Heavy Duty Balanced Opposed Compressors - Ariel Corporation

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FOR MODELS: JGZ AND JGU SECTION 5 - MAINTENANCE to a decimal dimension is the original minimum bore size. The tolerance is +0.002 to +0.004 inches (+0.05 to +0.10 mm) depending on size. Ariel machines the original cylinder bore concentric and square with the face and pilot diameter that fits the crosshead guide. Do not remove the shoulder location created at the bottom of the counterbores at each end of the main bore. Ethylene Glycol Contamination Ethylene glycol contamination of a compressor can result from water-cooled compressor rod packing or oil cooler leaks. Ethylene glycol anti-freeze coolant mixture leaking into the compressor crankcase oil can cause crankshaft seizure due to lack of adequate lubrication. Crankcase oil should be changed as recommended in Section 6, while being routinely sampled and analyzed by a qualified laboratory to verify suitability for continued use, including checking for ethylene glycol contamination. Even small quantities of ethylene glycol in the oil can be detrimental. If contamination is less than 5 percent, drain oil, replace filters and flush oil system with a 50/50 mixture of butoxyethanol (Dow Chemical Co. Dowanol EB or equal) and 10W oil using a motor driven pump. Flushing should be done on a warm compressor. Bearings should be continuously flushed for 1/2 hour while barring over crankshaft. All surfaces that come in contact with crankcase oil are to be flushed which includes spraying all interior surfaces in the crankcase. Completely drain cleaning mixture, being sure to drain all components of the oil system. Repeat flushing operation using a 60/40 mixture of 10W oil and kerosene or fuel oil. Completely drain system, install new filters and fill crankcase and filters with the proper oil. The coolant leak is to be found and repaired. If sampling indicates that glycol contamination is greater than 5 percent or the compressor has seized due to contamination, the unit is to be torn down, cleaned with 100 percent butoxyethanol, flushed with kerosene or fuel oil and repaired as required. All surfaces that come in contact with the crankcase oil must be cleaned with butoxyethanol, including all passages and piping, and then flushed with kerosene or fuel oil. Oil and filters must be changed. Coolant leak is to be found and repaired. Butoxyethanol presents health and safety hazards. Use proper eye and skin protection and adequate ventilation. Do not use near open flame or sparks. See manufacturer's Material Safety Data Sheet for complete details. Ethylene glycol, butoxyethanol, contaminated oils, and solvents must be properly disposed. A chemical disposal service should be used. 7/09 PAGE 5 - 65
FOR MODELS: JGZ AND JGU SECTION 5 - MAINTENANCE Cleaning, Handling and Thread Lubricants for Non-Lubricated Compressor Cylinders Cleaning and handling are critical to prevent premature wear and failure of non-metallic rings and packings in non-lube compressor cylinders. Proper cleaning, handling and assembly procedures will virtually eliminate oil and anti-seize compounds from the cylinder interior, piston rod assembly, valve and packing case areas. In non-lubricated applications, the non-metallic rings and packings transfer some material to the metallic running surfaces. This transferred film produces a “lubricated” surface that enables the compressor to function properly. If oil is present, the transferred film stability is inhibited and an abrasive paste forms from the film that will very quickly wear non-metallic elements during operation. Anti-seize compounds are oil based and also contain abrasive metallic components that will cause premature component wear. This procedure applies to all non-lube compressor cylinders. Ariel cleans and protects complete non-lube cylinders to non-lube service requirements prior to shipping. Follow the procedure below to clean internal parts shipped loose, contaminated internal surfaces, and spare parts prior to installation. This will extend non-lube compressor component life, and ultimately extend cylinder life. 1. Clean cylinder interior surfaces thoroughly with denatured alcohol until a clean, alcohol soaked, white paper towel or lint-free rag removes no more debris. This includes all surfaces of the bore, counter bore, valve pockets, suction and discharge areas, heads, packing case, valve components, steel gaskets, etc. Handle all cleaned parts with new or clean “rubber” gloves or new white cotton gloves. Do not use anti-seize compounds on the head’s steel-gaskets. Very lightly oil threaded holes and bolt head seating surfaces for valve cap, crank end, head end, and packing case mounting bolts, but prevent oil penetration into the cylinder interior. If the cylinder is an o-ring seal, apply only a very light film of oil to the cylinder seating surface to seal o-ring. CAUTION: 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, mono-goggles or face-mask, and impermeable apron. Contains methyl alcohol; poisonous if ingested. Avoid eye and skin contact. Handle and dispose of materials resulting from clean-up in a proper manner. See manufacturer Material Safety Data Sheets for more details. 2. Thoroughly clean piston, collar, rod, and nut with denatured alcohol until a clean, alcohol soaked paper towel or lint-free rag removes no more debris. Clean piston ring grooves especially well. Clean piston rings with denatured alcohol before assembling. 3. Use very small amounts of Never-Seez, Regular Grade on the nut and collar when assembling piston to rod. Do not lube threads for the piston rod tensioner. Use very small amounts of Never-Seez, Regular Grade on piston nut set screws. After assembly, thoroughly wipe off all Never-Seez from piston rod assembly exterior in the collar and nut areas with denatured alcohol until a clean, alcohol soaked, white paper towel or lint-free rag removes no more debris. 4. Disassemble the packing case. Clean all the surfaces with denatured alcohol. Reassemble. For water-cooled packing cases, test to Ariel Engineering Reference ER-51. Contact Ariel for latest version of ER-51. 5. Before installing the piston rod assembly into the cylinder, wipe with denatured alcohol. Leave no fingerprints on the rod before it contacts the packing case/rings. PAGE 5 - 66 7/09
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Heavy Duty Balanced Opposed Compressors - Ariel Corporation

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