oint - Gr Grade 8
420 (5 (570)
Crosshe Cro sshead ad Gu Guid ide e to Cyli Cylind nder er - Cap Scr Screw ew
7/8 9 7/8 - 14
12 P Po oint Grade 8 H ex Nut
280 (3 (380) 315 (425)
Crosshead G Gu uide S u up pport - C a ap p Screw
1-1/4 - 7
Hex - G Grrade 8 or or 9
770 (1 ( 1040)
1/2 - 13
44 (60) (60)
5/8 - 11
Head Hea d End Cylind Cylinder er Suppo Support rt to Cylind Cylinder er
88 (120)
Hex - Grad Grade e8
3/4 - 10
160 (215)
7/8 - 9
255 (345)
Eccent ric Vernier C a ap p - Cap S Sc crew
3/8 - 16
Hex - G Grrade 8
Hand W rre ench Ti T ight
Force Feed Lube Box- Bearing H ousing
1-3/8 - 20 LH
Bearing Housing
70 (95)
1”-14
Fo Forc rce e Fe Feed ed Lube Lube Bo Box x - Jam Nut
75 (102) (102)
Hex Jam
1-1/2 - 12
112 (152)
Idlerr Spr Idle Sprocket ocket Th Thro roug ugh h Cap Screw Screw - Lock Lock Nut
1/2 - 20 5/8 - 18
Hex - Prevailing Prevailing
41 (55) (55) 82 (110)
Sprocket /Flywheel to Crankshaf t - Cap Screw
3/4 - 1 6
Hex - Grade 9
215 (295)
7/ 8- 9 Rod Ro d Packi Packing ng - Ca Cap p Scre Screw
205 (27 (275) 5) 12 Point Point Grad Grade e 8 or 17-4 17-4PH PH
7/8 - 14
230 (310)
1-1/4 - 12 10 - 24 1/4 - 20
Hex Hex
700 (940) 20 lb x in. (2.3) 72 lb x in. (8.1)
R od Ca C at cher tto o Pa P acking
5/8 - 18
12 P Ptt - Gr Grade 8 8//17-4PH
105 (1 (140)
Piston N ut
2” - 12
Ariel Design
3970 (5380)a
C rosshead-Balance Nu N ut
2-1/4 - 8
Ariel Design
Slugging M Me ethodb
Lifting B Brracket to Fr Frame Rup Ru ptur ture Disk Disk - Blow-O w-Out Fitt ttiing Ca Cap p
1-1/2 - 6 1/4No /4Nom m. Tube
12 P Po oint - G Grrade 8 He Hex x - Tube Fitt ttiing
1200 (1 (1630) 40 lb x in. (4.5 .5))
Piston R Ro od Oi Oil Slinger Lo Lock Nut
1/4 - 2 28 8
H ex - J Ja am
95 llb b x in. (11)
Cylinder Mounting Mounting Flange Flange to For Forge ged d Stee Steell Cylinder Cylinder
1” - 14
12 Pt - G Grrade 8/ 8 /17-4PH
485 (655)
1-1/4 - 12
12 Pt - Grade 8/17-4PH
955 (1290)
Hold D ow n Nut
1-3/8 - 6
H ex Nut
1100 (1500)c
“Peanut ” D u ua al Nozz zzlle C o om mpanion Flanges
1/2 - 13
12 Pt - Grade 8/17-4PH
53 (71)
Valve C Ca ap As Assembly - Ca Cap N Nu ut
Al l
C ap Nu Nut
Hand Wr Wrench T Tiight
Valve Cap Seal Keeper - C ap ap Screw
5/16 - 18
12 Point - 1 7 7--4PH
120 lb x in. (14)
Unloader Ac A ctuator tto o Va V alve C Ca ap - Cap S Sc crew
1/2 - 13
Hex - Gr Grade 8
48 (6 (65)
Packi Packing ng Tie Tie Ro Rod d - Nu Nutt
Page A-4 of 5
REV: 10/14
For models models JGC:D:F JGC:D:F
Fastener
Cap Screwd • Valve Valve Cap • Cylinder Cylinder Head • Gas Passage • Unloader • VVCP • Arie Ariell supplied supplied companion companion flanges, flanges, except “Peanu “Pe anut” t” Dual Nozzle
Appe Appendix ndix A - Arie Ariell Fasteners Fasteners and Tor Torque ques s
Nominal Size Inch - tpi
Type
Torque LB x FT (N·m), unless specified
1/2- 13
40 (54) (54)
5/8 -11
N ote e
3/4 - 10
140 (190)
3/4 - 16 7/ 8 - 9 7/8 -14
Hex - Grad Grade e 8/9 or 12 Point Point Gr Grad ade e 8 or 17 17-4 -4PH PH
160 (220) 230 (310) 260 (350)
1” - 8
345 (465)
1” - 14
395 (535)
1 1/ 8 12 1/2- 13 5/8 - 11
Ta Tand ndem em Cylind Cylinder er to Cyli Cylind nder er - Cap Screw Screwd
3/4 - 10 3/4 - 16
560 (760) 44 (60) (60)
Hex - Grad Grade e 8/9 or 12 Point Point Gr Grad ade e 8 or 17 17-4 -4PH PH
88 (120) 160 (215) 180 (245)
1/2- 13
22 (30) (30)
5/8 - 11
44 (60)
Seating Sea ting Stud Studs s in Cylinder Cylinder
3/4 - 10
79 (105)
NOTE: In valve cap assemblies with a spring energized seal, install longer studs with Loctite 242.
3/4 - 16
90 (120)
Dog Point Point
7/ 8 - 9
130 (170)
7/8 - 14
145 (195)
D istribution B Bllock Tie R Ro od - Nu Nut
1” & Longer 1/4 - 2 28 8
H ex
200 (270) 68 llb b x in. (7.7)
D istribution Block Divider Valve - Cap Screw
1/4 - 28
Socket Head
75 lb x in. (8.5)
Fenner Drive A-11560
--
H ex
200 lb x in. (23)
Grade 5 - H He ex Cap S Sc crew
ALL
Hex - Gr Grade 5
H and Wr Wrench T Tiight
a. Or use 5400 psig (372 barg) hydraulic pressure and 100 (135) torque on pinion d rive with separately purchased purchased piston rod hydraulic tensioning tool. Tig tool. Tighten, hten, loo loosen, sen, then re-tighten pi piston ston nut to in insure sure proper torque. b. Or use 3500 psig (241 barg) hydraulic pressure on separately purchased crosshead (balance) nut torquing tool. c. Minimum ttorque orque to st stress ress recomm recommended ended 1-3/8 - 6 TP TPII hold-down stud to 55,000 psi (380 MPa). MPa). Use studs wit with h an ultimate ultim ate st strengt rength h of 100,00 100,000 0 psi (690 MPa) or great greater. er. If great greater, er, increase increase torque str stress ess to about 55% of ulti ultimat mate e strength, strengt h, as specif specified ied by packager. d. For st studs uds specified for cylinder applications, tighten nuts to to the same torque as cap screws in similar applications. e. See ER-1 ER-112 12 for 3-bolt valve cap ffast asteners eners on 20-1/ 20-1/8, 8, 22, 24-1/ 24-1/8, 8, & 26-1/ 26-1/2 2 class cylinders, cylinders, else use 79 (105) lb-ft. lb-ft.
TABLE A-4 JGC:D:F Connecting Rod Cap Fastener Torques Connecting Rod Part No.
Bearing Bearing Part No.a
Bolt Pre-Torq Pre-Torque ue lb-ftt (N·m) lb-f
Additional Bolt Turn, Degrees
Turn Indicator Part No.
165 (225)
110°
B-3993
90°
B-1803
D-413 D-4 131 1 or hig highe herr Par Partt Numbers
B-3093, B-3094, B-3995,, or B-4002 B-3995
D-1393, D-2033, D -226 -2266, 6, D-350 D-3 509 9 or D-4 D-406 066 6
B-3093, B-3094
90 (122)
B-3995, B-4002
165 (225)
a. Do not mix bear bearing ing shells on indiv individual idual connect connecting ing rods or m main ain bearings; both half shells m must ust have the the same P/ P/N. N.
REV: 10/14
Page A-5 of 5
Appendix B - Clearances TABLE B-1 JGC:D:F Main Component Clearances, in. (mm) D escription
Clearance
Cr Cran anksh kshaf aftt Dust Dust Sea Seal JG JGC:D: C:D:F/ F/2/ 2/4 4 (Feel Feele er Gaug auge - Cent Center ered ed))
0.007 .007 to 0.011 .011 (0.18 0.18 to 0.28 0.28))
Cra Cranksh ksha aft Dust Dust Se Sea al JGC: JGC:D:F D:F/6 /6 (Fee Feele lerr Gauge - Ce Cen nter tered)
0.00 .008 to 0.01 .012 (0.20 .20 to 0.30 .30)
Crankshaft Thrust (End)
0.0135 tto o 0. 0.0300 (0 (0.34 tto o 0. 0.76)
Cranksh kshaft Jou Journal Bearing (Ja Jack ck))
0.0040 to 0.0070 (0.10 to 0.18)
Cr Cra anks ksh haft Pin Pin toCo toCon nnectin cting g Ro Rod d Be Bea arin ing g (Ja Jack ck))
0.00 .0040 to 0.00 .0090 (0.1 .10 0 to0. to0.2 23)
C onnecting Rod T h hrrust (Side)
0.0150 t o 0 0..0330 (0.38 to 0. 0 .84)
Connecti cting R o od d Bushi shing to C ro ross ssh head Pin
0. 00 002 to 0.004 (0.05 to 0.10)
Cro Crosshe sshead Br Bro onze Bu Bush shin ing g to Cro Crossh sshe ead Pi Pin n - Iro Iron Cro Crosshe sshead
0.00 .0020 to 0.00 .0045 (0.05 .05 to 0.11 .11)
Cr Cro ossh sshead toCro toCrossh sshead Pin - BronzeCr zeCro ossh sshead
0.00 .0020 to0. to0.0 0035 (0.0 .05 5 to0. to0.0 09)
Cr Cro oss ssh head toGuid toGuide e - Babbit itte ted d Iro Iron (Fee Feele lerr Gauge)
0.0 .00 08 to 0.01 .013 (0.2 .20 0 to0. to0.3 33)
Cr Cro oss ssh head to Guide - Bab Babbitt tte ed Br Bro onze (Feele lerr Gauge)
0.0 .01 14 to 0.01 .019 (0.3 .36 6 to0. to0.4 48)
TABLE B-2 JGC:D:F Piston End Clearancesa, in. (mm) Cylinder Class
Crank End
Head End
Totalb
17-7/8, 20-1/8, 22, 24-1/8, and 26 26-1 -1/2 /2 C/D/F
0.05 .055 (1.4) .4)
0.09 .095 to 0.15 .155 (2.4 to 3.9) .9)
0.15 .150 to 0.21 .210 (3.8 to 5.3) .3)
5-3/8C/ /8C/D/ D/F F Tandem
0.0 .04 40 (1.0) .0)
0.06 .060 to0.1 to0.160 (1.5to 4.1) .1)
0.1 .10 00 to0.2 to0.200 (2.5to 5.1 .1))
All CL/DL/FL/CN/DN/FN CL/DL/FL/CN/DN /FN
0.300 0.300 (7.6) (7.6)
No Set
0.620 to 0.68 0.680 0 (15.7 (15.7 to 17.3) 17.3)
All CM/DM/FM, and all othe otherr C/D/F
0.040 0.040 (1.0) (1.0)
0.08 0.080 0 to 0.140 (2.0 to 3.6)
0.120 0.120 to 0.18 0.180 0 (3.0 to 4.6)
a. Measu Measured red clear clearances ances m may ay not agree due tto o oil fi films, lms, wear, etc etc.. Do not use plastigages, plastigages, solder, etc etc.. b. If tot total al pist piston on end clearance (cr (crank ank end + head end) is not within ttable able toler tolerance, ance, contact contact Pack Packager ager or Ariel. Ariel.
REV: 10/14
Page B-1 of 5
Appendix Appen dix B - Clearances Clearances
For models models JGC:D:F JGC:D:F
TABLE B-3 JGC:D:F Side Clearances of New Piston Rings, in. (mm) Nominal Width
Actual Groove Width
Teflon
PEEK
B ronze
5/1 /16 6 (7.94 .94)
0.3 .31 12 to 0.31 .314 (7.9 .92 2 to 7.98 .98)
0.00 .006 to 0.01 .010 (0.15 .15 to 0.25 .25)
3/8 (9.53 .53)
0.3 .37 75 to 0.37 .377 (9.53 .53 to 9.58 .58)
0.00 .007 to 0.01 .013 (0.18 .18 to 0.33 .33)
0.005 to 0.0 0.005 0.008 08 (0.1 (0.13 3 to 0.2 0.20) 0)
0.004 to 0.0 0.004 0.008 08 (0.10 (0.10 to 0.20) 0.20)
1/2 (12 12.7 .70) 0)
0.5 .500 00 to 0.502 .502 (12 12.7 .70 0 to 12.7 12.75) 5)
0.00 0.009 9 to 0.01 0.015 5 (0.23 .23 to 0.3 0.38)
5/8 (15 15.8 .88) 8)
0.6 .625 25 to 0.627 .627 (15 15.8 .88 8 to 15.9 15.93) 3)
0.01 0.011 1 to 0.01 0.016 6 (0.28 .28 to 0.4 0.41)
0.00 0.006 6 to 0.009 0.009 (0.1 (0.15 5 to 0.2 0.23) 3)
0.005 to 0.0 0.005 0.009 09 (0.13 (0.13 to 0.23) 0.23)
3/4 (19 19.0 .05) 5)
0.7 .750 50 to 0.752 .752 (19 19.0 .05 5 to 19.1 19.10) 0)
0.01 0.013 3 to 0.02 0.020 0 (0.33 .33 to 0.5 0.51)
0.00 0.008 8 to 0.011 0.011 (0.2 (0.20 0 to 0.2 0.28) 8)
0.006 to 0.0 0.006 0.010 10 (0.15 (0.15 to 0.25) 0.25)
TABLE B-4 JGC:D:F Side Clearances of New Packing Rings, in. (mm) Actual Groove Wi dth
Teflon
PEEK
Bronze
0.572 to 0.57 0.572 0.574 4 (14.5 (14.53 3 to 14.58 14.58))
0.017 to 0.0 0.017 0.022 22 (0.43 (0.43 to 0.56) 0.56)
0.017 to 0.0 0.017 0.022 22 (0.43 (0.43 to 0.56) 0.56)
0.006 to 0.0 0.006 0.008 08 (0.15 (0.15 to 0.20) 0.20)
TABLE B-5 JGC:D:F Side Clearances of New Wearbands, in. (mm) Actual Groove Width
Teflon
PEEK
2.0 .00 00 to2.0 to2.002 (50.8 .80 0 to50.8 to50.85 5)
0.0 .02 24 to0. to0.0 034 (0.61 .61 to0. to0.8 86)
0.01 .014 to0. to0.0 018 (0.36 .36 to0. to0.4 46)
3.0 .00 00 to3.0 to3.003 (76.2 .20 0 to76.2 to76.28 8)
0.0 .03 36 to0. to0.0 048 (0.91 .91 to1. to1.2 22)
0.02 .021 to0. to0.0 025 (0.53 .53 to0. to0.6 64)
Page B-2 of 5
REV: 10/14
For models models JGC:D:F JGC:D:F
Appendix Appendix B - Clear Clearances ances
TABLE B-6 JGC:D:F New N ew Piston Piston Diametrical Clearances, Clearances, Piston Piston Ring & Wearband End Ga Gaps, ps, in. (mm) (mm) PISTON TO CYLINDER B ore
Clearance
2.5 (63.5 (63.5)) 2.625 2.62 5 (66.7) (66.7) 3 (76.2 (76.2))
0.0 0.055 to 0.055 0.063 63 (1.40 (1 .40 to 1.6 1.60) 0)
PISTO PISTON N RING END GAPS (Filled Teflon) a New
WEAR BANDS - NEW
Maximum
Min. End Gap
0.015 to 0.0 0.015 0.025 25 (0.3 (0.38 8 to 0.6 0.64) 4)
0.07 0.0 75 (1.91 .91)
0.08 .080 (2.03 .03)
0.015 0.01 5 to 0.0 0.025 25 (0.3 (0.38 8 to 0.6 0.64) 4)
0.07 0.0 75 (1.91 .91)
0.08 .084 (2.13 .13)
0.08 0.0 81 (2.06 .06)
0.09 .096 (2.44 .44)
0.017 to 0.0 0.017 0.027 27
Radial Projection
0.018 to 0.0 0.018 0.025 25 (0.4 (0.46 6 to 0.6 0.64) 4)
(0.4 (0.43 3 to 0.6 0.69) 9) 0.011 0.0 11 to 0.0 0.018 18 (0.2 (0.28 8 to 0.4 0.46) 6)
0.05 0.0 54 (1.37 .37)
0.11 .118 (3.00 .00)
0.012 0.01 2 to 0.0 0.019 19 (0.3 (0.30 0 to 0.4 0.48) 8)
0.05 0.0 57 (1.45 .45)
0.12 .124 (3.15 .15)
0.051 to 0.0 0.051 0.061 61 (1.3 (1.30 0 to 1.5 1.55) 5)
0.18 0.1 83 (4.65 .65)
0.13 .136 (3.45 .45)
0.0 0.071 to 0.071 0.079 79 (1.80 (1 .80 to 2.0 2.01) 1)
0.053 0.05 3 to 0.0 0.063 63 (1.3 (1.35 5 to 1.6 1.60) 0)
0.18 0.1 89 (4.80 .80)
0.14 .140 (3.56 .56)
0.056 0.05 6 to 0.0 0.066 66 (1.4 (1.42 2 to 1.6 1.68) 8)
0.19 0.1 98 (5.03 .03)
0.14 .148 (3.76 .76)
0.18 0.1 80 (4.57 .57)
0.16 .160 (4.06 .06)
(1.2 (1.27 7 to 1.5 1.52) 2) 0.065 0.06 5 to 0.0 0.077 77 (1.6 (1.65 5 to 1.9 1.96) 6)
0.23 0.2 31 (4.88 .88)
0.17 .172 (4.37 .37)
0.059 0.05 9 to 0.0 0.071 71 (1.5 (1.50 0 to 1.8 1.80) 0)
0.21 0.2 13 (5.41 .41)
0.18 .188 (4.78 .78)
0.063 0.06 3 to 0.1 0.138 38 (1.6 (1.60 0 to 3.5 3.50) 0)
0.41 0.4 14 (10.52 .52)
0.20 .200 (5.08 .08)
0.068 to 0.0 0.068 0.081 81 (1.7 (1.73 3 to 2.0 2.06) 6)
0.243 (6.1 (6.17) 7)
0.0 0.087 to 0.087 0.096 96 (2.21 (2 .21 to 2.4 2.44) 4)
0.070 0.07 0 to 0.0 0.084 84 (1.7 (1.78 8 to 2.1 2.13) 3)
0.252 (6.4 (6.40) 0)
0.072 0.07 2 to 0.0 0.087 87 (1.8 (1.83 3 to 2.2 2.21) 1)
0.261 (6.6 (6.63) 3)
0.079 to 0.0 0.079 0.095 95 (2.0 (2.00 0 to 2.4 2.41) 1)
0.28 0.2 85 (7.24 .24)
0.25 .252 (6.40 .40)
0.084 0.08 4 to 0.1 0.100 00 (2.1 (2.13 3 to 2.5 2.54) 4)
0.30 0.3 00 (7.62 .62)
0.26 .268 (6.81 .81)
0.090 0.09 0 to 0.098 0.098 (2.29 (2 .29 to 2.5 2.51) 1)
0.105 to 0.1 0.105 0.125 25 (2.6 (2.67 7 to 3.1 3.18) 8)
0.37 0.3 75 (9.53 .53)
0.28 .280 (7.11 .11)
0.09 0.096 6 to 0.105 0.105 (2.44 (2 .44 to 2.6 2.67) 7)
0.091 to 0.1 0.091 0.110 10 (2.3 (2.31 1 to 2.7 2.79) 9)
0.33 0.3 30 (8.38 .38)
0.29 .291 (7.39 .39)
0.090 0.09 0 to 0.098 0.098 (2.29 (2 .29 to 2.5 2.51) 1)
0.111 to 0.1 0.111 0.131 31 (2.8 (2.82 2 to 3.3 3.33) 3)
0.39 0.3 93 (9.98 .98)
0.29 .296 (7.52 .52)
0.09 0.0 96 to 0.10 .105
0.09 .096 to 0.1 .11 16
0.34 .346 (8.79 .79)
0.30 .307 (7.80 .80)
3.5 (88.9 (88.9))
0.060 to 0.0 0.060 0.068 68 (1 (1.52 .52 to 1.73) 3) 1.7
3.875 3.87 5 (98.4) (98.4) 4.25 (10 (108) 8) 4.375 (111) (111) 4.625 (117) (117)
0.050 0.0 50 to 0.0 0.060 60
5 (1 (127 27))
5.375 (137) (137)
0.081 to 0.0 0.081 0.089 89 (2.06 (2 .06 to 2.26) 6) 2.2
5.875 (149) (149)
6.25 (15 (159) 9) 6.75 (17 (171) 1) 7.00 (17 (178) 8) 7.25 (18 (184) 4) 7.875 (200) (200)
0.092 to 0.1 0.092 0.101 01 (2.34 (2 .34 to 2.57) 7) 2.5
8.375 (213) (213) 8.75 (22 (222) 2) 9.125 (232) (232) 9.25 (23 (235) 5) 9.625 (244) (244)
0.216 (5.49)
0.224 (5.69)
0.232 (5.89)
0.018 to 0.0 0.018 0.026 26 (0.4 (0.46 6 to 0.6 0.66) 6)
0.023 0.02 3 to 0.031 0.031 (0.5 (0.58 8 to 0.7 0.79) 9)
0.026 0.02 6 to 0.033 0.033 (0.6 (0.66 6 to 0.8 0.84) 4)
0.023 0.02 3 to 0.031 0.031 (0.5 (0.58 8 to 0.7 0.79) 9)
0.027 to 0.0 0.027 0.035 35 (0.6 (0.69 9 to 0.8 0.89) 9)
0.029 to 0.0 0.029 0.037 37 (0.7 (0.74 4 to 0.9 0.94) 4)
0.031 to 0.0 0.031 0.040 40 (0.7 (0.79 9 to 1.0 1.02) 2)
REV: 10/14
0.030 0.03 0 to 0.039 0.039 (0.7 (0.76 6 to 0.9 0.99) 9)
0.033 0.03 3 to 0.042 0.042 (0.8 (0.84 4 to 1.0 1.07) 7)
0.030 0.03 0 to 0.039 0.039 (0.7 (0.76 6 to 0.9 0.99) 9)
0.033 to 0.042 0.033 0.042
Page B-3 of 5
Appendix Appen dix B - Clearances Clearances
PISTON TO CYLINDER B ore
For models models JGC:D:F JGC:D:F
PISTO PISTON N RING END GAPS (Filled Teflon) a
WEAR BANDS - NEW
Clearance
New
(2.44 to 2.67)
(2.44 to 2.95)
0.090 0.09 0 to 0.098 0.098 (2.29 (2 .29 to 2.51) 2.51)
0.117 to 0.1 0.117 0.137 37 (2.97 (2.97 to 3.49) 3.49)
0.41 0.4 11 (10.44 .44)
0.31 .312 (7.92 .92)
9.875 (251) (251)
0.10 0.109 9 to 0.118 0.118 (2.77 (2 .77 to 3.00) 3.00)
0.099 to 0.1 0.099 0.119 19 (2.51 (2.51 to 3.02) 3.02)
0.35 0.3 57 (9.07 .07)
0.3 .31 16 (8.03 .03)
10.25 (260) (260)
0.09 0.090 0 to 0.098 0.098 (2.29 (2 .29 to 2.51) 2.51)
0.110 to 0.1 0.110 0.132 32 (2.79 (2.79 to 3.35) 3.35)
0.39 0.3 96 (10.06 .06)
0.32 .327 (8.31 .31)
9.75 (24 (248) 8)
Maximum
Min. End Gap
Radial Projection (0.84 to 1.07)
0.030 0.03 0 to 0.0 0.039 39 (0.7 (0.76 6 to 0.9 0.99) 9)
0.037 0.03 7 to 0.0 0.047 47 (0.9 (0.94 4 to 1.1 1.19) 9)
0.033 0.03 3 to 0.0 0.040 40 (0.8 (0.84 4 to 1.0 1.02) 2)
0.10 0.109 9 to 0.118 0.118 (2.77 (2 .77 to 3.00) 3.00)
0.104 to 0.1 0.104 0.125 25 (2.64 (2.64 to 3.18) 3.18)
0.37 0.3 75 (9.53 .53)
0.3 .33 32 (8.43 .43)
0.114 0.11 4 to 0.123 0.123 (2.90 (2 .90 to 3.12) 3.12)
0.105 to 0.1 0.105 0.126 26 (2.67 (2.67 to 3.20) 3.20)
0.37 0.3 78 (9.60 .60)
0.3 .33 36 (8.53 .53)
0.09 0.090 0 to 0.098 0.098 (2.29 (2 .29 to 2.51) 2.51)
0.110 to 0.1 0.110 0.132 32 (2.79 (2.79 to 3.35) 3.35)
0.39 0.3 96 (10.06 .06)
0.34 .344 (8.74 .74)
0.108 to 0.1 0.108 0.130 30 (2.74 (2.74 to 3.30) 3.30)
0.39 0.3 93 (9.98 .98)
0.3 .34 48 (8.84 .84)
0.110 0.11 0 to 0.132 0.132 (2.79 (2.79 to 3.35) 3.35)
0.39 0.3 96 (10.06 .06)
0.35 .352 (8.94 .94)
10.375 10.3 75 (26 (264) 4) 10.5 (26 (267) 7) 10.75 (273) (273) 10.875 10.8 75 (27 (276) 6)
0.114 to 0.1 0.114 0.123 23 (2.90 (2 .90 to 3.12) 3.12)
11 (27 (279) 9) 11L&M 11L &M (279) (279)
0.09 0.090 0 to 0.0 0.098 98 (2.29 (2 .29 to 2.51) 2.51)
0.110 to 0.1 0.110 0.132 32 (2.79 (2.79 to 3.35) 3.35)
0.39 0.3 96 (10.06 .06)
0.35 .352 (8.94 .94)
11.25 (286) (286)
0.10 0.100 0 to 0.108 0.108 (2.54 (2 .54 to 2.74) 2.74)
0.135 to 0.1 0.135 0.159 59 (3.42 (3.42 to 4.04) 4.04)
0.47 0.4 77 (12.12 .12)
0.36 .360 (9.14 .14)
11.375 11.3 75 (28 (289) 9)
0.11 0.114 4 to 0.123 0.123 (2.90 (2 .90 to 3.12) 3.12)
0.114 to 0.1 0.114 0.137 37 (2.90 (2.90 to 3.48) 3.48)
0.41 0.4 11 (10.44 .44)
0.36 .364 (9.25 .25)
11.75 (298) (298)
0.10 0.100 0 to 0.108 0.108 (2.54 (2 .54 to 2.74) 2.74)
0.141 to 0.1 0.141 0.165 65 (3.58 (3.58 to 4.19) 4.19)
0.49 0.4 95 (12.57 .57)
0.37 .376 (9.55 .55)
0.117 0.11 7 to 0.128 0.128 (2.97 (2 .97 to 3.24) 3.24)
0.120 to 0.1 0.120 0.144 44 (3.05 (3.05 to 3.66) 3.66)
0.43 0.4 32 (10.97 .97)
0.38 .384 (9.75 .75)
12.25 (311) (311)
0.11 0.117 7 to 0.127 0.127 (2.97 (2 .97 to 3.23) 3.23)
0.123 to 0.1 0.123 0.147 47 (3.12 (3.12 to 3.73) 3.73)
0.44 0.4 41 (11.20 .20)
0.39 .392 (9.96 .96)
12.375 12.3 75 (31 (314) 4)
0.10 0.100 0 to 0.108 0.108 (2.54 (2 .54 to 2.74) 2.74)
0.148 to 0.1 0.148 0.172 72 (3.76 (3.76 to 4.37) 4.37)
0.516 0.5 16 (12.9 12.95 5)
0.39 0.396 6 (10.06 0.06))
0.125 to 0.1 0.125 0.150 50 (3.18 (3.18 to 3.81) 3.81)
0.450 0.4 50 (11.4 11.43 3)
0.40 0.400 0 (10.16 0.16))
0.131 to 0.1 0.131 0.158 58 (3.33 (3.33 to 4.01) 4.01)
0.474 0.4 74 (12.0 12.04 4)
0.41 0.419 9 (10.64 0.64))
0.136 0.13 6 to 0.164 0.164 (3.45 (3.45 to 4.17) 4.17)
0.490 0.4 90 (12.4 12.45 5)
0.43 0.435 5 (11.05 1.05))
0.141 0.14 1 to 0.170 0.170 (3.58 (3.58 to 4.32) 4.32)
0.508 0.5 08 (12.9 12.90 0)
0.45 0.451 1 (11.46 1.46))
0.171 0.17 1 to 0.1 0.195 95 (4.34 (4.34 to 4.95) 4.95)
0.585 0.5 85 (14.8 14.86 6)
0.45 0.456 6 (11.58 1.58))
0.177 to 0.2 0.177 0.201 01 (4.50 (4.50 to 5.11) 5.11)
0.603 0.6 03 (15.3 15.32 2)
0.47 0.472 2 (11.99 1.99))
12 (30 (305) 5)
12.5 (31 (318) 8)
0.117 0.117 to 0.128 0.128 (2.97 (2 .97 to 3.24) 3.24)
13.125 13.1 25 (33 (333) 3)
13.625 13.6 25 (34 (346) 6)
0.126 to 0.1 0.126 0.137 37 (3.20 (3 .20 to 3.48) 3.48)
14.125 14.1 25 (35 (359) 9)
14.25 (362) (362) 14.75 (375) (375)
0.12 0.126 6 to 0.137 0.137 (3.20 (3 .20 to 3.48) 3.48)
0.037 0.03 7 to 0.0 0.047 47 (0.9 (0.94 4 to 1.1 1.19) 9)
0.039 0.03 9 to 0.0 0.049 49 (0.9 (0.99 9 to 1.2 1.24) 4)
0.033 0.03 3 to 0.0 0.040 40 (0.8 (0.84 4 to 1.0 1.02) 2) 0.039 to 0.0 0.039 0.049 49 (0.9 (0.99 9 to 1.2 1.24) 4)
0.033 0.03 3 to 0.0 0.040 40 (0.8 (0.84 4 to 1.0 1.02) 2)
0.036 0.03 6 to 0.0 0.042 42 (0.9 (0.91 1 to 1.0 1.07) 7)
0.039 0.03 9 to 0.0 0.049 49 (0.9 (0.99 9 to 1.2 1.24) 4)
0.036 0.03 6 to 0.0 0.044 44 (0.9 (0.91 1 to 1.0 1.07) 7) 0.039 to 0.0 0.039 0.050 50 (0.9 (0.99 9 to 1.2 1.27) 7)
0.036 0.03 6 to 0.0 0.042 42 (0.9 (0.91 1 to 1.0 1.07) 7)
0.039 0.039 to 0.0 0.050 50 (0.9 (0.99 9 to 1.2 1.27) 7)
0.043 to 0.0 0.043 0.053 53 (1.0 (1.09 9 to 1.3 1.35) 5)
0.042 0.04 2 to 0.0 0.052 52 (1.0 (1.07 7 to 1.3 1.32) 2)
0.042 0.04 2 to 0.0 0.052 52 (1.0 (1.07 7 to 1.3 1.32) 2)
Page B-4 of 5
REV: 10/14
For models models JGC:D:F JGC:D:F
PISTON TO CYLINDER B ore 15.375 15.3 75 (39 (391) 1) 15.875 15.8 75 (40 (403) 3) 17.375 17.3 75 (44 (441) 1) 17.875 17.8 75 (45 (454) 4)
Clearance
Appendix Appendix B - Clear Clearances ances
PISTO PISTON N RING END GAPS (Filled Teflon) a
WEAR BANDS - NEW
Maximum
Min. End Gap
0.154 to 0.1 0.154 0.185 85 (3.9 (3.91 1 to 4.7 4.70) 0)
0.555 0.5 55 (14.1 14.10 0)
0.49 0.492 2 (12.50 2.50))
0.159 0.15 9 to 0.191 0.191 (4.0 (4.04 4 to 4.8 4.85) 5)
0.573 0.5 73 (14.5 14.55 5)
0.50 0.508 8 (12.90 2.90))
0.17 0.179 9 to 0.191 0.191 (4.55 (4 .55 to 4.8 4.85) 5)
0.174 to 0.2 0.174 0.209 09 (4.4 (4.42 2 to 5.3 5.31) 1)
0.627 0.6 27 (15.9 15.93 3)
0.55 0.556 6 (14.12 4.12))
0.181 0.181 to 0.193 0.193
0.179 0.1 79 to 0.2 0.215 15
0.645 0.6 45 (16.3 16.38 8)
0.57 0.572 2 (14.53 4.53))
0.127 to 0.1 0.127 0.138 38 (3.23 (3 .23 to 3.5 3.50) 0)
New
Radial Projection 0.038 to 0.0 0.038 0.050 50 (0.9 (0.97 7 to 1.2 1.27) 7)
0.044 to 0.0 0.044 0.057 57 (1.1 (1.12 2 to 1.4 1.45) 5)
(4.60 to 4.9 (4.60 4.90) 0) 0.187 0.187 to 0.199 0.199 19.625 19.6 25 (49 (498) 8) (4.75 (4 .75 to 5.0 5.05) 5)
(4.5 (4.55 5 to 5.4 5.46) 6) 0.236 0.2 36 to 0.2 0.268 68 (5.9 (5.99 9 to 6.8 6.81) 1)
0.18 0.185 5 to 0.197 0.197 (4.70 (4 .70 to 5.0 5.00) 0)
0.804 0.8 04 (20.4 20.42 2)
0.62 0.627 7 (15.93 5.93))
0.242 to 0.2 0.242 0.274 74 (6.1 (6.15 5 to 6.9 6.96) 6)
0.822 0.8 22 (20.8 20.88 8)
0.64 0.643 3 (16.33 6.33))
0.213 0.21 3 to 0.225 0.225 (5.41 (5 .41 to 5.7 5.72) 2)
0.264 to 0.3 0.264 0.304 04 (6.7 (6.71 1 to 7.7 7.72) 2)
0.912 0.9 12 (23.1 23.16 6)
0.70 0.703 3 (17.86 7.86))
0.21 0.214 4 to 0.226 0.226 (5.44 (5 .44 to 5.7 5.74) 4)
0.290 to 0.3 0.290 0.330 30 (7.3 (7.36 6 to 8.3 8.38) 8)
0.990 0.9 90 (25.1 25.15 5)
0.77 0.771 1 (19.58 9.58))
0.320 to 0.3 0.320 0.360 60 (8.1 (8.13 3 to 9.1 9.14) 4)
1.080 1.0 80 (27.4 27.43 3)
0.84 0.847 7 (21.51 1.51))
20.125 20.1 25 (51 (511) 1) 22 (55 (559) 9) 24.125 24.1 25 (61 (613) 3) 26.5 (67 (673) 3)
0.226 0.22 6 to 0.238 0.238 (5.74 (5 .74 to 6.0 6.05) 5)
0.050 to 0.0 0.050 0.063 63 (1.2 (1.27 7 to 1.6 1.60) 0)
0.059 0.05 9 to 0.0 0.072 72 (1.5 (1.50 0 to 1.8 1.83) 3)
0.056 0.05 6 to 0.0 0.069 69 (1.4 (1.42 2 to 1.7 1.75) 5)
0.058 0.05 8 to 0.0 0.071 71 (1.4 (1.47 7 to 1.8 1.80) 0)
a. For P PEEK EEK piston ring end gap values, multiply ttable able values by 0.3.
REV: 10/14
Page B-5 of 5
Appendix C - Frame Specifications JGC:D:F Frame Specifications For more more inform informati ation, on, see see the Ariel Ariel Perform Performanc ance e Program Program.. Rated Rated speed speeds s for no non-lu n-lube be an and d lubric lubricate ated d process proce ss applicat applications ions may vary. vary. TABLE C-1 JGC Frame Specifications Specification
JGC/2
JGC/4
Stroke, in. (mm)
6.5 (165)
Maximum Maximu m Allowable Allowable Speed, Speed,a RPM
1000
JGC/6
Minimum Minim um Speed, Speed,b R PM
500
Piston Spee Speed, d,c FPM (m/ s)
To 1083 (5.5)
Horsepow er, hp ((k kW)
2070 ((1 1544)
4140 ((3 3087)
6210 ((4 4631)
Maximum L Le ength, in. (m)
65 ((1 1.65)
116 ((2 2.95)
159 ((4 4.04)
Maximum Ove verrall Height, in. (m) Maximu Ma ximum m Width with Cylinder Cylinders s
37 (0.94) to top of aluminum co cov ver
See app approp ropria riate te frame frame,, guid guide, e, and cylinder outline outlin e drawings. drawings.
H eight - B ot ottom t o C rra ankshaft Centerline, in. (mm)
22 (5 ( 559)
Approximate Appr oximate Weigh Weightt with wit h Cylinder Cylinders s
See Arie Ariell Performan Performance ce Prog Program ram..
Connecting R o od d Centerline t o C e en nterline, in. (mm)
17 (4 ( 432)
Sump Ca Capacity, U S gal. (L) Oil Pump Pump Flow Rate, Rate,d GPM (L/s)
31 (1 (117) 21 (1.3)
68 ((2 257) 61 (3.8)
105 (3 (397) 96 (6.1)
Oil Hea Heat Rej Rejecti ction BTU/h U/hr (kW kW))
52,0 ,00 00 (15.5 .5))
106,0 ,00 00 (31.1) .1)
159,0 ,00 00 (46.6 .6))
Piston R Ro od Di Diameter, in. (mm)
2.5 (6 (64)
Internal Rod Load - Double Acting Compression + Tension, lbf. (kN )
114,000 ((5 507)
Tension, lbf. (kN)
57,000 (254)
Compression, lbf. (kN)
60,000 (2 (267)
Internal Rod Load - Single Acting Tension, lbf. (kN)
57,000 (254)
a. Maximum Allowable Speed is the highest (potential) speed at which the fframe rame design permit permits s continuous operation. Compressor frame frame data plate "Frame Rated Speed (RPM)" is application specific, and may be lower than Maximum Allowable Allow able Speed Speed.. Do not exceed the llowe owerr of frame ra rated ted sp speed, eed, lowe st cylin cylinder der rated (RPM), or driver rated speed . b. Minimum Speed is tthe he lowest frame s speed peed neede d to provide adequate oil flow to tthe he compressor bearings. c. Average Pist Piston on Speed is based on Maximum Allowable Speed (RPM). The cylinder data-plate data-plate rated speed (RPM) or frame rated rated speed may be less, resulting in a lower piston speed rating. d. Flow rat rate e at maximum rated speed and 180°F ((82°C) 82°C) oil.
REV: 10/14
Page C-1 of 4
Appendix Appen dix C - Frame Specific Specification ations s
For models models JGC:D:F JGC:D:F
TABLE C-2 JGD Frame Specifications Specification
JGD/2
JGD /4
Stroke, in. (mm)
5.5 (140)
Maximum Maximu m Allowable Allowable Spee Speed, d,a RPM
1200
Minimum Minim um Speed, Speed,b R PM
600
Piston Spee Speed, d,c FPM (m/s)
To 1100 (5.59)
JGD/6
Horsepow er, hp (k (k W )
2070 (1 (1544)
4140 (3 (3087)
6210 (4 (4631)
Maximum L Le ength, in. (m)
65 ((1 1.65)
116 ((2 2.95)
159 ((4 4.04)
Maximum Overall Height, in. (m)
37 (0.94) t o t op op of aluminum cover
Maximum Maxi mum Width with Cylinder Cylinders s
See app appro ropria priate te frame, frame, guid guide, e, and cylinder outline outlin e drawings. drawings.
Height - B ot ottom to C ra rankshaft Centerline, in. (mm)
22 (5 ( 559)
Approximate Appr oximate Weight Weight with wit h Cylinder Cylinders s
See Arie Ariell Performan Performance ce Prog Program ram..
Connecting R o od d C en enterline to C en enterline, in. (mm)
17 (4 ( 432)
Sump Ca Capacity, US gal. (L)
31 ((1 117)
68 ((2 257)
105 ((3 397)
Oil Pump Pump Flow Rate,d GPM (L/ s)
25 (1.6)
73 (4.6)
116 (7.3)
Oil Hea Heat Rej Rejecti ction BTU/ U/h hr (kW) kW)
59,00 ,000 (17.3) .3)
118,00 ,000 (34.6) .6)
177,00 ,000 (51.9 .9))
Piston Rod D iameter, in. (mm)
2.5 (64)
Internal Rod Load - Double Acting Compression + Tension, lbf. (kN) Tension, lbf. (kN )
114,000 ((5 507) 57,000 (254)
Compression, lbf. (kN)
60,000 (2 (267)
Internal Rod Load - Single Acting Tension, lbf. (kN )
57,000 (254)
a. Maximum Allowable Speed is the highest (potential) speed at which the fframe rame design permits permits continuous operation. Compressor frame frame data plate "Frame Rated Speed (RPM)" is application specific, and may be lower than Maximum Allowable Allow able Speed Speed.. Do not exceed the llowe owerr of frame ra rated ted sp speed, eed, lowe st cylin cylinder der rated (RPM), or driver rated speed . b. Minimum Speed is tthe he lowest frame s speed peed neede d to provide adequate oil flow to tthe he compressor bearings. c. Average Pist Piston on Speed is based on Maximum Allowable Speed (RPM). The cylinder data-plate data-plate rated speed (RPM) or frame rated rated speed may be less, resulting in a lower piston speed rating. d. Flow rat rate e at maximum rated speed and 180°F ((82°C) 82°C) oil.
Page C-2 of 4
REV: 10/14
For models models JGC:D:F JGC:D:F
Appendix Appendix C - Frame Frame Specifications Specifications
TABLE C-3 JGF Frame Specifications Specification
JGF/2
JGF/4
Stroke, in. (mm)
5 (127)
Maximum Maximu m Allowable Allowable Speed, Speed,a RPM
1400
Minimum Minim um Speed, Speed,b RPM
600
Piston Spee Speed, d,c FPM (m/s)
To 1167 (5.93)
JGF/6
Horsepower, hp ((k k W)
2070 ((1 1544)
4140 (3 (3087)
6210 (4 (4631)
Maximum L Le ength, in. (m)
65 ((1 1.65)
116 ((2 2.95)
159 ((4 4.04)
Maxi xim mum Overall Height, in. (m)
37 (0.94) to top of aluminum cove verr
Maximum Maxi mum Width with Cylinder Cylinders s
See app appro ropria priate te frame, frame, guid guide, e, and cylinder outline outlin e drawings. drawings.
Height - B ot ottom to C ra rankshaft Centerline, in. (mm)
22 (5 ( 559)
Approximate Appr oximate Weight with Cylinder Cylinders s
See Arie Ariell Performance Performance Pro Progra gram. m.
Connecting R o od d C en enterline to C en enterline, in. (mm)
17 (4 ( 432)
Sump Ca Capacity, US gal. (L)
31 (1 (117)
68 (2 (257)
105 ((3 397)
Oil Pump Pump Flow Rate,d GPM (L/ s)
30 (1.9)
86 (5.4)
136 (8.6)
Oil Hea Heat Rej Rejecti ction BTU/ U/h hr (kW kW))
65,00 ,000 (19.0) .0)
130,0 ,00 00 (38.1 .1))
195,00 ,000 (57.1) .1)
Pist on R Ro od Diameter, in. (mm)
2.5 (6 (64)
Internal Rod Load - Double Acting C ompression + Tension, lbf . (kN)
114,000 ((5 507)
Tension, lbf. (kN )
57, 000 (254)
Compression, lbf. (kN)
60, 000 (267)
Internal Rod Load - Single Acting Tension, lbf. (kN )
57, 000 (254)
a. Maximum A Allowable llowable Speed is the highest (potential) s speed peed at which the fframe rame design permits continuous operation. Compressor frame data plate "Frame "Frame Rated Speed (RPM)" is application specific, and may be lower than Maximum Allowable Allow able Speed. Do not excee exceed d the lowe r of frame rated speed , lowe st cylind er ra ted (RPM), (R PM), or d river rated speed . b. Minimum Speed is tthe he lowest fram frame e speed neede d to provide adequate oil flow to tthe he compressor bearings. c. Average Pist Piston on Speed is based on Maximum Allowable Speed (RPM). The cylinder data-plate data-plate rated speed (RPM) or frame rated rated speed may be less, resulting in a lower piston speed rating. d. Flow rat rate e at maximum rrated ated speed and 180°F ((82°C) 82°C) oil.
Opposed Throw - Reciprocating Weight Balancing Ariel recommend recommends s a reciprocat reciprocating ing weight differentia differentiall between between opposin opposing g throws of 2.5 pounds pounds (1.1kg) (1.1kg) or less les s for JGC:D:F JGC:D:F compr compres esso sors. rs. To replac replace e a conne connecti cting ng rod as asse semb mbly ly,, piston piston,, piston piston and rod as asse sembl mbly, y, ba balan lance ce nuts, nuts, or cross crosshe head, ad, weigh wei gh co comp mpon onen entt parts parts on a sc scal ale e ca calilibra brate ted d to 0.1 0.1 poun pounds ds (0.05 (0.05 kg kg)) an and d co comp mpare are to th the e Balan Balanci cing ng Record Reco rd in the compr compres esso sorr Parts Book. Book. If the weight weight chan change ges, s, recalc recalcula ulate te op oppos posing ing throw throw recipro reciproca catin ting g weight weig ht differe differenti ntial. al. If not within within recomm recommend ended ed limits limits,, the compr compres esso sorr may require require ne new w balan balance ce nuts nuts and/or and/ or crosshe crossheads ads..
REV: 10/14
Page C-3 of 4
Appendix Appen dix C - Frame Specific Specification ations s
For models models JGC:D:F JGC:D:F
To ex exch chang ange e op oppos posing ing throw throw cylin cylinder der locati locations ons,, ex exch chan ange ge all rec recipr iproc ocati ating ng comp compone onents nts to the op oppos posite ite throw, thro w, ex exce cept pt the conne connecti cting ng rod as asse semb mblie lies. s. Chec Check k the Balanc Balancin ing g Record Record an and d recalc recalcula ulate te recipro reciproca catin ting g weight weig ht di diffe fferen rentia tial, l, inclu includin ding g the weight weight of the conn connec ectin ting g rods. rods. If not within within rec recomm ommen ended ded limits limits,, the comp compres resso sorr may requir require e new cross crosshe head ad balanc balance e nuts nuts to reduc reduce e differe differenti ntial. al. If un unabl able e to ba balan lance ce op oppos posing ing throws throws within within recom recommen mended ded limits limits,, conta contact ct the pa pack ckag ager er or Ariel. Ariel. When When ap apply plying ing or re-app re-apply lying ing a di diffe fferen rentt cylin cylinder der to a thro throw, w, recalc recalcula ulate te oppos opposing ing throw throw recip reciproc rocati ating ng weight weight differe differenti ntial; al; new bala balanc nce e nuts nuts an and/o d/orr cro cross sshea heads ds may be require required. d. The force force feed feed oil distrib distributi ution on sy syste stem m may ma y also also ne need ed resiz resized. ed. Contac Contactt the packa packager ger or the Ariel Ariel Respon Response se Center Center for de detai tailed led in inform formati ation on ab abou outt recommend recom mended ed reciprocat reciprocating ing weight differentia differentiall between between opposing opposing throws. TABLE C-4 JGC:D:F Approximate Component Weights, Lbs (Kg)
Component
Weight
Component
Weight
Main/Connecting R od Bearing
2.5 (1.1)
Connecting Roda
166 (75 (75))
Spacer Bar
30 (14)
Crosshead Guide
1255 (569)
Top Cover, 2-Throw
118 (54)
Crosshead
See Notea
Top Co Cover, 4-Throw
229 ((1 104)
Crosshead P Piin
41 ((1 19)
Top Co C over, 6-Throw
341 ((1 155)
Lube O Oiil Pump 2 2--Throw
36 ((1 16)
End C Co over D Drrive En E nd
148 (6 (67)
Lube O Oiil Pump 4 & 6-Throw
125 (5 (57)
End Co Cove verr Auxi xilliary End
260 (118)
Frame Asse ssembly w/ w/o o Cyl Cylinders
Crankshaft, 2-Throw b
1040 (472)
VVCP
See Ariel Ariel
Crankshaft, 4-Throw b
1900 (8 ( 862)
Cylinder A s ss sembly
Performance Program.
Crankshaft, 6-Throw b
2740 (1243)
Pisto ston and Rod Rod Asse ssembly
Main J Jo ournal Caps
40 (1 (18)
a. For exac exactt weight weights, s, see Balancing Recor Record d sheet provide provided d by Ariel in the Par Parts ts Book Book for each comp compresso ressor. r. b. Cranks Crankshaft haft weight is withou withoutt fly flywheel, wheel, vibrat vibration ion det detuners, uners, or d damper. amper.
Page C-4 of 4
REV: 10/14
Appendix D - Compressor Clearance, Oil, and Temperature Record SERIAL NO. F- ________ ____________ _______ _______ ______ __ MODEL MODEL ___ _______ ________ ______ __ Date ____ Date ________ _______ _______ ________ ____ CRANKSHAFT THRUST (END) CLEARANCE, In. (mm) Crankshaft Serial Number
Thrust Clearance, I n. (mm)
CONNECTING CONNECT ING ROD THRUST (SIDE) CLEARANCE, CLEARANCE, In. (mm)
Throw 1
Throw 2
Throw 3
Throw 4
Throw 5
Throw 6
JACK CLEARANCES, In. (mm) Throw #
1
2
3
4
5
6
Main Bear B earing ing Conn. Rod Bearing After new bear After bearing ing install installation, ation, if measure measured d cleara clearances nces exceed toleran tolerances ces of Table B-1 in i n Append Ap pend ix B, contact your packager or Ariel before proceeding.
OIL PRESSURE AND TEMPERATURE TEMPERATURE Date
Time
R PM
Filter Inlet Oil Pressure psig (barg)
Filter Outlet Oil Pressure psig (barg)
Oil Temp. into Frame °F (°C)
Remarks
BEARING CAP TEM TEMPERATURE, PERATURE, °F (°C) (°C),, AFTER AFTER RUN TIME OF: 3 Minutes Idle Speed (engine, VFD)
Throw
1 Minute (single speed motor) No Gas Load Main
Rod
Additional 3-5 Minutes Full Speed No Gas Load Main
Rod
Additional 10-15 Minutes Full Speed Gas Load Main
Rod
1 2 3 4 5 6
REV: 10/14
Page D-1 of 1
Appendix E - Balance Valve Log TABLE E-1 Balance Valve Maintenance Log D at e
T ime
Pressure Pressure Gauge Description
Div. Block Pres Pressure sure Mi n .
Max.
Balance Valve Set Pressure
Div. Block Cycle Time (Seconds)
Notes
REV: 10/14
Page E-1 of 1
Appendix F - ER-34.1 Cleaning, Handling, and Assembly Lubricants for Non-Lubricated Compressor Cylinders Cleaning Cleanin g an and d ha handl ndling ing are critic critical al to preve prevent nt premat premature ure wear an and d fai failur lure e of no non-me n-metal tallic lic rings rings an and d pa pack cking ings s in non-lu non-lube be compre compress ssor or cylin cylinder ders. s. Proper Proper cl clea eanin ning g and handli handling ng will virtua virtually lly elimin eliminate ate oil an and d an anti-s ti-seiz eize e comp compoun ounds ds from the cylin cylinde derr interi interior, or, piston piston rod as asse semb mbly ly,, valv valve e an and d packin packing g case case areas areas.. In no non-lu n-lubri brica cated ted applic applicati ation ons, s, the no non-m n-meta etalli llic c rin rings gs an and d packin packings gs transfe transferr some some materi material al to the metall metallic ic runnin run ning g surfac surfaces es.. This This transfe transferred rred fil film m provid provides es a “lubric “lubricate ated” d” surfac surface e that that enable enables s the compre compress ssor or to functi fun ction on prope properly rly.. The prese presenc nce e of oil degrad degrades es the transfe transferred rred film, film, formin forming g an abras abrasiv ive e paste paste that that
qu quick ickly ly wears non-me non-metal tallic lic elemen elements ts du during ring operati operation on.. Anti-s Anti-seiz eize e compo compound unds s are oi oill ba base sed d an and d also also conta contain in ab abras rasiv ive e metal metallic lic comp compone onents nts that that caus cause e premat premature ure compo componen nentt wear. wear. This proce This procedu dure re ap appli plies es to all no non-lu n-lube be comp compres resso sorr cylin cylinde ders. rs. Ariel Ariel cl clean eans s and protec protects ts comp complet lete e no nonnlube lub e cylin cylinde ders rs to no non-lu n-lube be servi service ce require requireme ments nts be before fore shipp shipping ing.. Follow Follow the proce procedu dure re below below to cl clean ean intern internal al parts parts ship shipped ped loos loose, e, spare spare pa parts rts before before ins instal tallat lation ion,, and conta contamin minate ated d surfac surfaces es du durin ring g maintena main tenance nce.. This extends extends non-lube non-lube compress compressor or compone component nt life, life, and ultimatel ultimately, y, cylinde cylinderr life. life. Denatured alcohol presents health and safety hazards. Keep away from heat, sparks, flame and all other ignition sources. Use adequate ventilation, neoprene or butyl gloves, monogoggles or face-mask, and impermeable apron. Contains methyl alcohol; poisonous if ingested. Avoid eye and skin contact. Properly handle and dispose of materials resulting from clean-up. See manufacturer Material Safety Data Sheets for details. NOTE: Clean all table surfaces and tools that will come in contact with the cylinder, cylinder components, or piston components 1. Handl Handle e al alll cl clea eane ned d parts parts with with new new or cl clea ean n “rubb “rubber” er” glov gloves es or ne new w white white co cott tton on glov gloves es.. If glov gloves es beco become me co cont ntam amin inat ated ed or dirty dirty,, disp dispos ose e of them them and and use use a ne new w pa pair. ir. 2. Clean Clean cylin cylinde derr in interi terior or surfac surfaces es thorou thorough ghly ly with de dena nature tured d alcoh alcohol ol un until til a cl clea ean, n, alcoh alcohol ol soak soaked ed,, white whi te pape paperr to towel wel or lilint nt-fr -free ee rag remo remove ves s no more more debr debris is.. Th This is in incl clud udes es al alll surfa surface ces s of th the e bo bore, re, count counter er bore, bore, valve valve pocke pockets, ts, sucti suction on and disch discharg arge e ga gas s passa passages ges,, nozzle nozzles, s, etc. etc. 3. Lubri Lubrica cate te th the e th threa reads ds,, bolt bolt head head,, and and st stat at-o-o-se seal al of th the e cy cylilind nder er no nozz zzle le lube lube bo bolt lt with with ve very ry smal smalll amoun am ounts ts of Never-See Never-Seez, z, regula regularr grade grade,, an and d en ensu sure re all ma matin ting g surfac surfaces es are coate coated. d. 4. Use a smal smalll amou amount nt of Loct Loctit ite e 577 577 Pipe Pipe Seala Sealant nt on male male th threa reads ds when when in inst stal alliling ng pi pipe pe plug plugs. s. 5. Very Very ligh lightl tly y oi oill bolt bolt thre thread ads s and and head head se seat atin ing g su surfa rface ces s fo forr va valv lve e ca cap, p, he head ad,, an and d pack packin ing g ca case se mount mo unting ing bolts, bolts, bu butt preve prevent nt oil pe penet netrati ration on into into the cylin cylinde derr interio interior. r. 6. Thorou Thorough ghly ly cl clean ean pi pisto ston, n, colla collar, r, rod rod,, an and d nu nutt with denatu denatured red alcoh alcohol ol until until a cl clea ean, n, alcoh alcohol ol soak soaked ed pape paperr to towel wel or lilint nt-fr -free ee rag rem remov oves es no more more debri debris. s. Clean Clean pist piston on rin ring g groov grooves es an and d wear wear ba band nd groov gro oves es es espe pecia cially lly well. well. Clean Clean piston piston rings rings and wear ba bands nds with denatu denatured red alcoh alcohol ol before before assembling. 7. When When asse assemb mbliling ng pist piston on to rod, rod, use use ve very ry smal smalll amou amount nts s of NeverNever-See Seez, z, Regul Regular ar Grade rade on th the e nu nutt and and co collllar, ar, and and ensu ensure re all all mati mating ng su surfa rface ces s are co cove vered red.. Do no nott lube lube th threa reads ds fo forr th the e pi pist ston on ro rod d tensi ten sione oner. r. Clean Clean threads threads of hy hydra drauli ulic c tensi tensione onerr an and d all other other tensi tension oner er surfac surfaces es that that will conta contact ct the pi pist ston on.. Use ve very ry smal smalll amou amount nts s of Never Never-Se -Seez ez,, Regul Regular ar Grade rade on pist piston on nu nutt se sett sc screws rews.. After After asse assemb mbly ly,, th thoro oroug ughl hly y wipe wipe off off all all NeverNever-See Seez z from from the the pi pist ston on rod as asse semb mbly ly ex exte terio riorr in th the e co collllar ar an and d nut nut areas areas with with dena denatu tured red alco alcoho holl unti untill a cl clea ean, n, alco alcoho holl so soak aked ed,, white white pa pape perr to towel wel or lint lint-fr -free ee rag remov rem oves es no more more debris debris..
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Page F-1 of 4
Appendix Appen dix F - ER-34.1
For models models JGC:D:F JGC:D:F
8. The manufa manufact cturer urer shou should ld provid provide e pa pack ckin ing g case cases s cle clean aned, ed, prese preserve rved, d, an and d suita suitable ble for no non-lu n-lube be servi service ce.. Inspe Inspect ct pa pack ckin ing g case cases s for cl clean eanlin lines ess. s. If they they ap appea pearr coate coated d with an oil-ba oil-base sed d prese preserva rvativ tive, e, di disa sass ssem emble ble an and d cl clean ean them them with denatu denatured red alcoh alcohol, ol, then then reass reassemb emble. le. If disas disasse semb mbly ly is requir required ed for water-co wate r-coole oled d pa pack cking ing case cases, s, re-ass re-assem emble ble an and d test test to Ariel Ariel Eng Engine ineerin ering g Referen Reference ce ER-51 ER-51.. Contac Contactt Ariel for latest latest version version of ER-51. 9. Wipe Wipe do down wn pi pisto ston n rod with denatu denatured red alcoho alcoholl aft after er rod instal installat lation ion.. 10. Clean 10. Clean VVCP or FVCP co comp mpon onen ents ts with with dena denatu tured red alco alcoho hol. l. Sepa Separa rate te th the e un unlo load ader er he head ad from from th the e ad adap apter/ ter/ac actua tuator. tor. Clean Clean all intern internal al surfac surfaces es with de denat nature ured d al alco cohol hol includ including ing be behin hind d the unload unloader er pi pist ston on.. Do not not remov remove e VVCP unlo unload ader er st stem em se seal al.. Clean Clean pi pist ston on rin ring g with with de dena natu tured red alco alcoho hol. l. Do no nott use use anti anti-se -seiz ize e co comp mpou ound nds s or oil oil on the the st stee eell head head ga gask sket ets. s. Use a ve very ry th thin in film film of oil oil whe when n inst instal alliling ng orings.
11. anti 11. Clean Clea neize crank cra -end d head, hea head-e ndehe head, ad,l head and steel eel he head adIfgaske gas ts with de denat nature ured des alcoho alcan ohol. l. ing Do no notal, t us use an ti-s -sei ze nk-en co comp mpou ound nds sd,orhe oil oiad-end l on the th stee st eel he adst gask ga sket ets. s. th the ekets cr cran ank-e k-end nd he head ad us uses o-rin o-r g se seal , e appl apply y a ve very ry th thin in film film of oil oil to the the lead lead-in -in ch cham amfe ferr of the the cy cylilind nder er se seat atin ing g su surfa rface ce to he help lp preve prevent nt sheari shearing ng of the o-ring. o-ring. 12. The manufa 12. manufact cturer urer shou should ld provid provide e comp compres resso sorr valv valves es cl clea eaned ned,, prese preserve rved, d, an and d suita suitable ble for non-lu non-lube be servi service ce.. Inspe Inspect ct valv valves es for cl clean eanlin lines ess. s. If they they appea appearr coate coated d with an oil-ba oil-base sed d prese preserva rvativ tive, e, di disa sass ssem emble ble an and d cl clean ean them them with denatu denatured red alcoh alcohol, ol, then then reass reassemb emble. le. If they they appea appearr clean clean,, they they requi req uire re no ad addit dition ional al cl clea eanin ning g provi provided ded they they are seale sealed d in their their origin original al packa packagin ging g and have have not been been contaminated. 13. Clean 13. Clean valv valve e caps caps,, retaine retainers, rs, hig high h cl clea earan rance ce as asse semb mblie lies, s, an and d steel steel valv valve e ga gask skets ets with denatu denatured red al alco coho hol. l. Use only only a ve very ry thin thin film film of oil oil for for va valv lve e ca cap p o-rin o-rings gs.. Do no nott us use e an anti ti-s -sei eize ze co comp mpou ound nds s or oi oill on steell valve stee valve gaskets gaskets.. 14. As 14. Asse sembl mble e clean cleaned ed parts parts immed immediat iately ely.. If cylin cylinde derr will no nott see see immed immediat iate e servi service ce,, see see Ariel Ariel Engin Engineeri eering ng prese serva rvatio tion n instruc instructio tions ns.. Contac Contactt Ariel Ariel for lates latestt versi version on of ER-34. ER-34. Reference ER-34 for pre Do not use Ariel non-lube compressor cylinders for oxygen service.
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Appendix G - ER-82 Soft Foot and Top Plane Flatness Checks for Proper Main Bearing Bore Alignment in Reciprocating Compressors Main be Main bearin aring g bo bore re al align ignmen mentt is critic critical al to main main bearin bearing g an and d crank cranksh shaft aft life. life. Ariel Ariel ma manuf nufac acture tures s the top co cove verr moun mounti ting ng su surfa rface ce of a co comp mpres resso sorr frame frame in cl clos ose e to tole leran rance ce to a flat flat plan plane, e, to th the e main main be beari aring ng bores bores,, and and to th the e botto bottom m of the the co comp mpres resso sorr feet feet.. The The main main be beari aring ng bo bores res alig align n when when frame frame fe feet et are su supp pport orted ed so th the e to top p co cove verr moun mounti ting ng su surfa rface ce is flat flat and and "i "in n plan plane" e".. Per Perfo form rm a so soft ft fo foot ot ch chec eck k an and d to top p
plane pla ne fla flatne tness ss measu measurem rement ent at the these se tim times es:: • Setti Setting ng of a new compr compres esso sorr (pre and po post st groutin grouting). g). • Commi Commiss ssio ion n of a co comp mpres resso sorr in the the fiel field. d. • Reinstalla Reinstallation tion of a compress compressor. or. • Reloca Relocatio tion n of a packa package. ge. • Disco Discove very ry of loose loose hold hold down fasten fasteners ers.. • Performa Performanc nce e of recomm recommen ended ded sche schedul duled ed mainte maintenan nance ce inspe inspecti ction on ev every ery 6 months months or 4000 4000 ho hours urs.. With ne new w un unit it instal installat latio ions ns,, Ariel Ariel recomm recommend ends s chec checki king ng and record recording ing initi initial al top plane plane fla flatne tness ss be before fore shimm shimming ing the gu guide ide feet feet an and d aft after er initia initiall rou rough gh coup couplin ling g align alignmen ment. t. On compr compres esso sors rs shipp shipped ed disas dis asse sembl mbled, ed, perform perform the initi initial al chec check k be before fore guide guide and cy cylin linder der as asse semb mbly ly instal installa latio tion. n. Shim Shim or otherwis oth erwise e adjus adjustt the he heigh ightt to bri bring ng the top cove coverr mo mount unting ing surfac surface e within within the spec specifi ified ed plane plane tol tolera eranc nce. e. Reco Record rd ion subs subsequ equen ent t readin rea dings gs aft after er compl co mplete eteifguide gui de cylin cyder, linder der instal ins talla latio tion, n,instal and again aga in aft after erults any ve ssel el instal ins tallat lation an and d shimm sh imming ing. . Re-adjus Re-ad just t height hei ght gu guide ide,and , cylin cylinder, and/or and /or vess ve ssel el ins tallat lation ion result res s invess frame fram e top rai raill meas measure uremen ments ts out of Appendix Appendix G tolerances. JGB:V:Z:U JGB:V:Z :U and KBB:V:Z:U KBB:V:Z:U 4 an and d 6-throw 6-throw frames frames require require both a to top p pl plan ane e flat flatne ness ss and soft soft foot foot chec checks ks.. Fo Forr al alll ot othe herr frame frames, s, the the so soft ft foot foot ch chec eck k is requi required red;; the the top top plan plane e flat flatne ness ss meas measure ureme ment nt is op opti tion onal al,, exce except pt fo forr th the e JGI, JGI, which which requi require res s none none.. Use the proce procedur dure e below below to prope properly rly insta installll and periodi periodica cally lly inspe inspect ct comp compres resso sorr frames frames.. 1. To chec check k soft soft foot, foot, proper properly ly instal installl an and d torque torque compr compres esso sorr frame frame hold hold down boltin bolting. g. Lo Loos osen en each each hold hold down down bolt bolt in indi divi vidu dual ally ly while while ch chec ecki king ng the the fra frame me fo foot ot to sk skid id de defl flec ecti tion on with with a ca calilibra brate ted d di dial al in indi dica cato tor. r. Correc Correctt any any hold hold down down posi positi tion on that that defl deflec ects ts more more th than an 0. 0.00 002 2 in inch ches es (0.05 (0.05 mm) mm) when when re rele leas ased ed.. Re-torq Re-torque ue the the hold hold down down bolt bolt and and repea repeatt on ea each ch frame frame-to -to-s -ski kid d bo bolt lt.. See See fo forr pr prop oper er frame frame foott an foo and d cross crosshe head ad guide guide bolt bolt si size ze an and d torques torques.. 2. Remov Remove e or repos reposit itio ion n the the top top co cove ver(s r(s)) and and gask gasket et(s (s)) to ex expo pose se th the e fra frame me to top p co cove verr moun mounti ting ng surfac surface. e. Verify Verify it is clean clean.. NOTE: For KBZ:U frames only, the frame top rail has been coated with a light coat of Cortec VPCI 369 corrosion inhibitor or equivalent to protect the aluminum to cast iron joint. If the top cover cover is removed, clean both the top rail and the top cover and re-coat the frame top rail with a light coat of the same compound. If VPCI 369 or equivalent is not available, use marine grade grease. Apply only a light coat of the corrosion inhibitor; do not allow excess material to flow into the frame when the top cover is installed.
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Page 3 of 4
Appendix Appen dix G - ER-82
For models models JGC:D:F JGC:D:F
3. To chec check k top plane plane fla flatne tness ss,, us use e meas measure uremen mentt Tolerance Compressor Framea eq equip uipmen mentt with a pu publi blish shed ed ac accu curac racy y of +0.001 +0.001 inche inches s Inch (mm) (0.0 (0.025 25 mm) mm) over over th the e dist distan ance ce requ require ired d to meas measure ure the the JGM:N:P:Q/1/2. JG:A/2/4, 0.004 (0.1 0.004 (0.10) 0) enti entire re le leng ngth th of both both frame frame rail rails. s. Meas Measure ure the the top top JGR:J/2 su surfa rface ce of both both si side des s of the the frame frame rails rails at each each anch anchor or JGA/6, JGR/4, JGJ/4/6, JGH:E:K:T:C:D:F:Z:U/2/4, 0.006 0.00 6 (0.1 (0.15) 5) bo bolt lt (see (see Appen Appendix dix G), or be betwe tween en each each pa pair ir of an anch chor or a,KBZ:U/2/4, KBB:V/4 JGB:V/4 bolt bolts s fo forr frame frames s with with pairs pairs of anch anchor or bolt bolts s (see (see JGE:K:T/6, JGC:D:F/6, Appendix G). Reading Appendix Readings s be betwee tween n any two ad adjac jacen entt JGZ:U/6, JGB:V/6, 0.008 0.00 8 (0.2 (0.20) 0) poin points ts must must be withi within n 0.00 0.002 2 in. in. (0.05 (0.05 mm mm). ). For For prope proper r KBB:V:Z:U/6 al align ignmen ment, t, tot total al ac accu cumu mulat lated ed ou outt of plane plane fla flatne tness ss must must a. Underlined frames frames require both both soft foot and top be within within Appen Appendix dix G tolerances. plane flatness checks. NOTE: If the unit will not be restarted
immediately, re-preserve the unit in a manner appropriate to the time duration until restart.
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