Heavy Duty Balanced Opposed Compressors - Ariel Corporation

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FOR MODELS: JGZ AND JGU SECTION 5 - MAINTENANCE 9. See Connecting Rod Installation on page 5-6 for bearing shell installation. If clearance readings are not within tolerance after installing new bearings, contact your packager or <strong>Ariel</strong> before proceeding. Connecting Rod - Removal 1. Before rotating the crankshaft, operate the pre-lube pump to lubricate the bearings. 2. Remove the top covers from the crankcase, the side covers from the crosshead guides and gaskets. 3. Remove the top-cover spacer bars (middle bar of each set of three). Spacer bars are a sliding fit and should be capable of being removed by hand, without falling out or hammering to remove. If too loose or too tight contact your packager or <strong>Ariel</strong> before proceeding. 4. Remove the piston-rod-assembly as described in “Piston and Rod - Removal” on Page 5-36. 5. Manually rotate the crankshaft to position the throw to near the outer dead center position and remove the lock-nut, cap screw, end plates, and crosshead pin from the crosshead. Discard the old lock nut. 6. Remove the crosshead as described in “Crosshead - Removal” on Page 5-9. 7. While supporting the connecting rod so it does not drop and damage the crosshead guide, manually rotate the crankshaft to near to the highest throw position. Loosen the connecting rod-cap’s cap screws and unscrew partially out. The separately purchased hydraulic connecting rod/main bearing-caps cap screw torquing tool (see Figure 7-12 on Page 7-7), is used to loosen the cap bolting. This tool reacts against the opposite diagonal cap screw. Be sure that hydraulic tool is configured for loosening the connecting rod bolting. 8. Using the provided connecting rod cap removal tool (see Figure 7-2 on Page 7- 3), jack against the cap screw heads to pull the bearing cap free from the dowels. Remove the top two connecting rod cap screws and the rod bearing cap. The bottom two cap screws remain in the cap while the cap is being removed. NOTE: DO NOT PRY OR USE A CHISEL TO SEPARATE THE CAP FROM THE CON- NECTING ROD OR DAMAGE WILL RESULT. 9. Half of the bearing shell will come out with the cap. Remove the bearing half shell from the cap by rotating/sliding it out. 10. Carefully support the rod, while manually rotating the crankshaft until the rod can be taken out through the side cover openings in the crosshead guide. Take care to prevent personal injury. Half of the bearing shell will come out with the rod, remove by rotating/sliding it out of the rod. 11. After the removal of the connecting rods, be sure to protect the crank pins from being nicked or scratched. NOTE: ALL CONNECTING RODS MUST BE DETACHED FROM THE CRANKSHAFT AND RETRACTED INTO THE CROSSHEAD GUIDES PRIOR TO REMOVING THE CRANKSHAFT. Connecting Rod Bushing Replacement 1. Check crosshead pin to bushing clearance (see Table 1-4 on Page 1-13 for rec- 7/09 PAGE 5 - 5
FOR MODELS: JGZ AND JGU SECTION 5 - MAINTENANCE ommended clearance.) Wear on the pin can be determined by a visual inspection. Replace the pin if necessary. 2. If a replacement tri-metal (steel, bronze and babbitt with a tin flash) bushing is needed, the existing bushing should be filed or hacksawed to reduce the tightness of the shrink fit. From the inside diameter file or saw across the length of the bushing to within 1/32 inches (1 mm) of its radial thickness. It can then be easily drifted out. Be very careful, not to file or saw into the connecting rod, as any bore damage makes the rod unusable. 3. A hydraulic press in a qualified machine shop (approximately 3 tons (27kN) force required) will be needed to install a new bushing. Do not use a hammer to force the bushing into place as this will distort the bushing's bore. 4. Before installation, the new bushing must be cooled in a 95% alcohol with dry ice solution. The bushing needs to be left in the solution long enough to reach the same temperature as the solution, about -110°F (-80°C). 5. Position the connecting rod on the press table so that the chamfered edge of the rod bushing hole is on top. When applicable, be sure to locate the bushing oil hole at the connecting rod oil passage before installing. No more than 1/3 of the oil passage hole in the rod is to be covered by the bushing after installation. Check the crosshead pin to bushing clearance after replacing a bushing and/or pin, see Table 1-4 on Page 1-13. CAUTION: DO NOT TOUCH COLD SURFACES WITHOUT PROPER INSULATION TO PREVENT INJURY. ALCOHOL IS FLAMMABLE AND SHOULD ONLY BE USED IN OPEN AIR OR A WELL VENTILATED BUILDING. AVOID SPARKS AND OPEN FLAME. AVOID ALCOHOL VAPORS WHICH MAY CAUSE INJURY TO THE TISSUES OF THE NOSE AND EYES. DO NOT RETURN SOLUTION TO A CLOSED CONTAINER UNTIL IT HAS REACHED ROOM TEMPERATURE OR THE CONTAINER MAY EXPLODE. NOTE: ABSOLUTE CLEANLINESS IS REQUIRED OF BOTH THE BUSHING AND THE CONNECTING ROD TO PREVENT DIRT FROM ACCUMULATING BETWEEN THE BUSHING AND CONNECTING ROD. ASSEMBLY MUST BE IMMEDIATE SO THAT BUSHING DOES NOT WARM-UP AND STICK BEFORE IT IS IN PLACE. IF STICKING A NEW BUSHING, REMOVE THE BUSHING BY NOTCH- ING AS IN THE REMOVAL INSTRUCTIONS ABOVE. Connecting Rod - Installation 1. Operate the pre-lube pump to lubricate the main bearings. 2. If installing a new replacement connecting rod, stamp match mark numbers on the tops of the connecting rod and bearing cap, (with notches up), matching its throw location. See Figure 5-4 on Page 5-8. 3. Check new bearing shells to see they are free of handling damage, scratches, burrs, and loose material at the tabs. DO NOT RUB BEARING SURFACE WITH FINGERNAIL. NOTE: MAIN BEARINGS AND CONNECTING ROD BEARINGS ARE NOT FUNCTION- ALLY INTERCHANGEABLE. MAIN BEARINGS HAVE A WIDER GROOVE AND A LARGER OIL HOLE. DO NOT PUT A MAIN BEARING IN A CONNECTING ROD BEARING LOCATION. DO MIX BEARING SHELL PART NUMBERS ON AN INDIVIDUAL MAIN OR CONNECTING ROD. BOTH HALF SHELLS MUST HAVE THE SAME ARIEL PART NUMBER. PAGE 5 - 6 7/09
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Heavy Duty Balanced Opposed Compressors - Ariel Corporation

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