Heavy Duty Balanced Opposed Compressors - Ariel Corporation

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FOR MODELS: JGZ AND JGU TABLE OF CONTENTS Checking/Adjusting Balance Valves on Subsequent Start-up .........................4-51 Frame Lubricating System - Description ...............................................................4-52 Lube Oil Strainer, Filter & Filter Installation Instructions .......................................4-52 Lube Oil Strainer ..............................................................................................4-52 Lube Oil Filter ..................................................................................................4-52 Oil Filter Installation for Spin-On Type Filters ..................................................4-53 Oil Filter Element Installation for Cartridge Type Filters ..................................4-53 Lube Oil Pump & Lube Oil Pressure .....................................................................4-55 Description & Adjustment ................................................................................4-55 Lube Oil Pressure Regulating Valve ................................................................4-55 Low Oil Pressure Shutdown ..................................................................................4-56 Maintenance .......................................................................................... 5-1 General Introduction ...............................................................................................5-1 Positioning a Throw for Maintenance ......................................................................5-2 Connecting Rod ......................................................................................................5-2 Checking Connecting Rod (Crank Pin) Bearing Clearances .............................5-3 Connecting Rod - Removal ...............................................................................5-5 Connecting Rod Bushing Replacement .............................................................5-5 Connecting Rod - Installation ............................................................................5-6 Crosshead ...............................................................................................................5-9 Crosshead - Removal ........................................................................................5-9 Crosshead - Installation ...................................................................................5-12 BICERA Type Crankcase Over-Pressure Relief Valves .......................................5-16 Crankshaft .............................................................................................................5-17 Checking Main Bearing Clearances ................................................................5-17 Crankshaft - Removal ......................................................................................5-19 Crankshaft - Oil Slinger ...................................................................................5-21 Crankshaft - Chain Sprockets ..........................................................................5-22 Main Bearings - Removal/Installation w/Crankshaft Removed ........................5-23 Main Bearings - Removal/Installation w/Crankshaft In Place ..........................5-23 Crankshaft - Installation ...................................................................................5-26 Torsional Vibration Detuners - Installation on Crankshaft .....................................5-27 Chain Drive System ..............................................................................................5-29 Description .......................................................................................................5-29 Chain Adjustment ............................................................................................5-31 Chain and Sprocket Replacement ...................................................................5-32 Chain Idler Sprockets Replacement - (Eccentric Adjustment Caps) ...............5-33 Lube Oil Pump Chain Sprocket Replacement .................................................5-33 Force Feed Lubricator Chain Sprocket Replacement .....................................5-34 Piston and Rod - Removal ....................................................................................5-36 Piston and Rod - Disassembly and Reassembly ..................................................5-37 Piston and Rod - Disassembly ........................................................................5-37 Piston and Rod - Reassembly .........................................................................5-37 Piston and Rod - Installation .................................................................................5-40 Piston Rod Run Out ..............................................................................................5-40 Piston Rings ..........................................................................................................5-42 Determining Ring Wear: ..................................................................................5-42 iv 7/09
FOR MODELS: JGZ AND JGU TABLE OF CONTENTS Removal: ......................................................................................................... 5-42 Wear Bands .......................................................................................................... 5-42 Determining Wear Band Wear: ....................................................................... 5-42 Piston Rings - Installation ..................................................................................... 5-43 Special Purpose Piston Rings - High Pressure Face-Cut ............................... 5-43 Wear Band - Installation ....................................................................................... 5-43 Piston Rod Pressure Packing - Removal & Disassembly ..................................... 5-43 Piston Rod Packing - Reassembly ....................................................................... 5-44 Types of Piston Rod Packing Rings ..................................................................... 5-46 Type "P" Pressure Breaker ............................................................................. 5-46 Type "UP" Pressure Breaker ........................................................................... 5-47 Type “P1U” Pressure Breaker ......................................................................... 5-47 Type "BTR" Single Acting Seal Set ................................................................. 5-47 Type "BD" Double Acting Seal Set .................................................................. 5-48 Type "WAT" Double Acting Seal Set ............................................................... 5-48 Type “AL” Double Acting Seal Set .................................................................. 5-49 Type “BTU” Single Acting Seal Set ................................................................. 5-49 Type BTUU Single Acting Seal Set ................................................................. 5-50 Type “CU” Single Acting Seal Set ................................................................... 5-50 Type “CUU” Single Acting Seal Set ................................................................ 5-51 Type “STU” Single Acting Seal Set ................................................................. 5-52 Type “CR” Single Acting Seal Set ................................................................... 5-52 Type "3RWS" Oil Wiper Set ............................................................................ 5-52 Type “RTV” Oil Wiper Set ............................................................................... 5-53 Arrangement of Piston Rod Packing Rings .......................................................... 5-54 Piston Rod Packing Ring Material ........................................................................ 5-54 Water-Cooled Piston Rod Packing ....................................................................... 5-54 Water-Cooled Piston Rod Packing - Re-assembly ......................................... 5-54 Water-Cooled Piston Rod Packing - Testing ................................................... 5-55 Valves ................................................................................................................... 5-56 Valves - Removal ............................................................................................ 5-56 Valves - Maintenance ...................................................................................... 5-57 Valves - Reassembly ...................................................................................... 5-57 Tightening Valve Cap Bolting ............................................................................... 5-59 VVCP - Head-End Variable Volume Clearance Pocket ........................................ 5-61 VVCP - Removal ............................................................................................. 5-61 VVCP - Disassembly ....................................................................................... 5-62 VVCP - Maintenance ....................................................................................... 5-62 VVCP - Adjustment ......................................................................................... 5-62 Compressor Cylinder Re-Boring and Bore Reconditioning Guidelines ................ 5-63 Ethylene Glycol Contamination ............................................................................ 5-65 Cleaning, Handling & Thread Lubricants for Non-Lubricated Compr Cylinders ... 5-66 BEARING LOG FORM/CONDITIONS AFTER REPLACING BEARINGS ........... 5-68 Maintenance Intervals & Trouble Shooting ........................................ 6-1 Recommended Maintenance Intervals ................................................................... 6-1 Daily .................................................................................................................. 6-1 Monthly (in addition to Daily Requirements) ..................................................... 6-2 7/09 v
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Heavy Duty Balanced Opposed Compressors - Ariel Corporation

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