JGH-JGE-JGK-JGT-EN

Maintenance and Repair Manual For JGH:E:K:T Heavy Duty Balanced Opposed Reciprocating Compressors

ARIEL CORPORATION CORPORATION 35 BLAC BLACKJ KJAC ACK K ROAD, OAD, MOUN MOUNT VERN VERNON ON,, OHIO OHIO 4305 43050 0 TELEP TELEPHON HONE: E: 740-397 740-397-031 -0311 1 • FAX: FAX: 740-397 740-397-385 -3856 6 VISIT VISIT OUR WEB SITE: SITE: www.a www.arie rielc lcorp orp.com .com REV: 3/17 3/17

REVISION HISTORY Rev. 12/16 201601090 - 12-9-16: APPENDIX A - Fastener Torques (ER-96.2.4) - Page Page 4, "Crosshe "Crosshead ad Guidet Guidet o Suppor Support", t", Type: "Hex "Hex - Grade Grade 9 12 Point Point - Grade Grade 8"WAS"Hex 8"WAS"Hex - Grad Grade e 8 or9". Added Revision History Page. Rev. 12/16A 12-14-16: Section 4, "Piston and Rod Reassembly with Hydraulic Tool", #10: deleted deleted "erify "erify piston nut has turned turned a minimum minimum of 95° to achieve achieve properpre-lo properpre-load." ad." This is a portionof portionof a sentence sentence that belong belongs s only in the KBB:V KBB:V manual. manual. It mistakenly mistakenly appeare appeared d because because of a progra programmingerror. mmingerror. Rev. 3/17 201601385 - 2-8-17: SECTION 4- Valves (ER-96.5.2.2) - "Valve "Valve Installation" Installation",, #3: Moved Moved "Do not repl replace ace plastic plastic thumbscrews thumbscrews withmetal." to #4. "Valve "Valve Cap Installation" Installation",, 1st ¶, last sentence: sentence: "roundmetallic "roundmetallic gasket"WAS "roundgasket". "roundgasket". "Valve "Valve Caps with SpringEnerg SpringEnergizedSeals" izedSeals":: #1 - added added "Verify "Verify valve retaineropeni retaineropenings ngs arealigned arealigned with the cylinder cylinder gas passage. passage. Re-tightent Re-tightent humb screws, if applicab applicable."; le."; #3 - "so the roll roll pins pins engagethe engagethe clearan clearance ce slots in the sealk eeper." eeper." WAS". Alignvalve Alignvalve cap roll roll pins pins so they areparallelwith areparallelwith the mainbore of the cylinder. cylinder. This aligns aligns the retaineropeni retaineropenings ngs with the cylinder cylinder gas passage passage."; ."; deleted deleted "Tightent "Tightent humbscrews, if applicab applicable."; le."; #5 - deleted deleted.. 201600756 - 2-8-17: SECTION 3- Maintenance (ER-8.2) - Page Page 1: added added "Continu "Continuous ous Duty: The compressor compressor operates operates continuou continuously, sly, 24 hours hours a day, shuttingdown only only f or short durations, durations, usually usually for maintena maintenance nce andunexpected andunexpected shut-downs. shut-downs. Short-Term Short-Term Intermittent Intermittent Duty: The compressor compressor operates operates for short short duration durations, s, startingand stopping stopping perhap perhaps s s everal everal times per month/week/day, month/week/day, such as in many CNGf illingst illingst ationapplicatio ationapplications. ns. Long-Te Long-Term rm Intermittent Duty: The compressor compressor operates operates continuou continuously sly for extended extended duration durations, s, with extended extended shut-down shut-down period periods, s, such as in some storage/withdrawal applications applications and fuel gas booster applications." applications." One-Year One-Year Maintenance, #11, 4th bullet: bullet: added added ":C:D :F". 201700208 - 3-15-17: APPENDIX B- Clearances (ER-96.3.4) - Table Table 1: Title- "Frame "Frame andRunning andRunning Gear" Gear" was "MainCompone "MainComponent"; nt"; "Cran "Crankshaft kshaft Dust Seal Seal JGH:E:K:T/2/4 JGH:E:K:T/2/4 (FeelerGauge(FeelerGauge- Centered Centered)" )" was "Cranksha "Crankshaft ft Dust Seal Seal JGH:E:K:T/2/4"; JGH:E:K:T/2/4"; "Crankshaft "Crankshaft Dust Seal JGE:K:T/6 JGE:K:T/6 (Feeler (Feeler GaugeGaugeCentered)" was "Crankshaft "Crankshaft Dust Seal Seal JGE:K:T/6"; "Crankshaft "Crankshaft Thrust JGH:E:K:T/2/4 (End)" (End)" was "Crankshaft "Crankshaft Thrust JGH:E:K:T/ 2/4"; "Crankshaft "Crankshaft Thrust Thrust JGE:K:T/6 JGE:K:T/6 (End)"was (End)"was "Cranksha "Crankshaft ft Thrust Thrust JGE:K:T/6";"Cra JGE:K:T/6";"Cranksha nkshaft ft JournalBeari JournalBearing ng (Jack)"was "Cranksha "Crankshaft ft JournalBeari JournalBearing ng Jack"; "Connectin "Connecting g Rod Bearin Bearing g (Jack)"was "Conne "Connecting cting Rod BearingJack"; BearingJack"; "Connectin "Connecting g Rod Thrust Thrust (Side) (Side)"" was "Connecting "Connecting Rod Thrust"; Thrust"; "Crosshea "Crosshead d (Babbi (Babbitted tted Gray Gray andDuctile Iron)t o Guide(Feele Guide(Feelerr Gauge Gauge)" )" was "Crosshe "Crosshead ad to Guidet Guidet o BabbittedGray BabbittedGray and and DuctileI ron"; ron"; "Crosshead(Bab "Crosshead(Babbitted bitted ADI Iron)t o Guide(Feele Guide(Feelerr Gauge Gauge)" )" was "Crosshe "Crosshead ad to GuideGuide- BabbittedADI BabbittedADI Iron"; "Crosshe "Crosshead ad (Babbi (Babbitted tted Bronze)t Bronze)t o Guide(Feele Guide(Feelerr Gauge Gauge)" )" was "Crosshea "Crosshead d to GuideGuide- BabbittedBronze BabbittedBronze". ". Existing Existing tabledeletion: tabledeletion: Table3 "JGH:E:K:T "JGH:E:K:T Side Clearan Clearances ces f or New Piston/PackingRings Piston/PackingRings & Wearban Wearbands, ds, in. (mm)". New tableadditions (subsequent (subsequent tables re-numbere re-numbered d accordingly): accordingly): Table 3 "New Uncut Uncut Packing Ring Side Clearance, Clearance, in. (mm), (BTUU/CUU/BTU/CU/STU)"; (BTUU/CUU/BTU/CU/S TU)"; Table4 "New PressureBreake PressureBreakerr andSegmented andSegmented Packing Packing RingSide Clearan Clearance, ce, in. (mm), (BTR/CR/BD/BT/TR/P/UP/P1U) (BTR/CR/BD/BT/TR/P/UP/P1U)"; "; Table 5 "New "New Wiper RingSide Clearan Clearance, ce, in. (mm)"; Table Table 6 "Piston/Rid "Piston/Rider er RingSideClearance, RingSideClearance, in. (mm)"; Table Table 7 "Piston "Piston RingSideClearances, RingSideClearances, in. (mm)"; Table8 "Wearba "Wearband nd Side Side Clearan Clearances, ces, in. (mm)". Table Table 8 (was Table Table 4): Title: "and" "and" was "&"; "&"; Headings: Headings: "Pistont o Bore Bore Diametral Diametral Clearan Clearance" ce" was "Piston "Piston to Bore Bore Clearan Clearance"; ce"; "New Piston/Rid Piston/Rider er Ring EndGapb" EndGapb" was "Piston/Rid "Piston/Rider er RingEnd Gapb" Gapb".. Table 9 (was Table Table 5): Title: "and" "and" was "&"; "&"; Headings: Headings: "Diametral "Diametral Clearance" Clearance" was "Clearance" "Clearance";; "PISTON RING END GAP GAP (PTFE)b" was "PISTON "PISTON RING END GAPS GAPS (Filled (Filled Teflon)b" Teflon)b";; "WEAR BAND - NEW"was "WEAR "WEAR BANDS - NEW"; NEW"; "Minimum "Minimum EndGap"was "Min. "Min. EndGap". EndGap".

For models models JG JGH:E:K: H:E:K:T T

Table of Contents General Sa S afety for Reciprocating Compressors

vi

Throw and Data Plate Locations

vii

Other Ariel Resources

viii

Ariel Ariel Website Ariel Ariel Technical and and Service Schools Schools Ariel Ariel Contact Information Information

viii viii viii

SECTION 1- TOOLS

Ariel Optional Furnished Tools

1-1

Ariel Separately Purchased Tools

1-2

Ariel Separately Purchased Tool Kits

1-2

Recommended Tools

1-3

SECTION 2- INSTRUMENTATION

Notes

2-3

Digital No-Flow Timer (DNFT)

2-4

DNFT Installation Programmable DNFTs DNFT Battery Replacement Troubleshooting DNFT’s

Proximity Switch A-18255 Proximity Switch Installation Troubleshooting Proximity Switches

Main Bearing Temperature Alarms and Shutdown Thermocouples - J (Iron-Constantan) or or K (Chromel-Alumel) Resistance Temperature Devices (RTD’s)

2-4 2-7 2-8 2-9

2-10 2-10 2-12

2-13 2-13 2-13

SECTION SECTION 3- MAINTENANCE

Initial Maintenance Daily Maintenance Monthly Maintenance Six-Month (4,000-Hour) Maintenance One-Year (8,000-Hour) Maintenance Two-Year (16,000-Hour) Maintenance Three-Year (24,000-Hour) Maintenance Four-Year (32,000-Hour) Maintenance Six-Year (48,000-Hour) Maintenance

Frame Oil Viscosity Oil Pressure Oil Temperature Oil Maintenance Dry Sump Oil System Cleanliness

Frame Oil System Components REV: 3/17

3-2 3-3 3-4 3-4 3-5 3-6 3-6 3-6 3-7

3-7 3-7 3-7 3-9 3-9 3-9 3-9

3-11 i

For models JGH:E:K:T

Oil Strainer Oil Pump & Regulating Valve Oil Cooler Oil Temperature Control Valve Oil Filter Simplex Spin-on Filter Replacement Simplex Filter Cartridge Replacement Duplex Filter Cartridge Replacement Compressor Pre-lube System

3-13 3-13 3-13 3-14 3-14 3-14 3-15 3-16 3-16

Flushing to Change to a PAG Lubricant

3-17

Recommended Flushing Oil Flushing Procedure Flushing the Force Feed Lubrication System Common Oil Supply Independent Oil Supply

3-17 3-17 3-18 3-18 3-19

Cylinder and Packing Lubrication

3-20

Force Feed Lubricator Priming the Pump Pump Adjustment Auto-Relief Valve (ARV) ARV Operation Force Feed Lube Blow-Out Fittings, Rupture D isks, and Tubing Distribution Blocks Distribution Block Assembly Divider Valve Bypass Pressure Test Balance Valves Adjustment of Balance Valves Fed by a Divider Block Adjustment of Balance Valves Fed by Primary/Secondary Divider Blocks

3-20 3-20 3-21 3-21 3-22 3-23 3-24 3-24 3-25 3-26 3-27 3-28

Force Feed System Design, Operating Parameters, and Conditions

3-28

Common Oil Supply Independent Oil Supply

3-29 3-30

Force Feed Lubrication Conditions

3-30

Cycle Time Under/Over Lube Cylinder Lubrication Paper Test

3-30 3-31 3-31

Coolant System Requirements

3-32

SECTION 4- PART REPLACEMENT

Positioning a Throw

4-1

Variable Volume Clearance Pocket (VVCP)

4-2

VVCP Removal VVCP Disassembly VVCP Reassembly VVCP Installation VVCP Adjustment

4-2 4-3 4-4 4-5 4-6

Compressor Valves - Removal and Installation

4-6

Required Tools and Materials Valve Cap Removal Valve Caps on Cast Iron Cylinders or High-Pressure Caps without Spring Energized Seals Valve Cap with Spring Energized Seal ii

4-6 4-7 4-7 4-8

REV: 3/17


Valve Removal Valve Installation Valve Cap Installation Torque Valve Caps on Cast Iron Cylinders or High-Pressure Caps without Spring Energized Seals Valve Caps with Spring Energized Seals Gas Containment Fastener Torque Checks

Piston and Rod Piston and Rod Removal Piston and Rod Manual Disassembly and Reassembly Piston and Rod Manual Disassembly Piston and Rod Manual Reassembly Hydraulic Tensioner Tools Hydraulic Tensioner Tool Repair Kits Piston and Rod Disassembly with Hydraulic Tensioner Tool Piston and Rod Reassembly with Hydraulic Tool Piston and Rod Installation Piston Rod Runout

Piston Rings Seal-Joint Piston Rings High-Pressure Face-Cut Piston Rings Three-Piece Piston Rings Wear Bands

Piston Rod Packing Piston Rod Packing Removal Piston Rod Packing Reassembly Reassembling and Testing Cooled Packing Cases Reassembly Testing 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” Double-Acting Seal Set Double "WAT"Double-Acting Seal Set “AL” Double-Acting Seal Set “BT” Single-Acting Seal Set “BTUU” Single-Acting Seal Set “CU” Single-Acting Seal Set “CUU” Single-Acting Seal Set “STU” Single-Acting Seal Set “CR” Single-Acting Seal Set “3RWS” Oil Wiper Set

Crossheads Crosshead Removal Crosshead Installation

Connecting Rods Connecting Rod Removal Connecting Rod Bearing Removal Connecting Rod Bearing Installation REV: 3/17

4-8 4-9 4-9 4-10 4-10 4-11 4-11

4-11 4-12 4-12 4-12 4-13 4-14 4-15 4-15 4-16 4-17 4-19

4-20 4-20 4-21 4-22 4-22

4-22 4-22 4-23 4-24 4-25 4-25 4-25 4-26 4-26 4-26 4-26 4-27 4-27 4-27 4-27 4-28 4-28 4-28 4-28 4-29 4-29 4-29

4-30 4-30 4-31

4-33 4-33 4-34 4-35 iii


Connecting Rod Bushing Removal and Installation Connecting Rod Installation Connecting R od Bearing Vertical Jack Clearance Measurement Connecting Rod Thrust (Side) Clearance Measurement

4-36 4-37 4-38 4-38

Crankshaft

4-39

Oil Slinger Replacement Main Bearing Removal Main Bearing Installation Crankshaft Removal Crankshaft Installation Main Bearing Vertical Jack Clearance Measurement Crankshaft Thrust (End) Clearance Measurement

4-39 4-40 4-40 4-41 4-42 4-42 4-43

Chain Drive System

4-44

Chain and Sprocket Replacement

4-45

Chain I dler S procket Replacement (Eccentric Adjustment Caps) Lube Oil Pump Sprocket Replacement Force Feed Lubricator Chain Sprocket Replacement Crankshaft Chain Sprocket Replacement Chain Adjustment

4-45 4-46 4-47 4-47 4-48

Component Cleaning & Thread Lube for Non-Lube Compressor Cylinders

4-49

SECTION 5- START UP

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 Warranty Notification - Installation List Data

5-1 5-1

SECTION 6- COMPRESSOR TROUBLESHOOTING APPENDIX A - ARIEL FASTENERS AND TORQUES

Recommendations for Torque Accuracy

A-2

APPENDIX B - CLEARANCES

Measuring Head End Clearance for Forged Steel Tandem Cylinders with Concentric Valves B-8 APPENDIX C - FRAME SPECIFICATIONS

Opposed Throw - Reciprocating Weight Balancing

C-5

APPENDIX D - COMPRESSOR CLEARANCE, OIL, & TEMPERATURE RECORD APPENDIX E - BALANCE VALVE LOG APPENDIX F - ER-34.1

Cleaning, Handling, and Assembly Lubricants for Non-Lubricated Compressor Cylinders

F-1

APPENDIX G - ER-26

Hold-down Bolting to Resist Shaking Forces and Couples Requirements

iv

G-1 G-1

REV: 3/17


APPENDIX H - ER-82

Soft Foot and Top Plane Flatness Checks for Proper Main Bearing Bore Alignment in Reciprocating Compressors H-1 Soft Foot Check Top Plane Flatness Check

REV: 3/17

H-1 H-1

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 and shut-down information for both package and compressor. DO NOT attempt to start-up compressor without referring to the Start-Up Checklist in the appropriate Ariel Maintenance and Repair Manual and the Packager’s Operating Manual. • Sufficiently purge the compressor of any explosive mixture before loading. A gas/air mixture under pressure can explode and cause severe injury or death! • Follow in detail all start-up requirements for the other package 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. CAUTION: For JGT compressors with ET class cylinders, do not remove the pin from the crosshead guide to compressor cylinder mounting face. It is there to prevent installation of misapplied cylinders and avoid personal injury.

vi

REV: 3/17


Throw and Data Plate Locations When contacting Ariel with compressor questions, know throw locations and information on data plates fastened to the machine. This data helps Ariel representatives answer quickly and accurately. Contact Ariel for replacement if any data plates are missing.

1. VVCP Dimension Plate 2. VVCP Data Plate 3. Mechanical Inspector Plate and Frame Serial Number Stamp 4. Compressor Drive End

5. Rotation Direction Plate 6. Cylinder Data Plate 7. VVCP Serial Number, MAWP, and Hydrotest Stamp 8. Cylinder Serial Number, MAWP, and Hydrotest Stamp

9. Compressor Data Plate 10. Force Feed Lubricator Data Plate 11. Compressor Auxiliary End 12. Oil Filter Change Instruction Plate

FIGURE i-1 Separable Guide Compressor Throw and Data Plate Locations - Typical REV: 3/17

vii


Other Ariel Resources Ariel Website Visit www.arielcorp.com to view and print the latest documentation, such as: • Customer Technical Bulletins (CTB’s) provide important information on changes, corrections, or additions to Ariel products or services. Read these bulletins before operating or servicing equipment. • Engineering References (ER’s) provide standard procedures and other useful information for operation, maintenance, or repair of Ariel compressors or components. Read and follow these procedures for long and trouble-free service from your Ariel compressor. • Maintenance and Repair Manuals provide detailed maintenance and repair information on specific Ariel compressor models. • Packager Standards provide detailed requirements and recommendations on the installation of an Ariel compressor. • Application Manual provides detailed information on the use of Ariel compressors in different applications.

Ariel Technical and Service Schools Ariel schedules several in-plant schools each year, which include classroom and hands-on training. Ariel also sends representatives to provide customized training on location. Contact Ariel for details.

Ariel Contact Information Contact

Telephone

Fax

E-Mail

Ariel Response Center

888-397-7766 (toll free USA & Canada) or 740-397-3602 (International)

740-397-1060

[email protected]

740-393-5054

[email protected]

740-397-3856

--

740-397-0311

740-397-3856

Spare Parts Order Entry Ariel World HQ Technical Services

[email protected] [email protected]

Website: www.arielcorp.com

Ariel Response Center Technicians or Switchboard Operators answer telephones during Ariel business hours, Eastern Time - USA or after hours by voice mail. Contact an authorized distributor to purchase Ariel parts. Always provide Ariel equipment serial number(s) to order spare parts. The after-hours Telephone Emergency System works as follows: 1. Follow automated instructions to Technical Services Emergency Assistance or Spare Parts Emergency Service. Calls are answered by voice mail. 2. Leave a message: caller name and telephone number, serial number of equipment in question (frame, cylinder, unloader), and a brief description of the emergency. 3. Your voice mail routes to an on-call representative who responds as soon as possible.

viii

REV: 3/17

Section 1 - Tools Ariel Optional Furnished Tools Ariel offers an optional tool kit with every compressor. For JGH:E:K:T compressors, it contains the tools shown below, which are specifically designed for use on Ariel units. Clean all tools before use and verify full tool engagement with the part being removed or installed. If the Tool Kit is missing or if a single tool is missing, worn, or broken, call your distributor. Do not use worn or broken tools, or substitutes for Ariel furnished tools. See Parts List for individual tool part numbers.

1. 2. 3. 4.

Tool Box Peg Wrench Main Bearing Removal Tool 9/16 Socket Piston Turning Tool (included only for compressors with small cylinders) 5. 4-Inch Open End Wrench (included only for compressors with hex crosshead balance nuts) 6. Piston Nut Spanner 7. Ariel Bore & Thread Gauge 8. Connecting Rod Bolt 90° Turn Indicator Tool 9. Connecting Rod Cap Removal Tool 10. Piston Entering Sleeve (included only for compressors with forged steel, tail-rod cylinders with step to bore)

11. Crosshead Pin Alignment Tool 12. Forged 5/8 - 11 UNC Eyebolts (2 provided) 13. Forged 1/2 - 13 UNC Eyebolts (2 provided) 14. Forged 3/8 - 16 UNC Eyebolts (6 provided) 15. Cylinder Bolt Torque Adapter 16. Valve Removal Tool (included only for compressors with forged steel cylinders - tool size and style varies with cylinder size and valve center connection) 17. Piston Rod Entering Sleeve

18. 5/8 x 3/4 UNF Valve Tool 19. 5/16 x 1/2 UNF Valve Tool 20. 1/4 x 3/8 UNF Valve Tool 21. 3/4 x 1" UNC Valve Tool (for CT valves) 22. 3/4 Allen Wrench (1 provided) 23. 1/2 Allen Wrench (2 provided) 24. 3/8 Allen Wrench (1 provided) 25. 3/16 Allen Wrench (5 provided) 26. 5/32 Allen Wrench (5 provided) 27. Crosshead Installation Tool 28. ER-63 Fastener Torque Chart (not shown)

FIGURE 1-1 Optional Furnished Tools for JGH:E:K:T Compressors REV: 3/17

Page 1-1 of 3

Section 1 - Tools


Ariel Separately Purchased Tools

1. Hand Pump for hydraulic crosshead balance nut torquing tool and piston 4. Piston Rod Clamping Fixture 5. Force Feed Lubricator Bearing rod tensioning tool (includes hand pump, hose, coupler, and gauge) Housing Wrench 2. Hydraulic Crosshead Balance Nut Torquing Tool (includes tool and ram) 6. Force Feed Lubrication Hand 3. Hydraulic Piston Rod Tensioning Tool Purge Pump

FIGURE 1-2 Ariel Separately Purchased Tools for JGH:E:K:T Compressors

Ariel Separately Purchased Tool Kits 1. Ariel SAE Hand Measurement Tool Kit a. 0.0005 in. needle type dial indicator b. 0.001 in. 1-inch travel dial indicator c. Magnet base for dial indicator d. 3/8” drive calibrated torque wrench, 40 to 200 in x lbs e. 3/8” drive calibrated torque wrench, 10 to 100 ft x lbs f. 1/2” drive calibrated torque wrench, 50 to 250 ft x lbs g. 3/4” drive calibrated torque wrench, 120 to 600 ft x lbs h. 1” drive calibrated torque wrench, 200 to 1000 ft x lbs 2. Ariel SAE Hand Tool Kit a. 15-piece combination open/box end wrench set, 5/16” through 1-1/4” b. 8-piece slot and Phillips screwdriver set c. 3/8" square drive wrench set, including: Page 1-2 of 3

REV: 3/17

For models JGH:E:K:T • 12-piece, 12-point socket set, 5/16” through 1”

Section 1 - Tools

• Ball type universal joint

• 7” ratchet

• 3/8” to 1/2" drive adapter

• Speed handle

• 1/4” hex key socket

• Extensions, 1-1/2”, 3”, 6”, and 12”

• 8-1/2” breaker bar

d. 1/2" square drive wrench set, including: • 14-piece, 12-point socket set, 7/16” through 1-1/4” with clip rail

• 10-1/4” ratchet

• Extensions, 1-1/2”, 5”, and 10".

• Ball type universal joint

• Drive adapters: 1/2” to 3/8" and 1/2” to 3/4"

• 18” breaker bar

• 1-1/4” open end crow’s foot adapter

• 1/2” and 5/8” hex key sockets

• Speed handle

e. 3/4" square drive wrench set, including: • 18-piece, 12-point socket set, 3/4” through 2”

• 24” ratchet

• Extensions, 3-1/2”, 8”, and 16”

• 22” breaker bar

• Drive adapters: 3/4” to 1/2", 3/4” to 1", and 1” to 3/4" f. 1" square drive wrench set, including: • 14-piece, 12-point socket set, 1-7/16” through 2-5/8” • 30” ratchet • Extensions: 8” and 17” • 22” sliding T g. Adjustable wrenches: 12" and 18" h. Dead blow semi-soft faced hammers: 3 lb. and 6 lb i. 3/4” x 36” pry bar j. 12” long feeler gage set k. 12” machinist scale with 0.01 in. increments l. 13-piece Allen wrench set, 0.050 in. - 3/8”

Recommended Tools Ariel compressor maintenance and repair normally requires only Ariel furnished tools and separately purchased tools and tool kits. However, Ariel also recommends purchasing the additional tools below. Contact Ariel for questions about tools for Ariel units. 1. 12-point box end torque adapter extension wrench set, including 1-1/2 and 2-1/4 inch sizes 2. Tape measure 3. Flashlight 4. Small mirror on a flexible extension rod 5. Small magnet on a flexible extension rod 6. Electric and/or pneumatic drill 7. Twist drill set 8. Torque multiplier REV: 3/17

Page 1-3 of 3

Section 2 - Instrumentation Several optional instruments can aid in the operation of an Ariel compressor. Through the data they provide, some instruments can help decrease maintenance costs and downtime, and help diagnose lubrication and other types of problems. The use of “alarm” instead of “shutdown” for any minimum instrumentation requirement may result in equipment 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. CAUTION: Any arc welding on the skid and/or associated equipment and piping can permanently 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.

REV: 3/17

Page 2-1 of 13

Section 2 - Instrumentation


TABLE 2-1 Required Instrumentation Summary INSTRUMENT

SUPPLIER

SETTING/REQUIREMENT

Frame Oil System (see Section 3) Oil Pressure

Packager

• Start Permissive with Prelube Pump

30 psig (2.1 barg) for 2 minutes

• Run Permissive

45 psig (3.1 barg) within 10 seconds of start

• Alarm

• Shutdown

50 psig (3.4 barg)

Oil Filter Differential

45 psig (3.1 barg)

Ariel

• JG:A:M:P:N:Q:R:J:H: E: K:T & JGC:D:F/2

Change at 10 psi (0.7 bar) or 4000 hours, whichever occurs first

• JGC:D:F/4/6 & KBB:V:Z:U

Change at 15 psi (1.0 bar) or 4000 hours, whichever occurs first

Oil Temperature

Packager

• Minimum, start up

See“Viscosity” on page 3-7 for max. oil viscosity based on frame size.

• Minimum, to load

See“Viscosity” on page 3-7 for max. oil viscosity based on frame size.

• Minimum, operating

150°F (66°C)

• Maximum, shutdown

190°F (88°C)

Crankcase Level

Packager

1/2 to 2/3 sight glass level

• Low Level Shutdown Main Bearing Temp.

1/4 sight glass level

Thrust Bearing Temp.

Ariel

(Standard on B:V:Z:U. Recommended, but optional on JG:A:R:J:H:E:K:T:C:D:F)

Ariel

(Standard on B:V)

• Alarm

+20°F (11°C) above normal not to exceed 220°F (104°C)

• Shutdown

+30°F (17°C) above normal not to exceed 230°F (110°C)

• Differential Alarm

• Differential Shutdown

20°F (11°C)

Packing Case Temp.

Ariel

30°F (17°C) (Optional)

• Alarm

+20°F (11°C) above normal

• Shutdown

+30°F (17°C) above normal

Packing Case Vent

Packager

• Vent Flow Alarm

(Optional)

• Vent Flow Shutdown

2 - 4 scfm (per throw) > 4 scfm (per throw)

Scrubber Liquid Level Packager • High Liquid Level Control • High Liquid Level Shutdown Gas Conditions

Packager

• Inlet Temperature Indicator, each cylinder • Inlet Pressure Indicator, each stage • Discharge Pressure Indicator, each stage • Discharge Temperature Indicator, each cylinder, each nozzle on dual nozzle cylinders Page 2-2 of 13

REV: 3/17

For models JGH:E:K:T INSTRUMENT

SUPPLIER

SETTING/REQUIREMENT

• High Discharge Temperature Shutdown, each cylinder • Lubricated Cylinders


10% above normala (Not to exceed themaximumtemperaturesbelow)

350°F (177°C)

• Non-Lube/PRC Cylinders

325°F (163°C)

• Hydrogen Rich > 50% < 0.41 Specific Gravity

• Air

Not to exceed autoignition temperature of cylinder lubricant at discharge pressure

300°F (149°C)

Up to 150: • Relief Valve Setting above normal operating pressure (not to exceed MAWP)

15 psig (1.0 barg)

to 2500: 10%

to 3500: 8% to 5000: 6%

Over 5000: As agreed

See ER-56.04. Cylinder Rod Load Protection High Vibration Shutdown Over Speed

Packager Packager

As close to normal level as practical. See "Vibration Protection" in ER-56.07.

Packager

10% over rated speed for shutdown

a. Example: Normal Discharge Temp. = 270°F; Shutdown Setting = 270 x 1.1 = 297°F.

Notes 1. Install the compressor frame low lube oil pressure shutdown set to stop the unit if oil pressure downstream of the filter falls below 45 psig (3.1 barg). Compressor operation for only a few seconds without oil pressure causes major damage. Normal oil pressure is about 60 psig (4.1 barg) at full rated speed and normal operating temperature. The low oil pressure shutdown must activate after oil pressure exceeds 45 psig (3.1 barg) at start-up. Ariel provides a 1/4 inch tubing fitting to connect the low lube oil pressure shutdown and ties a tag to this connection before each compressor ships. Do not operate the compressor for prolonged periods at less than 50 psig (3.4 barg) oil pressure. 2. Automated pre-lube systems require a start permissive to sense minimum required pressure/time at oil gallery inlet. See “Compressor Pre-lube System” on page 3-16. Unit must shut down if the system fails to achieve 45 psig (3.1 barg) oil pressure within 10 seconds after crankshaft starts to turn. 3. Mount overhead lube oil supply tanks high enough to provide oil flow to the level control at all ambient temperatures. 4. On multi-nozzle cylinders, Ariel strongly recommends a temperature device in both discharge nozzles. 5. Install the high lube oil inlet temperature shutdown at the filter inlet connection. 6. At a minimum, install one vibration shutdown for two and four throw frames and two for six throw frames. Mount vibration devices near the top of the frame with the sensitive axis parallel to the piston rod axis. 7. Install all safety shutdowns, controls, instrumentation, ignition systems, electrical devices, and high temperature piping (gas discharge and engine exhaust) in accordance with good engineering practice and applicable codes for the area classification at the end user location. Ensure compatibility of all systems for area classification. 8. If packing vent temperature is monitored, alarm and shutdown set points should be confirmed through vent flow rates. REV: 3/17

Page 2-3 of 13



Digital No-Flow Timer (DNFT) CAUTION: See arc welding caution on Page 2-1. A DNFT is a totally enclosed electronic device, combining the latest technology in microprocessor and transistor components to detect slow-flow and no-flow of divider block lubrication systems. The DNFT uses an oscillating crystal to accurately monitor the lubrication system cycle time to enable precision timed shutdown capability. The magnet assembly and control housing mount directly to a divider valve. Lubricant flow through a divider valve assembly forces the piston to cycle back and forth causing a lateral movement of the DNFT magnet linked to the piston. The DNFT microprocessor monitors piston movement and resets the timer, lights the light emitting diode (LED), and allows the unit to continue operation, indicating one complete cycle of the lubrication system. If the microprocessor fails to receive this cycle within a predetermined time, a shutdown occurs. The DNFT automatically resets the alarm circuit when normal divider valve operation resumes. DNFTs utilize an LED to indicate each cycle of the divider valve, which allows easy adjustment and monitoring of lubrication rates. Programmable models display total pints, cycle time of divider valve, total cycles of divider valve, or pints per day pump flow rate on a liquid crystal display and operators can adjust alarm time from 20 to 255 seconds.

DNFT Installation 1. Loosen the Allen set screws on the DNFT and remove magnet housing. Do not remove magnet, spring, or spacer from magnet housing. 2. Remove piston enclosure plug from end of desired divider valve. The DNFT installs on any of the divider valves of the divider block. The DNFT requires the correct magnet assembly to match the divider valve manufacturer. NOTE: Do not install a DNFT on Lincoln divider valves with cycle indicator pins. 3. If applicable, verify O-ring or metal gasket is in place on magnet housing. Thread magnet housing into end of divider valve. Torque to 15 lbs x ft (20 N•m) maximum. 4. Slide DNFT all the way onto hex of magnet housing. Torque Allen set screws on hex of magnet housing to 25 lbs x inch, (2.8 N•m) maximum.

Page 2-4 of 13

FIGURE 2-1 Typical DNFT Magnet Assemblies

REV: 3/17



5. The LED on the DNFT indicates each divider valve cycle to allow lubricator pump adjustment for Ariel recommended cycle time and oil consumption. If the LED fails to blink during compressor operation or by manually pumping oil into the divider valve, then the DNFT requires adjustment. 6. The divider valve must cycle during DNFT adjustment. To cycle it, either run the compressor or manually pump oil through the distribution block with a purge gun.

1. Divider Valve Piston 2. Magnet 3. Magnet Housing

4. 5. 6. 7.

Set Screws (2) LED Control Housing Wire Leads

8. O-Ring 9. Divider Valve 10. Piston Enclosure Plug

7. To adjust, slide DNFT all the way onto hex of magnet housing. Tighten Allen set screws to 25 lbs x inch (2.8 FIGURE 2-2 Typical DNFT Installation N•m) maximum. A blinking LED indicates correct adjustment. If the LED fails to blink with divider valve cycling, slide DNFT back on the hex of the magnet housing in 1/16" increments until it does.

8. Make all conduit and connections appropriate for area classification. Insulate unused wires from ground, other wires, and the case. Support conduit and fittings to avoid bending the magnet housing. 9. After DNFT installation and before compressor start-up, purge all air from divider block lubrication system with a purge gun. 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 or skid. Improper grounding can result in unreliable monitor operation.

FIGURE 2-3 A-10754 Programmable DNFT Wiring Connections for Unit in Operation

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Page 2-5 of 13



FIGURE 2-4 A-10753 and A-10772 DNFT Wiring Connections for Unit in Operation

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

Page 2-6 of 13

REV: 3/17



Programmable DNFTs Programmable DNFTs come with a small liquid crystal display (LCD) screen to display total divider valve cycles (Mode 1), cycle time of divider valve in seconds (Mode 2), total pints of oil used (Mode 3), or pump flow rate in pints per day (Mode 4). Operators can also adjust alarm time in Mode 1. CAUTION: Program DNFT before installing 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 program:

7. 1/8" recessed 1. Magnet opening for pro2. Magnet Housing gramming 3. Allen Set Screws magnet 4. LED 8. Wire Leads 5. Control Housing 9. Programming 6. LCD Magnet

FIGURE 2-7 Typical 1. Insert the programming magnet into the 1/8" recessed openProgrammable DNFT ing on the face of the DNFT. The current programming mode (1, 2, 3, or 4) immediately displays on the LCD followed by "0" 2 seconds later. "0" indicates the current mode is ready for programming. 2. If the desired programming mode does not display, remove and re-insert the programming magnet into the recessed opening until it does. Leave the programming magnet in the recessed opening when the desired programming mode displays. 3. Select one of the programming modes below: a. Mode 1 - LCD displays total divider valve cycles; program alarm time. • To set alarm time, press and release the spring-loaded magnet assembly until the desired alarm time in seconds displays on the LCD. Set alarm time from a minimum of 20 seconds to a maximum of 255 seconds. If not set, device defaults to 120 seconds. • Remove programming magnet. DNFT displays total divider valve cycles if left in this mode and alarm time is now set. b. Mode 2 - LCD displays cycle time of divider valve in seconds. • Remove programming magnet when Mode 2 displays. LCD counts each divider valve cycle in seconds, counting up from zero until the divider valve completes one full cycle. When divider valve completes one full cycle, the LCD resets to zero and repeats the count until another cycle is completed. The LED blinks in all modes to indicate each divider valve cycle. This blink enables the operator to set pump flow rate. c. Mode 3 - LCD displays total pints used; program divider valve total. • To set divider valve total, add the sizes of the divider valve sections on which the DNFT will be installed. Example: 24 + 24 + 24 = 72. • Press and release the spring-loaded magnet until the divider valve total displays on the LCD. Maximum value: 120. If not set, device defaults to zero and prevents Mode 4 flow rate display. • Remove programming magnet. The DNFT displays total pints on the LCD if left in this mode. d. Mode 4 - LCD displays pump flow rate in pints per day.

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Page 2-7 of 13



• Remove programming magnet with Mode 4 displays. LCD displays pump flow rate in pints per day based upon the divider valve total set in Mode 3. Mode 4 requires a minimum 4 second cycle time. The DNFT stores all programmed information until the operator inserts the programming magnet into the recessed opening, selects Mode 1 or Mode 3, and presses the spring loaded magnet assembly. This action resets the unit to zero and allows entry of a new value. NOTE: Power interruption to the DNFT requires reprogramming Mode 1 and Mode 3.

DNFT Battery Replacement The DNFT operates on a field-replaceable lithium battery that should last six to ten years. If battery voltage drops below 2.5 VDC, the DNFT shuts down and the compressor cannot be restarted until the battery is replaced. CAUTION: Do not open a DNFT in an explosive gas atmosphere. 1. Shut down compressor. 2. Disconnect DNFT wiring 3. Use 1/8 inch Allen wrench to loosen Allen set screws and remove control housing to a safe atmosphere. 4. Use 3/8 inch ratchet wrench to remove pipe plug. 5. Remove battery and disconnect from polarized connector.

1. Magnet Housing 2. Magnet 3. O-Ring 4. Control Housing 5. Polarized Connector 6. Field Replaceable Battery

7. 1/2" Pipe Plug 8. #22 AWG 18" (0.46 m) Leads 9. Spring 10. Spacer 11. Allen Set Screws

FIGURE 2-8 Typical Digital No-Flow Timer Switch (DNFT)

6. Test battery. The voltage should read 3.6 VDC. 7. Connect new battery to polarized connector. 8. Insert new battery and reinstall pipe plug. Apply teflon tape to plug threads and torque to 25 ft x lb (34 N•m). 9. Place DNFT control housing on the magnet housing in its original position and tighten set screws. Reattach wiring and conduit. 10. Programmable DNFTs require reprogramming of the alarm time (Mode 1) and divider valve total (Mode 3) after a power interruption. See programming section of this document. 11. To verify DNFT operation, pre-lube the system and check for LED blink.

Page 2-8 of 13

REV: 3/17



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. See ER-105.3.1 for DNFT bench test procedures. Problem

Possible Cause Improperly adjusted DNFT.

LED does not Broken spring blink and or magnet in control panel magnet indicates lube housing. no-flow. (see Low battery also Erratic voltage. Shutdown) Bent magnet housing.

Solution

Loosen set screws, slide DNFT all the way onto hex of magnet housing and torque to 25 lbs x inch (2.8 N•m) max. (Do not over tighten). Either pump clean oil through lubrication system with a purge gun or run the compressor to cycle the divider valve. If necessary, slide DNFT back in 1/16“ increments until LED blinks with each divider valve cycle. Loosen set s crews, remove DNFT from magnet housing. Remove magnet housing from divider valve. Remove magnet, spring, and spacer and check for damage. Replace damaged components. Re-install magnet housing on divider valve and DNFT on magnet housing. If necessary, adjust DN FT, check for LED blink. Purge air from system with purge gun. Remove battery from DNFT and test it. Replace battery with a factory recommended replacement lithium battery if voltage is below 2.5 VDC. Loosen set screws, remove DNFT from magnet housing. Check for damaged or bent magnet housing. Remove magnet assembly from divider valve. Replace magnet housing, magnet, spring, and spacer. Re-install new magnet housing on divider valve and DNFT on magnet housing. If necessary, adjust DNFT, check for LED blink. Purge air from system with purge gun.

Wrong magnet Loosen set screws and remove DNFT from magnet housing. Check for correct housing magnet housing for divider valve manufacturer. Remove and replace with cor ARV installed on rect magnet housing. Re-install DNFT on new magnet housing. If necessary bypasses or divider valve. adjust DNFT, check for LED blink. Purge air from system with purge gun. rupture disk Check sys tem pressure to verify oil flows to divider valves. If needed, install bursts and pressure gauge to monitor lubrication system operation: divider valve Air or • Loosen outlet plugs in front of valve blocks. Purge lubrication system with a seizes after debris in purge gun until clean, clear, air-free oil flows from plugs. DNFT divider valve • Loosen, but do not remove, each piston enclosure plug individually to purge installation. air from behind piston. Tighten all divider valve plugs. Adjust DNFT. assembly. To ensure proper lubrication system operation, all tubing and components MUST be filled with oil and free of air before start-up. • Normally Open - Attach ohmmeter to red wires. Should read A-10753 Faulty wiring 10MΩ in operation and less than 10Ω in alarm. A-10772 • Normally Closed - Attach ohmmeter to orange wires. Should from DNFT to A-20513 read less than 10Ω in operation and open loop in alarm. control panel or air in system • Normally Open - Attach ohmmeter to orange wires; insulate (see above for A-10754 violet wires from each other. Should read 10Ω or less in alarm. • Normally Closed - Attach ohmmeter to orange wires. Short A-20514 Erratic shut- air in system). violet wires together. Should read open loop in alarm. down orLED Check system pressure to verify oil flows to pump and divider valves. If blink. needed, install pressure gauge to monitor lubrication system operation. Check Faulty lube gauge to verify pump builds sufficient pressure to inject oil into cylinder. Do not pump. remove tubing from check valve and pump oil to atmosphere to check oil flow into cylinder. Replace pump. Overtightened Step-torque divider valves to 75 lb x in (8.5 N•m) to the backplate. divider valves

REV: 3/17

Page 2-9 of 13



Proximity Switch A-18255 CAUTION: See arc welding caution on Page 2-1. A proximity switch installs into a divider valve in place of a piston end plug and can be used to actuate any device. It consists of a reed switch and a magnet. When installed, the magnet rests against the divider valve piston and parallel to the reed switch. With every divider valve cycle, the piston moves the magnet, which opens and closes the reed switch contacts. The time for the proximity switch to repeat a contact transition (ex. from open to closed) is known as the cycle time of the divider valve assembly. The proximity switch must work with a PLC or some other counter/timer device to produce a shutdown. See "Instrumentation" in the Ariel Packager Standards for interpretation of proximity switch pulse output.

Proximity Switch Installation 1. Loosen the Allen set screws on the proximity switch housing and remove magnet housing. Do not remove magnet, spring, or spacer from magnet housing. 2. Remove piston enclosure plug from end of desired divider valve. The proximity switch installs on any of the divider valves of the divider block. The proximity switch requires the correct magnet assembly to match the divider valve manufacturer. NOTE: Do not install a proximity switch on Lincoln divider valves with cycle indicator pins. 3. If applicable, verify O-ring or metal gasket is in place on magnet housing. Thread magnet housing into end of divider valve. Torque to 15 lbs x ft maximum. 4. Slide proximity switch all the way onto hex of magnet housing. Torque Allen set screws on hex of magnet housing to 25 lbs x inch, maximum.

Page 2-10 of 13

FIGURE 2-9 Typical Magnet Assemblies

REV: 3/17



5. Connect an ohm meter across the two yellow switch leads exiting the proximity switch housing. 6. The divider valve must cycle during proximity switch adjustment. To cycle it, either run the compressor or manually pump oil through the distribution block with a purge gun. 7. To adjust, slide proximity switch all the way onto hex of magnet housing. Tighten Allen set screws to 25 lbs x inch maximum. The ohm meter showing the switch changing state as the divider valve cycles indicates correct adjustment. If the switch state fails to change, slide proximity switch back on the hex of the magnet housing in 1/16" increments until it does. 8. Make all conduit and connections appropriate for area classification. Support conduit and fittings to avoid bending the magnet housing.

1. 2. 3. 4. 5. 6.

Divider Valve Piston Magnet Magnet Housing Allen Set Screw (2) Spacer Spring

7. Switch Housing 8. Wire Leads (yellow) 9. Ground Wire (green) 10. O-Ring 11. Divider Valve 12. Piston End Plug

FIGURE 2-10 Typ. Proximity Switch Installation

9. After proximity switch installation and before compressor start-up, purge all air from divider block lubrication system with a purge gun. NOTE: When installing multiple proximity switches, 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

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Page 2-11 of 13



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

Switch does not cycle and control panel indicates lube no-flow. (see also Erratic Operation)

ARV bypasses or rupture disk bursts and divider valve seizes after proximity switch installation.

Erratic Operation.

Page 2-12 of 13

Possible Cause

Solution

Improperly adjusted proximity switch.

Loosen set screws, slide proximity switch all the way onto hex of magnet housing and torque to 25 lbs x inch max. (Do not over tighten). Either pump clean oil through lubrication system with a purge gun or run the compressor to cycle the divider valve. If necessary, slide proximity switch back in 1/16“ increments until the switch opens/closes with each divider valve cycle.

Broken spring or magnet in magnet housing.

Loosen set screws, remove proximity switch from magnet housing. Remove magnet housing from divider valve. Remove magnet, spring, and spacer and check for damage. Replace damaged components. Re-install magnet housing on divider valve and proximity switch on magnet housing. If necessary, adjust proximity switch and test switch functionality. Purge air from system with purge gun.

Bent magnet housing.

Loosen set screws, remove proximity switch from magnet housing. Check for damaged or bent magnet housing. Remove magnet assembly from divider valve. Replace magnet housing, magnet, spring, and spacer. Re-install new magnet housing on divider valve and proximity switch on magnet housing. If necessary, adjust proximity switch and test switch functionality. Purge air from system with purge gun.

Wrong magnet housing installed on divider valve.

Loosen set screws and remove proximity switch from magnet housing. Check for correct magnet housing for divider valve manufacturer. Remove and replace with correct magnet housing. Re-install proximity switc h on new magnet housing. If necessary adjust proximity switch and test switch functionality. Purge air from system with purge gun.

Check sys tem pressure to verify oil flows to divider valves. If needed, install pressure gauge to monitor lubrication system operation: • Loosen outlet plugs in front of valve blocks. Purge lubrication system with a Air or purge gun until clean, clear, air-free oil flows from plugs. debris in • Loosen, but do not remove, each piston enclosure plug individually to purge divider valve air from behind piston. Tighten all divider valve plugs. Adjust 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 proximity switch to control panel or air in system (see above for air in system).

Check electrical wiring and connections for damage or poor contact. See FIGURE 2-11.

Faulty lube pump.

Check system pressure to verify oil flows to pump and divider valves. If needed, install pressure gauge to monitor lubrication system operation. Check gauge to verify pump builds s ufficient pressure to inject oil into cylinder. Do not remove tubing from check valve and pump oil to atmosphere to check oil flow into cylinder. Replace pump.

REV: 3/17



Main Bearing Temperature Alarms and Shutdown Main bearing thermocouples or RTD temperature sensors are optional for JGH:E:K:T frames.

Thermocouples - J (Iron-Constantan) or K (Chromel-Alumel) A thermocouple is two dissimilar conductors joined together at one end to form a sensor that produces a thermoelectric voltage as an accurate function of temperature. Appropriate controls interpret the thermocouple voltage as temperature.

Resistance Temperature Devices (RTD’s) An RTD is a sensor that produces electrical resistance as an accurate function of temperature. Appropriate controls interpret the electrical resistance as temperature. A typical measurement technique sends a small constant current through the sensor and measures voltage across the sensor with a digital voltmeter to indicate resistance by a computer and wave-fitting equations. For main or thrust bearing temperature sensing, Ariel supplies dual element, six-wire, 100 Ohm (at 0°C) RTD’s. Dual element RTD’s allow rewiring instead of sensor replacement if an element fails. Insulate unused wire ends from each other and conduit ground. To simplify wiring, RTD's come with two green wires and one black for one element, and two red wires and one white for the other. See FIGURE 2-12. A Zone 1 environment may require the installation of proper, intrinsically safe or equivalent protection to fulfill electrical requirements.

REV: 3/17

FIGURE 2-12 Typical Dual Element RTD Wiring Diagram

Page 2-13 of 13

Section 3 - Maintenance Ariel compress compressors, ors, like all industrial industrial equipme equipment, nt, require require maintena maintenance nce.. The severity severity of compress compressor or service vice directl directly y influ influenc ences es the frequen frequency cy and and amoun amountt of maint maintena enanc nce e neede needed. d. Below Below are recom recommen mende ded d interv intervals als for inspec inspectio tions ns and and replac replacem ement ents s to help help determ determine ine appro appropria priate te interv intervals als for a given given comcompress pressor or appli applica catio tion. n. Careful Careful docum document entati ation on of inspe inspecti ction on result results s is critic critical al to estab establis lish h whether whether recomm recommend ended ed interv intervals als are adequ adequate ate or requi require re more more or less less frequen frequency cy.. Continuous Duty: The compr compres esso sorr operate operates s conti continuo nuous usly ly,, 24 hours hours a day, day, shutt shutting ing down down only only for short short durations durations,, usually usually for maintena maintenance nce and unexpec unexpected ted shut-downs shut-downs.. Short-Term Intermittent Duty: The compr compres esso sorr operate operates s for short short durati durations ons,, startin starting g and stopp stopping ing perha perhaps ps seve several ral times times per per month month/wee /week/d k/day ay,, such such as in many many CNG fillin filling g statio station n appli applica catio tions ns that that requir require e operat operatio ion n based based on cons consume umerr deman demand. d. Long-Term Intermittent Duty: The compre compress ssor or opera operates tes conti continu nuou ously sly for exten extende ded d durati durations ons,, with exten extended ded shut-d shut-down own period periods, s, such such as in some some storag storage/wi e/withd thdrawal rawal applic applicati ation ons s and fuel fuel gas boos booster ter applications. NOTE: For intermittent duty service, see ER-8.2.2 ER-8.2.2.. As part of your your maintena maintenance nce program, program, Ariel recommend recommends: s: • Consis Consisten tentt adhere adherenc nce e to safet safety y polici policies es,, proce procedu dures res,, and equip equipmen mentt warning warning labels labels.. • Daily operation operational al checks. checks. Routine trending trending and review review of operation operational al parameters parameters.. • Routine • Routine Routine oil analy analysi sis s and trendin trending. g. • Detaile Detailed d record records s of all mainte maintena nanc nce. e. To avoi avoid d cont contam amin inat atio ion, n, keep keep all all cove covers rs in plac place e where where acce access ss is not not requi required red.. Use lint lint free free clot cloths hs or paper paper towels during during internal internal maintena maintenance nce.. 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. 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.

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Page Page 3-1 3-1 of 32

Sectio Section n 3 - Mainte Maintena nanc nce e

For models models JGH:E:K:T TABLE 3-1 Thermal Growth of JGH:E:K:T Compressors

Initial Maintenance Comply Comply with Ariel Ariel Packa Package ger r Standa Standards rds and the comp compres resso sor r Start Start Up Check Check List List.. Adhe Adhere re to all all item items s befo before re and and afte afterr start start-up. For cold cold align alignmen ment, t, acco accoun untt for the differe differenc nce e in therma thermall growth growth heigh heightt betwee between n the compress compressor or and driver. driver. TABLE TAB LE 3-1 lists lists compress compressor or centerlin centerline e height height change change based on 6.5 x 10-6/°F /°F (11. (11.7 7x 10-6/°C).

FIGURE 3-1 Thermal Growth

NOTE: NOTE: Therm Thermal al growth growth numb numbers ers were were calc calcul ulat ated ed usin using g 170°F 170°F (77°C) (77°C) as the the frame frame operat operatin ing g tempe temperatu rature. re. Initia Initiall frame frame tempe temperatu rature re is the temper temperatu ature re of the frame frame during during cold cold alignm alignment ent.. Obtai Obtain n driver driver therma thermall growth growth predic predictio tions ns from the drive driverr manufa manufactu cturer. rer.

Initial Frame Temp. °F (°C)

Thermal Growth Inch (mm)

0 (-18) (-18)

0.019 0.019 (0. (0.48)

10 (-12) (-12)

0.018 0.018 (0.45) (0.45)

20 (-7) (-7)

0.017 0.017 (0. (0.42)

30 (-1) (-1)

0.015 0.015 (0. (0.39)

40 (4) (4)

0.01 0.014 4 (0. (0.37) 37)

50 (10) (10)

0.013 0.013 (0. (0.34)

60 (16) (16)

0.012 0.012 (0. (0.31)

70 (21) (21)

0.011 0.011 (0. (0.28)

80 (27) (27)

0.010 0.010 (0. (0.25)

90 (32) (32)

0.009 0.009 (0. (0.23)

100 (38) (38)

0.008 0.008 (0.20) (0.20)

110 (43) (43)

0.007 0.007 (0.17) (0.17)

120 (49) (49)

0.006 0.006 (0.14) (0.14)

130 (54) (54)

0.004 0.004 (0.12) (0.12)

Cente Centerr the the coup coupliling ng betwe between en the the drive driverr and and comp compres resso sorr so it does does not not thrus thrustt or force force the crank cranksh shaft aft agains againstt eithe eitherr thrust thrust face. face. To ensure ensure parall parallel el and and conc concent entric ric drive drive train train alignme alignment, nt, position position connec connected ted equipmen equipmentt so misal misalign ignmen mentt is as clos close e to zero zero as poss possib ible. le. Maxim Maximum um rim (outsi (outside de diame diameter) ter) mismisalig alignm nmen entt is 0.00 0.005 5 inch inches es (0.13 (0.13 mm) mm) for for tota totall indic indicato atorr readin reading g (TIR) or 0.0025 0.0025 inch inches es (0.06 (0.064 4 mm) mm) for for lase laserr alig alignm nmen entt tool tool.. Face Face (angu (angular) lar) misal misalign ignme ment nt is to be within within 0.005 0.005 inc inches hes (0.1 (0.13 3 mm) mm) for for hub hub diam diamet eter ers s up to 17 inch inches es (430 (430 mm). mm). For For hubs hubs great greater er than than 17 inches inches (430 (430 mm), mm), use use the follo following wing formula formula:: Hub O.D. O.D. x 0.00 0.0002 029 9 = max max angu angula larr mismisalignme alignment. nt. See FI FIGURE GURE 33-2 2 After running running a new, relocated relocated,, reconfigu reconfigured, red, or overh overhaul auled ed compr compres esso sorr for 24 hours hours,, shut shut down, down, vent vent the the gas gas syst system em,, and and perfo perform rm the the following maintenance: maintenance:

FIGURE 3-2 Angular Coupling-Hub Face Alignment Limits

1. Perfo Perform rm a ho hott al alig ignm nmen entt ch chec eck k wit withi hin n 30 mi minu nute tes s of sh shut utdo down wn as de desc scrib ribed ed ab abov ove. e. Ad Adju just st discharge bottl bottle e supp supports orts and head head end end supp supports orts,, if appli applica cable ble.. NOTE: To avoid cylinder distortion, lift discharge bottles only 0.003 to 0.005 inch (0.08 to 0.13 mm) using the supports. 2. Check Check fasten fastener er torque torque on gas gas nozz nozzle le flang flanges es,, valv valve e caps caps,, cylin cylinde derr heads heads,, piston piston rod packin packing g flange flanges, s, cross crosshea head d guide guide hold hold down, down, frame frame hold hold down, down, cross crosshe head ad guide guide to cylin cylinde der, r, and and cross crosshe head ad guide guide to frame frame bolti bolting, ng, if appli applica cable ble.. See TABL TABLE E A-3 in Appen in Appendix dix A for correc correctt torque torques. s.


REV: 3/17


Section Section 3 - Mainte Maintena nance nce

3. Repeat Repeat torq torque ue ch chec eck k aft after er 75 750 0 ho hours urs.. Rec Rechec heck k fasten fasteners ers found found loose loose in any any of these these interv intervals als after after an additi additiona onall 750 hours. hours. If loose loosenin ning g conti continue nues, s, conta contact ct your your packa package ge suppl supplier ier immed immediat iately ely..

Daily Maintenance 1. Log Log and and trend trend the the foll followi owing ng:: • Operat peratin ing g RPM, gas gas press pressure ure and and temp tempera eratu tures res - dete determi rmine ne if the the unit unit is opera operati ting ng withi within n desi design gn parameters parameters 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 temper temperatu atures res - if the unit unit is equipp equipped ed with main main bearin bearing g tempe temperatu rature re sens sensors ors.. • Compre Compress ssor or frame frame oil oil press pressure ure - at oper operat atin ing g temp tempera eratu ture re (190° (190°F F (88°C) (88°C) max. max. inle inlett oil oil temtemperat perature ure), ), it shou should ld be 50 to 60 psig psig (3.5 (3.5 to 4.2 4.2 barg) barg) at the the filt filter er gaug gauges es.. If press pressure ure fall falls s belo below w 50 psig psig (3.5 (3.5 barg) barg),, shut shut down down the the comp compres resso sorr then then dete determi rmine ne and and corre correct ct the the caus cause. e. • Compres Compresso sorr frame frame inlet inlet oil tempe temperatu rature. re. • Compress Compressor or frame frame oil filter filter differe differenti ntial al press pressure ure - differe differenti ntial al press pressure ure exce exceed eding ing the filter filter chang change e valu value e indi indica cate tes s a need need for for a filt filter er chan change ge.. See filt filter er info informa rmati tion on plat plate e on top top cove coverr or “O or “Oilil Fi Filt lter” er” on page pa ge 3-1 3-14 4 for procedure. procedure. 2. Chec Check k comp compres resso sorr frame frame oil oil leve level. l. It shou should ld be abou aboutt midmid-le leve vell in the the sigh sightt glas glass s and and free free of foam foam when when runni running ng.. If not, not, dete determi rmine ne and and corre correct ct the the caus cause. e. Do not not overf overfilill. l. Check Check oil oil make makeup up tank tank for for sufsuffici ficien entt oil oil supp supply ly.. For For dry sump sump frame frames, s, chec check k the the pack packag age e sump sump oil oil leve level. l. Do not not add add oil oil to the the crank crankca case se through through the breath breather er hole hole while while the unit unit runs. runs. This This caus causes es oil foamin foaming g and unnec unneces essa sary ry no-flo no-flow w shutd shutdowns owns in the force force feed feed lubric lubricati ation on syste system. m. 3. Check Check forc force e feed feed lubri lubrica cato torr box box oil oil leve level. l. It shou should ld be full full to the the overf overflo low w line line.. 4. Log and and trend trend piston piston rod pack packing ing vent/ vent/dra drain in tempe temperatu rature re and and chec check k distan distance ce piec piece e vents vents for leakleakage. age. If the the pist piston on rod pack packin ing g vent vent/d /drai rain n temp tempera eratu ture re is trend trendin ing g high high,, then then verif verify y leak leak rate rate befo before re performing maintenance. maintenance. 5. If applic applicab able, le, chec check k suct suction ion valv valve e unloa unloader der actua actuator tor vents vents for leaka leakage ge.. 6. If applic applicab able, le, chec check k head head end end cleara clearanc nce e pock pocket et vents vents for leaka leakage. ge. 7. Verif Verify y all all cyli cylind nder er high high disc discha harge rge gas gas temp tempera eratu ture re shut shutdo downs wns are set set to withi within n 10% 10% or as clos close e as practi practica call abov above e the normal normal opera operatin ting g disch discharge arge tempe temperatu rature. re. Do not not exce exceed ed the maxim maximum um disdischarg charge e tempe temperatu rature re shutd shutdown own setti setting ng for the applic applicati ation on.. Log and and trend trend cylin cylinde derr valv valve e cap cap tempera temperature tures. s. 8. Log 9. Check Check lubri lubrica cato torr bloc block k cycl cycle e time time.. See See lubr lubric icat ator or box box data data plat plate e for for corre correct ct cycl cycle e time time.. Chang Changes es in gas gas comp compos osit itio ion n may may requi require re a revi review ew of cycl cycle e time time.. Check Check lube lube shee sheett for for unit units s not not runn runnin ing g at rated rated speed. 10. Check Check for for gas, gas, oil, oil, and and cool coolan antt leak leaks. s. CAUTION: Do not attempt to repair leaks while the unit is operating or pressurized. 11. Che 11. Check ck for unus unusual ual noise noises s or vibra vibratio tions ns.. 12. See pack package agerr docume documenta ntatio tion n for addit addition ional al recomm recommend ended ed chec checks ks,, i.e. i.e. scrub scrubbe berr liqui liquid d levels levels,, dump dump valve valve operati operation on,, cool cooler er louve louverr posit position ions, s, etc. etc.

REV: 3/17


Section 3 - Maintenance


Monthly Maintenance 1. Perform all Daily maintenance. 2. Verify safety shutdown functionality. 3. Sample compressor frame oil and send it to a reputable lubricant lab for analysis. See ER-56.06 for a list of what an oil analysis should provide. If analysis results indicate increasing levels of lead, tin, or copper particles in the oil, shut down unit. Remove frame top cover and crosshead guide side covers. Visually inspect for debris. Do not disassemble further without good reason. If debris indicates, replace affected parts, then change oil, oil filter, and clean the strainer with a suitable solvent. 4. Check and log cylinder clearance devices in use and their settings.

Six-Month (4,000-Hour) Maintenance 1. Perform all Daily and Monthly maintenance. 2. Shut down unit and allow sufficient time for components to cool. 3. Drain and replace force feed lubricator box oil. 4. Where applicable, clean sintered element in the small oil filter on the force feed lubrication system now or at every main oil filter change. Use a suitable solvent. Where applicable, replace force feed lubricator inlet filter in independent supply system. 5. Change compressor oil filter. See top cover filter information plate or “Oil Filter” on page 3-14 for procedure. NOTE: For replaceable element style filters, drain the canister completely before removing the element. Inspect elements for cleanliness and damage. Do not install dirty or damaged elements. 6. Change compressor oil. Extremely dirty environments, oil supplier recommendations, or oil analysis results may dictate a different oil change interval. Follow these steps: • Drain oil from frame, associated piping, and oil cooler. • Clean oil strainer with a suitable solvent. In dry sump applications, the strainer is located at the oil reservoir. • Remove frame top cover and crosshead guide side covers. Visually inspect for debris. Do not disassemble further without good reason. If debris indicates, replace affected parts, then change the oil filter and clean the strainer with a suitable solvent. • Refill compressor frame with fresh, clean oil. 7. Check cylinder lubrication. See “Cylinder Lubrication Paper Test” on page 3-31 for procedure. 8. Re-tighten hold down fasteners to proper torque (compressor frame feet and crosshead guide/distance piece support feet). Inspect for frame twist or bending to verify main bearing bore alignment. See Appendix H for flatness and soft foot requirements. 9. Perform a coupling alignment (see "Initial Maintenance" above). 10. Remove and inspect inlet screens on each stage; clean if clogged with debris or replace if damaged. Clean inlet screens regularly to avoid increased pressure that may collapse them. More debris in the screen may dictate more frequent inspections. Inlet screens may be removed if they catch little or no debris and the gas stream is clean (optional).

Page 3-4 of 32

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One-Year (8,000-Hour) Maintenance 1. Perform all Daily, Monthly, and Six-Month maintenance. 2. Grease VVCP stem threads at grease fitting, with 2 to 3 pumps of cylinder lube compatible grease using a standard hand pump grease gun. Turn VVCP adjustment handle all the way in and all the way out to lubricate the threads. Measure or count turns to return the handle to its original position. 3. Open force feed lubricator box and visually inspect pump followers, cams, and gears for wear. 4. Pressure test distribution blocks. See “Divider Valve Bypass Pressure Test” on page 3-25 for procedure. 5. Measure, log, and trend the following: • Main bearing, connecting rod bearing, and crankshaft jack and thrust clearances. See page 4-38 and page 4-42 NOTE: Clearance trends along with oil analysis and crankcase visual inspection can indicate the need for bearing replacement. Contact Ariel for original assembly clearances. • Crosshead to guide clearances. • Piston rod runout. See“Piston Rod Runout” on page 4-19 If any of the above items are outside limits listed in Appendix B, find the cause and correct it. It may require part replacement. 6. Remove valves and valve gaskets: a. Visually inspect valve pockets for damage. Verify all old valve seat gaskets are removed. b. Have a qualified valve repair shop disassemble, visually inspect, and refurbish the valves where needed. Provide the valve repair shop an Ariel torque chart and valve service guide. c. Visually inspect cylinder gas passages and clean them of all debris. 7. If applicable, visually inspect suction valve unloader actuator stems for damage or wear. Visually inspect stem seals for damage or wear and confirm that the actuator moves freely. 8. If applicable, visually inspect pneumatic clearance pockets for damage or wear (seating surface and stems/stem seals). Confirm that actuator moves freely. 9. Inspect cylinder bores for damage or wear. Replace the cylinder body or restore the bore if any of the following conditions exist: • Bore surface blemishes or gouges. • Bore out of round more than 0.001 inch per inch of bore diameter (0.001 mm/mm) or tapered. • Main bore is worn to counterbore diameter or larger. 10. Inspect piston rings and wearband: a. Measure and log piston ring condition, end gap, and side clearance. b. Replace rings that are damaged or outside limits listed in Appendix B . c. When replacing rings, re-measure and log ring side clearance to check for groove wear. d. Measure and log radial projection of wear band. 11. Inspect piston rods for damage and excessive wear. Replace rod if any of these conditions exist: • Gouges or scratches on the rod. REV: 3/17

Page 3-5 of 32



• Under size more than 0.005 inch (0.13 mm). • Out of round more than 0.001 inch (0.03 mm). • Tapered more than 0.002 inch (0.05 mm) . 12. Rebuild piston rod pressure packing cases. See “Piston Rod Packing” on page 4-22 for procedure. 13. Re-install valves, retainers, and valve caps using new valve seat gaskets and valve cap O-rings/seals. See “Valve Installation” on page 4-9. Use proper installation techniques and torque procedures for valve caps. 14. Check and re-calibrate all required instrumentation. 15. Clean crankcase breather filter with suitable solvent. 16. Check and, if needed, adjust drive chains. See “Chain Adjustment” on page 4-48 for procedure. 17. If the compressor is equipped with crankcase over-pressure relief valves, visually inspect and exercise valves to manufacturer recommendations. 18. Check fastener torques of gas nozzle flanges, head end head or unloader, valve caps, piston rod packings, crosshead pin thru- bolts, crosshead guide to frame, crosshead guide to cylinder, cylinder mounting flange to forged steel cylinder, distance piece to cylinder, distance piece to crosshead guide, and tandem cylinder to cylinder.

Two-Year (16,000-Hour) Maintenance 1. Perform all Daily, Monthly, Six-Month, and One-Year maintenance. 2. Rebuild oil wiper cases. 3. If applicable, use new piston and stem seals to rebuild actuators on suction valve unloaders and fixed volume pneumatic pockets. Replace piston stem assemblies where stem is damaged or worn. 4. Check auxiliary end chain drive for undercut sprocket teeth and chain for excessive stretching. Replace as required.

Three-Year (24,000-Hour) Maintenance 1. Perform all Daily, Monthly, Six-Month, and One-Year maintenance. 2. Replace non-ELP connecting rod bearings for JGE:T models. See “Connecting Rods” on page 433. 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 all Daily, Monthly, Six-Month, One-Year, and Two-Year maintenance. 2. Remove crosshead pins. Measure and log crosshead pin to crosshead pin bore and connecting rod bushing bore clearances. Check crosshead pin end caps and thru-bolt for wear. Replace if needed. 3. Check for bushing wear in the auxiliary end drive chain tightener. 4. Check for ring groove wear in pistons.

Page 3-6 of 32

REV: 3/17



Six-Year (48,000-Hour) Maintenance 1. Perform all Daily, Monthly, Six-Month, One-Year, Two-Year, and Three-Year maintenance. 2. Replace lubricator distribution blocks. 3. Replace crosshead bushings and connecting rod bushings. See “Crossheads” on page 4-30 and “Connecting Rods” on page 4-33. 4. Replace connecting rod bearings. See “Connecting Rods” on page 4-33. 5. Replace main bearings. See “Crankshaft” on page 4-39.

Frame Oil There are several oil specifications, maintenance procedures, and operating conditions which affect oil performance. For optimal performance, ensure the oil meets the specifications below and is suitable for the given application, and diligently complete maintenance procedures.

Viscosity The minimum allowable viscosity of the oil entering the frame is 16 cSt. Typically, this is the viscosity of ISO 150 grade oil at about 190°F (88°C). The maximum viscosity at this temperature is 60 cSt. For JGH:E:K:T frames, the maximum viscosity to start the compressor is 3,300 cSt and the maximum viscosity to load the compressor is 1,000 cSt. See FIGURE 3-3.

Oil Pressure The factory sets normal pressure on the discharge side of the oil filter at 60 psig (4.1 barg) for compressors tested mechanically complete (inspector tag displayed). If factory tested as mechanically incomplete (no inspector tag), the packager sets normal oil pressure at initial start-up to 60 psig (4.1 barg) at the lower of the frame or cylinder rated speed, or driver speed at normal operating temperature. Adjust the oil pressure after the filter to 60 psig at minimum operating speed and normal operating temperature. Ariel uses the pump safety relief valve to regulate pressure into the compressor. If oil pressure into the compressor at minimum operating speed and normal operating temperature does not read about 60 psig (4.1 barg), adjust the pump safety relief valve. With compressor running at minimum operating speed, turn the adjustment screw clockwise to increase oil pressure, or counter-clockwise to decrease it. The compressor requires a 45 psig (3.1 barg) low oil pressure shutdown for protection. 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.

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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

FIGURE 3-3 Viscosity vs. Temperature Graph of Different Lubricants R E V : 3 / 1 7

F o r m o d e l s J G H : E : K : T


Section Section 3 - Mainte Maintena nance nce

Oil Temperature Main Mainta tain in frame frame inle inlett oil oil temp tempera eratu ture re as clos close e to 170° 170°F F (77°C) (77°C) as poss possib ible le.. Mini Minimu mum m lube lube oil oil opera operati ting ng temp temper erat ature ure is 150° 150°F F (66°C) (66°C) to drive drive off off water water vapo vapor. r. Maxi Maximu mum m allo allowab wable le oil oil temp tempera eratu ture re into into the the comcompress pressor or frame frame is 190° 190°F F (88°C) (88°C).. Highe Higherr temp tempera eratu ture res s incre increas ase e the the oxid oxidat atio ion n rate rate of mine mineral ral oil. oil. Every Every 18°F 18°F (10°C) (10°C) withi within n the the opera operati ting ng range range doub double les s the the oxid oxidat atio ion n rate rate of mine mineral ral oil. oil. For prope properr opera operatio tion n of the thermos thermostat tatic ic contro controll valv valve, e, the maxim maximum um differe differenti ntial al press pressure ure betwee between n the hot hot oil oil suppl upply y line line and and the the cool cooled ed oil oil retu return rn line line is 10 psid psid (0.7 (0.7 bard bard). ).

Oil Maintenance An oil analys analysis is program program is the most most effective effective way to determine determine frame oil change change intervals intervals.. Consistent Consistent oil anal analys ysis is can can iden identi tify fy when when to chan change ge oil oil on the the basi basis s of need need rathe ratherr than than a sche schedu dule led d inte interv rval al.. Depen Dependding ing on servi service ce,, oil oil analy analysi sis s can can signi signific fican antly tly exten extend d oil chan change ge interv intervals als.. Inst Instal alll a samp sampliling ng poin pointt betwe between en the the oil oil pump pump and and filt filter er at an easi easily ly acce access ssib ible le loca locati tion on.. Mini Minimi mize ze dirt dirt or debri debris s that that can can coll collec ectt aroun around d it. it. Use a need needle le valv valve e to bett better er cont contro roll pres pressu suriz rized ed oil oil flow. flow. Collec Collectt and analy analyze ze oil sampl samples es to verify verify suita suitabil bility ity for conti continue nued d servi service ce.. Oil Oil analy analysi sis s shoul should d includ include: e: • Visco Viscosi sity ty test testin ing g at 104°F 104°F (40°C) (40°C) and and 212° 212°F F (100° (100°C). C). This This verif verifie ies s that that oil oil has has not not mixe mixed d with with cyli cylind nder er oils oils or proce process ss gas. gas. • Parti Particl cle e coun counti ting ng to the the late latest st versi version on of ISO 4406 4406.. • Spectrosc Spectroscopy opy to determine determine wear metals, metals, contami contaminant nants, s, and additiv additives. es. • FTIR (Fourie (Fourierr Transfo Transform rm Infrare Infrared d Spectro Spectrosc scop opy) y) to chec check k for oxida oxidatio tion, n, water water or coola coolant nt concontami tamina nati tion on,, and and addi additi tive ve depl deplet etio ion. n. This This is more more impo importa rtant nt if the the sump sump oil oil is not not cons consum umed ed by the the forc force e feed system. system.

Dry Sump Compre Compress ssor ors s subj subjec ectt to trans transie ient nt moti motion on,, roll, roll, and and yaw yaw on board board a ship ship or a floa floati ting ng plat platfo form rm may may requi require re a dry sump sump (“dry” (“dry” cran crankc kcas ase e and and sepa separat rate e oil oil reser reservo voir) ir).. With With a dry sump sump,, drai drains ns are supp supplilied ed at each each end end of the the comp compres resso sorr frame frame and and an addi additi tion onal al oil oil pump pump chai chain n oile oilerr is provi provide ded d by Ariel Ariel.. The The pack packag ager er must must provi provide de a lube lube oil oil reserv reservoi oirr size sized d and and loca locate ted d so that that the the oil oil pump pump has has oil oil suct suctio ion n regard regardle less ss of the the tilt tilt of the the ship ship or floa floati ting ng plat platfo form. rm. An oil oil sump sump stra strain iner er must must be inst instal alle led d in the the pump pump suct suctio ion n line line at the the outl outlet et of the the sepa separa rate te lube lube oil oil reser reservo voir ir (unmo (unmoun unte ted d strai straine nerr is provi provide ded d by Ariel Ariel with with a new new dry sump sump comp compres resso sor). r).

Oil System Cleanliness Clean Clean the the comp compres resso sorr frame frame oil oil pipi piping ng syst system em and and comp compon onen ents ts of all all fore foreig ign n matt matter er such such as sand sand,, rust, rust, mill mill scale scale,, metal metal chips chips,, weld spatt spatter, er, greas grease, e, and and paint paint.. Use proper proper clean cleaning ing proce procedure dures s with proper proper clea cleaner ners, s, acids acids,, and/o and/orr mechan mechanic ical al clea cleanin ning g to meet meet clean cleanlin lines ess s requir requireme ements nts.. Ariel Ariel recomm recommend ends s flush flush-ing ing all oil-pi oil-pipin ping g syste systems ms with an electri electric c or pneum pneumati atic c driven driven pump pump and and filtere filtered, d, clean clean produc productio tion n oil. oil. Ariel thoroughl thoroughly y 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).

REV: 3/17


Sectio Section n 3 - Mainte Maintena nanc nce e

For models models JGH:E:K:T

Prior Prior to start-u start-up, p, flush flush all all comp compres resso sors rs instal installed led with an elec electric tric or pneuma pneumatic tic powered powered pre-lu pre-lube be pump pump and and less less than than 50 feet feet (15 m) of oil oil pipi piping ng as outl outlin ined ed belo below. w. Incl Includ ude e cool cooler er oil oil pass passag ages es in the the flus flushi hing ng loop. loop. While While oil syste systems ms for comp compres resso sors rs without without an elect electric ric or pneum pneumati atic c powered powered pre-lu pre-lube be pump pump and and less less than than 50 feet feet (15 m) of oil oil pipi piping ng must must be clea clean, n, oil oil flus flushi hing ng is desi desirab rable le,, but but not not requi required red.. For For all all comp compre ress ssors ors with with oil oil pipi piping ng syst system ems s great greater er than than 50 feet feet (15 m), clea cleani ning ng and and flus flushi hing ng must must resresult ult in a clea cleanl nlin ines ess s leve levell to ISO-44 ISO-4406 06,, Grad Grade e 13/1 13/10/ 0/9 9 and/ and/or or NAS-163 NAS-1638, 8, Class Class 5 (see (see TAB TABLE LE 3-2 3-2), ), prior prior to start-u start-up. p. 1. Prior Prior to asse assemb mbliling ng lube lube oil oil pipi piping ng,, remov remove e scal scale, e, weld weld slag slag,, rust rust and and any any othe otherr matt matter er that that coul could d concontamina taminate te lube lube oil. oil. Confirm: Confirm: • Comp Complet lete e and close closed d lube lube oil syste system. m. • Crankca Crankcase se filled filled to the correc correctt level level with appro appropria priate te oil. oil. • Prope Properr and and correc correctly tly instal installed led lube lube oil filters filters.. • Opera Operatio tiona nall and viewab viewable le oil press pressure ure transd transduc ucer er or gauge gauge,, oil filter filter differe differenti ntial-p al-pres ressu sure re transtransduce ducers rs or gaug gauges es,, and and oil tempe temperatu rature re RTD or indica indicator. tor. 2. Start Start pre-lub pre-lube e pump. pump. Record Record oil press pressure, ure, oil filter filter differe differenti ntialal-pre press ssure ure,, and and oil temper temperatu ature. re. MinMinimum imum oil oil pres pressu sure re is 30 psig psig (2.1 (2.1 barg) barg) for for effe effect ctiv ive e flus flushi hing ng.. Do not not exce exceed ed 90 psig psig (6.2 (6.2 barg barg). ). 3. Flush Flush conti continuo nuous usly ly for one hour. hour. Oil Oil filter filter differe differenti ntialal-pre press ssure ure must must not increa increase se more than than 10% 10% of meas measure ured d oil press pressure ure into into the filter. filter. Record Record the oil press pressure ure,, oil filter filter differe differenti ntial al press pressure ure,, and and 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 than than 10°F 10°F (5.5°C) (5.5°C) durin during g an hour hour of flush flushing ing invali invalida date te the syst system em clean cleanlin lines ess s test, test, due due to oil visc viscos osity ity chang change. e. TABLE 3-2 3-2 Oil Flush Cleanliness Cleanliness Requirement Requirements s 4. After After one one hour hour of pre-lu pre-lube be flus flushi hing ng,, if difdifferential ferential pressure pressure or temperature temperature increase increases s ISO-4406 GRADE 13/10/9 exce exceed ed the limits limits abov above, e, conti continu nue e flush flushing ing.. If Grade Particle Size Particles the lube lube oil filter filter differe differenti ntial al press pressure ure Requirement µm/ml Oil Sample Allowed exce exceeds eds chan change ge filter filter limits limits,, stop stop the prepre/13 Greater th than 4 40 to to 80 80 lube lube pump pump and and chan change ge the the oil oil filt filter. er. To ensu ensure re syste system m clea cleanli nline ness ss,, re-set re-set time time and /10 Greater th than 6 5 to to 10 10 continu continue e flushing flushing until until the compress compressor or /9 Greater th than 14 14 2.5 to to 5 achie achieve ves s a conti continuo nuous us hour hour of flush flushing ing NAS-1638 GRADE 5 within differentia differentiall pressure pressure and temperature temperature Particle Size Range Grade 5 Maximum increase increase limits. limits.

See ISO-44 ISO-4406 06 "Intern "Internati ation onal al Standar Standard dHydrau Hydraulilic c flui fluid d power power - Fluid Fluids s - Meth Method od for for codcoding leve levell of conta contamin minati ation on by solid solid partic particle les" s" and/o and/orr NAS-1638 NAS-1638 "Nation "National al Aerosp Aerospac ace e StandStandard, Aerospace Aerospace Industries Industries Associa Association tion of America, America, Inc. - Cleanlines Cleanliness s Requirement Requirements s for Parts Parts Used in Hydrauli Hydraulic c System Systems" s" for compl complete ete info informa rmati tion on.. Use a comp compet eten entt oil oil lab lab for for samp sample le testing.

Page Page 3-10 3-10 of 32 32

µm/100ml Oil Sample

Particles Allowed

5 to 15

8,000

15 to 25

1,424

25 to 50

253

50 to 100

45

Over 100

8

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Frame Oil System Components

Oil Connections(see Ariel outline drawing for details)

System Components

A1 Packager connection from oil pump A2 A3 A4

A5 A6 A7

A8

1. Y-Strainer 2. Compressor driven oil pump (with safety relief valve for Packager connection to oil filter pressure regulation, or in models with a separate regulating valve (6), for relief) Oil connection from compressor crankcase (oil sump) 3. Thermostatic control valve, 170°F (77°C) nominal ratLube oil compressor inlet connection to gallery tube ing - required (purchase separately from Ariel) Oil flows to crankshaft main bearings, connecting rod 4. Pre-lube oil pump - required (shown with oil heating cirbearings, crosshead pins, and bushings. cuit, when applicable), or auxiliary pump. 5. Optional duplex oil filter Pressure regulating valve return connection to oil 6. Oil filter sump (when applicable) 7. Pressure regulating valve with overflow return to oil Filter vent return connection to oil sump (when applicsump (when applicable) able on some models) 8. Oil cooler - required 9. Check valve Oil tubing connections from frame gallery tube to top 10. Heater (when applicable). and bottom of crosshead guides to lubricate 11. Temperature indicator crossheads. 12. Pressure indicator Compressor crankcase oil drain (oil sump drain) 13. Pressure indicator/shutdown connection

A9 Pre-lube/recirculation/heater connections (4)

FIGURE 3-4 Standard Frame Lube Oil Schematic

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Page 3-11 of 32



System Components 1. Separate lube oil reservoir (oil sump) - required, vent reservoir to above frame height Packager connection from compressor-driven oil 2. Heater pump 3. Y-Strainer - required (supplied unmounted by Ariel) 4. Check valve Packager connection to oil filter 5. Compressor driven oil pump (with safety relief valve for pressure regulation, or in models with a separate Packager connection - oil from compressor crankcase regulating valve (13), for relief) Lube oil compressor-inlet-connection to gallery tube 6. Oil cooler - required and bearings 7. Thermostatic control valve, 170°F (77°C) nominal rating - required (available option from Ariel) Pressure regulating valve return connection to crank8. Pre-lube oil pump - required (with oil heating circuit, case (when applicable on some models) when applicable), or auxiliary pump Filter vent return connection to the crankcase (when 9. Optional duplex oil filter applicable on some models) 10. Temperature indicator 11. Pressure indicator Oil tubing connections from frame gallery tube to top 12. Oil filter and bottom of crosshead guides to lubricate 13. Pressure regulating valve with overflow return to crossheads crankcase (when applicable for some models) Compressor crankcase oil drain 14. Pressure indicator/shutdown connection

Oil Connections(see Ariel outline drawing for details) A1

A2 A3 A4 A5 A6 A7

A8

NOTE: See ER-93 for further details about dry sump lubrication systems.

FIGURE 3-5 Optional Dry Sump Frame Lube Oil Schematic - Typical Page 3-12 of 32

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Oil Strainer An oil strainer installed upstream of the pump prevents debris from entering the pump and damaging it. Ariel supplies a 30 mesh (595 microns) strainer on all JGH:E:K:T compressors. It is located on the auxiliary end of the crankcase below oil level. Remove the strainer basket and wash it in an appropriate solvent whenever lubricating oil is changed.

Oil Pump & Regulating Valve The oil pump constantly supplies oil to all journal bearings, bushings, and crosshead sliding surfaces. The crankshaft drives it by a chain and sprocket to provide adequate oil flow to bearings when the compressor operates at the minimum speed rating (typically half of maximum rated speed). JGH:E:K:T compressors maintain oil pressure with a spring-loaded safety relief valve within the pump head. To adjust, remove the dust cap to expose the safety relief valve adjustment screw.

FIGURE 3-6 Typical Lube Oil Pump

When installing a new oil pump on a compressor or after maintenance on an existing oil pump, Ariel recommends priming the pump (wetting the gears with oil) before start-up to ensure proper operation. Upon compressor start-up after oil pump replacement, oil pressure should immediately reach 50-60 psi. If oil pressure fails to reach 50-60 psi immediately, shut down the compressor and correct the problem. Dry oil pump gears sometimes contribute to the problem. Be sure to wet the gears with oil at any new oil pump installation.

Oil Cooler An oil cooler is required to remove heat from the frame lube oil.When sizing an oil cooler, consider temperature and flow rate of both cooling medium and lube oil. Insufficient cooling water flow rate is the primary cause of high oil temperatures. Mount cooler as close to the compressor as possible with piping of adequate size to minimize pressure drop of both lube oil and cooling medium. The Application Manual lists required cooling water temperature and flow rate to properly cool oil with Ariel supplied coolers. The Ariel Performance Program lists oil heat rejection data for each frame in the frame details section (contact Ariel for details).

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Oil Temperature Control Valve The lube oil system requires a thermostatic valve to control compressor oil temperature. A thermostatic valve is a three-way valve with a temperature sensitive element. As the oil heats, the sensing element opens the third port in the valve. Ariel recommends a thermostatic valve with a 170°F (77°C) element. Install the valve in mixing mode to more directly control oil temperature into the frame (see FIGURE 3-7).

Oil Filter

Thermostatic control valve configuration may vary from this schematic depending on valve size. Valve connections A-B-C are marked on the valve.

FIGURE 3-7 Thermostatic Valve in Mixing Mode

All compressor frames require oil filters to remove particle contamination that can damage equipment and oil. Contaminants that damage equipment include wear particles from equipment, airborne particles such as dust or sand, and particulates in new oil. Contaminants that damage oil include oxidized oil components and air bubbles. • Ariel filters are not designed for reverse flow often caused by pumping oil out of the compressor through the filter. This can invert and tear the filter media, sending dirty oil to crankshaft bearings. • With canister style filters, always drain oil filter housing before element removal or dirty oil will be sent to crankshaft bearings. • Keep new filter elements sealed in their original packaging during storage. Visually inspect filter internal/external surfaces prior to installation. Do not install damaged, corroded, or contaminated filters. • When using a remotely mounted duplex filter, leave the frame mounted spin-on or canister filter in place as a polishing filter. At a minimum, leave frame mounted filters in place until they are verified free of solid contaminants of any size. JGH:E:K:T2/4 compressors ship with simplex, spin-on, non-bypassing, resin-impregnated filters as standard. Spin-on filters carry a 5 micron nominal and 17 micron absolute rating. The Beta ratings are ß5 = 2 and ß17 = 75. Many spin-on filters fit an Ariel compressor, but very few meet filtration ratings of Ariel filters. Do not use aftermarket filters. JGE:K:T/6 compressors ship with simplex or duplex cartridge style pleated synthetic filters as standard. Cartridge filters are rated as 1 micron nominal and 12 micron absolute filters. The Beta ratings are ß1 = 2, ß5 = 10 and ß12 = 75. Pressure gauges monitor pressure drop across the filter. High differential pressure indicates a plugged filter. Ariel recommends lube oil filter replacement every 6 months, or 4000 hours, or when oil filter differential pressure at normal operating temperature reaches 10 psid (0.7 bard) for spin-on filters or 15 psid (1.0 bard) for cartridge filters, whichever comes first. On start-up, differential pressure may exceed the filter replacement limit until the oil reaches operating temperature. On the same schedule, or with every main oil filter change, clean the sintered element in the small oil filter of the force feed lubricator.

Simplex Spin-on Filter Replacement NOTE: Replace oil filters only with Ariel approved filters. 1. Remove old filter, clean filter base surfaces, and verify old gasket is removed. 2. Inspect new filter for damage or debris. Do not install damaged or dirty filters. Never operate a unit with a damaged or leaking oil filter. 3. Apply clean oil to the filter gasket and thread the filter with gasket onto the base. Page 3-14 of 32

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4. Tighten the filter one turn after the filter gasket contacts the base. 5. Use the compressor pre-lube pump to fill the oil filter with oil and purge air from the oil system. Manually filling the filter with oil can introduce debris on the clean side of the filter. This debris can damage the compressor to the point of catastrophic bearing failure. 6. After starting the unit, check for leaks, and retighten if necessary.

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. Remove 3/4” NPT drain plug and drain oil completely.

1. 2. 3. 4.

3/4" NPT Vent Top Cover Top Cover O-Ring Spring Plate Assembly 5. Filter Element 6. Filter Vessel 7. Drain Plug

2. While the oil drains, open 3/4” NPT vent. 3. After the oil drains completely, remove top cover, spring plate assembly, and filter element. 4. Inspect interior of filter vessel for debris. Clean if needed. 5. Place new element over seat in bottom of vessel. 6. Re-install spring plate assembly. 7. Inspect cover O-ring for wear. Replace if needed. 8. Close drain. 9. Install cover. Torque nuts to 70-80 Lb x Ft (95-110 N•m). 10. Use compressor pre-lube pump to fill the oil filter with oil and purge air from the oil system. Manually filling the filter with oil can introduce debris on the clean side of FIGURE 3-8 Typical Oil Filter Vessel the filter. Debris can damage the compressor to the point of catastrophic bearing failure. 11. Release trapped air through vent. Check for leaks.

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Duplex 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. Open equalization valve to equalize pressure between the filters. 2. The triangle indicator on top of the transfer valve handle points toward the active filter. Turn transfer valve handle until it stops to make the inactive filter the active filter. 3. Close equalization valve. 4. Verify no oil is flowing through the inactive filter. Vent trapped air, if necessary. 5. Follow steps of "Simplex Filter Cartridge Replacement" for the inactive filter.

Compressor Pre-lube System Ariel compressors must be pre-lubed anytime the crankshaft is turned and prior to starting. Ariel strongly recommends an automated pre-lube system to extend driveline component life.

FIGURE 3-9 Typical Duplex Oil Filter

Ariel requires automated pre-lube systems for compressors that meet any of the following criteria: • Electric motor driven compressors. • Unattended-start compressors, regardless of driver type. • Compressor models JGC:D:F:Z:U:B:V and KBZ:U:B:V. See FIGURE 3-4 for pre-lube circuit design. NOTE: The pre-lube return into the frame must be upstream of the oil filter. For on-demand compressor applications, the pre-lube pump can circulate oil continuously through the bearings while on standby. Ariel requirements are based on a pre-lube pump sized for 25% of frame oil pump flow to ensure oil flow to bearings, bushings, and oil-filled clearances prior to turning or start-up (see Appendix C for frame oil pump flow rates). Pre-lube pressure shall be 30 psig (2.1 barg) at the oil gallery for a minimum of 2 minutes prior to turning or starting. NOTE: A 10 to 15 minute pre-lube is required after: • Any major drive line maintenance • The main lube oil system is drained • Oil filter replacement

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Instrumentation: Automated pre-lube systems require a start permissive logic and instrumentation to satisfy the minimum required pressure and duration at the oil gallery inlet. It is highly recommended that the compressor low oil pressure shutdown be Class B. Inhibited time shall be no longer than 10 seconds after idle speed is achieved on gas engines or start initiation for electric motors. If the compressor fails to achieve 45 psig (3.1 barg) oil pressure within 10 seconds after reaching engine idle speed or electric motor start initiation, ensure shutdown and correct the cause. Repeat prelube before each start attempt. 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.

Flushing to Change to a PAG Lubricant Cylinder and frame lubrication systems require flushing when changing to or from a PAG lubricant or when applying a PAG lubricant to newly installed equipment.

Recommended Flushing Oil The preferred flushing oil is soluble in both the original oil and PAG lubricant. A linear diester is preferred, such as Shell Corena DE 150 or Mobil Rarus 829. If this is unavailable, use the desired PAG lubricant fill oil as the initial flushing oil.

Flushing Procedure Below is a general flushing procedure recommended to change from mineral or PAO oils to a synthetic PAG lubricant. 1. Drain old oil from frame while the oil is still warm. 2. Drain all supply and return lines upstream of the frame lube oil filter, filter housing (if applicable), coolers, and other peripheral equipment in the lubricant supply loop. 3. Remove standing oil in the frame and guide compartment low points. Remove as much oil as possible with a vacuum hose. If heavy deposits are visible, remove them as best as possible by hand using clean, dry, lint-free rags. 4. Install new frame lube oil filters. 5. Remove and either clean or replace the Y-strainer element. 6. Reconnect oil piping and install drain plug in frame. 7. Connect a diaphragm pump upstream of the frame mounted oil filter. 8. Feed the diaphragm pump flushing oil (see "Recommended Flushing Oil") from a clean reservoir and prime the lube oil system. Prime until old oil is purged from oil passages and flushing oil steadily flows from all bearings and crosshead bushings. 9. Drain frame. Remove standing oil in the frame and guide compartment low points. Remove as much oil as possible with a vacuum hose. 10. Remove diaphragm pump and plug connection upstream of frame mounted oil filter. 11. Install drain plug in frame. 12. Refill the frame with flushing oil (see "Recommended Flushing Oil"). REV: 3/17

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13. Circulate flushing oil for at least four hours, and up to 24 hours if needed, to loosen existing debris and deposits. Monitor lube oil filter differential pressure during flushing. The filter may need to be taken off line or changed several times during flushing, as loosened deposits tend to plug it quickly. 14. Drain the first flushing oil from the frame while the oil is still warm. Take care to also drain all supply and return lines, filter housing, and other peripheral equipment in the lubricant supply loop. If standing oil remains in the frame, remove as much as possible with a vacuum hose. 15. Refill the frame with the PAG lubricant of the recommended viscosity for the application. At this time, as much as 2-3% of the initial oil may still remain in the system. Circulate this fill for at least four hours and up to 24 hours if possible. Replace filters as needed. 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 second flushing (PAG lubricant) oil from the frame while the oil is still warm. 17. Refill frame with PAG lubricant of the recommended viscosity and circulate for at least four hours. At this point, the initial oil remaining in the system should be less than 0.5%. Sample the oil and examine it for any emulsion or debris. If the oil is clear and bright (a slight haze is acceptable), then continue normal operation and top off as needed. If significant emulsion or debris remains, then conduct one more drain and flush. If the frame uses the same oil as the force-feed cylinder lubrication system, the overflow line on the lubricator box can remain attached to the frame auxiliary end cover. If the frame oil and cylinder oil are incompatible or of different ISO grades, disconnect overflow line on the lubricator box (see "Independent Oil Supply"). Fill the force-feed lubricator box with the same oil used to lubricate the compressor cylinders/packings. To change the lubricator box lubricant from a mineral oil or synthetic PAO lubricant to a PAG synthetic lubricant: 1. Drain old oil from lubricator box. 2. Rinse lubricator box with flushing oil (see "Recommended Flushing Oil"). 3. Fill lubricator box with PAG lubricant to be used for the cylinders.

Flushing the Force Feed Lubrication System Common Oil Supply 1. If installed, drain the sintered filter and clean the element with solvent. 2. Drain the lube line upstream of the force feed pump inlet. 3. Drain tubing/manifold feeding the force feed pump(s). 4. Remove the purge/vent connection on the outlet of each force feed pump. 5. Use a purge gun filled with clean/filtered flushing oil (see "Recommended Flushing Oil") to prime each force feed pump by forcing oil through the pump inlet and out the purge/vent connection. 6. Reconnect the purge gun to the force feed pump purge/vent outlet connection. If pumps are paired together at their outlets, close one of the purge/vent connections. 7. For the zone fed by the force feed pump being primed, disconnect lube lines at the inlet of the double-ball check valves.

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8. Place paper towels or suitable collection containers beneath each disconnected lube line to catch flushing oil during priming. 9. Prime flushing oil from the force feed pump purge/vent connection to downstream tubing, divider blocks, and check valves. 10. Prime until no air bubbles appear in the flushing oil at all disconnected lube lines in the zone. 11. Reconnect lube lines to double ball check valves in the primed zone. 12. Continue to prime 2 fluid ounces of oil per throw through the primed zone. 13. Repeat steps 6 thru 12 for remaining zones.

Independent Oil Supply 1. Drain daytank, oil filter, and lube lines upstream of the force feed pump inlet. Oil trapped in piping can be vacuumed out or flushing oil can be pumped through these lines to displace the old oil. 2. If installed, drain the sintered filter and clean the element with solvent. 3. Drain tubing/manifold feeding the force feed pump(s). 4. Remove the purge/vent connection on the outlet of each force feed pump. 5. Use a purge gun filled with clean/filtered flushing oil (See "Recommended Flushing Oil") to prime each force feed pump by forcing oil through the pump inlet and out the purge/vent connection. 6. Reconnect the purge gun to the force feed pump purge/vent outlet connection. If pumps are paired together at their outlets, close one of the purge/vent connections. 7. For the zone fed by the force feed pump being primed, disconnect lube lines at the inlet of the double-ball check valves. 8. Place paper towels or suitable collection containers beneath each disconnected lube line to catch flushing oil during priming. 9. Prime flushing oil from the force feed pump purge/vent connection to downstream tubing, divider blocks, and check valves. 10. Prime until no air bubbles appear in the flushing oil at all disconnected lube lines in the zone. 11. Reconnect lube lines to double ball check valves in the primed zone. 12. Continue to prime 2 fluid ounces of flushing oil per throw through the primed zone. 13. Disconnect the purge gun and install cap for purge/vent connection. 14. Repeat steps 6 thru 12 for remaining zones. 15. Install a new oil filter. 16. Reconnect lube lines between daytank and pump inlets. Reinstall sintered filter (if provided). 17. Place a collection container beneath the disconnected lube line near the force feed pump inlet connection. 18. Add enough flushing oil to the daytank to prime the system up to the disconnected line in step 17. 19. Collect oil until no air bubbles appear in the flushing oil. 20. Reconnect feed line to force feed pump.

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21. Bleed trapped air by loosening tube connections nearest each pump inlet.

Cylinder and Packing Lubrication The cylinder lubrication system injects lubrication into cylinder bores and packings. The system consists of an oil supply, an oil filter, a force feed lubricator pump, divider blocks, pressure indicators, check valves, and flow monitoring shutdown devices. The system is progressive; each piston in the divider block must complete a cycle before the system cycles again. This type of system offers better lubrication precision and eases monitoring.

Force Feed Lubricator The force feed lubrication system oils the compressor cylinders and piston rod packings. Oil flows to the suction side of the force feed lubricator pump directly from the pressure side of the frame lubrication system, or from an overhead tank. A self-contained oil reservoir oils the force feed lubricator worm gear and cam. The force feed lubricator sight glass shows the reservoir oil level. 1. 2. 3. 4.

Auto-Relief Valve (ARV) ARV Manifold Priming Stem Pump Plunger Stroke Adjustment Screw 5. Lock Nut 6. Lubricator Oil Fill Connection 7. Sight Glass 8. Mounting Flange Capscrews (4) 9. Drain Plug 10. Priming Pump Connection 11. Pump Outlet to Distribution Block 12. Inlet to ARV 13. Lubricator Overflow 14. Force Feed Lubricator Sprocket 15. O-ring 16. Inlet Header 17. Pump Inlet from Header 18. Rupture Disk Assembly

FIGURE 3-10 Typical Force Feed Lubricator

Priming the Pump Use filtered oil when priming the pump and force feed system (minimum 5 micron nominal filter). Refer to FIGURE 3-11 during priming.

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1. Remove and discard the plastic plugs in the pump inlet and outlet. 2. Apply thread sealant (user supplied) to inlet and outlet line fittings. 3. Install the inlet and outlet fittings on the pump. 4. Connect the inlet line to the inlet fitting. 5. Introduce oil into the inlet line using a clean priming pump filled with cylinder oil connected to the priming pump connection. If installed, open oil supply valve from day tank (located upstream from pump). 6. Wipe the pump priming stem clean and lubricate with oil. 7. Manually prime pump by using a priming pump or by pressing the pump priming stem repeatedly (if connected to a day tank) until clean, air-free oil flows from the outlet fitting. 8. Connect outlet line to outlet fitting. 9. Manually prime pump by using a priming pump until clean, air-free oil flows from the outlet line at the cylinder and packing lube points. 10. Connect the outlet line to the lube point.

1. O-ring 2. Flow Adjustment Screw Locknut 3. Pump Priming Stem 4. Flow Adjustment Screw 5. Pump Inlet 6. Pump Outlet

FIGURE 3-11 Pump Priming and Adjustment

11. After startup, adjust individual pumps to meet required flow rates. See "Pump Adjustment".

Pump Adjustment The flow adjustment screw controls pump flow rate; turning it changes the length of the piston stroke which changes the pump discharge volume. Refer to FIGURE 3-11 during adjustment. 1. Loosen the flow adjustment screw locknut. 2. Lubricate the o-ring beneath the adjustment screw locknut with oil. 3. Turn the flow adjustment screw. Counterclockwise increases flow and decreases cycle time; clockwise decreases flow and increases cycle time. 4. Check force feed lubricator data plate or Ariel lube sheets for correct cycle time. Adjust flow until desired cycle time is achieved with the force feed system operating. 5. Repeat Steps 2 and 3 as needed. 6. After adjustment to the proper cycle time, tighten the adjustment screw locknut. NOTE: Inconsistent flow can occur if pump stroke is set below 20% of maximum stroke. A dust seal inside the flow adjustment screw holds the priming stem stationary during operation.

Auto-Relief Valve (ARV) An auto-relief valve (ARV) is a mechanical valve that protects force-feed lubrication systems from overpressure conditions. Unlike a rupture disk assembly, the ARV is reusable and does not expel oil onto the compressor skid.

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1. Spring Barrel 2. O-ring 3. Washer 4. Indicator Pin 5. Spring


6. Spring Piston 7. O-ring Retainer 8. Manifold 9. Pressure Pin 10. Intermediate Barrel

11. ARV Inle t 12. Adapter 13. E-Clip 14. ARV Outlet (Bypass Port)

FIGURE 3-12 Auto-Relief Valve Components

ARV Operation When a force-feed pump encounters a downstream restriction, pump discharge pressure increases. If discharge pressure exceeds ARV cracking pressure, the ARV bypasses excess oil back to the lowpressure inlet side of the pump (FIGURE 3-13 – High Pressure). Bypassing oil limits the pressure created by the pump. The pump will operate in bypass condition until either the divider valve noflow device times out due to lack of flow or pressure downstream of the pump decreases allowing the ARV to close (FIGURE 3-13 – Pressure Relieved). When the ARV begins bypassing, an indicator pin protrudes from the top of the ARV indicating an over-pressure condition. The indicator pin is a “tattle tale” and remains protruding after the ARV bypasses oil (FIGURE 3-13 – Pressure Relieved). Two bypass conditions are possible:

FIGURE 3-13 ARV Operation

Intermittent blockage downstream of the pump - A brief condition or one-time event that prevents the shutdown device from timing out and allows the compressor to continue to operate. Significant blockage downstream of the pump - A condition of long enough duration to cause the shutdown device to timeout and shutdown the compressor. After downstream blockage/restriction removal, the indicator pin can be manually reset by depressing the indicator pin until it is flush with the ARV housing.

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Force Feed Lube Blow-Out Fittings, Rupture Disks, and Tubing Force feed lube pump TABLE 3-3 Blow-Out Fittings, Replacement Rupture Disks, & Tubing discharge lines require Standard Tubing blow-out fittings and the Blow-out Replacement Rupture Disk properly rated rupture Fitting Rating Ariel Size Rating Color Ariel P/N disk installed. The disk Ariel P/N psig (barg) P/N in. (mm) psig (barg) color should show at the A-0080 3250 (224) A-0124 Purple 1/4 x 0.035 fitting blow-out hole. A PT0200CB A-3531 3700 (255) A-3536 Yellow (6.4 x 0.9) 5100 (352) system blockage causes (304 SS) wall pressure build-up that A-3532 4600 (317) A-3537 Red ruptures the disk. Vent A-3533 5500 (379) A-3538 Orange 1/4 x 0.065 ing the system through PT0201CD A-3534 6400 (441) A-3539 Pink (6.4 x 1.7) 10,200 (703) the rupture disk causes (316 SS) wall A-3535 7300 (503) A-3540 Blue the no-flow shutdown switch to shut down the compressor. Ariel force feed lube blow-out fitting rupture disks are color-coded to identify rupture pressure ratings. Some disks come with half the finished face coated. If the disk color coating is less than half the face surface, the color may not show through the small centered blow-out hole when installed in the blow-out fitting. When this happens, a visual inspection for color coding may not indicate the correct disk is installed, and fitting disassembly is required to confirm the proper disk installation. To correct this issue in the future, the finished face of rupture disks supplied to Ariel after March 2005 are completely coated with color. Disks need not be replaced because of this change and existing disk stock may be used-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. When installing a rupture disk, tighten the blow-out hex fitting cap to 40 lb. x in. (4.5 N•m) torque. Do not over tighten cap or blow-out pressure may decrease, which may increase nuisance shutdowns.

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Distribution Blocks Distribution blocks consist of three to seven divider valves and an optional bypass block fastened to a segmented baseplate. Viton Orings (90 Durometer) seal between the divider valves and baseplate and between baseplate segments. Check valves are installed at all lube port outlets. Divider valves contain metering pistons that discharge a predetermined amount of oil with each cycle in a single line, progressive lubrication system. NOTE: Pistons are matched to a specific divider valve. Do not try to place a different piston into a divider valve. Single or twin valves may be externally singled or cross-ported. Plug unused outlets when singling or cross-porting. Bypass blocks can replace a divider valve section to eliminate the lubrication points. Plug both outlets below the bypass block. A bypass block can mount in any baseplate loc6. Check Valve 1. Piston ation, but it requires at least three working 2. Crossport Plate 7. Intermed iate Blocks 8. Outlet Port (correct divider valves in the block assembly (i.e. 3. Inlet Port position is off-center 4. Inlet Block bypass blocks cannot be used on 3-section toward inlet block) 5. O-Rings baseplates).

9. End Block 10. Tie Rod Nut 11. Tie Rod 12. Divider Valve 13. Valve Screw

FIGURE 3-14 Typical Distribution Block The baseplate contains the divider valve inlet and outlet connections, interrelated passageways, and built-in check valves. All lubricant piping to and from the distribution block connects to the baseplate. The baseplate consists of one inlet block, three to seven intermediate blocks, one end block, and three tie rods. The number of baseplate intermediate blocks determines the number of divider valves allowed. Each distribution block requires a minimum of three divider valves.

Distribution Block Assembly NOTE: See specific frame Parts Book for available divider valve assembly drawings, parts lists, and repair kits. 1. Thread three tie rods into inlet block until the ends flush with the top surface of the block. 2. Slide Intermediate blocks onto tie rods. Verify all O-rings are installed and discharge ports are off center toward the inlet block. 3. Slide end block onto tie rods. 4. Lay base plate assembly on a flat surface. Use "Recommendations for Torque Accuracy" to tighten the tie rod nuts to the correct torque listed in TABLE A-3. 5. Mount the divider valves with O-rings onto the base plate. Use "Recommendations for Torque Accuracy" to tighten the socket head cap screws to the correct torque listed in TABLE A-3.

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Divider Valve Bypass Pressure Test Lubricant can leak (by-pass) from a divider valve when the divider valve piston becomes worn. Pressure test or replace all divider valves every twelve months. Testing verifies the piston fits tightly enough in the divider valve bore for adequate pressure to force oil into the injection point. The supplier pressure tests all new Ariel divider valves. To test distribution blocks for valve by-passing requires a manual purge gun with a pressure gauge capable of developing 5000 psig (350 barg). Ariel offers an optional force feed lubrication hand purge gun with a pressure gauge (see Section 1). Pressure test each divider valve one at a time, complete with pin indicators installed. Distribution Block All Outlets Open

Testing "T" Divider Valve Block

Testing "S" Divider Valve Block

FIGURE 3-15 Pressure Testing Divider Valves 1. For new divider valves, verify working piston section fastener torque is 75 lb x in (8.5 N•m). Loosen the section fasteners, then step-torque them first to 40 lb x in (4.5 N•m), and then to 75 lb x in (8.5 N•m). Used divider valves can be tested “as is”, with approximate section fastener torque verified after testing. 2. Place the distribution block in an open container with all base outlets open. Connect purge gun filled with room temperature [65°F (18°C)] 10 wt. (ISO 32) mineral oil to the divider block inlet. Pump the purge gun to purge air from the divider block assembly. Verify that oil flows freely from all outlets (see FIGURE 3-15 “Divider Block All Outlets Open”). Testing with 10 wt. mineral oil at 65°F (18°C) simulates divider block operation at 120°F (49°C) with 40 wt. (ISO 150) mineral oil. If 10 wt. (ISO 32) mineral oil is unavailable, use 40 wt. (ISO 150); however, the pressure test will be less sensitive in detecting a bypassing divider valve. 3. The divider block assembly should cycle at less than 300 psi (2068 kPa) while purging at a steady rate. Cycle pressures above 300 psi (2068 kPa) indicate inhibited piston movement, possibly caused by the piston rubbing the bore, oil contamination, part geometry, or bore distortion due to over-tightening the section fasteners. If re-torquing the valve section fails to improve cycle pressure, replace the divider valve section. Do not attempt to alter the piston/bore fit by polishing components. 4. For divider valves stamped with a “T” (for “twin”), use a 1/8 inch (3.2 mm) pipe or tubing plug to plug only one base outlet when testing that side of the piston, and leave all other outlets open. Plug and test each base outlet of divider valves stamped with a “T” one side at a time. See FIGURE 3-15 “Testing ‘T’ Divider Valve”. Individual testing of each outlet ensures both sides of the piston build adequate pressure. For all divider valves stamped with an “S” on the front (for “single”), plug the

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working outlet as well to test both sides of the piston for by-passing simultaneously. See FIGURE 315 “Testing ‘S’ Divider Valve”. 5. Pump the purge gun until the pressure gauge indicates 3000 psi (20684 kPa). Hold this pressure for 5 seconds, then increase it to 3500 psi (24132 kPa). Stop pumping at 3500 psi (24132 kPa). 6. Start timer and monitor the pressure drop from 3500 psi (24132 kPa) for 30 seconds. Check discharge outlet(s) plug(s) to confirm no external leaks. Also check O-rings for external leakage. If the valve bypasses rapidly, repeat the test to ensure the bypass wasn’t due to trapped air. New valves should not exceed a 400 psi (2758 kPa) pressure drop in 30 seconds. Used valves should not exceed 1000 psi (6895 kPa) pressure drop in 30 seconds. If pressure drops exceed these limits, the divider valve fails the test. 7. Repeat Steps 4 thru 6 for the remaining outlets on the divider block assembly. NOTE: Test distribution blocks at higher pressures if the application dictates higher system operating pressure. If a divider valve fails, replace it. Discard worn divider valves. If the tested valve passes the test, relieve the pressure, move the plug to the next outlet, and repeat the test for all divider valves. When all divider valves either pass this pressure test or are replaced, reassemble the distribution block, purge it with the proper force feed lubricant, and put it into service. This distribution block pressure test procedure is not infallible. Ariel recommends periodic tests for proper cylinder bore lubrication rates and/or aftermarket devices that measure flow.

Balance Valves Install balance valves on low-pressure lube lines to artificially increase lube line pressure and reduce differential pressure between lube points downstream of a divider block. Important considerations: • Set and maintain balance valves downstream of a divider block within 500 psi (3400kPa) of each other or less. The closer the balance valve set pressures, the more reliable the system. • Avoid situations in which the balance valve set pressure is the greatest contributor of pressure to the divider block immediately upstream. • With a balanced divider block, the upstream divider block pressure gauge should exhibit no erratic needle movement as the divider block cycles. To maintain the force feed lube system, record the maximum injection pressure indicated at each divider block gauge, balance valve set pressures, and divider block cycle time at least once a day for each zone in the system. See Appendix E. Do not adjust balance valves prior to operating the unit. Verify the tightness of all fittings and fix any known leaks. To remove any trapped air or gas in the force feed lube system, use a high-pressure hand purge pump and the same oil recommended for the cylinder application to purge it. DO NOT USE ANY OTHER FLUIDS FOR PURGING! Call the Ariel Response Center for details about purchasing a hand purge pump. To prepare for balance valve adjustment: 1. Start the compressor and bring the cylinders up to normal operating pressure. 2. Allow operating pressures to stabilize. 3. See the cylinder lube sheets for balance valve locations and proper spring type for each device.

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Adjustment of Balance Valves Fed by a Divider Block 1. Select one divider block that feeds one or more balance valves nearest the compressor cylinder/packing. 2. For each balance valve downstream of the selected divider block, loosen the balance valve lock nut and rotate the adjustment cap counter-clockwise until the cap is loose. Some residual pressure may remain on the balance valve gauge. 3. Monitor the selected divider block gauge for one minute and record the minimum and maximum pressures in Appendix E. 4. Calculate the balance valve set pressure by multiplying the maximum recorded pressure by 0.85.

1. Balance Valve 2. Balance Valve Pressure Gauge 3. Adjustment Cap

4. Lock Nut 5. Divider Block Pressure Gauge 6. Divider Block

FIGURE 3-16 Balance Valves Fed by Divider Block

5. Set balance valve(s) downstream of the selected divider block to the pressure calculated in step 4 by rotating the adjustment cap clockwise to increase pressure. Set pressure within ±50 psi (3.5 bar) of the calculated value. 6. Monitor the divider block gauge for one minute and record the minimum and maximum pressures in Appendix E. The difference between the minimum and maximum should not exceed 1200 psig (82.7 barg). If it does, repeat steps 2 through 6. 7. Tighten the balance valve lock nut. DO NOT lock wire the adjustment cap. 8. Repeat steps 2 through 7 for any remaining divider block that feeds one or more balance valves nearest the compressor cylinder/packing. 9. After setting all balance valves in the force feed system, operate the system for 4 to 6 hours, then repeat step 6 for each divider block.

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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. Select one secondary divider block that feeds one or more secondary balance valves nearest the compressor cylinder/packing. 2. For the selected secondary divider block and secondary balance valves, perform steps 2 through 7 in "Adjustment of Balance Valves Fed by a Divider Block" above. 3. Repeat steps 1 and 2 for any remaining secondary divider blocks that feed one or more secondary balance valves nearest the compressor cylinder/packing. 4. Select one primary divider block that feeds one or more primary balance valves located prior to a secondary divider block or lube point. 5. For the selected primary divider block and balance valves, perform steps 2 through 7 in "Adjustment of Balance Valves Fed by a Divider Block" above.

1. Primary Balance 5. Primary Divider 8. Secondary Block Pressure Divider Block Valve Gauge 9. Secondary 2. Primary Balance 6. Primary Divider Balance Valve Valve Pressure Block 10. Secondary Gauge 7. Secondary Balance Valve 3. Adjustment Cap Divider Pressure 4. Lock Nut Block Pressure Gauge Gauge

FIGURE 3-17 Primary/Secondary Divider Block System

6. Repeat steps 4 and 5 for any remaining primary divider block that feeds one or more balance valves located prior to a secondary divider block or lube point. 7. After setting all balance valves in the force feed system, operate the system for 4 to 6 hours, then repeat steps 3 through 7 in "Adjustment of Balance Valves Fed by a Divider Block" above for each primary or secondary divider block.

Force Feed System Design, Operating Parameters, and Conditions See specific packager data to confirm designed gas composition, operating pressures, and speed. If operating outside design conditions, system may need to be reviewed. To optimize force-feed lubrication system operation, Ariel uses these general guidelines: 1. Maintain lube rates within prescribed limits and cycle times as low as possible (normally 10 sec minimum) to lubricate each point as frequently as possible. 2. Multiple pumps may be manifolded to achieve required lubrication rates.

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3. Do not operate pumps below 20% of full stroke or they become inconsistent. When two or more pumps are manifolded to feed one distribution block, adjust them equally. Start with pumps wide open, and adjust them together so that when break-in cycle time is set, the pumps stroke about the same. After break-in period, adjust the pumps in the same manner, provided the final pump stroke is not too short. Try to keep the stroke greater than 20% of maximum; a shorter stroke produces unreliable pump output. If needed, close one pump to stop its flow and open the other(s) to make the “normal” cycle time, and maintain a stroke greater than 20% in the functioning pump(s). 4. In some applications, one divider valve delivers lubrication to both a packing and a cylinder to optimize lubrication system operation. In some applications, cross-ported divider valves deliver the proper proportion of lubricant to a given point. 5. During operation, verify oil fills the lubricator reservoir sight glass to the overflow line. Reservoir oil lubricates the worm gear and cam; it does not flow through the system. The reservoir also catches force feed lube pump leakage. Add oil only if needed to raise reservoir oil level. See . 6. Ariel primes the force feed system with mineral oil. If tubing is missing, or if the system is drained, fill and prime the system through a 1/8 inch plug on the discharge end of the force feed lubricator pump. 7. Prime the force feed lubrication system with a proper priming pump just prior to starting the compressor (see Section 1 for pump illustration). Use clean force feed lubricating oil of same type and grade as used in service. Do not use any other fluid type or grade to prime. 8. For recently overhauled units, adjust force feed cycle time for maximum delivery. Loosen adjusting screw locknut. Turn plunger stroke adjustment screw to the full up position. Tighten adjusting screw locknut. After two hours of operation or before leaving site, reset to “normal” cycle time.

Common Oil Supply FIGURE 3-18 shows the force feed lube system installation when compressor frame lube oil is also used for cylinder and packing lubrication. 1. Frame Oil Gallery 2. Single Ball Check Valve 3. Sintered Bronze Filter (if applicable) 4. Force Feed Lubricator Pump 5. ARV or Rupture Disk 6. Pressure Gauge 7. Divider Valves/Distribution Block 8. Fluid Flow Monitor No-Flow Timer Shutdown Switch 9. Double Ball Check Valve 10. Top Cylinder Injection Point 11. Bottom Cylinder Injection Point 12. Packing Injection Point

FIGURE 3-18 Force Feed Lubrication System Common Oil Supply

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Independent Oil Supply When cylinders and packing require oil different from frame oil, the force feed lubricator system requires an independent oil supply system (see FIGURE 3-19). An elevated tank must supply pressurized force feed lube oil at a minimum of 3 psig (0.2 barg) to the force feed pump inlet manifold.

1. Oil Supply Tank 2. Oil Filter (max. 5 micron) 3. System Inlet 1/4-inch NPT (female) customer connection 4. Sintered Bronze Filter (if applicable) 5. Force Feed Lubricator Pump 6. ARV or Rupture Disk 7. Pressure Gauge 8. Divider Valves Distribution Block 9. Fluid Flow Monitor No-Flow Timer Shutdown Switch

To prevent force feed oil from contaminating compressor frame oil, disconnect lubricator box overflow tubing from compressor frame and direct it to a suitable drain system. Independent force feed lube systems require oil with a viscosity below 1100 cSt at the lubricator pump inlet (e.g. ISO 320 at 73°F (23°C), contact lube supplier about specific lubricants). Possible ways to ensure force feed pump is fed oil during suction stroke: • Increase pipe and fitting size from tank to force feed pump.

FIGURE 3-19 Force Feed Lubrication System Independent Oil Supply

1/4-inch NPT (female) overflow. Pipe or tube to appropriate isolatedc ustomerc onnection. Do not drain to crank case.

• Heat the oil. • Heat trace and insulate the line from the tank. • Pressurize the supply tank (tank must be designed for pressure).

Force Feed Lubrication Conditions CAUTION: To prevent personal injury, verify driver or compressor cylinder gas pressure cannot turn compressor crankshaft during maintenance. 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.

Cycle Time Lubricant flow rates are measured in seconds per cycle of the distribution block. The calculated break-in and normal cycle times are stamped on the lubricator box data plate. These cycle times are calculated based on the gas analysis, operating conditions, and applied speed specified in the compressor order. If gas conditions were not supplied with the compressor order, the data plate/lube sheet rates default to clean, dry, 0.65 specific gravity, sweet gas and cylinder MAWP. If the applied speed is not specified, the cycle time is based on maximum rated speed of the frame or cylinders, whichever is less. The lube sheets in the Ariel Parts Book state gas conditions and list the base rate multiplier at each lube point.

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Break-in Rate - Set the break-in lube rate about twice the recommended daily rate (150% minimum); i.e. set the break-in cycle time about half the normal cycle time (67% max.) to increase lube rate. Maintain break-in rate for 200 hours of operation for new equipment. Contact Ariel if existing pump is incapable of minimum flow rate required. Lube Rate and Speed - Recommended lube rates for break-in or normal operation, in seconds per cycle, are calculated at the frame rated speed (RPM) stamped on the frame data plate or the cylinder rated RPM stamped on the cylinder data plate, whichever is lower. Lube rate decreases with speed, (as compressor actual running speed decreases, cycle time increases, reducing lube rate): (RPMmax ÷ RPMactual) x cycle time seconds from lube plate = cycle time seconds at actual running speed. See the Ariel Parts Book Lubrication Sheets for the Cycle Time (seconds) vs. RPM (compressor speed) table at various running speeds at stated gas operating conditions and lubricant. Adjusting the cycle time changes the lubrication rate for all the compressor cylinders and packings supplied by a particular pump. To change the lubrication rate for only one cylinder or packing requires individual divider valve changes. Contact your packager or Ariel for information. To set proper force-feed lubricator pump flow rate, read or measure the cycle time from the installed device. For a magnetic cycle indicator assembly, time the cycle from initial indicator pin movement at the fully retracted position to the time when the pin returns to the fully retracted position and just begins initial movement out again. Adjust the lubricator pump to provide the required cycle time. NOTE: Pump output can become inconsistent if flow rate is set too low. “Force Feed System Design, Operating Parameters, and Conditions” on page 3-28 Changes in operating conditions (such as gas properties or pressures, temperatures, flow requirements, or cylinder re-configuration) require lubrication rate re-calculation and possible force-feed lubrication system alteration. Consult the Ariel Packager Standards, the Packager, and/or Ariel.

Under/Over Lube Inadequate lubrication causes premature wear of piston and packing ring materials. Indications of under lubrication are black, gummy deposits in the distance piece, packing case, cylinder, and valves. When symptoms indicate under lubrication: • Verify proper operation of force feed lubricator pumps. • Confirm distribution block cycle time matches the lube sheet or force feed lubricator data plate. • Verify all tubing and fitting tightness; check for leakage. Check fittings inside cylinder gas passages. • Pressure test or replace divider valves to ensure they do not bypass. Over lubrication can result in excessive oil carryover into the gas stream, and increased valve and gas passage deposits. Valve plate breakage and packing failure may also indicate over-lubrication.

Cylinder Lubrication Paper Test 1. Remove head end head and position piston for the desired cylinder at inner dead center. 2. Using light pressure, wipe the cylinder bore with two layers of regular unwaxed cigarette paper together. Begin at the top and wipe downward about 20° along the bore circumference. The paper against the bore surface should be stained (wetted with oil), but the second paper should not be soaked through. 3. Repeat the test at both sides of the bore at about 90° from the top, using two clean papers for each side. Paper against the bore surface not stained through may indicate under-lubrication; both papers stained through may indicate over-lubrication. In either case, Ariel normally recommends changing lubrication rate accordingly and repeating all paper tests until passed. REV: 3/17

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4. Repeat this procedure for all cylinders. If the test indicates a lubrication rate reduction or increase for a cylinder, change in 5% increments by adjusting cycle time at the force feed lube pump (see “Pump Adjustment” on page 3-21). Repeat oil film testing, for affected cylinders, after 24 hours of operation. 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 appear to produce an adequate film or flow, but dilution will reduce lubricant effectiveness below requirements.

Coolant System Requirements Coolant flow = number of packing cases x 1 US gallon per minute (gpm), minimum for each inch of piston rod diameter (No. cases x 0.149 l/min for each mm of piston rod diameter). Based on using a solution of 50/50 treated water/glycol solution. See FIGURE 3-20. Example: JGK/2 with 2.0 inch (50.8 mm) diameter piston rod. 2 packing cases x 1 gpm per inch of rod diameter x 2.0 inch rod diameter = 4 gpm (2 packing cases x 0.149 l/min per mm of rod diameter x 50.8 mm rod diameter = 15.1 l/min)

1. Packing Case 2. Throttling Valve 3. Isolation Valve 4. Surge Tank 5. Strainer 6. Water Pump 7. Cooler 8. Thermostatic Valve

Cooler size = number of cases x 70 BTU/minute/inch PI = Pressure Indicator of rod diameter (number of cases x 0.05 kW/mm of TI = Temperature Indicator FI = Flow Indicator rod diameter). Pressure drop depends on several LG = Level Gauge factors including flow rate and fluid, but should generally be at least 10-30 psi (0.7-2.1 bar). Coolant into FIGURE 3-20 Typical Packing Cooling the packing must not exceed 130°F maximum (54°C System max.). Lower coolant temperature increases heat transfer from the packing and may be required in high-pressure applications.

Coolant inlet pressure should be at least 40-80 psi (2.8-5.5 bar). 300 psi (20.7 bar) is the maximum to preserve the o-ring seal between the cups.

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Section 4 - Part Replacement Major frame assembly components include the crankcase, crankshaft and bearings, connecting rods, chain drive system, crossheads, and guides/distance pieces. Removable end covers, an aluminum top cover, and crosshead guide side covers provide easy access to internal components. Below are general guidelines to follow during maintenance. 1. Cleanliness during part replacement: • Use lint-free wiping cloths. • When not working on a frame with access covers removed, cover it to protect the interior from rain, dust, and other airborne debris. • Place removed components in a safe place away from work area to prevent damage. Take precautions to keep parts from rusting. 2. Gasket maintenance: • When dismantling the machine, carefully inspect gaskets at non-pressure locations. If damaged, replace them. • Always replace pressure-retaining gaskets. • Always apply an anti-seize lubricant to both sides of metallic gaskets. 3. For major overhauls, drain and flush the crankcase. If replacing a connecting rod assembly, piston, piston and rod assembly, crosshead-balance nuts, or crosshead, weigh component parts and compare to the Compressor Balancing Record included in the parts manual with each compressor. If there are weight changes, recalculate opposing throw reciprocating weight differential. See “Opposed Throw - Reciprocating Weight Balancing” on page C-5 . 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. 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 Component replacement often requires manually turning the crankshaft to position a throw in one of two positions: inner dead center or outer dead center. During normal operation, crossheads slide back and forth in the crosshead guides. In the inner dead center position, the crossheads slide toward the crankcase as far as possible. In the outer dead center position, the crossheads slide away from the crankcase as far as possible (see figure below). Some procedures require a dial indicator with magnetic base to locate the precise inner or outer dead center. At other times, a procedure may require turning the crankshaft so a throw occupies its highest or lowest position. In the figure below, the throw on the left is in its highest position and the throw on the right is in its lowest position.

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Page 4-1 of 49

Section 4 - Part Replacement Inner Dead Center Position

For models JGH:E:K:T Outer Dead Center Position

Highest/Lowest Throw Position

FIGURE 4-1 Throw Positioning

Variable Volume Clearance Pocket (VVCP) A VVCP changes the clearance volume of the head end of a cylinder. The amount of clearance depends on the position of the clearance pocket piston. Users turn the piston/stem assembly counterclockwise to increase clearance, and clockwise to decrease it. In the event that gas begins to leak from the VVCP vent, replace the V-packing or seal within the VVCP.

VVCP Removal CAUTION: Completely vent the cylinder before VVCP removal. Attempting to remove the VVCP without venting may result in equipment damage, personal injury, or death. 1. After venting the cylinder, loosen the locking handle so the adjustment handle can turn freely. Turn the adjustment handle. CAUTION: A hard to turn adjustment handle or piston stem may indicate pressurized gas trapped within the VVCP. See VVCP Disassembly caution below. 2. Tighten the locking handle. 3. Disconnect the packing vent.

1. 2. 3. 4. 5.

Cylinder Eyebolt Packing Vent Locking Handle Adjustment Handle 6. Flange Bolts 7. Bellows Thread Protector

FIGURE 4-2 Typical VVCP

4. Remove plastic plug from eyebolt hole and thread an eyebolt into the eyebolt hole. 5. Use the Ariel supplied eyebolt to support the weight of the VVCP. 6. Remove all flange bolts and slide the VVCP out from the cylinder. The Ariel Performance Program contains approximate VVCP weights. If the VVCP does not slide out easily, loosen the valve cap bolts. If it still does not slide out easily: a. Remove head end valves. b. Clean the area between the VVCP head and the cylinder. c. Loosen discharge bottle supports. 7. Discard the head gasket and transport the VVCP to a suitable work area for disassembly.

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Section 4 - Part Replacement

VVCP Disassembly The VVCP piston ring is not gas-tight to allow a nearly balanced gas pressure, which eases VVCP adjustment with the cylinder pressurized. Gas pressure behind the VVCP piston normally vents when the cylinder vents. Process debris or rust around the piston ring can form a seal that traps gas within the VVCP assembly, sometimes at substantial pressure. 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. 1. Place the VVCP on a table, adapter up. 2. The bellows thread protector grips a lip on the adjustment handle. Use pliers to pull the bellows from the adjustment handle lip. Do not tear the bellows. 3. Remove locknut. 4. Remove adjustment handle. The adjustment handle is a tapered fit onto the piston stem; use a soft hammer or puller to break the fit. 5. Thread the locking handle off of the piston stem. Leave the bellows thread protector attached to the locking handle.

1. Locknut 2. Adjustment Handle 3. Adjustment Handle Lip 4. Bellows Thread Protector 5. Locking Handle 6. Grease Fitting

7. Adapter 8. Match Mark 9. Piston Stem 10. Socket 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. Depending on size, a VVCP may have two to four socket head bolts. Use a marker to draw match marks on the side FIGURE 4-3 VVCP Disassembly/Assembly of the VVCP where the adapter and head join at each socket head bolt location. Loosen the socket head bolts evenly and incrementally to release any potentially high-pressure gas. Do not breathe gas emission from VVCP.

7. Remove socket head bolts and turn the adapter counterclockwise to thread it off of the piston stem. Place adapter flange up next to the head. 8. Remove the piston stem and piston assembly from the head. The piston stem and piston are permanently joined; do not attempt to disassemble them. 9. Remove the piston ring from the piston. REV: 3/17

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10. Depending on VVCP size, Ariel machines a groove for the O-ring into either the face of the head or the base of the adapter. Remove and discard the O-ring. 11. Some adapters use a bolted retaining plate while others use a snap ring and spring retainer: a. Retaining Plate - Remove retaining plate bolts and retaining plate. b. Snap Ring and Spring Retainer • Thread a nut onto a threaded rod that is a few inches longer than the adapter height. • Slide a washer wider than the main bore of the adapter down to the nut. • Insert the threaded rod end with no nut into the main bore of the adapter until it protrudes from the base of the adapter.

1. Washer 2. Snap Ring 3. Threaded Rod 4. Nut 5. Backup Ring 6. Spring Retainer 7. Compression Spring 8. V-Packing or Seal

• Slide a washer wide enough to overlap spring retainer but less wide than the snap ring onto the protruding threaded rod. • Thread a nut onto the threaded rod protruding from the base. Tighten nut until compression spring compresses enough to separate spring retainer from snap ring. • Use snap ring pliers to remove snap ring. • Remove nut from threaded rod. Remove threaded rod and washers from adapter main bore.

FIGURE 4-4 Spring Compression for Snap Ring Removal

12. Remove spring retainer, compression spring, and backup ring from the adapter counterbore. 13. Remove V-packing or seal from adapter counterbore. Find a strong, foot-long metal 3/16 inch rod or pipe and bend about .75 inch at 90°. Insert the rod into the adapter counterbore and slide the .75 inch beneath the V-packing or seal. Pull up on the rod or pipe to pull the V-packing or seal from the adapter counterbore.

VVCP Reassembly Clean all VVCP parts of all debris, rust, etc. Replace worn or damaged parts. 1. With flange up, place the head on a table. With flange up, place the adapter beside the head. 2. Depending on VVCP size, Ariel machines a groove for the O-ring into either the face of the head or the base of adapter. Oil and insert a new O-ring into O-ring groove. 3. Install the piston ring onto the piston. 4. Oil the head bore, then insert stem and piston assembly into the head cavity. 5. Oil the adapter counterbore and insert V-packing or seal. The V-packing or seal consists of five partitions; insert V-packing or seal into the counterbore with the thickest partition down and the thinnest partition up. NOTE: When properly installed, a V-packing gives resistance when the stem is inserted. If there is no resistance, remove the stem and use a solid cylinder of wood or metal to tap the V-packing or seal two or three times into the counterbore to ensure proper seating. 6. Insert backup ring into adapter counterbore. Page 4-4 of 49

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7. Insert compression spring into adapter counterbore. 8. Place spring retainer on top of the compression spring. 9. Some adapters use a bolted retaining plate while others use a snap ring and spring retainer: a. Retaining Plate - Place the retaining plate on top of the spring retainer and press down to compress the compression spring. Install retaining plate bolts through the retaining plate and into the adapter. Tighten the retaining plate bolts hand tight. b. Snap Ring and Spring Retainer • Compress the compression spring (see FIGURE 4-4). • Use snap ring pliers to install the snap ring above the spring retainer. • Remove the nut from the threaded rod, then remove the threaded rod and washers from the main bore of the adapter. 10. Grease piston stem threads and install adapter onto piston stem. Install adapter as far as possible on the piston stem, then turn the adapter counter-clockwise to align the socket head bolt match marks on the adapter flange with the match marks on the head. 11. Install the socket head bolts. Tighten socket head bolts hand tight. 12. Install locking handle onto the piston stem, but do not lock it. Assemble the locking handle with the bellows thread protector facing up. 13. Slide the adjustment handle onto the piston stem and use a soft hammer to ensure full engagement of the tapered fit. 14. Use the adjustment handle to turn the piston stem counter-clockwise to tighten the seal between the adapter and head, then lock the locking handle. 15. Istall the locknut onto the piston stem and tighten it to prevent the adjustment handle from loosening. 16. Slide thread protector bellows onto the adjustment handle lip and verify that it grips securely. 17. Torque socket head bolts. See Appendix A for proper torque value and torque procedure. 18. Apply 3-4 pumps of all-purpose petroleum grease with a grease gun at the grease fitting.

VVCP Installation Install the VVCP prior to installing valves and torqueing valve caps. Use the Ariel supplied eyebolt to support the weight of the VVCP. 1. Apply an anti-sieze lubricant to both the new head gasket and the cylinder seating surface. Stick the new head gasket to the cylinder seating surface. 2. Slide the VVCP into the cylinder and align the adapter flange bolt holes with the cylinder bolt holes. 3. Lubricate and torque flange bolts per Appendix A. 4. Reconnect packing vent. Verify piston end clearances. See TABLE 1 in Appendix B .

1. Cylinder 2. Head Gasket

3. Eyebolt 4. Packing Vent 5. Flange Bolts

FIGURE 4-5 VVCP Installation

5. Install valves and torque the valve caps. See "Compressor Valves - Removal and Installation" REV: 3/17

Page 4-5 of 49



VVCP Adjustment Users may change VVCP clearance volume with the compressor running or stopped. The expected change in compressor flow and absorbed power depends on compression ratio and properties of the compressed gas. Consult packager instructions regarding where to set the VVCP. Also see the VVCP data sheet in the Ariel Parts Book. To open VVCP to a desired percentage: 1. Loosen the locking handle so the adjustment handle can turn freely. 2. Find the VVCP dimension plate. 3. Subtract fully closed dimension from fully open dimension. The Ariel Performance program also lists these dimensions if the VVCP dimension plate is missing. 4. Multiply the step 3 result by the desired percentage expressed as a decimal.

FIGURE 4-6 VVCP Dimension Plate

5. Add the step 4 result to the fully closed dimension. 6. Turn the adjustment handle until the measurement from the base of the locking handle, when locked, to the top of the adjustment handle equals the step 5 result.

Compressor Valves - Removal and Installation Before servicing any valve, see the correct valve assembly drawing, parts list, and service literature in the Ariel Parts Book. The cylinder cover sheet in the Ariel Parts Book lists the valve originally supplied with each cylinder. Changes in operating pressures, temperatures, RPM, or gas composition may require alternate valve configuration including springing and lift. Contact your Packager and/or Ariel for help in valve selection. 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. 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 • Appropriate Ariel parts list • Appropriate Ariel Maintenance and Repair manual • Calibrated torque wrench with the appropriate range for target values • Lubricant specified in Appendix A • Appropriate personal protection equipment • Bottle brush • Pressurized liquid solvent • Valve Tool Page 4-6 of 49

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Valve Cap Removal Valve Caps on Cast Iron Cylinders or High-Pressure Caps without Spring Energized Seals 1. Slightly loosen all cap screws in steps and evenly on a valve cap; the cap should stay in its original position. If it pushes outward, STOP! Completely vent the cylinder. See Caution above. 2. After the above safety checks and with cap screws still in place but loosened, pry the valve cap out until the O-ring clears the cylinder to confirm proper cylinder venting. Use a pair of pry bars, one on each side of the cap, to remove the cap. 3. Remove cap screws and valve cap. Take care to prevent damage to fasteners. 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. Cap Screw 2. Valve Cap 3. O-Ring

4. Valve Retainer 5. Valve Assembly 6. Valve Seat Gasket

FIGURE 4-7 Valve Cap Assembly for Cast Iron Cylinder

1. Valve Cap 2. Valve Retainer 3. Valve Assembly

4. Valve Seat Gasket 5. Metallic Wire Gasket

FIGURE 4-8 High-Pressure Valve Cap Assembly without Spring Energized Seal

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Valve Cap with Spring Energized Seal 1. Remove cap nuts from long studs. 2. Slightly loosen all hex nuts on each valve cap in steps and evenly. With all the nuts loose, the cap should stay in its original position. If it pushes out of its own accord, STOP! Completely vent the cylinder. See Caution above. 3. After the above safety checks and with hex nuts still in place but loosened, remove hex nuts from short studs. 4. Evenly back off hex nuts on long studs while pulling the valve cap from the cylinder. Use a pair of pry bars, one on each side of the cap, to remove the cap. Ensure the spring energized seal completely disengages from the cylinder before removing the hex nuts from long studs.

6. Valve 9. 2-Piece 1. Hex Nut Wedge Lock 7. Valve Gas2. Cap Nut Washer ket 3. Valve Cap 10. Spring Ener4. Seal Keeper 8. Keeper gized Seal Bolt 5. Retainer

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 long stud hex nuts and valve cap. 6. Inspect seal for damage. If undamaged, the spring energized seal is re-usable. 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 the valve cap removed and the valve retainer still in place, install a valve tool onto the valve center bolt or threaded washer. See Section 1 for an illustration of the tool. 2. It may be necessary to loosen the plastic thumb screws in the valve retainers. In some cylinder classes, the discharge valve retainer is held in place with an O-ring - simply pull the retainer out to remove it. 3. For high pressure applications that use a metallic wire gasket seal under the valve cap, the cylinder vents upon loosening the cap screws. Use the valve tool to unseat the metallic wire gasket. 4. Remove the valve and retainer together. 5. In most cases, the flat metal gasket remains in the pocket. It is difficult to see. A flashlight and a small mirror on an adjustable rod are the best tools to see the gasket clearly. On cylinders with horizontal valves, the gasket may fall into the gas passage. Use a small magnet on a flexible extension rod to remove gasket from cylinder. 6. Head end tandem cylinders may require removal of suction and discharge piping and the cylinder head to access the concentric valve. A concentric valve combines suction and discharge valves in one assembly.

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Valve Installation 1. Coat valve seat gasket with Never Seez. Either insert it into the valve pocket or stick it on the valve. In either case, do not allow the gasket to fall into the gas passage. Replace valve seat gaskets anytime a valve is removed from a cylinder, if the unit has been in service. 2. Install suction valves only in suction pockets and discharge valves only in discharge pockets. The 5. Guard 9. Valve Cap Bolt 1. 12-Point Capscrew 6. Valve 10. Retainer-Keeper valve pockets have (Center Bolt) (Thumbscrew) 7. Cylinder Bore identification plates. 2. Threaded Washer 8. Valve Seat Gasket 11. Valve Cap O-Ring Install all valves with 3. Valve Retainer 12. Valve Cap 4. Seat valve fastener(s) positioned away from the FIGURE 4-10 Typical Valve Assemblies cylinder bore (see Item 1, FIGURE 4-10). If a valve is not marked for suction or discharge, manually depress the valve plate to verify the type. Preferably, use a tool softer than the valve plate material or exercise care to prevent damage to the plate. A suction valve plate may be depressed only from the valve fastener (bolting) side of the valve; a discharge valve plate may be depressed only from the side of the valve that faces the cylinder bore. 3. Use the valve tool to insert the valve and retainer into the pocket together (see tools for your compressor model in Section 1). Verify the valve seats properly in the pocket. When installed correctly, the valve rotates freely by hand. 4. Plastic thumbscrews or o-rings hold valve retainers in position in bottom valve pockets. Tighten thumbscrews just enough to provide friction so retainers and valves in bottom pockets stay in position during valve cap installation. Do not replace plastic thumbscrews with metal. 5. Lubricate a new O-ring with oil and install it in the groove on the valve cap nose. Some high pressure cylinders use a soft metallic wire gasket or spring-energized seal in lieu of the O-ring. Continue to "Valve Cap Installation".

Valve Cap Installation Depending on the application, Ariel compressor cylinders utilize different styles of valve caps. Cast iron cylinders utilize valve caps in which an O-ring on the valve cap seals gas within the cylinder. Forged steel cylinders utilize a valve cap with either a spring-energized seal or a round metallic gasket to seal gas within the cylinder. The valve cap presses the round metallic gasket into a triangular cross section during the torque procedure.

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Page 4-9 of 49



It is critical to torque the valve cap following the torque procedure below. Valve cap bolt failures can occur if the cap is torqued improperly. Draw bolting to full torque in even, gradual steps, without bias on one bolt or cocking the valve cap in the bore. Such bias or cocking can unevenly crush the gasket, which may cause leakage and/or bolt failure. Ensure all threads are clean and free of debris or burrs. Use a bottle brush and pressurized liquid solvent to clean threaded holes thoroughly. Avoid sending debris into cylinder gas passage. Bolts should thread into hole and bottom out on the valve cap by hand without resistance or use of a wrench. If bolts do not thread into hole freely, contact ARC for thread repair instructions.

Torque See Appendix A for information on torque accuracy. For fasteners in a circular arrangement, torque in a crisscross order. For 3-bolt valve caps, make multiple passes using the following pattern: 123, 231, 312 (see figure to the right). Initially torque fasteners to 25% of final torque, then torque them up to 100% in 25% increments. In correct assemblies with new valves, the distance from the underside of the cap to the surface of the cylinder is a uniform 1/8 inch (3 mm). The distance is slightly less with re-worked valves.

FIGURE 4-11 Torquing Sequence

Fastener joints with wire gaskets (pressure packing, and some forged steel valve caps) require multiple rounds of torque after reaching 100% of final torque to properly seat and crush the gasket. Continue in a crisscross pattern until no turns on the bolts are observed. Proper tensioning of gas containment fasteners is critical to ensure safe and reliable operation. CAUTION: Severe personal injury and property damage may result from improperly torqued valve cap bolts. See Appendix A for correct torque and detailed recommendations.

Valve Caps on Cast Iron Cylinders or High-Pressure Caps without Spring Energized Seals 1. Install valve assembly (and high clearance spacer, if applicable), with the valve seat gasket and valve retainer in the valve pocket. See “Valve Installation” on page 4-9. 2. For high-pressure valve caps only: Place a new, round, metallic wire gasket. Always use a new wire gasket when installing a high-pressure valve cap; gaskets are not re-useable. 3. Oil and install a new O-ring on the valve cap. Install the valve cap. 4. For standard fasteners in iron cylinders, lubricate threads and bolt seating surfaces with mineral oil. For stainless steel fasteners or in 1. Cylinder 3. Metallic Wire Gasket steel cylinders, lubricate threads and bolt seating surfaces with 2. Valve 4. Valve Retainer Cap Never Seez regular grade. Do not use Never Seez on standard fasteners. See Appendix A for correct valve cap bolt torque. See FIGURE 4-12 Gasket Crush "Torque" above. NOTE: For high-pressure applications, the valve cap joint design requires pressing a round metallic wire gasket into a triangular cross section (see FIGURE 4-12). This requires multiple passes in a crisscross pattern with the torque wrench. See "Torque" above.

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Valve Caps with Spring Energized Seals 1. Install valve assembly with valve seat gasket and valve retainer in the valve pocket. See “Valve Installation” on page 4-9. Verify valve retainer openings are aligned with the cylinder gas passage. Re-tighten thumb screws, if applicable. 2. Inspect and lightly lubricate spring energized seal with petroleum oil. 3. Install valve cap so the roll pins engage the clearance slots in the seal keeper. Be careful not to gouge the bore, or distort or damage the gasket. 4. Liberally coat the valve cap stud threads and hex nut seating surface with Never-Seez. 5. See Appendix A for correct valve cap fastener torque. See "Torque" above for torque procedure. 6. Continue to torque the valve cap at 100% torque value until no bolt movement is observed. Even minute bolt movement warrants another pass around the valve cap in a crisscross pattern. 7. Tighten cap nuts on long studs, hand wrench tight.

Gas Containment Fastener Torque Checks Per Section 5 (start-up checklists) and Section 3 (Recommended Maintenance Intervals), Ariel recommends checking all gas containment fastener torques by the schedule below and including this schedule in your computerized maintenance management system (CMMS):

1. Valve Gasket 2. Valve 3. Retainer (openings aligned with gas passage) 4. Thumb Screws

5. Roll Pins 6. Seal Keeper 7. Spring Energized Seal 8. Valve Cap 9. Hex nut 10. Cap Nut

FIGURE 4-13 High-Pressure Valve Cap Assembly with SpringEnergized Seal

• Prior to start-up • 24 hours after start-up • 750 hours after start-up • Every 8,000 hours after start-up Per Section 3, re-check any fasteners found loose in any of these intervals after an additional 750 hours. If loosening continues, contact your packager immediately.

Piston and Rod CAUTION: To prevent personal injury, verify neither driver nor compressor cylinder gas pressure can turn the crankshaft during maintenance. 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.

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Piston and Rod Removal NOTE: See Section 1 for illustrations of tools mentioned below. For non-lube cylinders, see “Component Cleaning & Thread Lube for Non-Lube Compressor Cylinders” on page 4-49. 1. Loosen cylinder head bolts. Remove cylinder head and all crosshead guide side covers. 2. Move crosshead to inner dead center. Back off, but do not remove, the crosshead balance nut set screws. Loosen crosshead balance nut with the special slugging wrench. Use the open end wrench for hex nuts or the peg wrench for round nuts, or use the separately purchased hydraulic crosshead balance nut torque tool. 3. In tandem cylinders, where the outboard cylinder bore is smaller than the inboard bore, remove the outboard cylinder. Support such cylinders during removal and installation, to avoid excessive weight on the piston and rod assembly that may bend them. 4. If the piston uses a wear band, measure piston to cylinder clearance at bottom of piston with a feeler gauge. See Appendix B for tolerances. If out of tolerance, replace wearband. 5. Move crosshead to outer dead center, then use the piston nut spanner to turn the piston and rod assembly out of the crosshead. The two dowels on the tool fit the piston nut holes. Remove the crosshead nut from the piston rod. 6. Slide the piston rod entering sleeve over the piston rod threads. With extreme care, slowly slide piston rod through packing so as not to damage wiper or packing rings. 7. For one-piece piston rings, slide the piston rod assembly from the cylinder, then carefully remove the piston rings. For two-piece piston rings (in high pressure applications), slide the piston rod assembly out of cylinder until a fraction of the first ring clears the cylinder. Hold the first ring in the piston groove by hand, or use a band for larger sizes, until the ring clears the cylinder, then carefully remove the ring. This prevents the ring from popping out of the groove and damaging the ring. Remove succeeding two-piece rings and wear band in the same way. Handle all piston rings carefully with clean tools and hands to protect them from nicks, marring, and bending. Despite their toughness in service, some rings are fragile when removed. 8. The weight of the piston and rod assembly is stamped on the head end. Support the piston either manually or with a crane as appropriate as it slides from the cylinder bore. The piston rod must remain parallel with the bore until it leaves the bore completely. Take care not to ding any surfaces.

Piston and Rod Manual Disassembly and Reassembly Piston and Rod Manual Disassembly CAUTION: Trapped gas pressure in hollow pistons can present a personal safety hazard when servicing the piston and rod assembly. Work in a well-ventilated, non-sparking area. Do not breathe gas emitted from pistons when venting trapped gas.

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For models JGH:E:K:T NOTE: Ariel offers a clamping fixture for 1.125 to 2 inches (29 to 51 mm) diameter piston rods.

Section 4 - Part Replacement Nom. Piston Clamping Force Rod Diameter Required Inches (mm) Ton (kN)

1. Securely bolt clamping fixture to a base to prevent it from turning with the piston rod. Place it at a height of about three feet (0.9 m). 2. Verify the clamping fixture saddle where the clamping ring seats, the clamping ring, and the piston rod are clean, dry, and free of any oil. Even a small amount of oil can cause the piston rod to turn in the fixture during torquing, and a small amount of debris clamped under high force can damage a piston rod. 3. Clamp the piston and rod assembly in an appropriate clamping fixture using the appropriate clamping ring for the rod size. Clamp it as close to the collar as possible without fixture interference with the piston. Torque the four fixture cap screws to 344 lb x ft (466 N•m) to prevent the rod from turning. The fixture properly holds the piston rod to prevent damage to the parts and promote safety during disassembly and reassembly.

1.125 (29)

8.67 (19.3)

1.5 (38)

20.4 (45.4)

2 (51)

35 (78)

FIGURE 4-14 Clamping Fixture with Clamping Rings (Ariel P/N D-0961) and Required Clamping Force

2. Torque Multiplier 3. Clamping Fixture 4. Spanner (bolts to 1. Allen Wrench (for piston nut) piston nut setscrews) 5. Torque Wrench

FIGURE 4-15 Piston and Rod Clamping Fixture

4. Remove the setscrews from the piston nut. Use an Allen wrench to force them out by turning them past the small lip formed by staking. 5. Remove piston nut using piston nut spanner. 6. After piston nut removal, slip the piston and collar off the end of the piston rod.

Piston and Rod Manual Reassembly 1. Clean all piston and rod assembly parts thoroughly. Verify piston is internally clean and dry. NOTE: Any reassembly of used parts requires re-cleaning and re-lubrication of threads and seating surfaces. 2. Inspect collar (or collar area on rod, when collar is integral and not separable), piston, and piston nut for nicks, burrs, or scratches. Replace if surfaces are damaged, worn, or galled. Inspect piston ring grooves. If damaged, or ring groove width is out of tolerance, replace the piston (see Appendix B for tolerances). Dress surfaces with a fine grit stone as required. Fit collar and nut into piston to verify the outside diameter fits and turns freely by hand in the piston. 3. Inspect piston rod threads and collar shoulder. Clean, de-burr, and lubricate threads. Install collar and nut onto piston rod to verify inside diameter fits and rotates freely. Tighten piston nut until piston threads protrude to verify freedom of thread engagement. Remove nut and collar. 4. Verify the clamping fixture saddle where the clamping ring seats, the clamping ring, and the piston rod are clean, dry, and free of any oil. Even a small amount of oil can cause the piston rod to turn in

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Page 4-13 of 49



the fixture during torquing, and a small amount of debris clamped under high force can damage a piston rod. 5. Clamp the piston and rod assembly in an appropriate clamping fixture using the appropriate clamping ring for the rod size. Clamp it as close to the collar as possible without fixture interference with the piston. Torque the four fixture cap screws to 344 lb x ft (466 N•m) to prevent the rod from turning. The fixture properly holds the piston rod to prevent damage to the parts and promote safety during disassembly and reassembly. 6. Apply a thin coat of Never-Seez Regular Grade to piston rod shoulder, rod collar locating band, and collar face in contact with piston, then slide collar onto rod. 7. Apply a thin coat of Never-Seez Regular Grade to piston rod threads at the piston end, then slide piston onto rod and collar. 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, 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 4-17. 8. Apply a thin coat of Never-Seez Regular Grade to piston nut threads and piston mating face. Install nut and hand tighten to make up the piston rod assembly. 9. Use the piston nut spanner and clamping fixture to torque piston nut to the torque listed in Appendix A . A torque multiplier may be necessary to achieve required torque. Loosen the piston nut in 1/8 increments without disassembling and re-tighten to required torque. Repeating the torque properly seats components and enhances the integrity of the assembly. NOTE: To calculate torque wrench setting when using a torque multiplier, divide desired fastener torque by the multiplier actual mechanical advantage, not design mechanical advantage. Example: A multiplier with a design mechanical advantage of 4.0, but an actual mechanical advantage of 3.6 requires 442 lb x ft (599 N•m) of applied torque to achieve a 1590 lb x ft (2156 N•m) torque. 10. After tightening, the piston rod should not protrude more than 0.010 inch (0.25 mm) past the piston face. If it does, contact your packager and/or Ariel. 11. Apply a thin coat of Never-Seez Regular Grade to two new Allen set screws. To install a set screw, tighten it 15° past the Allen wrench yield point. Discard the deformed Allen wrench, and use a new Allen wrench to tighten the other set screw in the same way. If Allen wrenches are unavailable, torque the set screws to 165 lb x in (18.64 N•m). 12. Use a punch within 1/16 inch (1.5 mm) of set screw threads to deform the threads and stake set screws in place. FIGURE 4-16 13. Use a calibrated scale to weigh piston rod assembly with piston rings and Staking wear band. Stamp weight on piston head end. Flatten any raised lips to a Set Screw avoid clearance measurement errors. Record weight on a new balance sheet and send to Ariel. See “Opposed Throw - Reciprocating Weight Balancing” on page C-5

Hydraulic Tensioner Tools Proper preload is essential for piston nuts. Ariel offers a hydraulic tensioner tool as an option (see figure below). It is used to assemble and disassemble JGH:E:K:T piston rod assemblies.

Page 4-14 of 49

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1. Piston Nut (with 2 setscrews) 2. Dowel Drive Pin (4 provided) 3. Tensioner Tool (separately purchased, not a part of standard tool box) 4. Puller-Bolt Insert (2 provided) 5. Puller-Bolt Stem 6. Puller-Bolt Nut 7. Tool Piston 8. Piston Return Springs 9. Separately purchased manual hydraulic pump kit may power the tool at this connection. 10. 9/16 inch Hex Pinion Gear Drive 11. Bevel Gear 12. Bushing 13. Adapter Base Plate (3 Provided)

FIGURE 4-17 Typical B-6911 Hydraulic Piston Nut Tensioner Tool for JGH:E:K:T Frames

Hydraulic Tensioner Tool Repair Kits Ariel offers repair kits for hydraulic tensioner tools. Contact the Ariel Response Center for details. Also, the B-6911 tool was preceded by A-9047. See CTB-201 and ER-105.14.1 to convert existing A-9047 tools to B-6911.

Piston and Rod Disassembly with Hydraulic Tensioner 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. Remove the two Allen set screws from the piston nut and discard. 2. Clean and lubricate threaded hole in piston rod. 3. Set up tensioner tool with correct adapter endplate, dowels, and puller-bolt insert for the particular piston and rod. The tool comes with two different size puller-bolt inserts, two pairs of different size dowel drive pins to match each puller-bolt, and three adapter base plates. A change in puller-bolt size requires a change in dowel drive pins. Puller-bolts with wrench flats and dowel drive pins with recessed Allen sockets facilitate removal and installation.

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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. Position tensioner tool with the two dowels inserted into the piston nut. Tighten puller-bolt until tensioner tool is completely tight against the piston rod assembly. CAUTION: 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. Then back off 1/4 turn. 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: The puller-bolt nut of the tensioner tool comes with barring holes to insert a 3/8 inch (9.5 mm) rod to tighten or loosen the puller-bolt. 5. Apply hydraulic pressure to the tensioner tool to stretch piston rod (see Appendix A). Use clean hydraulic fluid in pump/tool system. CAUTION: Do not overpressure torque tool. It can cause tool failure and/or excessive piston rod pre-load, which may cause piston rod failure and/or personal injury. 6. Loosen piston rod nut. Turn the hex pinion drive counterclockwise with a socket wrench. Release hydraulic pressure, remove tensioner tool, and then remove the piston nut.

Piston and Rod Reassembly with Hydraulic Tool 1. Clean all piston and rod assembly parts thoroughly. Verify piston is internally clean and dry. NOTE: Any reassembly of used parts requires re-cleaning and re-lubrication of threads and seating surfaces. 2. Inspect collar (or collar area on rod, when collar is integral and not separable), piston, and piston nut for nicks, burrs, or scratches. Replace if surfaces are damaged, worn, or galled. Inspect piston ring grooves. If damaged, or ring groove width is out of tolerance, replace the piston (see Appendix B for tolerances). Dress surfaces with a fine grit stone as required. Fit collar and nut into piston to verify the outside diameter fits and turns freely by hand in the piston. 3. Inspect piston rod threads and collar shoulder. Clean, de-burr, and lubricate threads. Install collar and nut onto piston rod to verify inside diameter fits and rotates freely. Tighten piston nut until piston threads protrude to verify freedom of thread engagement. Remove nut and collar. 4. Apply a thin coat of Never-Seez Regular Grade to piston rod shoulder, rod collar locating band, and collar face in contact with piston, then slide collar onto rod. 5. Apply a thin coat of Never-Seez Regular Grade to piston rod threads at the piston end, then slide piston onto rod and collar. 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, and the piston has the same number of piston ring grooves on Page 4-16 of 49

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Section 4 - Part Replacement For models JGH:E:K:T 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 4-17.

6. Apply a thin coat of Never-Seez Regular Grade to piston nut threads and piston mating face. Install nut and hand tighten to make up the piston rod assembly. 7. Mark a line across piston and nut prior to torquing to ensure the nut turns. Verify the threaded hole in the rod is clean and oiled. Position the tensioner tool with the two dowels placed into the piston rod nut. Tighten puller-bolt head, until tensioner tool is completely tight against the piston rod assembly. CAUTION: 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. Then back off 1/4 turn. 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: The puller head comes with barring holes to insert a rod to help tighten or loosen the puller, if necessary. 8. Apply hydraulic pressure listed in Appendix A to tensioner tool to stretch the piston rod. To tighten piston rod nut, use a calibrated torque wrench to torque the hex pinion drive to the torque listed in Appendix A . CAUTION: Do not overpressure torque tool. It can cause tool failure and/or excessive piston rod pre-load, which may cause piston rod failure and/or personal injury. NOTE: Periodically calibrate hydraulic pressure gauges for the required pressure. Use optional Ariel hydraulic hand pump kit. 9. Release hydraulic pressure. Reapply hydraulic pressure, loosen piston nut without disassembling, and then re-tighten to the recommended torque. This double-torquing ensures piston assembly integrity. 10. Release hydraulic pressure and remove tensioner tool. Inspect the piston rod at the end of the piston; it should not protrude more than 0.010 inch (0.25 mm) past the piston face. The nut should be flush or recessed. 11. Apply a thin coat of Never-Seez Regular Grade to two new Allen set screws. To install a set screw, tighten it 15° past the Allen wrench yield point. Discard the deformed Allen wrench, and use a new Allen wrench to tighten the other set screw in the same way. If Allen wrenches are unavailable, torque the set screws to 165 lb x in (18.64 N•m). 12. Use a punch within 1/16 inch (1.5 mm) of set screw threads to deform the threads and stake set screws in place. FIGURE 4-18 13. Use a calibrated scale to weigh piston rod assembly with piston rings and Staking wear band. Stamp weight on piston head end. Flatten any raised lips to a Set Screw avoid clearance measurement errors. Record weight on a new balance sheet and send to Ariel. See “Opposed Throw - Reciprocating Weight Balancing” on page C-5

Piston and Rod Installation 1. Install piston rings in cylinder main bore without piston to measure end gaps. Ariel recommends replacing piston rings when the end gap equals three times its original specification. See Appendix REV: 3/17

Page 4-17 of 49



B for specification. 2. Except for non-lube cylinders, liberally lubricate the cylinder bore, piston rod, piston rings, wearbands and piston with compatible cylinder oil. Install rings on the piston with ring gaps staggered. a. For cylinders requiring two-piece piston rings, verify that they are a set by the match marks. Twopiece rings use dots as match marks -verify the dots face the pressure side of cylinder. Piston rings are manufactured as matched sets; mixing ring halves may result in incorrect end gaps. b. For all other rings, see "Piston Rings" below. 3. Slide the piston rod entering sleeve over the piston rod threads. Slide piston rod with piston rings and wear band into cylinder bore. Damage to the packing rings is likely if an entry sleeve is not used. 4. Using a dial indicator, position the crosshead at the inner dead center position. 5. Verify the balance nut and crosshead mating surfaces are flat and free from dings or other disparities. If necessary use a flat stone to smooth the surfaces. 6. Lubricate the piston rod and crosshead threads with Never-Seez Regular Grade. Spin the balance nut onto the piston rod. Turn the piston rod into the crosshead. Visually center the packing flange around the piston rod and torque packing bolts per Appendix A. 7. Set piston end clearance (see Appendix B): a. Using the piston nut spanner, turn the piston rod into the crosshead. b. Place a long feeler gauge equal to the crank end clearance required in the crank end top valve pocket between the piston and the crank end head. c. Snug piston against the feeler gauge so the feeler gauge cannot be pulled out. d. Snug the crosshead nut against the crosshead. e. Tighten the crosshead nut by the slugging method or by hydraulic torquing device. See “Crosshead Installation” on page 4-31 for hydraulic torquing device. f. Tighten the balance nut set screws and be sure to remove the piston nut spanner. 8. See“Crosshead Installation” on page 4-31 for details to re-attach piston rod to crosshead, check piston end clearance, piston rod runout and crosshead clearances, and re-assemble to close cylinder and crosshead guide. See Appendix B and“Piston Rod Runout” on page 4-19. 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.

Page 4-18 of 49

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Section Section 4 - Part Part Replace Replacemen mentt

1. Crosshead 2. Crosshead Nut

3. Set Screw Screw 4. Piston Piston Nut Spanner

FIGURE 4-19 Typical Piston and Rod Installation

Piston Rod Runout Check Check piston piston rod runout runout after after new unit unit insta installa llatio tion, n, unit unit reloca relocatio tion, n, or mainte maintena nanc nce e that that may affec affectt rod runout. TABLE 4-1 JGH:E:K:T Max. PisPosi Positi tion on the the stem stem of a 0.00 0.0001 01 inch inch (0.00 (0.001 1 mm) mm) incr increm emen entt cali calibra brate ted d a dial dial indi indica cato torr agai agains nstt the the pist piston on rod, rod, clos close e to the the pack packin ing g case case.. Set the the ton Rod Runout, Inch (mm) indi indica cato torr to zero zero with with the the pist piston on toward toward the the cran crank k end. end. Bar over over crank crank-Vertical 0.0020 (0.051) (0.051) shaft shaft and and record record indic indicato atorr readin readings gs with the piston piston at mid-s mid-strok troke e and Horizontal 0.0010 (0.025) (0.025) H. E. positi position ons, s, in both both vertic vertical al and horiz horizon ontal tal direc directio tions ns.. Record Record a. Machines with readings falling falling outupward upward verti vertica call rod move moveme ment nt as posi positi tive ve and and downwa downward rd as negnegside the limits require disposition ative ative.. Record Record horiz horizon ontal tal rod movem movement ent toward toward the auxili auxiliary ary end of by Ariel. the the frame frame as posi positi tive ve and and towar toward d the the drive drive end end as nega negati tive ve.. Copy the the table table below below to record record readin readings gs and and compa compare re to TAB TABLE LE 4-1 values.

Piston Rod Runout, Inches Throw Piston @ C. E. Vertical (0°)

1

2

3

4

5

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 @ H. E. Piston @ C. E.

Horizontal (0°)

Mid-Stroke Piston @ H. E.

If a vertical reading is greater than the maximum acceptable, use this procedure to determine component acceptability: Break Break the the bala balanc nce e nut nut loos loose. e. Look Lookin ing g from from the the head head end, end, turn turn the the pisto piston n 90º coun counter-c ter-clo lock ckwise wise,, and and re-torqu re-torque e the balan balance ce nut. nut. Record Record both both vertic vertical al and and horiz horizont ontal al readreadings ings in the the tabl table e belo below. w. If readi reading ngs s are withi within n 0.00 0.0003 03 inch inch of the the origi origina nall runou runoutt readi reading ngs s abov above, e, the the rod is acce accept ptab able le - break break the the bala balanc nce e nut nut loos loose. e. Re-set Re-set C.E. clea clearan rance ce and and re-to re-torqu rque e the the bala balanc nce e nut. nut. If rod runou runoutt is not not withi within n 0.00 0.0003 03 inch inch of the the origi origina nall readi reading ng abov above, e, cont contac actt Ariel Ariel..

REV: 3/17


Secti Section on 4 - Part Part Repla Replace ceme ment nt

For models models JGH:E:K:T

Alternate Piston Rod Runout, Inches Throw Piston @ C. E. Vertical (90°)

1

2

3

4

5

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 @ H. E. Piston @ C. E.

Horizontal (90°)

Mid-Stroke Piston @ H. E.

Vert. Runout Differencea Horiz. Runout Differencea a. Piston Piston @ H. E., E., original minus minus alternate. alternate.

Piston Rings Most Most cylin cylinde ders rs use use one-p one-piec iece e angleangle-cu cutt filled filled PTFE pisto piston n rings. rings. High-pre High-press ssure ure cylin cylinders ders use use two-piec two-piece e thermopla thermoplastic stic rings. rings. Ariel recommend recommends s replacing replacing rings when the end gap increase increases s to three times the new dimensio dimension. n. To meas measure ure end end gaps, gaps, insert insert rings rings in the cylin cylinders ders withou withoutt pisto pistons ns (see (see Appen Appendix dix B for new and maximu maximum m end gap dimensi dimensions ons). ).

Seal-Joint Piston Rings Seal-j Seal-join ointt piston piston rings rings are standa standard rd for tandem tandem comp compres resso sorr cylin cylinde ders rs and and option optional al for doubl double e actin acting g cylcylinders inders.. Seal-jo Seal-joint int rings rings provid provide e a better better seal seal for light light gase gases s and leaka leakage ge minim minimiza izatio tion. n. Seal-jo Seal-joint int piston piston rings rings are directi direction onal al and requi require re correc correctt insta installa llatio tion. n.

Page Page 4-20 4-20 of 49 49

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Section Section 4 - Part Part Replace Replacemen mentt

FIGURE 4-20 Seal-Joint Piston Ring Installation Orientation

High-Pressure Face-Cut Piston Rings Face Face-c -cut ut pist piston on rings rings are typi typica calllly y used used in cyli cylind nders ers with with 2500 2500 psi psi MAWP MAWP or high higher er,, and and gene general 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 with with the the face face cuts cuts toward toward the the high highes estt press pressure ure,, or toward toward the the neare nearest st head head.. Gas Gas press pressure ure in the the wear wear band band area area esca escape pes s past past the the pist piston on rings rings via via the the face face cuts cuts durin during g the the suct suctio ion n strok stroke e to preve prevent nt load loadin ing g the the wear wear band band and and incr increa ease se serv servic ice e life life.. Also, Also, do not not alig align n the the ring ring end end gaps gaps;; stag stagge gerr them them to mini minimi mize ze gas gas leak leakag age. e.

1. Piston Piston Rod 2. Crank End

3. Piston 4. Piston Rings

5. Wear Band 6. Head End

7. Notches 8. Staggered End Gaps Gaps

FIGURE 4-21 High-Pressure Face-Cut Piston Ring Orientation

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Three-Piece Piston Rings This ring style consists of two “outer” rings installed over an “inner” ring. The inner ring rests in the bottom of the piston ring groove. The inner ring and one outer ring have face cuts that install facing the highest pressure or toward the nearest head (see FIGURE 4-22). Install three-piece ring sets with the end gaps staggered to prevent leakage.

Wear Bands Most pistons use a single, one-piece angle-cut filled PTFE wear band. High-pressure cylinders use twopiece thermoplastic wear bands (see ).

FIGURE 4-22 Three-Piece Piston Ring Installation Orientation

Since wear bands do not work as sealing rings, end gap is not critical. Wear band projection beyond the outer piston diameter is important. To check wear band projection, measure piston to cylinder bore clearance at the bottom of the bore. There is no need to remove the piston from the cylinder. Replace wear band before it wears enough to allow the piston to touch the cylinder bore.

Piston Rod Packing The piston rod packing prevents gas from entering the crosshead guide. Piston rod rings within the packing wear over time and need replacement.

Piston Rod Packing Removal 1. Remove piston and piston rod. See “Piston and Rod Removal” on page 4-12. 2. Remove packing diaphragm (if applicable) and oil wiper packing. 3. Disconnect all tubing and instrumentation (if applicable) from packing flange. Ensure there is no debris in the tubing between the check valve and packing flange. Remove the twelve-point cap screws that hold the pressure packing gland to the crank end of the cylinder/head. 4. Typically, the small nuts are not removed from the studs as they hold the packing case together for removal as an assembly. However, some packings are too big to fit through the distance piece or crosshead guide doors, so removal of the small nuts and the packing flange is necessary. For the longer packings, knurled nuts hold the remaining packing assembly together to assist with installation and removal. 5. Remove the pressure packing and take it to a clean place for disassembly. 6. Set pressure packing on a clean surface on its nose cup or cylinder end. Usually, packing cups are marked to represent the assembly order starting with the cup closest to the cylinder as number 1. If the cups are not matchmarked, then match mark the outside diameter of the cups and flange for proper reassembly. Long tie studs hold the pressure packing together. The stud holes are unequally spaced to prevent misalignment of the stack of parts. Remove the nuts and unstack the pressure packing. Replace these nuts each time the pressure packing is serviced. 7. To check ring wear, place assembled rings (note match-marks) on the piston rod. Check end gap clearance. If the ends butt, or nearly butt, replace the rings. See “Types of Piston Rod Packing Rings” on page 4-26 for correct ring orientation.

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8. Pry loose the metal gasket on the end cup with a sharp awl. Do not scratch the sides of the gasket groove. 9. Before reassembly, clean all parts thoroughly.

Piston Rod Packing Reassembly 1. Refer to the pressure packing assembly in your parts book. Ariel supplies parts books with each unit. Contact your distributor to obtain a parts book. Each pressure packing re-build kit includes a pressure packing assembly drawing. 2. Take care not to scratch mating surfaces of the cups. Cup surfaces must be clean and dry for reassembly. 3. To install a new set of rod rings in an existing packing case, inspect case parts for wear. Cups should be smooth and flat on the back side where the rod rings must seal. If cups or grooves are concave or tapered, regrind or relap them. Contact Ariel for appropriate rework thickness dimensions. It is rarely necessary to alter the crosshead side of cups, but if necessary, take care not to destroy the correct side clearance for the renewal rings. NOTE: If premature wear is suspected, see “Force Feed Lubrication Conditions” on page 3-30. 4. Before a packing case installation, disassemble and thoroughly clean it in an appropriate solvent for the intended service. 5. Verify the proper position of each rod ring and FIGURE 4-23 Piston Rod Packing Case cup and, unless non-lube, coat rings liberally Lube Cups with new, clean lubricant before reassembly. Use only the same lubricant in the force feed lube system. If non-lube, see “Component Cleaning & Thread Lube for Non-Lube Compressor Cylinders” on page 4-49. Ensure tie studs are completely threaded into the end cup. Examine all parts for unusual nicks or burrs which may interfere with the free floating of the rod rings in the cups. Take particular care with rod rings made of soft materials, such as bronze or PTFE. It is extremely important to handle and install wiper rings to prevent damage to the scraping edges. If packing case is cooled, see “Cooled Piston Rod Packing” on page 1. 6. Lay out parts on a work bench for progressive installation, with each part in its correct position and the rod rings with their proper faces toward the pressure. Long tie studs hold the pressure packing together. The stud holes are unequally spaced to prevent misalignment of the stack of parts. Note that all rod ring segments are carefully lettered; assemble them accordingly. This is most important for proper sealing. Center side-loaded WAT and AL rings prior to tightening tie stud nuts. Install tie nuts and tighten to the torques in Appendix A. Manually verify all rings move freely, radially, in their grooves. Side-loaded rings are snug, but should still move manually. Center these rings. Packing reassembly: a. Install the studs into the end cup (cup # 1). b. Using cylinder oil, lubricate the cup and the pressure breaker ring or ring set, then install them into cup (see pressure packing assembly drawing for correct orientation). c. Install cup # 2 and repeat Step b for the seal ring sets. REV: 3/17

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d. Repeat steps above for cups #3, #4, etc, until packing case is reassembled per the pressure packing assembly drawing. e. Using a clean oil gun filled with cylinder oil, squirt oil into the lube fitting(s). If the packing is assembled correctly, the oil will come out the lube cup. If not, disassemble the packing and correct the error. f. Using pressurized air, repeat the above process for vent and purge lines. g. For cooled packings the cooling circuit must be pressure tested (see “Cooled Piston Rod Packing” on page 1. 7. For new installations, carefully clean all accumulated dirt in the lines and compressor. Any foreign material lodges in the packing and becomes destructively abrasive. 8. Replace the end cup gasket. Verify the gasket surface in the packing counter bore on the crank end of the cylinder/head is clean and not scratched. 9. Reinstall complete packing case assembly with oil supply point on top. Use rod packing bolts to pull packing into place. 10. Reinstall packing diaphragm (if applicable) and wiper packing. 11. Reinstall piston and rod. See “Piston and Rod Installation” on page 4-17. 12. After tightening the crosshead nut, visually align the packing, to maintain a uniform clearance between the packing case bore and the piston rod. Tighten rod packing bolts evenly in a criss-cross pattern to the recommended torque in Appendix A. This procedure squares the pressure packing on its nose gasket. Rod packing bolt tightening on high pressure cylinders requires a torque multiplier. 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. Retighten tie stud nuts. Reinstall tubing connections and instruments (if applicable). Take care not to cross-thread tubing nuts. Tubing nuts must be tight. NOTE: After pressure packing installation, see “Force Feed Lubricator” on page 3-20 to prime the force feed lube system and obtain recommended lubrication rates for new machine break-in. Priming may be necessary after extended down time. Break-in lube rates are approximately twice the normal rates, or half the normal indicator pin cycle time. 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.

Reassembling and Testing Cooled Packing Cases In the event of disassembly, the procedures below detail the reassembly of cooled rod packing cases and testing for proper assembly. See also “Piston Rod Packing Reassembly” on page 4-23 and “Types of Piston Rod Packing Rings” on page 4-26.

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Reassembly See pressure packing assembly in the parts book supplied with the unit. Contact the distributor to obtain a parts book. A pressure packing assembly drawing comes with each pressure packing re-build kit. Cooled cases are lapped. Take special care not to scratch cup mating surfaces; it can cause significant problems. Cup surfaces must be clean and dry for reassembly. 1. The cups are numbered on the outside diameter. Assemble them in consecutive order, starting with the end cup. The offset studs allow the cups to fit only one way. 2. Ensure the tie studs thread completely into the end cup. Install the proper ring facing the proper direction in the groove. Do not scratch lapped faces when sliding parts onto tie studs. 3. Install next cup. Install the rings and verify installation of the two (2) small O-rings around the coolant holes.

FIGURE 4-24 Cooled Packing Turnaround Cups

4. Repeat step 3 to assemble remaining parts in consecutive order per the packing case drawing. 5. Install tie stud nuts. Tighten 10-24 nuts to 20 lb-in. and 1/4”-20 to 72 lb-in. Verify all rings move freely, radially, in the grooves. Side loaded WAT and AL rings are snug, but should move manually.

Testing 1. Verify 100% function for all internal passages. Blow dry, oil-free compressed air through the connection taps on the flange and verify that air exits at the proper holes. Air applied to the connection tap stamped “Coolant In” should exit the connection tap stamped “Coolant Out”. Air applied to the tap stamped “Lube” should exit the appropriate cup on the inside diameter of the case. 2. Pressure leak test packing cases as follows: a. Plug the “Coolant Out” connection. b. Apply 60 to 100 psig dry, oil-free compressed air to the “Coolant In” connection through a ball valve with a calibrated pressure gauge located between the ball valve and packing case. c. Close the ball valve and disconnect the air supply. There should be no pressure drop for 5 minutes, minimum. 3. Disassemble, inspect, correct, re-assemble, and re-test any case that fails testing. To aid sealing, bolt a packing case into place in a cylinder head with properly torqued original packing retention bolts.

Long Two-Compartment Intermediate Packing Compressors supplied with long two-compartment distance pieces include an intermediate packing assembly that seals around the rod between the outboard and inboard distance pieces. This packing assembly includes a single AL ring set. For lubricated service, the force feed lube oils the top of the ring set at a very low rate because this ring set is not subject to cylinder pressures and temperatures. The end-to-end seal in the cup and the low lube rate of AL ring sets, ensures newly installed rings run virtually dry for the first few hours of operation. To avoid damage to the rings and rod, copiously oil the ring set during installation, before rod REV: 3/17

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installation. Use only the same lubricant in the force feed lube system. If non-lube, see “Component Cleaning & Thread Lube for Non-Lube Compressor Cylinders” on page 4-49 .

Types of Piston Rod Packing Rings There are several types of piston rod packing rings depending on the application. Below are those used in Ariel JGH:E:K:T compressors.

“P” Pressure Breaker This single ring is cut radially into three equal segments. It breaks down or slows gas flow without sealing it completely.

FIGURE 4-25 “P” Pressure Breaker

“UP” Pressure Breaker This single solid ring breaks down or slows gas flow without sealing it completely.

FIGURE 4-26 “UP” Pressure Breaker

“P1U” Pressure Breaker This two-ring set allows controlled leakage in one direction only and installs in the first or second packing cup (closest to the piston). The first ring (pressure side) is one-piece with a single radial cut; the second ring is solid and has a bore larger than the rod diameter.

FIGURE 4-27 “P1U” Pressure Breaker

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“BTR” Single-Acting Seal Set This three-ring set seals in one direction only. The first ring (pressure side) is radially cut. The second ring is tangentially step cut and made of the same material as the first ring. These two rings are doweled to stagger the cuts from one ring to the other. The third ring is called a back-up ring. It is radially cut and has a bore larger than the rod diameter. This allows the radial joints to form a tight gas seal. This ring needs no dowel.

FIGURE 4-28 “BTR” Single-Acting Seal Set

“BD” Double-Acting Seal Set This two-ring set consists of tangentially step cut rings doweled to stagger the tangential cuts from one ring to the other. This double acting set seals in either direction. In cylinders operating near atmospheric pressure, it prevents air from entering the cylinder. Install with the match mark letters facing towards the cylinder.

FIGURE 4-29 “BD” Double-Acting Seal Set

Double "WAT" Double-Acting Seal Set In this three-ring PTFE set, the first two rings (pressure side) are radially cut; the third is tangentially step cut. The last two rings are doweled to stagger the cuts from one ring to the other. The first ring, along with the center ring, forms a wedge that overcomes rod friction and holds the ring set against both groove faces during either direction of rod FIGURE 4-30 Double “WAT” Double-Acting travel. Use this ring set primarily for low pressure Seal Set applications. WAT rings must be centered when installed in the packing case.

“AL” Double-Acting Seal Set This five-ring PTFE set functions like a double-ended “WAT” ring set. AL rings must be centered when installed in the packing case.

FIGURE 4-31 “AL” Double-Acting Seal Set

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“BT” Single-Acting Seal Set This two-ring set seals in one direction only. The first ring (pressure side) is radially cut; the second is tangentially step cut. The rings are doweled to stagger the cuts from one ring to the other and form a tight gas seal.

FIGURE 4-32 “BT” SingleActing Seal Set

“BTUU” Single-Acting Seal Set This four-ring set seals in one direction only. The first ring (pressure side) is radially cut; the second is tangentially step cut. These rings are doweled to stagger the cuts from one ring to the other. The third and fourth rings are solid and have bores larger than the rod diameter, allowing the radial joints of the first two rings to form a tight gas seal.

FIGURE 4-33 “BTUU” Single-Acting Seal Set

“CU” Single-Acting Seal Set This three-ring set seals in one direction only. The first ring (pressure side) is radially cut. The second ring is tangentially cut. The first two rings are doweled to stagger the cuts from one ring to the other. The third ring is a solid back-up ring and has a bore larger than the rod diameter, allowing radial joints of the first two rings to form a tight gas seal.

FIGURE 4-34 “CU” Single-Acting Seal Set

“CUU” Single-Acting Seal Set This four-ring set seals in one direction only. The first ring (pressure side) is radially cut; the second is tangentially cut. These rings are doweled to stagger the cuts from one ring to the other. The third and fourth rings are solid and have bores larger than the rod diameter, allowing the radial joints of the first two rings to form a tight gas seal. FIGURE 4-35 “CUU” Single-Acting Seal Set

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“STU” Single-Acting Seal Set This three-ring set seals in one direction only. The first ring (pressure side) is solid, with radial grooves on the pressure side. The second ring is tangentially cut. The third ring is solid.

FIGURE 4-36 “STU” Single-Acting Seal Set

“CR” Single-Acting Seal Set This three-ring set seals in one direction only. The first ring (pressure side) is radially cut. The second ring is tangentially cut. The first two rings are doweled to stagger the cuts from one ring to the other. The third ring is called a back-up ring. It is radially cut and has a bore larger than the rod diameter to allow the radial joints to form a tight gas seal. FIGURE 4-37 “CR” Single-Acting Seal Set

“3RWS” Oil Wiper Set The three rings in this set are radially cut and doweled to stagger the cuts from one ring to the other. They keep crankcase oil out of the packing and cylinder. Assemble with the blank face towards the oil (crankcase) and the slotted side towards the pressure packing.

FIGURE 4-38 “3RWS” Oil Wiper Set

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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.

Crosshead Removal NOTE: See Section 1 for illustrations of tools mentioned below. 1. Remove crosshead guide side covers and (head end) cylinder head or unloader. 2. Move crosshead to its inner dead center position. Back off, but do not remove, the crosshead nut set screws. 3. Loosen crosshead nut with the special slugging peg or open end wrench, depending on nut type. Or use separately purchased hydraulic crosshead nut torque tool.

4. End Plate 1. Shoe Area 5. Thru Bolt 2. Bushing Lock Nut 3. Crosshead Pin

6. Crosshead Nut 9. Set Screw (loosen before 7. Roll Pin turning nut) 8. Thru Bolt

FIGURE 4-39 Typical Crosshead

4. Use the piston nut spanner to turn the piston rod out of the crosshead. The two dowels on the spanner fit holes in the piston nut. Remove crosshead nut from piston rod. Install the piston rod entry sleeve and push the rod end forward towards the cylinder until the rod end clears the wiper packing assembly. 5. With crosshead in its outer dead center position, remove crosshead pin thru-bolt, lock nut, endplates and pin. Discard old lock nut. 6. Turn crankshaft to its inner dead center position. 7. Remove oil wiper packing from crosshead guide diaphragm. 8. Install crosshead installation/removal tool. 9. Move crosshead to its outer dead center position, free of the connecting rod. Support connecting rod so it does not drop and damage the crosshead guide surface. 10. Push crosshead onto crosshead installation/removal tool and rotate crosshead 90°.S 11. Slide a metal plate into the gap between the crosshead and crosshead guide, 3/16 inch (5 mm) thick (see ). JG:A:M:P:N:Q:R:J do not require a plate. 12. Remove diaphragm from crosshead guide and slide crosshead out of crosshead guide onto the plate. 13. Check crosshead pin to bushing clearance (see Appendix B ). Determine pin wear by inspection. Page 4-30 of 49

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14. Replace pin, if necessary. To replace bushings, hacksaw or file to within 1/32 inches (1 mm) of their thickness, then drift them out. 15. New bushing installation requires a press. To install a bushing in the crosshead, cool the bushing in 95% alcohol with dry ice solution. Leave the bushing in the solution long enough to reach the same temperature as the solution, about -110°F (-80°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 the crosshead (see FIGURE 4-40). Thoroughly clean bushing and crosshead to prevent dirt accumulation between bushing and crosshead bore.

FIGURE 4-40 Crosshead Bushing Replacement

16. Where applicable, verify oil holes in the bushing line up with the holes in the crosshead. 17. Inspect shoe surfaces. Except for light polishing, there should be no wear whatsoever.

Crosshead Installation NOTE: Return crossheads to their original throw location. Use frame oil for lubrication where needed. 1. Lay an installation plate in the bottom of the crosshead guide, 3/16 inch (5 mm) thick, and lay crosshead on its side (see FIGURE 4-41). JG:A:M:P:N:Q:R:J do not require an installation plate. Oil crosshead and guide surfaces and push crosshead into position. 2. Mount crosshead installation tool onto crosshead guide diaphragm and oil tool bearing surfaces (see FIGURE 4-41). Slide crosshead onto tool.

FIGURE 4-41 Crosshead Installation

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.

3. Remove the plate. Rotate crosshead 90°. If crosshead becomes wedged, do not force it; it will damage the crosshead shoe surface. Use a box end wrench on the connecting rod bolt to lever the small end of the connecting rod into the centered position, then slide the crosshead into the guide under the connecting rod and off of the installation tool. Be careful not to damage crosshead shoe or crosshead slide surfaces during installation. 4. Remove crosshead installation tool and reinstall wiper packing. 5. Turn crankshaft to its outer dead center position to locate the connecting rod in position and insert crosshead pin. Deburr and clean the crosshead pin alignment tool for use on the opposite side of the crosshead to assist pin insertion. Oil crosshead pin, alignment tool, crosshead, and connecting rod bushings prior to installation. Install crosshead pin end-plates (be careful to align roll pins with REV: 3/17

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holes in the end plates), thru-bolt, and a new lock nut. Tighten thru-bolt and lock nut to the torque listed in Appendix A . 6. Reposition throw to inner dead center and push the piston rod assembly toward the crosshead far enough to remove piston rod entry sleeve. 7. Lubricate piston rod threads with Never-Seez regular grade. Install crosshead-balance nut onto piston rod. 8. Push the rod into the crosshead and turn the piston rod assembly until the required crank end piston clearance is reached. 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 B . 9. Insert a feeler gauge, equal to the required crank end clearance, through an open valve FIGURE 4-42 Crosshead Alignment Tool pocket. For 13 in. (330 mm) and larger cylinders, insert feeler gauge through a bottom valve pocket. Tighten the piston rod into the crosshead until piston is tight against the feeler gauge, and the feeler gauge can be removed manually. 10. Tighten crosshead-balance nut in one of two ways: a. Strike the special slugging peg or open end wrench with a dead blow semi-soft faced hammer until an audible difference can be heard or the wrench “bounces” indicating a tight nut. Some mechanics obtain desired tightness in 3 to 4 strikes; others may require more. b. Use a separately purchased crossheadbalance nut hydraulic torque tool and hand pump kit. See Appendix A for the hydraulic pressure to apply to the torque tool. When initially installing the tool, position the spanner wrench adapter open area toward the spanner wrench as shown in FIGURE 4-43. Apply hydraulic pressure to the ram to tighten the crosshead-balance nut. When the ram ends its travel, release pressure and index the ram to the spanner wrench slot and/or spanner wrench FIGURE 4-43 Typical Crosshead Balance Nut Hydraulic Torque to adapter, until the nut Tool - Tightening Position stops moving at the specified hydraulic pressure Page 4-32 of 49

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(see Appendix A). During tightening, if the adapter open area turns 90° before the nut is tight, remove the spanner wrench. Remove the bolting in the spanner wrench adapter to the crosshead-balance nut and reposition the adapter so the open area again faces the spanner wrench. CAUTION: Do not allow open areas of the spanner wrench and adapter to overlap, as the spanner wrench can be sprung. If the wrench becomes sprung, destroy and replace it. When nut is tight, remove feeler gage. Verify removal of all tools from cylinder and crosshead. 11. With the head end head or unloader properly installed (closed position) and fasteners tightened, rotate crankshaft 180° to outer dead center position of throw. Remove a top head end valve. Determine required piston head end clearance limits from cylinder data plate or Appendix B . Measure head end clearance at the top of the head end, using feeler gages through the open valve pocket. Determine if measured clearance is within tolerance. Tighten the crosshead-balance nut set screws. Re-install valve assemblies and properly tighten fasteners. See “Valve Installation” on page 4-9. 12. Check piston rod runout and crosshead clearances upon re-assembly, any time a piston rod is removed. See Appendix B for crosshead clearances. 13. Examine top cover and side cover seals. If there is doubt about their condition, replace them. Apply Never-seez Regular Grade to both sides of the gasket to ease future removal. Replace top cover and crosshead guide side covers. Tighten all cap screws hand wrench tight.

Connecting Rods A connecting rod assembly consists of a rod with bushing, a rod cap, rod cap bolts (4), and two half bearing shells. The bearing shells join together to form the connecting rod bearing. CAUTION: 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 Removal 1. Remove top cover from crankcase and side covers from crosshead guides. 2. Remove the middle frame spacer bar of the three over the desired pair of throws. Spacer bars fit snugly, but should remove manually without hammering. They should not fall out. If fit is too loose or tight contact your packager or Ariel before proceeding. 3. Move throw to outer dead center position. 4. Remove lock nut, bolt, end plates, and crosshead pin from crosshead. Discard old lock nut. 5. Remove crosshead as described in “Crosshead Removal” on page 4-30. 6. Support connecting rod so it does not drop and damage the crosshead guide, then turn the crankshaft until the throw is at its highest point. Loosen all the rod cap bolts part way. Using the connecting rod cap removal tool (see Section 1), jack against the bolt heads to pull the rod cap free

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from the dowels. Remove the top two rod cap bolts and the rod bearing cap. The bottom two bolts remain in the cap during cap removal. NOTE: Do not pry or chisel to separate cap from rod; it damages the connecting rod. 7. Half of the bearing shell comes out with the cap. Slide out the other half from the rod. 8. Turn crankshaft until rod can be removed through the crosshead guide side cover openings. 9. After removing connecting rod(s), protect crank pins from nicks or scratches.

Connecting Rod Bearing Removal NOTE: See Customer Technical Bulletin 192 for important information regarding JGE:K:T connecting rods and connecting rod bearings. 1. Remove frame top cover, all crosshead guide covers and applicable distance piece covers to access the wiper packing gland bolts. 2. Remove all head end heads. 3. Remove the middle frame spacer bar of the three over each pair of throws. If replacing main and rod bearings, remove all spacer bars. If spacer bar bolts are difficult to loosen, use a 12-point slugging wrench and hammer. Spacer bars fit snugly, but should slide out by hand without hammering. They should not fall out. If fit is too loose or tight, contact your packager or Ariel before proceeding. 4. Turn the crankshaft until the throw is at its highest point. Loosen all four bolts, but keep them snug against the rod cap. 5. Turn the crankshaft until the throw is at outer dead center. 6. Loosen all connecting rod bolts approximately 3/4 in. (19 mm). 7. Use the connecting rod cap removal tool to jack against the bolt heads and pull the rod cap free from the dowels (see FIGURE 4-46). If the cap does not separate easily from the rod, STOP; the rod cap may be in a bind, which can break the dowel pins. If binding occurs, re-tighten the connecting rod bolts and repeat the procedure. NOTE: Do not pry or chisel to separate cap from rod; it damages the connecting rod and can break the alignment dowel pins.

1. Top Face 2. Connecting Rod Bolts

3. Threaded Hole for Eyebolt

4. Rod Cap 5. Rod

FIGURE 4-44 Rod/Rod Cap Separation

8. After the cap separates from the rod, remove the cap removal tool and back out the connecting rod bolts completely, but do not remove them. Do not remove the bolts and cap until step 11. 9. Support the cap and rod by hand or crane while another person pries the crank end of the crosshead toward the cylinder until it bottoms out. When the connecting rod is clear of the crankshaft, rest it on the crosshead guide slide. Do not allow the rod or cap to drop, as damage can occur. 10. Rotate the rod cap around the crankshaft until the bolts are vertical. Remove bolts, then remove cap. Always remove the bolts before the cap to prevent damage to the crankshaft. Page 4-34 of 49

FIGURE 4-45 Connecting Rod Cap Removal Tool

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11. Lift the cap while holding the bearing in the cap because oil causes the bearing to stick to the crankshaft pin. 12. Rotate the crank to inner dead center and remove the connecting rod bearing. 13. After removing bearings, clean any coking or debris from both the rod and rod cap surfaces with a non-metallic Scotch-Brite or similar scouring pad and solvent. Check for raised edges on machined surfaces. All surfaces should be as clean and dry as possible.

Connecting Rod Bearing Installation 1. Check new bearing shells for handling damage, scratches, burrs, and loose material at the tabs. DO NOT RUB BEARING SURFACE WITH FINGERNAIL. New bearing shells and crankshaft crank pin bearing surfaces must be absolutely clean. Fit the tab of a new, dry half bearing shell into the rod notch.

1. Rod 2. Rod Bushing 3. Rod Dowel Holes 4. Rod Notch

5. Bearing Shell 6. Bearing Shell Tab 7. Rod Cap Dowels 8. Rod Cap Notch 9. Rod Cap

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 FIGURE 4-46 Connecting Rod Bearing Installation same part number. 2. Thoroughly inspect the crank pin for dings and scratches. If needed, use an Arkansas stone to dress dings and scratches (Norton Hard Translucent Arkansas Stone, 3” x 1/2” x 1/2”, product number HF-43). Lightly slide the stone around the circumference of the crank pin surface to remove any high spots; do not slide it back and forth over the length of the crank pin. After dressing, ensure the crank pin is clean and dry. If the crank is scored around the circumference, use 600 grit emery cloth to remove high spots. 3. Apply clean, new lube oil liberally to the crank pin. 4. Fit the tab of the other bearing shell into the rod cap notch. 5. Attach the rod cap to the rod: a. Rotate crankshaft to approximately outer dead center. b. Carefully lower the connecting rod cap (WITHOUT BOLTS!) onto the crank pin. Verify rod bolts are undamaged and free of dirt. Lubricate them per Appendix A , then place all four bolts into the rod cap. 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. Rotate cap so the bolts align with the connecting rod bolt holes. Support the rod cap while another person carefully pries the connecting rod towards the crankshaft until it bottoms out. Align the rod cap dowels with the rod dowel holes and push the rod cap onto the rod with even pressure. The rod cap fits onto the rod only one way. Do not force the rod cap onto the rod; the

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dowels should slide into the rod holes without difficulty. After ensuring the rod cap seats properly on the rod, snug all four bolts and pre-torque according to Appendix A . d. Rotate the crankshaft until the throw is at its highest point and tighten all conn rod bolts to the torque listed in Appendix A . 6. Repeat steps 1-5 for all remaining connecting rods. 7. Measure each connecting rod bearing jack and thrust clearance as detailed in this document. If clearance readings are not within tolerances of Appendix B , contact your packager or Ariel before proceeding. NOTE: If replacing main bearings, continue to "Main Bearing Removal". If not replacing main bearings, continue to Step 8. 8. Install spacer bars so the match mark is up and next to the spacer bar boss with the same mark. Tighten all spacer-bar cap screws to the torque listed in Appendix A . 9. Account for all tools, equipment, supplies, and parts to ensure none are left inside the crankcase. 10. Examine top cover and side cover seals. If there is doubt about their condition, replace them.Apply Never-seez Regular Grade to both sides of the gasket to ease future removal. Replace top cover and crosshead guide side covers. Tighten all cap screws hand wrench tight. 11. Reverse lockout procedures. 12. After replacing bearings, thoroughly pre-lube compressor to ensure bearing lubrication and to help remove foreign materials from the lube system. 13. Run the compressor according to the time intervals listed on the form in Appendix D. After each run, shut down and remove the frame top cover. Measure main and connecting rod bearing cap temperatures with a hand held thermocouple probe or infrared thermometer and record them on a copy of the form in Appendix D. Complete the form and email or fax it to Ariel Field Service.

Connecting Rod Bushing Removal and Installation 1. Check crosshead pin to bushing clearance (see Appendix B ). Determine pin wear by inspection. Replace pin, if necessary. 2. To replace a bushing, file or hacksaw the existing bushing 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. DO NOT file or saw into the connecting rod; any bore damage renders the rod useless and requires rod replacement. 3. Use a hydraulic press in a qualified machine shop to install the new bushing. Do not hammer bushing into place; it will distort the bushing bore. 4. Before installation, cool new bushing in a 95% alcohol and dry ice solution. Leave bushing in solution long enough to reach the solution temperature, about -110°F (-80°C). 5. Position connecting rod on the press table so the chamfered edge of the rod bushing bore is on top. Press bushing into rod bore. Align bushing oil hole with connecting rod oil passage (if applicable) before pressing bushing in. The bushing has an annular groove around its outside diameter aligned with the oil hole; if the bushing shifts in the connecting rod during operation, oil still travels to the bushing inside diameter and to the crosshead pin. However, a new bushing installation should cover no more than 1/3 of the rod oil passage hole. For ELP units with no drilled hole in the connecting rod, bushing hole alignment is not critical (see CTB-192).

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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: 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.

Connecting Rod Installation 1. To install a new connecting rod, stamp match mark numbers matching the throw location on the tops of the connecting rod and bearing cap (with notches up). See FIGURE 4-47. 2. Check new bearing shells for handling damage, scratches, burrs, and loose material at the tabs. DO NOT RUB BEARING SURFACE WITH FINGERNAIL. New bearing shells and crankshaft crank pin bearing surfaces must be absolutely clean. Snap a new, dry half bearing shell into the rod with the bearing tab properly located in the rod notch. With the crankcase top cover off, turn the throw to inner dead center position and slide the rod into the crosshead guide space. Oil crankshaft crank pin bearing surfaces with new clean lubricating oil, the same type used in the frame, before connecting rod cap installation. 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 sequence, see . Always install rods with numbers up. Protect crank pin at all times. 3. Fit connecting rod to crank pin and turn to the highest position. Carefully lower the connecting rod cap (without bolts!!) onto the crank pin. Verify rod bolts are undamaged and free of dirt. Lubricate them per Appendix A , then insert all bolts into rod cap and snug them; do not tighten to full torque. 4. Reconnect rod and crosshead with pin. Install end plates, thru-bolt, and new lock nut. Tighten lock nut to the torque listed in the Appendix A . 5. Follow the"Recommendations for Torque Accuracy" in Appendix A to tighten connecting rod cap screws to the recommended torque. 6. Place a turn indicator onto the wrench socket, and slide the socket onto the bolt head. Turn the indicator so the vial faces up with the bubble centered, then tighten the indicator thumbscrew. Turn the connecting rod cap screws to the angle recommended in Appendix A . FIGURE 4-47 Typical Connecting Rod 7. Measure each connecting rod bearing to crankshaft jack clearance and connecting rod thrust (side) clearance (see "Connecting Rod Bearing Vertical Jack Clearance Measurement" and "Connecting Rod Thrust (Side) Clearance Measurement" below). Record measurements on a copy of the form in Appendix D. If meas-

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urements are out of tolerance after installing new bearings, contact your packager or Ariel before proceeding 8. Reinstall spacer bars. All spacer bars are match-marked for proper location; reinstall them in their original location. Tighten all spacer bar bolts to the torque listed in Appendix 1 9. Examine top cover and side cover seals. If there is doubt about their condition, replace them. Apply Never-seez Regular Grade to both sides of the gasket to ease future removal. Replace top cover and crosshead guide side covers. Tighten all cap screws hand wrench tight.

Connecting Rod Bearing Vertical Jack Clearance Measurement 1. Turn the crankshaft pin of the desired throw to its highest position. For JGH:E:K:T:C:D:F:Z:U:B:V and KBZ:U:B:V models, thread an eye bolt into the connecting rod (see FIGURE 4-48). 2. Attach the magnetic base of a needle dial indicator to the crankshaft web adjacent to the connecting rod. Place the point of the dial indicator against the top of the connecting rod near the center of the cap seam. 3. Zero the dial indicator. Insert a pry bar into the eye bolt and pry against the frame to force the connecting rod up until the dial indicator needle stops moving. For JG:A:M:P:N:Q:R:J:W models, pry against the top conn rod bolts. While maintaining upward pressure, note the reading. 4. Release upward pressure and push downward on the rod until the indicator reads zero again. If a zero reading cannot be obtained, zero the indicator again and repeat steps 3 and 4. Repeat the measurement process until the measurement returns to zero twice in a row to verify accuracy. 5. Repeat measurement process for every rod. If a reading is outside the tolerances of Appendix B, contact your packager or Ariel. NOTE: Remove eye bolts, magnetic bases, dial indicators, and pry bars after measurement.

Dial indicator magnetic stand placement on top of crankshaft web, and pry bar inserted into eye bolt.

Use pry bar to check jack clearance.

FIGURE 4-48 Typical Connecting Rod Vertical Jack Clearance Measurement

Connecting Rod Thrust (Side) Clearance Measurement 1. Turn the crankshaft pin of the desired throw to its highest position. 2. Attach the magnetic base of a button dial indicator to the side of the crankshaft web adjacent to the connecting rod. Place the button of the dial indicator against the thrust surface of the connecting rod (see FIGURE 4-49). 3. Use a pry bar to pry against the crankshaft web and thrust the connecting rod tight toward the dial indicator (do not pry on rod cap). Release pressure and zero the dial indicator.

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4. Thrust the connecting rod tight in the opposite direction until the dial indicator needle stops moving. Release pressure and note reading. Repeat steps 3 and 4 to verify measurement accuracy. 5. Repeat the measurement process for every rod. If a reading is outside the tolerances in Appendix B, contact your packager or Ariel. NOTE: Remove magnetic bases, dial indicators, and pry bars after measurement.

Dial indicator magnetic stand placement.

Dial indicator button placement.

Thrust rod tight toward and away from dial indicator.

FIGURE 4-49 Typical Connecting Rod Thrust (Side) Clearance Measurement

Crankshaft The crankshaft is the heart of the compressor. With proper maintenance, it should provide years of trouble-free service.

Oil Slinger Replacement CAUTION: Do not touch hot surfaces without proper protection. Although the slinger should last indefinitely with proper care, it may become nicked. To replace it on a JGH:E:K:T/2/4: 1. Suspend the crankshaft as detailed in "Crankshaft Removal" and heat the slinger to about 400°F (204°C). When it expands, it is easily removed. 2. Slide a minimum ½-inch (13mm) diameter rod through the new slinger. Do not mar slinger surfaces, and be careful of its sharp outer edge. Suspend the slinger and heat it with a small torch. When it reaches about 400°F (204°C), slip it over the drive end of the crankshaft. Hold the slinger in place with high temperature gloves or two pieces of clean wood. Rotate it slightly to ensure squareness, until it cools enough to shrink onto the crankshaft. JGE:K:T/6 frames have a bolt-on oil slinger that requires no heat for removal or installation. Tighten bolts to the torque listed in Appendix A

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1. Puller Nut - turn to pull bearing cap straight up. Remove top cover and spacer 2. Rectangular bars. If spacer bar bolts are difSteel Bar ficult to loosen, use a 12-point Clearance Hole: 11/16 in. (18 mm) slugging wrench and hammer. Length:21 in. (533 mm) Spacer bars fit snugly, but should 3. Drill Hole slide out by hand without ham4. Threaded Rod Nominal Size: mering. They should not fall out. 5/8 in. - 11 If fit is too loose or tight contact Length:11 in. (280 mm) your packager or Ariel before pro- 5. Lock Nut ceeding. 6. Puller Hole 7. Crankshaft

Main Bearing Removal 1.

2. Remove main (journal) bearing cap screws. Pull caps straight up FIGURE 4-50 Main Bearing Cap Puller to prevent damage to the dowel fit. If cap is tight, use a bearing cap puller (see FIGURE 4-50). Remove shells from main bearing caps.

3. Remove main journal bearing shells from under the crankshaft one at a time. If needed, attach clean nylon straps around the crankshaft and lift it 0.003 - 0.005 inch to lessen weight on the bearings and allow easier removal. To remove, rotate shell under the crankshaft tab side out first, by pushing or tapping with a non-metallic tool on the opposite side. Ariel provides an optional tool (B-3340) to push the shell out. Do not damage crankshaft bearing surfaces. Replace with new bearing shell, before rotating out the next main bearing shell. 4. Clean any coking or debris from both saddle and main bearing cap surfaces. Check for raised edges on machined surfaces. Verify all surfaces are clean and dry as possible and no bolting is damaged.

Main Bearing Installation 1. Check new bearing shells for damage, scratches, burrs, and loose material at the tab. DO NOT RUB BEARING SURFACE WITH FINGERNAIL. Keep the backs of shells dry and clean; installation requires perfectly clean bearing shells. Install bearing shells in caps, and frame journals, properly located in the tab notch, (rotate in the un-tabbed end first). 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 a liberal amount of clean, new lube oil to crankshaft bearing surfaces. 3. Main bearing caps have position match-marks corresponding with frame spacer bars and spacer bar bosses. Install main bearing caps with new bearing shells in their correct locations. Seat the cap by tapping it with the handle of a hammer or screwdriver. It is a machined fit, not a press fit, and the cap should not rock in the jaw fit when it seats. Do not use bolting to force the cap to seat. Snug the cap screws. Starting at the end, tighten the main bearing cap bolts to the torque listed in Appendix A . 4. Verify proper alignment of main bearing cap dowels with the holes in the crankcase base. A set screw on top of each dowel prevents it from backing out. 5. Check crankshaft journal bearing jack (at each bearing) and crankshaft thrust clearances to values in Appendix B (see procedure below). Record readings on a copy of the form in Appendix D. If Page 4-40 of 49

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readings are out of tolerance after new bearing installation, contact your packager or Ariel before proceeding. 6. Install spacer bars so the match mark is up and next to the spacer bar boss with the same mark. Tighten all spacer-bar cap screws to the torque listed in Appendix A . 7. Account for all tools, equipment, supplies, and parts to ensure none are left inside the crankcase. Reinstall gaskets and top cover(s). Tighten cover bolts hand wrench tight. 8. Reverse lockout procedures. 9. After replacing bearings, pre-lube compressor for 10-15 minutes at 30 psi to ensure bearing lubrication and to help remove foreign materials from the lube system. 10. Run the compressor according to the time intervals listed on the form in Appendix D. After each run, shut down and remove the frame top cover. Measure main and connecting rod bearing cap temperatures with a hand held thermocouple probe or infrared thermometer and record them on a copy of the form in Appendix D. Complete the form and email or fax it to Ariel Field Service.

Crankshaft Removal 1. Remove coupling disk pack. The coupling hub may be removed now, but it may be easier after crankshaft removal. If the hub is not removed, the drive end cover cannot be removed and must lift out with the crankshaft. Remove all drive end cover mounting bolts. Remove the two tapered dowel pins from the drive end cover. 2. Remove top cover and spacer bars. If spacer bar bolts are difficult to loosen, use a 12-point hammer wrench. 3. Do not damage the sharp corners on each end of the crankcase top. They form a junction between the end covers, top cover, and base; keep them sharp and unmarred to prevent oil leaks. 4. Detach connecting rods and move them to their full outer position. See “Connecting Rod Bearing Removal” on page 4-34. 5. Remove chain eccentric adjustment capscrews. Turn the eccentric to loosen the chain and slip it off the crankshaft sprocket. For more clearance while lifting the crankshaft, remove the force feed lubricator drive sprocket. 6. Remove main bearing caps. See “Main Bearing Removal” on page 4-40. 7. Before removing the crankshaft, prepare wooden saddles or blocks of wood with sides high enough to prevent the webs or oil slinger from touching the floor to store the crankshaft during maintenance even if for only a short time. Also, protect the crankshaft from above so dropped tools or equipment cannot mar pin and journal surfaces. 1. Oil Slinger 8. Turn the crankshaft so that sling lifting points are 4. Crank Pins 2. Main Bearing Journals above the shaft center of gravity to prevent rotation 5. Counterweights 3. Chain Sprocket when lifted. Lift straight up with the crankshaft FIGURE 4-51 Typical Crankshaft ends parallel to the frame. The crankshaft weight requires two men and a crane to safely remove it. Use appropriate sized nylon slings to prevent marring the crankshaft running surface.

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NOTE: Lower half bearing shells sometimes stick to the shaft journals. After lifting the 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 one person raises the crane very slowly, the second person must grasp the crankshaft at the drive end with one hand on the counterweight or one of the throws and the other on the shaft end to keep the crankshaft level. It may be necessary to lower the crank and reposition the straps to achieve a balanced lift. Wear clean gloves for a good grip, to avoid cuts from the slinger, and to avoid marring the running surface. As the shaft slowly raises, lift the drive and auxiliary ends at the same rate. Carefully guide the crankshaft to avoid marring its surfaces.

Crankshaft Installation 1. Thoroughly clean the oil gallery that runs from the drive end to the auxiliary end of the crankcase and the vertical and horizontal intersecting oil passages that lube the main bearings and crosshead guides. Any debris left in the oil gallery or intersecting passageways could cause bearing or crosshead failure. Deburr and clean main bearing caps to prepare for installation. 2. Thoroughly clean new main bearing half shells and install them in the frame saddles. 3. Lubricate bearing surfaces with clean crankcase oil. Cover bearings with clean paper towels to prevent debris contamination. Remove towels just before seating the crank in the saddles. 4. Move connecting rods to full outer position if not already there. 5. Install the crankshaft. While the crankshaft lowers very slowly into the crankcase (suspended by a crane with clean nylon slings), one man wearing clean gloves should grasp the drive end and slowly maneuver the drive end and auxiliary end straight down into the crankcase. Both drive end and auxiliary end journals should touch the bottom bearing shells at the same time. 6. Before connecting rod installation, measure each crankshaft journal bearing jack clearance with a dial indicator (see procedure on page 4-42 and allowable clearances in Appendix B ). 7. Reattach connecting rods (See “Connecting Rod Installation” on page 4-37), packing diaphragms, and unloaders/head end heads. 8. Reinstall chain drive. (See“Chain Drive System” on page 4-44). 9. Replace spacer bars. Locate spacer bar match mark. Install spacer bar so the match mark is up and next to the spacer bar boss with the same marking. 10. Install drive end cover with new gasket using the tapered dowel pins to properly align the cover. Verify at least 0.008 inch (0.2 mm) clearance exists between the dust seal housing and crankshaft. Then install a new dust seal. 11. Use a knife to trim excess from end cover gaskets flush to the compressor frame top cover rail. 12. Examine top cover and side cover seals. If there is doubt about their condition, replace them.Apply Never-seez Regular Grade to both sides of the gasket to ease future removal. Replace top cover and crosshead guide side covers. Tighten all cap screws hand wrench tight.

Main Bearing Vertical Jack Clearance Measurement 1. Turn crankshaft until the web adjacent to the desired main bearing is vertical (see FIGURE 4-52). 2. Loop a lifting strap around the crankshaft web adjacent to the main bearing and attach the strap to a crane.

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Section 4 - Part Replacement For models JGH:E:K:T 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. Attach the magnetic base of a needle dial indicator to the top of the main bearing cap. Place the point of the dial indicator against the top of the adjacent web and zero it. 4. GENTLY lift crankshaft. The dial indicator needle moves steadily until the crane/hoist overcomes crankshaft oil stiction, at which point the needle jumps a little. Stop lifting immediately at this point, and note the reading. 5. Release crane/hoist pressure and repeat step 4 to verify the measurement. 6. Repeat the measurement process for each main bearing. If a reading is outside the tolerances in Appendix B, contact your packager or Ariel. NOTE: Remove magnetic bases, dial indicators, and lifting strap after measurement.

Dial Indicator magnetic stand place- Needle-type dial Indicator placement Place lifting strap around crankshaft ment on top of a main bearing cap. on top of adjacent crankshaft web. web - attach strap to a crane.

FIGURE 4-52 Typical Crankshaft Journal Bearing Vertical Jack Clearance Measurement

Crankshaft Thrust (End) Clearance Measurement 1. Attach the magnetic base of a button dial indicator to the top of a main bearing cap. Place the button of the dial indicator against the side of the adjacent crankshaft web (see FIGURE 4-53). 2. Use a pry bar to pry against the compressor frame and thrust the crankshaft tight toward the dial indicator. Release pressure and zero the dial indicator. 3. Thrust the crankshaft tight in the opposite direction until the dial indicator needle stops moving, then release pressure. Note reading. Repeat steps 2 and 3 to verify measurement accuracy. 4. If the measurement is outside the tolerances in Appendix B , contact your packager or Ariel. NOTE: Remove magnetic bases, dial indicators, and pry bar after measurement.

Dial Indicator magnetic stand place- Button-type dial Indicator p lacement Pry against compressor frame to ment on top of a main bearing cap. against the side of crankshaft web. thrust crankshaft back and forth.

FIGURE 4-53 Typical Crankshaft Thrust Clearance Measurement

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Chain Drive System The chain drive system is crankshaft-driven at the auxiliary end of the frame. For JGH:E:K:T/2/4 compressors, a single chain runs the lube oil pump and force feed lubricator. An idler sprocket attached to the eccentric adjustment cap controls chain tightness. The chain dips into the crankcase oil for constant lubrication. In dry sump applications, an oil sprayer lubricates the chain.

1. Force Feed Lubricator Sprocket 2. Crankshaft Sprocket 3. Eccentric Adjustment

4. 5. 6. 7.

Cap Screw Dust Plug Chain Oil Pump Sprocket

For JGE:K:T/6 compressors, one chain runs the lube oil pump and another runs the force feed lubricator. A separate idler sprocket for each chain, each attached to FIGURE 4-54 JGH:E:K:T/2/4 Chain Drive Systems its own eccentric adjustment cap, controls chain tightness. The lube oil pump chain dips into the crankcase oil and splash action oils the force feed lubricator chain as well. In dry sump applications, an oil sprayer lubricates the chains.

1. Force Feed Lubricator Sprocket 2. Force Feed Lubricator Chain

3. Force Feed 5. Lubricator 6. Eccentric Adjust-7. ment 4. Crankshaft 8. Sprocket 9.

Oil Pump Chain Oil Pump Sprocket Oil Pump Eccentric Adjustment Cap Screw Dust Plug

FIGURE 4-55 JGE:K:T/6 Chain Drive Systems

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Chain and Sprocket Replacement Replace chain(s) if elongation exceeds 0.084 inches (2.13 mm) over a 10 pitch length. Measure the section of chain with vernier calipers while it is stretched tight in position in the compressor. Add a measurement outside the rollers at 10 pitches (X) to a measurement between the inside of the same rollers (Y), and then FIGURE 4-56 Measuring to Check Chain divide by two. Replace the chain if the result exceeds Elongation 5.084 inches (129.1 mm) Replace sprockets showing any undercutting or other damage.

Chain Idler Sprocket Replacement (Eccentric Adjustment Caps) 1. Chain idler sprocket location varies for standard versus reverse rotation. 2. Remove frame top cover. 3. Remove all dust plugs from the eccentric cap and all cap screws holding the eccentric cap to the end cover. Rotate eccentric cap to loosen chain for removal. Drop the chain off the idler sprocket and remove entire assembly from the end cover.

1. Dust Plug 2. Cap Screw

3. Stat-O-Seal 4. Self-Lock Nut

5. Washer 6. Sprocket

7. Thru Bolt

FIGURE 4-57 Typical Chain Idler Sprockets (Eccentrics)

4. Remove and discard lock nut, hex cap screw, stat-o-seal, washer, and cap O-ring. 5. Reassemble new cap screw, stat-o-seal, washer, sprocket, and lock nut. Tighten idler lock nut to recommended torque in Appendix A. 6. Apply oil and install a new O-ring. Install assembly and chain. 7. Take care when measuring and adjusting the force feed idler sprocket; it is thinner than the force feed lubricator and drive sprockets. To center the idler sprockets in the chain, subtract the force feed idler sprocket thickness from the drive sprocket thickness and divide the difference by 2. Add this value to the measurement from the inside face of the auxiliary end cover to the outside face of the force feed idler sprocket. Adjust driven sprockets to the drive sprocket measurements, aligned within 1/32 inch (1 mm). Non-alignment may require disassembly and shimming eccentrics. 8. Adjust chain according to “Chain Adjustment” on page 4-48.

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Lube Oil Pump Sprocket Replacement 1. Remove all pump piping. Remove fasteners from pump mounting flange. After chain removal, the pump with sprocket comes free through the end cover hole. 2. To position the new sprocket, use a machinist rule to measure the exact distance from sprocket drive face to pump mounting flange face (X). Note this measurement for future reference. 1. Gaskets

4. Sprocket

3. With the oil pump on a bench, use an 5. Adapter 2. Key Allen wrench to remove the sprocket 3. Set Screws 6. Pump set screws, then pull the sprocket from FIGURE 4-58 Typical Lube Oil Pump Chain Sprocket the shaft. 4. Remove the key from the shaft and file the shaft to smooth burrs raised by the set screw cup point. 5. Install a new key (see build book for type and dimensions). First verify it fits into the new sprocket. If too thick, polish the key with emery cloth on a flat surface until it easily slides into the notch. The top edge may also require a little polishing. 6. Install new sprocket to the original measurement between the sprocket drive face and the pump mounting flange face. When in position, tighten set screws. 7. Lubricate both sides of gaskets with anti-seize lubricant or multi-purpose grease to ease future removal. Install new gaskets. 8. Reinstall pump onto end cover. Using a straight edge, to within 1/32 inch (1 mm), check alignment to crankshaft drive sprocket with crankshaft centered in end play. If misaligned, adjust sprocket position as needed. 9. Adjust chain according to “Chain Adjustment” on page 4-48. 10. Reinstall all piping to pump.

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Force Feed Lubricator Chain Sprocket Replacement 1. With a good machinist rule, measure exact distance from inside face of auxiliary end cover to near face of lubricator sprocket. Note measurement for proper positioning of new sprocket. Remove chain. 2. Remove sprocket set screw and sprocket. Detach all tubing from lubricator. 3. Remove mounting bracket cap screws and lubricator. 4. With the lubricator on the bench, remove key from shaft and file shaft to remove burrs raised by set screw cup point. Oil and install a new O-ring. 5. Dig out the shaft oil seal with an awl and install a new one. 6. Install a new key. Verify it fits into the new sprocket (see build book for key type and dimensions). If too thick, polish it with emery cloth on a flat surface until it easily slides into the notch. The top edge may also require a little polishing.

4. 1. Mounting Bracket 5. Cap Screws (4) 6. 2. Auxiliary End Cover 7. 3. O-Ring

Shaft Oil Seal Key Set Screw Sprocket

FIGURE 4-59 Force Feed Lubricator Chain Sprocket

7. After new key installation, verify the new sprocket fits, oil the new O-ring, and remount lubricator to the end cover. 8. Slide new sprocket onto the shaft and set to dimension measured in step 1. Tighten set screw. 9. Using a straight edge, to within 1/32 inch (1 mm), check alignment to crankshaft drive sprocket with crankshaft centered in end play. When aligning this sprocket with the idler sprocket, take into account that the idler sprocket is thinner than the other sprockets. If misaligned, adjust sprocket position as needed. 10. Install chain and adjust according to “Chain Adjustment” on page 4-48. 11. Re-attach all tubing to lubricator.

Crankshaft Chain Sprocket Replacement CAUTION: Do not touch hot surfaces without proper protection. Examine sprocket carefully for wear; sprockets operating for five years or more may require replacement. To replace a sprocket on a JGH:E:K:T: FIGURE 4-60 1. Drill a hole in the sprocket hub parallel to the shaft centerline and big Crankshaft Sprocket enough to remove most of the hub cross section (see figure to the right). Removal Multiple smaller holes may be required. DO NOT touch shaft with drill. Mark the drill with tape to avoid drilling through the sprocket and into the crankshaft face. The hole relieves most of the shrink, and a few radial strikes with a hammer and chisel opens the sprocket enough for easy removal. 2. Suspend the new sprocket with a wire and heat it with a small torch to about 400°F (204°C), then slip it over the auxiliary end of the crankshaft. Hold the sprocket in place and rotate it slightly to ensure squareness until it cools enough to shrink onto the crankshaft.

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Page 4-47 of 49



Chain Adjustment 1. Roll the crankshaft to the tightest position of the chain. This prevents snugging the chain at a slack position and breaking rollers, or ruining the pump and lubricator bearings when the chain goes through its tightest position. 2. Use a tape measure to measure the longest most easily accessible span from sprocket center to sprocket center, where the deflection will be gauged. Determine allowable deflection limits for the measured span as defined by the shaded area in FIGURE 4-62. 3. Measure chain deflection from a straight edge held on the chain rollers where it FIGURE 4-61 Typical Chain Deflection wraps over the two sprockets of the span Measurement (see FIGURE 4-61). Using a machinist’s scale with 0.01 inch or (1.0 mm) increments, apply finger pressure to measure the distance from the straight edge to a chain roller at the center of the span. Record the measurement and check to see if it is in tolerance. 4. If adjustment is required, remove the cap screws and plastic plugs from the eccentric cap. Rotate the cap clockwise to line up the first two new cap screw holes. If this tightens the chain too much, turn the cap counterclockwise for a different hole alignment. 5. Replace and tighten the two cap screws hand wrench tight. CAUTION: Over tightening may result in bent shafts. 6. Roll the crankshaft to check tightness in several positions. At its tightest position, the chain should deflect within the shaded limits in FIGURE 4-62 . Replace plastic caps to keep the holes clean.

FIGURE 4-62 Allowable Chain Deflection, Inches (mm) Page 4-48 of 49

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Component Cleaning & Thread Lube for Non-Lube Compressor Cylinders Ariel cleans and protects complete non-lube cylinders to non-lube service requirements. Clean all internal parts shipped loose, contaminated internal surfaces, and repair parts prior to installation, to extend the life of rings and non-lube compressors. Clean cylinder bore thoroughly with denatured alcohol until a clean, alcohol-soaked, white paper towel removes no more debris. This includes all surfaces of the bore, counter bore, valve pockets, etc. Do not use Never-Seez on steel gaskets. Apply a light film of oil to cylinder seating surfaces to seal o-rings. 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 use any lubricants or anti-seize compounds on parts that may contact the gas stream. Use very small amounts of Never-Seez regular grade on nut and collar when assembling piston assembly. Thoroughly clean piston (especially the ring grooves) with denatured alcohol until a clean, alcohol-soaked towel removes no more debris. Disassemble packing case. Wipe all surfaces clean with denatured alcohol. Re-assemble. When the packing case is water cooled, re-assemble and test to “Testing” on page 4-25. Handle cleaned parts with new or clean "rubber" or new white cotton gloves. Before piston rod installation, wipe it with denatured alcohol. Be careful not to leave fingerprints on the rod before it contacts the packing rings. Wipe the rod with denatured alcohol after installation. Clean the head end head or unloader components with denatured alcohol. Use minimal amounts of oil for the bolt-holes to ensure oil does not run into the cylinder. Also install the head end steel gasket without Never-Seez. Disassemble and clean the valves with denatured alcohol, then re-assemble, wipe them again, and install. Clean retainers and high clearance assemblies with denatured alcohol. Use only a thin film of oil for the valve cap O-rings and bolt-holes. Assemble cleaned parts immediately to avoid contamination and corrosion. If cylinder will not commence immediate service, contact Ariel for preservation instructions to ER-34.

REV: 3/17

Page 4-49 of 49

Section 5 - Start Up 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 following forms are designed to ensure a successful start-up of Ariel reciprocating compressors. Ariel warranty coverage requires these completed forms be sent to: Administrative Assistant - Sales, Ariel Corporation 35 Blackjack Road • Mount Vernon, Ohio 43050 USA Phone: 740-397-0311 • FAX: 740-397-3856

Warranty Notification - Installation List Data Date:__________________ Name: ___________________________________________________ Unassigned

Resale

Direct Sale

Lease-Purchase

Rental/Lease Unit

Compressor Frame Frame Model:_____________________________ Frame Serial #:_______________________________________ Frame Lubricant Make and Grade:_________________________________________________________________ Package Startup Date:________________________________

Distributor/Fabricator Company:_________________________________________ Name:_____________________________________ Address:___ ____ ____ ________ ____ ____ ________ ____ ____ ________ ____ ____ ________ ____ ____ ________ _ City:________________________________ State:_______ Zip:________________ Country:__________________ Fabricator Unit Number:_______________________________________

Application Air/Nitrogen Refrigeration

CNG/GNC

FPSO

Gathering

Fuel Gas Booster

Pipeline

PRC

Injection

Storage/Withdrawal

Miscellaneous

Elevation:_____________________________ H2S%:_____________ CO2%:_____________ Specific Gravity:__________________ Non-Lube:

REV: 3/17

Yes

No

Page 5-1 of 9

Section5 - Start Up


Unit Location Customer Name:_______________________________________________________________________________ Project/Lease Name: ___________________________________________________________________________ Closest Town:________________________________ State:______ Country:_____________ Offshore:

Yes

No Directions to Location or GPS:____________________________________________________________________ ____ ________ ____ ____ _______________ ____ ____ ________ ____ ____ ________ ____ ____ ________ ____ ____ _ ____ ________ ____ ____ _______________ ____ ____ ________ ____ ____ ________ ____ ____ ________ ____ ____ _ ____ ________ ____ ____ _______________ ____ ____ ________ ____ ____ ________ ____ ____ ________ ____ ____ _ Customer Contact Person:__________________________________ Contact Phone:_________________________ Contact Email:___________________________________________________________ OK to contact:

Yes

No

Driver Driver Manufacturer:___________________________________________ Driver Model:______________________ Driver Type:_________________________ Applied RPM:_____________ Name Plate HP (kW):________________ Coupling Manufacturer:________________________________________ Coupling Model:____________________

Compressor Cylinders and Operating Conditions Cylinder Class

Stage Number

Throw Number

Serial Number

Bore Dia. In. (mm)

Inlet Temp. °F (°C)

Inlet Pres. psig (barg)

Disc. Temp °F (°C)

Disc. Pres. psig (barg)

_________

_________

_________

_________

_________

_________

_________

_________

_________

_________

_________

_________

_________

_________

_________

_________

_________

_________

_________

_________

_________

_________

_________

_________

_________

_________

_________

_________

_________

_________

_________

_________

_________

_________

_________

_________

_________

_________

_________

_________

_________

_________

_________

_________

_________

_________

_________

_________

_________

_________

_________

_________

_________

_________

Cylinder Lubricant Make and Grade:______________________________________________________________________________

Documentation and Accessories Check all items included in the shipment: Maintenance andRepair Manual

Yes

No

Recommended Spares List

Yes

No

Start-UpSpare Parts

Yes

No

Unit Start and Stop Procedures

Yes

No

Toolbox w/Ariel Tools

Yes

No

Toolbox with Hydraulic Tools (optional)

Yes

No

Unit Parts List

Yes

No

Toolbox with SAE Hand Tools (optional)

Yes

No

Commissioning Agent Name:_________________________________________ Company:_____________________________________ Address:__ ________ ____ ____ ________ ____ ____ ________ ____ ____ ________ ____ ____ ________ ____ ____ ___ City:________________________________ State:_______ Zip:________________ Country:__________________ Phone:_______________________________________ Email:__________________________________________

Page 5-2 of 9

REV: 3/17


Section 5 - Start Up

START-UP CHECK LIST - ITEMS TO CHECK IN THE FIELD AT COMMISSIONING Description

Date Checked

Date Verified

1.

Check and verify the top cover data plate of the compressor frame for compressor design limitations such as rod load, maximum and minimum speed, and maximum lube oil temperature.

Commissioning Agent: __________________

Distributor: __________________

2.

Check and verify the availability of correct start-up spares, hand tools, special tools, compressor parts list and drawings, and technical manuals at installation.


Distributor: __________________

3.

Check and verify the Ariel lube sheet and Lubrication Specification matches the recommended oil grade and viscosity for the service.


Distributor: __________________

4.

Check and verify all lube oil piping cleanliness per Ariel lubrication specifications (see “Oil System Cleanliness” on page 39).


Distributor: __________________

5.

Verify lube oil storage and supply line cleanliness per “Oil System Cleanliness” on page 3-9). Verify crankcase oil supply isolation valve is open.


Distributor: __________________

6.

Verify pre-lube piping cleanliness per “Oil System Cleanliness” on page 3-9) and correct circuit operation.


Distributor: __________________

7.

Verify there is an oil cooler and high temperature shutdown for the oil into the compressor frame.


Distributor: __________________

8.

Verify whether the temperature control valve installation is blending or diverting (blending preferred). __________________


Distributor: __________________

9.

Check compressor crankcase oil level controller for proper installation, operation, levelness, and venting.


Distributor: __________________

10. If applicable, check cooling water circuit cleanliness for the oil cooler and cooled packing per Maintenance and Repair Manual. Verify correct routing and test pump rotation. Set pressure appropriately per Maintenance and Repair Manual and leak test.


Distributor: __________________

11. Verify correct filter element installation. Prime the oil filter element and all lube oil piping with oil.


Distributor: __________________

12. Verify proper compressor crankcase oil level before starting (about 7/8 full in site glass).


Distributor: __________________

13. Verify correct installation of a low oil pressure shutdown tubed to the downstream side of the oil filter. 14. Operate pre-lube system.

REV: 3/17


Distributor: __________________


Distributor: __________________

Page 5-3 of 9

Section5 - Start Up



Date Checked

Date Verified

15. OPTIONAL STEP: Record “out of plane” readings (pre-grout) - see Appendix H - ER-82. _________ _________ _________ _________ _________ _________ Drive End _________ _________ _________ _________ _________ _________ Auxiliary End Flatness measuring device Manufacturer / Model:______________________________________ Date of last calibration:______________________ Calibration Due:________________________ Commissioning Agent: __________________

Distributor: __________________

16. Record soft foot readings. Over 0.002 inches (0.05 mm) pull-down on any frame foot requires correction. _________ _________ _________ _________ _________ _________ Drive End _________ _________ _________ _________ _________ _________ Auxiliary End

17. Check crosshead guide shimming for correct pre-load and hold down bolt torque.


Distributor: __________________


Distributor: __________________

18. Record piston end clearances with feeler gages (see Maintenance and Repair Manual, Appendix B). Throw

1

2

3

4

5

6

Head End ___________ ___________ ___________ ___________ ___________ ___________ Crank End ___________ ___________ ___________ ___________ ___________ ___________ NOTE: Pre-lube compressor before turning crankshaft.


Distributor: __________________

19. Measure and record rod runout (see Maintenance and Repair Manual for maximum acceptable readings). Throw

1

2

3

4

5

6

Vertical: Piston @ CE ___________ ___________ ___________ ___________ ___________ ___________ Mid-Stroke ___________ ___________ ___________ ___________ ___________ ___________ Piston @ HE ___________ ___________ ___________ ___________ ___________ ___________ Horizontal: Piston @ CE ___________ ___________ ___________ ___________ ___________ ___________ Mid-Stroke ___________ ___________ ___________ ___________ ___________ ___________ Piston @ HE ___________ ___________ ___________ ___________ ___________ ___________ NOTE: Pre-lube compressor before turning crankshaft.

Page 5-4 of 9


Distributor: __________________

REV: 3/17




Date Checked

Date Verified


Distributor: __________________

21. For electric motor drivers, check and verify the motor shaft is set at its magnetic center before positioning axial clearance. With the coupling disconnected, check and verify driver rotation matches the compressor rotation arrow.


Distributor: __________________

22. Check coupling bolt torque to coupling manufacturer recommendations.


Distributor: __________________


Distributor: __________________


Distributor: __________________

20. Measure crosshead clearances with cylinders mounted. To check top, insert 0.5 inch (12.7 mm) wide feelers from one side edge across to the opposite side, at both ends. See Maintenance and Repair Manual, Appendix B for limits. To check bottom, insert a 0.0015 inch (0.038 mm) feeler at the four corners; feeler should insert no more than 0.50 (13 mm). Record values: Throw

Top Min.

Top Max.

Bottom Max. (Corners)

1

_________

_________

_________

2

_________

_________

_________

3

_________

_________

_________

4

_________

_________

_________

5

_________

_________

_________

6

_________

_________

_________

23. Check and verify compressor to driver alignment (installed on site, cold). Record dial indicator readings in inches (mm) at the 3, 6, 9 and 12 o’clock positions or attach alignment tool print-out.

If using a laser alignment tool, make a print out and attach it to this document. 24. Check and verify compressor crankshaft thrust clearance. The shaft should remain stationary after thrusting each direction (see Appendix B). ________________________ _________________________

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Page 5-5 of 9

Section5 - Start Up


START-UP CHECK LIST - PROCESS PIPING VENTS AND DRAINS Description

Date Checked

Date Verified


Distributor: __________________


Distributor: __________________


Distributor: __________________

1.

Verify the bottle and process pipe installation contains no bolt bound flanges or elevation differences that may stress the compressor cylinders

2.

Verify cold adjustment of any bottle or cylinder supports.

3.

Verify correct inlet screen orientation in process piping.

4.

Check and verify vents and drains of the primary and secondary packing-case and the crosshead distance piece are open and tubed to a safe atmosphere.


Distributor: __________________

5.

Check and verify safety relief valve installation to protect cylinders, piping, and cooler for each compression stage.


Distributor: __________________

6.

Record method of suction pressure control and valve size. _________________________ _________________________


Distributor: __________________

7.

Check and verify crankcase breather element is open to atmosphere and clean.


Distributor: __________________

8.

Check and verify torque to spec on all gas containment and other fasteners where loosening may result in a safety hazard or equipment failure including: gas nozzle flanges, valve caps, cylinder heads, compressor rod packing, and crosshead guide support. See Appendix A .


Distributor: __________________

START-UP CHECK LIST - INSTRUMENTATION Description 1.

Check and verify the set point for the high compressor oil temperature shutdown at 190°F (88°C) maximum.

2.

Check and verify proper vibration shutdown installation and operation. Record alarm and shut down settings.

_______________________________________________________

Date Checked

Date Verified


Distributor: __________________


Distributor: __________________


Distributor: __________________


Distributor: __________________

_______________________________________________________ _______________________________________________________ 3.

Verify operation of suction, inter-stage, and discharge pressure shutdowns. Record alarm and shutdown settings.

_______________________________________________________ _______________________________________________________ _______________________________________________________ 4.

Check, verify, and record the over speed setting: _____________

Page 5-6 of 9

REV: 3/17



START-UP CHECK LIST - FORCE FEED LUBRICATION SYSTEM Description 1.

Check and verify force feed lubricator box for proper oil level.

2. Prime the force feed lubrication system through the purge port at the force feed pump discharge manifold. Check and verify each tube connection for tightness.

Date Checked

Date Verified


Distributor: __________________


Distributor: __________________

3.

Check and verify operation of force feed lubrication system no flow shutdowns.


Distributor: __________________

4.

Record color of force feed blow out discs (seeTABLE 3-3 for disc ratings): ______________________________ If fitted with an ARV, verify the cracking pressure marked on the relief valve and the pin indicator color match the lube sheet specification.


Distributor: __________________


Distributor: __________________

5.

Check, verify, and record recommended lube feed rates from lubricator data plate or “Parts Book” Cylinder Lubrication sheet.

_______________________________________________________

FINAL PRE-START C HECK LIST Description

Date Checked

Date Verified


Distributor: __________________

1.

Operate pre-lube system. Record pre-lube pressure:_________

2.

For engine driven units, disable ignition and roll the engine with the starter to check and verify the compressor rolls freely. Check and verify oil pressure increases noticeably while rolling on the starter.


Distributor: __________________

3.

For electric motors, bar the compressor over manually to check and verify it rolls freely.


Distributor: __________________

4.

For machines compressing a combustible gas, purge the entire system including the piping, by-pass, recycle line, and compressor cylinders of all air.


Distributor: __________________

5.

Review start-up instructions for all other package components.


Distributor: __________________

6.

Complete the required review of the Start-Up and Operating Instructions for the unit with the unit operator.


Distributor: __________________

INITIAL POST START-UP CHECK LIST Description

Date Checked

Date Verified

1.

Check and verify immediate oil pressure increase. Enable oil pressure shutdown and bearing temperature shutdowns. Record initial pressure at operating speed._____________________


Distributor: __________________

2.

Check and verify oil filter pressure gauges. Record initial differential: __________________________________________


Distributor: __________________

REV: 3/17

Page 5-7 of 9

Section5 - Start Up


INITIAL POST START-UP CHECK LIST Description

Date Checked

Date Verified

3.

Check and verify the low oil pressure shutdown is active and set at 45 psig (3.1 barg).


Distributor: __________________

4.

Check and verify lube oil pressure set at 50 to 60 psig (3.5 to 4.2 barg) at operating speed and temperature (see“Oil Pressure” on page 3-7). Record final setting:__________


Distributor: __________________

5.

Record oil filter maximum differential reference value listed on the compressor top cover filter data plate: __________________


Distributor: __________________

6.

Listen and feel for any strange noises or vibration in the compressor or piping. Record any occurrences. Commissioning Agent: __________________

Distributor: __________________

_______________________________________________________ _______________________________________________________ _______________________________________________________ _______________________________________________________ 7.

Check and verify high discharge gas temperature shutdowns are set about 10% above normal operating temperature (350 °F (177 °C) maximum) and functioning.


Distributor: __________________

8.

Check and verify distribution block cycle time indicator and set lubricator pump for proper break-in rate.


Distributor: __________________

9.

Check and verify the unit and piping is free from any gas or fluid leaks. Record any occurrences. Commissioning Agent: __________________

Distributor: __________________

10. Check and verify scrubber high level shutdowns operation and check scrubber dumps operation and frequency.


Distributor: __________________

11. Check, verify, and record tank levels that indicate the amount of liquids removed from the gas. ____________________________


Distributor: __________________

12. Check and verify piston rod packings s eal properly in the primary packing vents.


Distributor: __________________

13. Check and verify operation of all safety functions to ensure unit shutdown upon indication.


Distributor: __________________

14. If applicable, check and verify main bearing temperatures and record. Watch for even bearing temperature increase.


Distributor: __________________

15. During various operational conditions, use the Ariel performance program to check and verify operational characteristics of various load steps.


Distributor: __________________

_______________________________________________________ _______________________________________________________ _______________________________________________________ _______________________________________________________

Page 5-8 of 9

REV: 3/17


Section 5 - Start Up 24-HOUR POST START-UP CHECK LIST Description

1.

Date Checked

Date Verified


Distributor: __________________

Record "hot" alignment readings after reaching normal operating temperatures and components become heat soaked. Shutdown and vent gas system. Within 30 minutes and while components are still hot, record dial indicator readings in inches (mm) at the 3, 6, 9 and 12 o’clock positions on lines provided below:

If using a laser alignment tool, make a print out and attach it to this document. 2.

If using a discharge bottle or head end cylinder supports, adjust when components are heat soaked to ensure no excessive forces exist to cause detrimental cylinder deflection.


Distributor: __________________

3.

Check and verify torque on gas nozzle flange, valve cap, cylinder head, compressor rod packing flange, and guide to frame bolting.


Distributor: __________________

4.

Verify inlet screens are clean by monitoring differential pressure across the screen. If differential pressure is unavailable, a visual inspection may be required. Remove and replace damaged inlet screens. Clean inlet screens regularly to avoid increased pressure that may collapse them. More debris in the screen may dictate more frequent inspections.


Distributor: __________________

Complete Ariel’s “Compressor Warranty Notification - Installation List Data” (pages 5-1 and 5-2).


Distributor: __________________

5.

750-HOUR POST START-UP CHECK LIST Description 1.

2.

3.

Date Checked

Date Verified

Check and verify torque on gas nozzle flange, valve cap, cylinder head, and compressor rod packing flange bolting. Re-check fasteners found loose in any of these intervals after an additional 750 hours. If loosening continues, contact your package supplier immediately.


Distributor: __________________

Verify inlet screens are clean by monitoring differential pressure across the screen. If differential pressure is unavailable, a visual inspection may be required. Remove and replace damaged inlet screens. Clean inlet screens regularly to avoid increased pressure that may collapse them. More debris in the screen may dictate more frequent inspections.


Distributor: __________________

Send completed form and check lists (pages 5-1 to 5-9) to Ariel as noted on page 5-1


Distributor: __________________

REV: 3/17

Page 5-9 of 9

Section 6 - Compressor Troubleshooting Expect minor problems during routine operation of an Ariel compressor. These troubles most often trace to liquid, dirt, improper adjustment, or operators unfamiliar with Ariel compressors. These difficulties can usually be corrected by cleaning, proper adjustment, elimination of an adverse condition, part replacement, or proper training. Major problems usually trace to long periods of operation with unsuitable lubrication, careless operation, lack of routine maintenance, or using the compressor for purposes not intended. Recording inter-stage pressures and temperatures on multistage units is valuable. Any variation when operating at a given load point indicates trouble in one of the stages. Normally, a decrease in interstage pressure indicates trouble in the lower pressure cylinder. An increase usually indicates trouble in the higher pressure cylinder. Below is a list of common problems and possible causes. Problem

Possible Causes

Low Oil Pressure

• Oil pump pressure regulating valve set too low or sticking. • Oil pump or oil pump drive failure. • Oil foaming from counterweights striking oil surface (oil level in sight glass too high), or from vortex at strainer inlet (oil level in sight glass too low), or from leaks in pump suction line. • Cold oil. • Dirty oil filter. • Interior frame oil leaks. • Excessive leakage at bearings. • Improper low oil pressure switch setting. • Oil pump relief valve set too low. • Defective pressure gauge. • Plugged oil sump strainer. • Improper end clearance in oil pump.

High/Low Suction Pressure

• Suction control valve malfunction. • Faulty pressure gauges. • Frozen/plugged inlet line. • Plugged intake screen or filter. • Scrubber dump valve stuck open. • Recycle malfunction. • Site production equipment problems.

• Faulty valves or rings. • Gas leak. • Frozen cooler section or tubing to panel. High/Low Inter-Stage Pressure • Faulty pressure gauges. • Scrubber dump valve stuck open. • Load change.

Noise in Cylinder

Frame Knocks

REV: 3/17

• Loose piston. • Piston hitting cylinder head end head or crank end head. • Loose crosshead balance nut. • Broken or leaking valve(s). • Worn or broken piston rings or wear bands. • Valve improperly seated or damaged seat gasket. • Liquids in cylinder. • Loose crosshead pin or pin caps. • Loose or worn main, crankpin, or crosshead bearings. • Low oil pressure. • Cold oil. • Incorrect oil.

Page 6-1 of 3

Section 6 - Compressor Troubleshooting

Problem


Possible Causes • Knock is actually from cylinder end. • Low fluid level in damper.

Excessive Carbon on Valves

Relief Valve Popping

High Discharge Temperature

High Frame Oil Temperature

• Excessive lube oil. • Improper lube oil. • Oil carry-over from inlet system or previous stage. • Broken or leaking valves causing high temperature. • Excessive temperature due to high pressure ratio across cylinders. • Faulty relief valve. • Leaking suction valves or rings on next higher stage. • Obstruction, closed or faulty valve in discharge line. • Excessive ratio across cylinder due to leaking inlet valves or rings on next higher stage. • Fouled inter-cooler piping. • Leaking discharge valves or piston rings. • High inlet temperature. • Improper lube oil and/or lube rate. • Faulty temperature gauge. • Dirty oil filters. • High oil level. • Faulty thermostatic element. • Faulty thermostatic control valve. • Clogged or blocked oil cooler. • Binding or tightness in the compressor.

Packing Over Heating

• Lubrication failure. • Improper lube oil and/or insufficient lube rate. • Worn packing rings. • Dirt in packing. • Improper ring side or end gap clearance. • Scored, tapered or out of round piston rod. • Excessive piston rod runout.

Excessive Packing Leakage

• Worn packing rings. • Improper lube oil and or insufficient lube rate. • Dirt in packing. • Packing rings assembled incorrectly. • Improper ring side or end gap clearance. • Plugged packing vent system. • Scored, tapered or out of round piston rod. • Excessive piston rod runout. • Packing not seated or properly run in.

Drive End of Crankshaft Oil Leaks

• Clogged vent or vent piping. • Excessive cylinder packing leakage.

Piston Rod Oil Wiper Leaks

• Worn wiper rings. • Wipers incorrectly assembled. • Worn/scored rod. • Improper fit of rings to rod/side clearance.

Force Feed Lubrication Shutdown

• Force feed pump or lubricator block failure. • Loss of oil supply to force feed pump. • Lubricator drive failure. • DNFT not programmed correctly. • DNFT battery failure or power loss.

Page 6-2 of 3

REV: 3/17

For models JGH:E:K:T Problem

Section 6 - Compressor Troubleshooting Possible Causes • Loose or grounded control wiring. • Pin assembly not completely pushed into the DNFT housing.

• Joint not tight. • Pipe sealant was omitted. • Defective or damaged pipe threads. Oil Leaks at Pipe Threaded Con• NPTF Dryseal threads not being used. nections • Pressure too high for pipe threaded connection use. • Pipe thread sealant incompatible with the synthetic oil used. • Cracked pipe or fittings.

Vibration Shutdown

REV: 3/17

• Short in wire to panel. • Incorrectly positioned vibration switch. • Loose mounting bolts. • High scrubber level (liquid carry-over). • Broken valve, piston, or piston rod. • Main drive-line or coupling failure.

Page 6-3 of 3

Appendix A - Ariel Fasteners and Torques This document lists fastener lubrication and torque requirements for proper assembly of JGH:E:K:T reciprocating compressors. For older units with lower specified torque values, do not assume higher values without consulting the packager and/or Ariel. • Use only Ariel specified fasteners tightened to the correct torque. • Connecting rod, valve cap, and suction/discharge nozzle (Ariel supplied flange) fasteners are modified to prevent fatigue; do not replace them with standard cap screws. For questions about replacing other fasteners with standard cap screws, contact y our packager or Ariel. • Clean and de-burr all threads.

TABLE A-1 Fastener Thread & Seating Surface Lubrication NOTE: Lubricate all fasteners both under the head and on the threads. Application

Lubricant

• Frame: spacer bars, jack screws • Steel Cylinders: valve cap, cylinder mounting flange to cylinder body, packing, crank end and head end head, gas passage • Pistons: piston nuts, set screws, piston collar, crosshead threads • All stainless steel fasteners

Never-Seez Regular Grade

Fasteners specified with Loctite on threads

Use Loctite only with no additional lube

Connecting rod f asteners

Lubriplate 630

All other fasteners

Mineral oil (ISO 100-150)

• Do not use molybdenum disulfide lubricants.

• Do not use Never-Seez for fastener lubrication unless specified or excessive stresses may result with specified torques. See TABLE A-1. • Use anti-seize lubricants sparingly; excessive amounts c ause oil analysis to indicate contamination and may unnecessarily increase maintenance costs. • Re-preserve any fasteners subject to corrosion after installation.

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.

REV: 3/17

Page A-1 of 6

Appendix A - Ariel Fasteners and Torques


Recommendations for Torque Accuracy 1. Qualified personnel must use a properly calibrated torque wrench to correctly torque fasteners. 2. Determine torque wrench accuracy range - most are not accurate over their entire range. 3. Clean and de-burr all threads before assembly. 4. Tighten all multi-bolt assemblies in steps (optional for Grade 5 cap screws). Snug opposing pairs of cap screws until all are snug. Next, tighten each cap screw to 25% of full torque in the same pattern. Repeat this step for 50%, 75%, and 100% of full torque. For main bearing stud nuts and connecting rod bolts, repeat the 100% step to verify proper pre-torque of fasteners prior to the final partial turn. 5. Always apply a steady slow force to a torque wrench, and stop immediately when the wrench clicks; do not bounce or jerk the wrench. Bouncing or jerking a torque wrench may apply up to one and a half times the torque setting. 6. Perform final tightening with a torque wrench. Do not tighten fasteners with a ratchet or impact wrench, and then "check" the torque with a torque wrench. 7. Do not double tap a torque wrench; it increases the set torque significantly. 8. When checking the torque of a tightened fastener, set torque wrench to required torque, then apply a slow steady force until the wrench clicks. 9. When finished, reset torque wrench to its lowest setting to relax the spring and help retain accuracy. A torque wrench left in a high setting stresses the spring and decreases accuracy with time. 10. Do not break fasteners loose with a torque wrench; it may overload the wrench and/or destroy calibration. 11. To determine the torque wrench setting when using a torque multiplier on larger fasteners, divide the desired fastener torque by the multiplier actual mechanical advantage, not the design mechanical advantage. Example: An X4 torque multiplier, model TD-1000 has a design mechanical advantage of 4.0, but an actual mechanical advantage of 3.6. 12. For hard to access fasteners requiring a boxed end or crow's foot adapter with a torque wrench, the torque setting is not the actual torque applied to the fastener, unless the adapter is 90° to the torque wrench. The ratio of actual fastener torque (Ta) with the torque setting (Tw) is a function of the length the adapter adds to the torque wrench (A), FIGURE A-2 Torque Wrench with Angled and the location of the applied force. Adapter Tw = Ta x [L ÷ (L + A)] Tw = Torque wrench setting, lb x ft or N·m. Ta = Torque required at fastener, lb x ft or N·m. NOTE: Lb x In ÷ 12 = Lb x Ft L = Length of wrench, ft or m (from square drive end to center point of force on handle). A = Wrench length added by adapter, ft or m (measured through end of adapter on a line parallel to the center line of the wrench). 13. When studs are specified for cylinder applications, tighten nuts to the same values as cap screws in similar applications. 14. Install pipe threads using Loctite 577 thread sealant. Synthetic oils may require Loctite 545 and Loctite Activator 7649 (N). These are general guidelines for proper torque wrench use. Call a torque wrench dealer for details. Page A-2 of 6

REV: 3/17



TABLE A-2 Hoerbiger Valve Assembly Fastener Torques Fastener

Nominal Size Inch - TPI 5/16 - 24

Center Cap Screw a

Type

LB x FT (N·m), unless specified

12 Point - Steel Grade 5

3/8 - 24 7/16 - 20 5/16 - 24

12 Point - Steel Grade 5

Single-piece Lock Nuts (Greer, Flexloc, Selflock)

35 (48) 22 (30) 40 (54)

Material Parts: SPL or SPL5

65 (88) 14 (19)

3/8 - 24

12 Point - Stainless Steel Grade B8M

7/16 - 20

Material Parts: SPL6

35 (48)

5/16 - 24

Peripheral Cap Screw

14 (19) 24 (33)

Material Parts: SPL3 & 4

3/8 - 24 7/16 - 20

Torque

24 (33)

#10 - 32

25 lb x in. (2.8)

#12 - 28

43 lb x in. (4.9)

1/4 - 20

Hex Socket Head

110 lb x in. (12)

5/16 - 18

176 lb x in. (20)

3/8 - 16

21 (28)

Nominal Size

Torque LB x FT (N·m), unless specified

Inch - TPI

SPLb

Other

5/16 - 24

15 (20)

109 lb x in. (12)

3/8 - 24

26 (35)

17 (23)

7/16 - 20

48 (65)

26 (35)

1/2 - 20

67 (91)

41 (55)

5/8 - 18

110 (150)

82 (110)

3/4 - 16

195 (265)

145 (195)

7/8 - 14

295 (400)

230 (310)

Center Stud Drake 2-Piece Beam Lock Nut

Inch - TPI

Bottom Half

Top Half

1/4 - 28

103 lb x in. (12)

66 lb x in. (7.5)

Top Half

5/16 - 24

120 lb x in. (14)

66 lb x in. (7.5)

3/8 - 24

16 (22)

96 lb x in. (11)

1/2 - 20

36 (49) c

20 (27)

5/8 - 18

73 (99)

40 (54)

3/4 - 16

130 (175)

70 (95)

7/8 - 14

210 (285)

115 (155)

(Microlock, Spiralock b)

Bottom Half

a. Center cap screw valve assemblies have Spiralock® (SPL) threads to prevent loosening. See bottom of valve assembly for SPL material parts number (3, 4, 5 or 6) and select proper torque from the table. Lubricate both threads and seating surfaces with a petroleum type lubricant ONLY. If using older valve assemblies not covered in the table, see the original torque chart provided in the compressor tool box, or contact Ariel for instructions. Spiralock® threads cannot be dressed with a standard tap. Clean center cap screws in valve assemblies not marked SPL with Loctite safety solvent and lock them with one or two drops of Loctite #272 thread locking compound. DO NOT use petroleum lub ricants. b. Microlock and Spiralock nuts are marked "SPL" on one of the flats. c. Use 29 (39) for 1/2 - 20 bottom half Drake lock nut with non-metallic valve plates in liftwasher valves.

REV: 3/17

Page A-3 of 6



TABLE A-3 JGH:E:K:T Fastener Torques Fastener

Nominal Size Inch - TPI

Main Bearing Cap - Cap Screw

7/8 - 9

Connecting Rod Cap - Cap Screw

7/8 - 14

Type

Torque LB x FT (N·m), unlessspecified

12 Point - Grade 8

280 (380) 80 (108) + 90°

12 Point - Grade 8

Note: Use Ariel turn indicator, B-1495

1” - 14

Torsional Vibration Detuner - Cap Screw

1” - 14

12 Point - G rade 8

530 (715)

Crankshaft Flange to Nut Plate (JGE:K:T/6)

1/2 - 2 0

12 Point - G rade 8

46 (62)

Crosshead P in Thru C ap S crew - Lock Nut

1/2 - 20

Hex - N ylon I nsert

61 (83)

Frame t o Spacer Bar - Cap Screw

1-1/8 - 12

12 Point - Grade 8

560 (760)

Crosshead Guide t o Frame - Cap Screw

7/8 - 9

12 Point - Grade 8

280 (380)

5/8 - 11 Crosshead Guide to Cylinder

Crosshead Guide to Support - Cap Screw

7/8 - 9

90 (120) + 90°

97 (130)

12 Point - Grade 8

280 (380)

7/8 - 14

Hex Nut

315 (425)

7/8-9

Hex - Grade 9

255 (345)

1” - 8

12 Point - Grade 8

380 (515)

1/2 - 13 Head End Cylinder Support to Cylinder

5/8 - 11 3/4 - 10

44 (60) 88 (120)

Hex - Grade 8

160 (215)

7/8 - 9 Eccentric Vernier C ap - Cap S crew Idler Sprocket Thru Cap Screw - Lock Nut External Thrust Bearing Adapter to Crankshaft - Cap Screw

5/16 - 18 1/2 - 20 5/8 - 18 1/2 - 20 3/4 - 10

Rod Packing - Cap Screw b

3/4 - 16 7/8 - 14

Packing Tie Rod - Nut

#10 - 24 1/4 - 20

255 (345) Hex - Grade 8

Hand W rench T ight 41 (55)

Hex - Prevailing

82 (110)

12 Point - Grade 8

66 (90) 125 (170)

12 Point Grade 8 or 17-4PH

145 (195) 230 (310) 20 lb x in. (2.3)

Hex

72 lb x in. (8.1)

Rod Catcher to Packing

1/2 - 20

12 Pt - Grade 8/17-4PH

Piston Nut

1-5/8 - 12

Ariel Design

1590 (2150) c

Crosshead Balance Nut

1-3/4 - 12

Ariel Design

Slugging Methodd

ForceFeed Lube Box - Bearing Housing

1-3/8 - 20 - LH

Bearing Housing

70 (95)

Force Feed Lube Box - Jam Nut

1”-14 1-1/2 - 12

Hex

51 (69)

75 (100) 112 (152)

Force Feed Lube Pump Mounting

1/4 - 20

Hex - Grade 5

50 lb x in (5.6)

Auto Relief Valve

1/2 e

Ariel Design

75 lb x in (8.5)

#10 - 24

Ariel Design

50 lb x in (5.6)

1/4 NPT

Hex

Hand Wrench Tight

3/4 - 16

Ariel Design

160 (215)

Auto Relief Valve Manifold Plug Roller Thrust Bearing Retainer Clamp Cap Screw

Page A-4 of 6

REV: 3/17


Fastener Rupture Disk - Blow-Out Fitting Cap Flywheel to Hub Piston Rod Oil Slinger Bolt - Lock Nut



1/4 Nom. Tube 1”-8 1” - 14 1/4 - 28

Type


Hex - Tube Fitting

40 lbx in. (4.5) 460 (620)

12 Point - Grade 8

530 (715)

Hex Jam - Prevailing

95 lb x in. (11)

Cap Nut

Hand Wrench T ight

7/8 - 14 Valve Cap Assembly - Cap Nut

1" - 14 1-1/8 - 12

Valve Cap Seal Keeper - Cap Screw

5/16 - 18

12 Point - 17-4PH

120 lb x in. (14)

Cylinder Mounting Flange to Forged Steel Cylinder

1”-14

485 (660)

1-1/4 - 12

12 Pt - Grade 8/17-4PH or Hex Grade 9

955 (1290)

Frame Foot & Crosshead Guide Foot Hold Down

1-1/8 - 7

Hex Nut

600 (810)f

Crankshaft Flange to Flywheel or Coupling Adapter - Drive End

1” - 14

12 Point - Grade 8

530 (715)

Lifting B racket to F rame J GE:K:T/6

1-1/4 - 7

12 P oint - Grade 8

690 (935)

Fenner Drive A-7352

7/8

Hex

100 (140)

Cap Screw g • Valve Cap • Cylinder Head • Gas Passage Cap • Unloader • VVCP • Ariel supplied companion flanges, except “Peanut” Dual Nozzle

3/8 - 16

193 lb x in (22)

1/2 - 13

40 (54)

5/8 -11

79 (105)

3/4 - 10

140 (190)

3/4 - 16 7/8 - 9 7/8 -14 1” - 8

260 (350) 345 (465) 395 (535)

1-1/8 - 12

560 (760)

1-1/4 - 12

780 (1060)

1/2 - 13

Hex - Grade 8

Companion Flange “Peanut” Dual Nozzle

1/2 - 13

12 Pt - Grade 8/17-4PH

1/2 - 13 5/8 - 11 3/4 - 10 3/4 - 16 1-1/8 - 12

REV: 3/17

230 (310)

1” - 14

Unloader Actuator to Valve C ap - Cap Screw

Tandem Cylinder to Cylinder - Cap Screw g

160 (215)

Hex - Grade 8 or 9 or 12 Point Grade 8 or 17-4PH

48 (65)

53 (71) 44 (60)

Hex - Grade 8 or 9 or 12 Point Grade 8 or 17-4PH

88 (120) 160 (215) 180 (245) 620 (840)

Page A-5 of 6


Fastener

Seating Studs in Cylinder NOTE: In valve cap assemblies with a spring energized seal, install longer studs with Loctite 242.



Type


3/8 - 16

107 lb x in (12)

1/2 - 13

22 (30)

5/8 - 11

44 (60)

3/4 - 10 3/4 - 16 7/8 - 9

Dog Point Grade 8 or 17-4PH

79 (105) 90 (120) 130 (175)

7/8 - 14

145 (195)

1” and larger

200 (270)

Distribution Block Tie Rod - Nut

1/4 - 28

Hex

68 lb x in. (7.7)

Distribution Block Divider Valve - Cap Screw

1/4 - 2 8

Socket Head

75 lb x in. (8.5)

Grade 5 - Hex Cap Screw

ALL

Hex - Grade 5

Hand Wrench Tight

a. Torque opposing pairs of fasteners incrementally until all reach full torque. b. Repeat final torque for rod packing bolts until they no longer turn before the torque wrench clicks. c. Or use 3500 psig (241 barg) hydraulic pressure and 50 (68) torque on pinion drive with separately purchased piston rod hydraulic tensioning tool. Tighten, loosen, then re-tighten piston nut to insure proper torque. d. Or use 3500 psig (241 barg) hydraulic pressure on separately purchased crosshead (balance) nut torquing tool. e. "1/2" indicates the wrench size. Auto relief valve can swivel in the manifold once torqued. See assembly drawing. f. Minimum torque to stress recommended 1-1/8 - 7 hold-down stud to 55,000 psi (380 MPa). Use studs with an ultimate strength of 100,000 psi (690 MPa) or greater. If greater, increase torque stress to about 55% of ultimate strength, as specified by packager. g. For studs specified for cylinder applications, tighten nuts to the same torque as cap screws in similar applications.

Page A-6 of 6

REV: 3/17

Appendix B - Clearances TABLE B-1 JGH:E:K:T Frame and Running Gear Clearances, in. (mm) Description

Clearance

Crankshaft Dust Seal JGH:E:K:T/2/4 (Feeler Gauge - Centered)

0.008 to 0.010 (0.20 to 0.25)

Crankshaft Dust Seal JGE:K:T/6 (Feeler Gauge - Centered)

0.010 to 0.018 (0.25 to 0.46)

Crankshaft Thrust JGH:E:K:T/2/4(End)

0.0085 to0.0200 (0.216 to0.508)

Crankshaft Thrust JGE:K:T/6 (End)

0.014 to 0.033 (0.356 to 0.838)

Crankshaft Journal Bearing (Jack)

0.0015 to 0.0050 (0.038 to 0.127)

Connecting Rod Bearing (Jack)

0.0035 to 0.0070 (0.089 to 0.178)

Connecting R od T hrust (Side)

0.007 t o 0.018 (0.178 t o 0.457)

Connecting Rod Bushing toCrosshead Pin

0.002 to 0.004 (0.05 to 0.10)

Crosshead (Ductile and ADI Iron) Bronze Bushing to Crosshead Pin

0.0020 to 0.0042 (0.05 to 0.11)

Crosshead (Gray Iron) toCrosshead Pin (JGH)

0.0020 to0.0035 (0.05 to0.09)

Crosshead (Bronze) toCrosshead Pin (JGH)

0.0020 to0.0035 (0.05 to0.09)

Crosshead (Babbitted Gray and Ductile Iron) to Guide (Feeler Gauge)

0.007 to 0.012 (0.18 to 0.30)

Crosshead (Babbitted ADI Iron) to Guide (Feeler Gauge)

0.009 to 0.014 (0.23 to 0.36)

Crosshead (Babbitted Bronze) to Guide (Feeler Gauge)

0.011 to 0.016 (0.28 to 0.41)

TABLE B-2 JGH:E:K:T Piston End Clearances, in. (mm) a, b Cylinder Class

Crank End

Head End

Total

22-1/2 E:ET:H

0.050 (1.3)

0.070 to 0.130 (1.8to3.3)

0.120 to 0.180 (3.0 to 4.6)

All other E:ET:H

0.040 (1.0)

0.050 to 0.110 (1.3 to 2.8)

0.090 to 0.150 (2.3 to 3.8)

17-7/8, 20-1/8, 22, 24-1/8, and 26-1/2 K:T

0.055 (1.4)

0.095 to0.155 (2.4 to3.9)

0.150 to0.210 (3.8 to5.3)

5-3/8 K:T Tandem

0.040 (1.0)

0.060 to 0.160 (1.5to4.1)

0.100 to 0.200 (2.5 to 5.1)

All KL:TL

0.300 (7.6)

No Set

0.620 to 0.680 (15.7 to 17.3)

All KM:TM and all other K:T

0.040 (1.0)

0.080 to 0.140 (2.0 to 3.6)

0.120 to 0.180 (3.0 to 4.6)

a. Measured clearances may not agree because of oil films, assembly tolerances, wear, etc. Do not use plastigages, solder, etc. b. If total piston end clearance is not within table tolerance, contact your Packager or Ariel.

REV: 3/17

Page B-1 of 9

Appendix B - Clearances


TABLE B-3 New Uncut Packing Ring Side Clearance, in. (mm), (BTUU/CUU/BTU/CU/STU)

TABLE B-4 New Pressure Breaker and Segmented Packing Ring Side Clearance, in. (mm),

Actual Groove Width

Side Clearance

(BTR/CR/BD/BT/TR/P/UP/P1U)

0.572 to 0.574 (14.53 to 14.58)

0.023 to 0.028 (0.58 to 0.71)

Actual Groove Width

Side Clearance

0.625 to 0.627 (15.88 to 15.93)

0.025 to 0.030 (0.64 to 0.76)

0.375 to 0.377 (9.52 to 9.58)

0.011 to 0.015 (0.28 to 0.38)

0.750 to 0.752 (19.05 to 19.10)

0.030 to 0.035 (0.76 to 0.89)

0.447 to 0.449 (11.35 to 11.40)

0.013 to 0.017 (0.33 to 0.43)

0.572 to 0.574 (14.53 to 14.58)

0.023 to 0.028 (0.58 to 0.71)

0.625 to 0.627 (15.88 to 15.93)

0.025 to 0.030 (0.64 to 0.76)

TABLE B-5 New Wiper Ring Side Clearance, in. (mm)

Wiper Ring Type 2RWS, 2RUG 3RWS, 3RUG

Side Clearance

0.004 to 0.006 (0.010 to 0.015)

0.006 to 0.009 (0.15 to 0.23)

RTV

0.000

TABLE B-6 Piston Ring Side Clearances, in. (mm) Actual Groove Width

PTFE

PEEK

0.188 to0.190 (4.78 to4.83)

0.003 to0.008 (0.09 to0.21)

0.002 to0.007 (0.05 to0.17)

0.250 to0.252 (6.35 to6.40)

0.005 to0.010 (0.11 to0.24)

0.003 to0.008 (0.06 to0.19)

0.312 to0.314 (7.92 to7.98)

0.006 to0.011 (0.14 to0.27)

0.003 to0.008 (0.08 to0.21)

0.375 to0.377 (9.53 to9.58)

0.007 to0.012 (0.17 to0.30)

0.004 to0.009 (0.10 to0.22)

0.438 to0.440 (11.13 to11.18)

0.008 to0.013 (0.20 to0.33)

0.004 to0.009 (0.11 to0.24)

0.500 to0.502 (12.70 to12.75)

0.009 to0.014 (0.23 to0.36)

0.005 to0.010 (0.13 to0.25)

0.563 to0.565 (14.30 to14.35)

0.010 to0.015 (0.26 to0.38)

0.006 to0.011 (0.14 to0.27)

0.625 to0.627 (15.88 to15.93)

0.011 to0.016 (0.29 to0.41)

0.006 to0.011 (0.16 to0.29)

0.688 to0.690 (17.48 to17.53)

0.012 to0.017 (0.31 to0.44)

0.007 to0.012 (0.17 to0.30)

0.750 to0.752 (19.05 to19.10)

0.014 to0.019 (0.34 to0.47)

0.008 to0.013 (0.19 to0.32)

Page B-2 of 9

REV: 3/17



TABLE B-7 Wearband Side Clearances, in. (mm) Actual Groove Width

PTFE

PEEK

0.500 to0.502 (12.70 to12.75)

0.006 to0.011 (0.15 to0.28)

0.004 to0.009 (0.09 to0.22)

0.750 to0.752 (19.05 to19.10)

0.009 to0.014 (0.23 to0.36)

0.005 to0.010 (0.13 to0.26)

0.875 to0.877 (22.23 to22.28)

0.011 to0.016 (0.27 to0.39)

0.006 to0.011 (0.16 to0.28)

1.000 to1.002 (25.40 to25.45)

0.012 to0.017 (0.30 to0.43)

0.007 to0.012 (0.18 to0.30)

1.250 to1.252 (31.75 to31.80)

0.015 to0.020 (0.38 to0.51)

0.009 to0.014 (0.22 to0.35)

1.375 to1.377 (34.93 to34.98)

0.017 to0.022 (0.42 to0.55)

0.010 to0.015 (0.24 to0.37)

1.500 to1.502 (38.10 to38.15)

0.018 to0.023 (0.46 to0.58)

0.011 to0.016 (0.27 to0.39)

1.625 to1.627 (41.28 to41.33)

0.020 to0.025 (0.50 to0.62)

0.011 to0.016 (0.29 to0.42)

1.750 to1.752 (44.45 to44.50)

0.021 to0.026 (0.53 to0.66)

0.012 to0.017 (0.31 to0.44)

1.875 to1.877 (47.63 to47.68)

0.023 to0.028 (0.57 to0.70)

0.013 to0.018 (0.33 to0.46)

2.000 to2.002 (50.80 to50.85)

0.024 to0.029 (0.61 to0.74)

0.014 to0.019 (0.36 to0.48)

2.125 to2.127 (53.98 to54.03)

0.026 to0.031 (0.65 to0.77)

0.015 to0.020 (0.38 to0.50)

2.250 to2.252 (57.15 to57.20)

0.027 to0.032 (0.69 to0.81)

0.016 to0.021 (0.40 to0.53)

2.500 to2.502 (63.50 to63.55)

0.030 to0.035 (0.76 to0.89)

0.018 to0.023 (0.44 to0.57)

2.750 to2.752 (69.85 to69.90)

0.033 to0.038 (0.84 to0.97)

0.019 to0.024 (0.49 to0.62)

2.875 to2.877 (73.03 to73.08)

0.035 to0.040 (0.88 to1.00)

0.020 to0.025 (0.51 to0.64)

3.000 to3.003 (76.20 to76.28)

0.036 to0.041 (0.91 to1.04)

0.021 to0.026 (0.53 to0.66)

3.250 to3.253 (82.55 to82.63)

0.039 to0.044 (0.99 to1.12)

0.023 to0.028 (0.58 to0.70)

3.500 to3.503 (88.90 to88.98)

0.042 to0.047 (1.07 to1.19)

0.025 to0.030 (0.62 to0.75)

3.750 to3.753 (95.25 to95.33)

0.045 to0.050 (1.14 to1.27)

0.026 to0.031 (0.67 to0.79)

4.000 to 4.004 (101.60 to 101.70)

0.048 to 0.053 (1.22 to1.35)

0.028 to 0.033 (0.71 to 0.84)

REV: 3/17

Page B-3 of 9



TABLE B-8 Piston-Bore Clearances and H:E:ET Cylinder Piston/Rider Ring End Gaps, in. (mm) Piston to Bore Diametral Clearance

Bore Diameter 4.25 (108)

4.625 (117)

0.012 to 0.017 (0.30 to 0.43)

5.125 (130) 5.5 (140)

0.013 to 0.018 (0.33 to 0.46)

6.0 (152) 6.375 (162)

Conventional Piston Rings 0.011 to 0.016 (.028 to 0.41)

7.0 (178)

0.014 to 0.019 (0.36 to 0.48) 0.015 to 0.020 (0.38 to 0.51)

7.375 (187)

0.016 to 0.022 (0.41 to 0.56) 0.017 to 0.023 8.375 (213) (0.43 to 0.58) 0.019 to 0.025 9.25 (235) (0.48 to 0.64) 0.020 to 0.026 9.75 (248) (0.51 to 0.66) 0.022 to 0.028 11 (279) (0.56 to 0.71) 0.023 to 0.029 11.5 (292) (0.58 to 0.74) 0.026 to 0.032 13 (330) (0.66 to 0.81) 0.027 to 0.033 13.5 (343) (0.69 to 0.84) 0.030 to 0.037 15.250 (387) (0.76 to 0.94) 0.031 to 0.038 15.75 (400) (0.79 to 0.97) 0.033 to 0.040 16.75 (425) (0.84 to 1.02) 0.034 to 0.041 17.25 (438) (0.86 to 1.04) 19 (483) 0.038 to 0.046 (0.97 to 1.17) 0.039 to 0.047 19.5 (495) (0.99 to 1.19) 22.5 (572) 8.0 (203)

Piston/Rider Ringsa

Conventional Piston Ring End Gap New

Maximum

0.051 to 0.075 0.225 (5.72) (1.30 to 1.91) 0.056 to 0.080 0.240 (6.10) (1.42 to 2.03) 0.061 to 0.085 0.255 (6.48) (1.55 to 2.16) 0.066 to 0.090 0.270 (6.86) (1.68 to 2.29) 0.072 to 0.112 0.336 (8.53) (1.83 to 2.84) 0.077 to 0.117 0.351 (8.92) (1.96 to 2.97) 0.084 to 0.124 0.372 (9.45) (2.13 to 3.15) 0.089 to 0.129 0.387 (9.83) (2.26 to 3.28) 0.090 to 0.096 (2.29 to 2.44) 0.096 to 0.136 0.408 (10.36) (2.44 to 3.45) 0.101 to 0.141 0.423 (10.74) (2.57 to 3.58) 0.111 to 0.151 0.453 (11.51) (2.82 to 3.84) 0.117 to 0.157 (2.97 to 3.99) 0.471 (11.96) 0.131 to 0.179 0.537 (13.64) (3.33 to 4.55) 0.138 to 0.186 0.558 (14.17) (3.51 to 4.72) 0.156 to 0.204 0.612 (15.54) (3.96 to 5.18) 0.162 to 0.210 0.630 (16.00) (4.11 to 5.33) 0.183 to 0.231 0.693 (17.60) (4.65 to 5.87) 0.189 to 0.237 0.711 (18.06) (4.80 to 6.02) 0.090 to 0.097 (2.29 to 2.46) 0.201 to 0.251 0.753 (19.13) (5.11 to 6.38) 0.207 to 0.259 0.777 (19.74) (5.26 to 6.58) 0.228 to 0.292 0.876 (22.25) (5.79 to 7.42) 0.090 to 0.098 (2.29 to 2.49) 0.234 to 0.298 0.894 (22.71) (5.94 to 7.57) Uses wearbands - See TABLE B-9.

New Piston/Rider Ring End Gap b 0.050 to 0.066 (1.27 to 1.68) 0.056 to 0.072 (1.42 to 1.83) 0.062 to 0.078 (1.57 to 1.98) 0.068 to 0.084 (1.73 to 2.13) 0.074 to 0.090 (1.88 to 2.29) 0.073 to 0.103 (1.85 to 2.62) 0.091 to 0.121 (2.31 to 3.07) 0.097 to 0.127 (2.46 to 3.23) 0.095 to 0.125 (2.41 to 3.18) 0.100 to 0.130 (2.54 to 3.30) 0.112 to 0.142 (2.84 to 3.61) 0.119 to 0.149 (3.02 to 3.78) 0.136 to 0.166 (3.45 to 4.22) 0.143 to 0.173 (3.63 to 4.39) 0.182 to 0.212 (4.62 to 5.38) 0.190 to 0.220 (4.83 to 5.59) 0.216 to 0.246 (5.49 to 6.25) 0.224 to 0.254 (5.69 to 6.45) 0.239 to 0.269 (6.07 to 6.83) 0.247 to 0.277 (6.27 to 7.04) 0.273 to 0.303 (6.93 to 7.70) 0.281 to 0.311 (7.14 to 7.90)

a. Piston/rider rings are standard on all ET & all E Class cylinders except 22.5 (572). Conventional piston rings are standard on H class cylinders and p iston/rider rings are optional on bore diameters of 4.25 to 11.5 (108 to 292) with the exception of bore diameters 4.625 (117), 5.5 (140), 6.375 (162). Piston/rider rings are standard on H class cylinders with bore diameters of 4.625 (117), 5.5 (140), 6.375 (162), and 13 to 19.5 (330 to 495). H & E class cylinders are out-of-production; use them only if they meet application requirements. Consult your packager and/or Ariel when re-applying cylinders. b. Piston/rider ring radial p rojection is 0.026 to 0.033 (0.66 to 0.84) and side clearance is 0.008 to 0.013 (0.20 to 0.33).

Page B-4 of 9

REV: 3/17



TABLE B-9 Clearance Specifications for K, T, and 22-1/2 E:ET:H a Cylinders, in. (mm) PISTON TO CYLINDER

PISTON RING END GAP (PTFE) b

Diametral

WEAR BAND - NEW

New

Maximum

Minimum End Gap

0.015 to 0.025 (0.38 to 0.64)

0.075 (1.91)

0.080 (2.03)

0.015 to 0.025 (0.38 to 0.64)

0.075 (1.91)

0.084 (2.13)

3 (76.2)

0.017 to 0.027 (0.43 to 0.69)

0.081 (2.06)

0.096 (2.44)

3.5 (88.9)

0.011 to 0.018 (0.28 to 0.46)

0.054 (1.37)

0.112 (2.84)

3.875 (98.4)

0.012 to 0.019 (0.30 to 0.48)

0.057 (1.45)

0.124 (3.15)

4.25 (108)

0.051 to 0.061 (1.30 to 1.55)

0.183 (4.65)

0.136 (3.45)

0.023 to 0.031 (0.58 to 0.79)

0.053 to 0.063 (1.35 to 1.60)

0.189 (4.80)

0.140 (3.56)

0.026 to 0.033 (0.66 to 0.84)

4.625 (117)

0.056 to 0.066 (1.42 to 1.68)

0.198 (5.03)

0.148 (3.76)

0.023 to 0.031 (0.58 to 0.79)

5 (127)

0.050 to 0.060 (1.27 to 1.52)

0.180 (4.57)

0.160 (4.06)

5.375 (137)

0.065 to 0.077 (1.65 to 1.96)

0.231 (4.88)

0.172 (4.37)

0.059 to 0.071 (1.50 to 1.80)

0.213 (5.41)

0.188 (4.78)

6.25 (159)

0.063 to 0.138 (1.60 to 3.50)

0.414 (10.52)

0.200 (5.08)

6.75 (171)

0.068 to 0.081 (1.73 to 2.06)

0.243 (6.17)

0.216 (5.49)

0.070 to 0.084 (1.78 to 2.13)

0.252 (6.40)

0.224 (5.69)

7.25 (184)

0.072 to 0.087 (1.83 to 2.21)

0.261 (6.63)

0.232 (5.89)

7.875 (200)

0.079 to 0.095 (2.00 to 2.41)

0.285 (7.24)

0.252 (6.40)

0.084 to 0.100 (2.13 to 2.54)

0.300 (7.62)

0.268 (6.81)

Bore Clearance 2.5 (63.5) 2.625 (66.7)

4.375 (111)

5.875 (149)

7.00 (178)

8.375 (213)

0.055 to 0.063 (1.40 to 1.60)

0.060 to 0.068 (1.52 to 1.73)

0.071 to 0.079 (1.80 to 2.01)

0.081 to 0.089 (2.06 to 2.26)

0.087 to 0.096 (2.21 to 2.44)

0.092 to 0.101 (2.34 to 2.57)

Radial Projection

0.018 to 0.025 (0.46 to 0.64)

0.018 to 0.026 (0.46 to 0.66)

0.027 to 0.035 (0.69 to 0.89)

0.029 to 0.037 (0.74 to 0.94)

0.031 to 0.040 (0.79 to 1.02)

8.75 (222)

0.090 to 0.098 (2.29 to 2.51)

0.105 to 0.125 (2.67 to 3.18)

0.375 (9.53)

0.280 (7.11)

0.030 to 0.039 (0.76 to 0.99)

9.125 (232)

0.096 to 0.105 (2.44 to 2.67)

0.091 to 0.110 (2.31 to 2.79)

0.330 (8.38)

0.291 (7.39)

0.033 to 0.042 (0.84 to 1.07)

9.25 (235)

0.090 to 0.098 (2.29 to 2.51)

0.111 to 0.131 (2.82 to 3.33)

0.393 (9.98)

0.296 (7.52)

0.030 to 0.039 (0.76 to 0.99)

9.625 (244)

0.096 to 0.105 (2.44 to 2.67)

0.096 to 0.116 (2.44 to 2.95)

0.346 (8.79)

0.307 (7.80)

0.033 to 0.042 (0.84 to 1.07)

9.75 (248)

0.090 to 0.098 (2.29 to 2.51)

0.117 to 0.137 (2.97 to 3.49)

0.411 (10.44)

0.312 (7.92)

0.030 to 0.039 (0.76 to 0.99)

REV: 3/17

Page B-5 of 9


PISTON TO CYLINDER


PISTON RING END GAP (PTFE) b

Diametral Bore

WEAR BAND - NEW

New

Maximum

Minimum End Gap

Radial Projection

Clearance 9.875 (251)

0.109 to 0.118 (2.77 to 3.00)

0.099 to 0.119 (2.51 to 3.02)

0.357 (9.07)

0.316 (8.03)

0.037 to 0.047 (0.94 to 1.19)

10.25 (260)

0.090 to 0.098 (2.29 to 2.51)

0.110 to 0.132 (2.79 to 3.35)

0.396 (10.06)

0.327 (8.31)

0.033 to 0.040 (0.84 to 1.02)

10.375 (264)

0.109 to 0.118 (2.77 to 3.00)

0.104 to 0.125 (2.64 to 3.18)

0.375 (9.53)

0.332 (8.43)

0.037 to 0.047 (0.94 to 1.19)

10.5 (267)

0.114 to 0.123 (2.90 to 3.12)

0.105 to 0.126 (2.67 to 3.20)

0.378 (9.60)

0.336 (8.53)

0.039 to 0.049 (0.99 to 1.24)

10.75 (273)

0.090 to 0.098 (2.29 to 2.51)

0.110 to 0.132 (2.79 to 3.35)

0.396 (10.06)

0.344 (8.74)

0.033 to 0.040 (0.84 to 1.02)

10.875 (276)

0.114 to 0.123 (2.90 to 3.12)

0.108 to 0.130 (2.74 to 3.30)

0.393 (9.98)

0.348 (8.84)

11 (279)

0.114 to 0.123 (2.90 to 3.12)

0.110 to 0.132 (2.79 to 3.35)

0.396 (10.06)

0.352 (8.94)

11 (L&M) (279)

0.090 to 0.098 (2.29 to 2.51)

0.110 to 0.132 (2.79 to 3.35)

0.396 (10.06)

0.352 (8.94)

0.033 to 0.040 (0.84 to 1.02)

11.25 (286)

0.100 to 0.108 (2.54 to 2.74)

0.135 to 0.159 (3.42 to 4.04)

0.477 (12.12)

0.360 (9.14)

0.036 to 0.042 (0.91 to 1.07)

11.375 (289)

0.114 to 0.123 (2.90 to 3.12)

0.114 to 0.137 (2.90 to 3.48)

0.411 (10.44)

0.364 (9.25)

0.039 to 0.049 (0.99 to 1.24)

11.75 (298)

0.100 to 0.108 (2.54 to 2.74)

0.141 to 0.165 (3.58 to 4.19)

0.495 (12.57)

0.376 (9.55)

0.036 to 0.044 (0.91 to 1.07)

12 (305)

0.117 to 0.128 (2.97 to 3.24)

0.120 to 0.144 (3.05 to 3.66)

0.432 (10.97)

0.384 (9.75)

12.25 (311)

0.117 to 0.128 (2.97 to 3.23)

0.123 to 0.147 (3.12 to 3.73)

0.441 (11.20)

0.392 (9.96)

12.375 (314)

0.100 to 0.108 (2.54 to 2.74)

0.148 to 0.172 (3.76 to 4.37)

0.516 (12.95)

0.396 (10.06)

0.036 to 0.042 (0.91 to 1.07)

12.5 (318)

0.117 to 0.128 (2.97 to 3.24)

0.125 to 0.150 (3.18 to 3.81)

0.450 (11.43)

0.400 (10.16)

0.039 to 0.050 (0.99 to 1.27)

13.125 (333)

0.131 to 0.158 (3.33 to 4.01)

0.474 (12.04)

0.419 (10.64)

13.625 (346)

0.136 to 0.164 (3.45 to 4.17)

0.490 (12.45)

0.435 (11.05)

0.141 to 0.170 (3.58 to 4.32)

0.508 (12.90)

0.451 (11.46)

0.171 to 0.195 (4.34 to 4.95)

0.585 (14.86)

0.456 (11.58)

0.177 to 0.201 (4.50 to 5.11)

0.603 (15.32)

0.472 (11.99)

14.125 (359)

0.126 to 0.137 (3.20 to 3.48)

14.25 (362) 14.75 (375)

0.039 to 0.049 (0.99 to 1.24)

0.039 to 0.050 (0.99 to 1.27)

0.043 to 0.053 (1.09 to 1.35)

0.042 to 0.052 (1.07 to 1.32)

15.375 (391)

0.127 to 0.138 (3.23 to 3.50)

0.154 to 0.185 (3.91 to 4.70)

0.555 (14.10)

0.492 (12.50)

0.038 to 0.050 (0.97 to 1.27)

15.875 (403)

0.127 to 0.138 (3.23 to 3.50)

0.159 to 0.191 (4.04 to 4.85)

0.573 (14.55)

0.508 (12.90)

0.038 to 0.050 (0.97 to 1.27)

17.375 (441)

0.179 to 0.191

0.174 to 0.209

0.627 (15.93)

0.556 (14.12)

0.044 to 0.057

Page B-6 of 9

REV: 3/17

For models JGH:E:K:T PISTON TO CYLINDER

Appendix B - Clearances PISTON RING END GAP (PTFE) b

Diametral Bore

New

WEAR BAND - NEW

Maximum

Minimum End Gap

Clearance

Radial Projection

(4.55 to 4.85)

(4.42 to 5.31)

17.875 (454)

0.181 to 0.193 (4.60 to 4.90)

0.179 to 0.215 (4.55 to 5.46)

0.645 (16.38)

0.572 (14.53)

19.625 (498)

0.187 to 0.199 (4.75 to 5.05)

0.236 to 0.268 (5.99 to 6.81)

0.804 (20.42)

0.627 (15.93)

20.125 (511)

0.185 to 0.197 (4.70 to 5.00)

0.242 to 0.274 (6.15 to 6.96)

0.822 (20.88)

0.643 (16.33)

22 (559)

0.213 to 0.225 (5.41 to 5.72)

0.264 to 0.304 (6.71 to 7.72)

0.912 (23.16)

0.703 (17.86)

22.5 (572)

0.152 to 0.164 (3.86 to 4.17)

0.270 to 0.310 (6.86 to 7.87)

0.930 (23.62)

0.734 (18.64)

24.125 (613)

0.214 to 0.226 (5.44 to 5.74)

0.290 to 0.330 (7.36 to 8.38)

0.990 (25.15)

0.771 (19.58)

0.056 to 0.069 (1.42 to 1.75)

26.5 (673)

0.226 to 0.238 (5.74 to 6.05)

0.320 to 0.360 (8.13 to 9.14)

1.080 (27.43)

0.847 (21.51)

0.058 to 0.071 (1.47 to 1.80)

(1.12 to 1.45)

0.050 to 0.063 (1.27 to 1.60)

0.059 to 0.072 (1.50 to 1.83)

a. E & H Class Cylinders are out-of-production; use existing E & H cylinders only if they meet application requirements. Consult your packager and/or Ariel when re-applying cylinders. b. For PEEK piston ring end gap valu es, multiply table values by 0.3.

REV: 3/17

Page B-7 of 9



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 crank end piston clearance to the proper feeler gauge specification stamped on the cylinder data plate or printed in the Ariel Technical manual. 2. With head end components removed, position the piston for the desired cylinder at outer dead center. Position a dial indicator to index off of the crosshead or crosshead nut outer face, with the cylinder near to outer dead center. Manually turn crankshaft to find the 0.010 inch (0.25 mm) position, before and after outer dead center. Then turn crankshaft to position piston at outer dead center (see picture to the right). 3. Dimension A: Measure from cylinder head end to piston head end to the nearest thousandth inch and record. See illustration on the following page. 4. Dimension B: With gasket removed, measure from head end cylinder face to the gasket seat and record. 5. Dimension C: Use 0.055 inch (1.40 mm) for nominal 0.060 inch (1.52 mm) thick steel gasket and record. 6. Calculate Head End Clearance: A - B + C = Head End Clearance A _______________ - B _______________ + C 0.055 (1.40 mm) = _______________ 7. Compare calculated head end piston clearance to clearance tolerances stamped on the cylinder data plate or printed in the Ariel Technical manual. If tolerances are unavailable or if calculated clearance is outside tolerance, contact your packager or Ariel before proceeding.

Page B-8 of 9

REV: 3/17



8. Measure head end piston clearance prior to new start up, as required by recommended maintenance intervals in Section 3, or after installation, removal, or replacement of any one of the following: • Crankshaft • Connecting Rod

• Crosshead Guide • Piston and/or Piston Rod

• Either Tandem Cylinder Body • Crosshead and/or Crosshead Nut

9. Re-assemble all components according to the Ariel Maintenance and Repair Manual supplied with your compressor. Verify installation of all gaskets and manually bar over the compressor to confirm the crankshaft rotates freely.

REV: 3/17

Page B-9 of 9

Appendix C - Frame Specifications For more information, see the Ariel Performance Program. Rated speeds for non-lube and lubricated process applications may vary. TABLE C-1 JGH Frame Specifications Specification

JGH/2

JGH/4

Stroke, in. (mm)

4.50 (114)

Maximum Allowable Speed,a RPM

1200

Minimum Speed,b RPM

600

Piston Speed,c FPM (m/s)

To 900 (4.57)

Horsepower, hp (kW)

680 (507)

1360 (1014)

Maximum Length, in. (m)

53 (1.35)

98 (2.49)

Maximum Overall Height, in. (m)

29 (0.74) to top of aluminum cover

Maximum Width with Cylinders

See appropriate frame, guide, and cylinder outline drawings.

Height - B ottom to Crankshaft Centerline, in. (mm)

17 (432)

Approximate Weight with Cylinders

See Ariel Performance Program.

Connecting Rod Centerline to Centerline, in. (mm)

13.75 (349)

Sump Capacity, US gallons (L)

15 (57)

37 (140)

Oil Pump Flow Rate, d GPM (L/s)

13 (0.82)

26 (1.64)

Oil Heat Rejection, BTU/hr. (kW)

25,000 (7.3)

50,000 (14.7)

Piston Rod Diameter, in. (mm)

2.00 (51)

Internal Rod Load - Double Acting Compression + Tension, lbf. (kN)

48,000 (214)

Tension, lbf. (kN)

24,000 (107)

Compression, lbf. (kN)

30,000 (133)

Internal Rod Load - Single Acting Tension, lbf. (kN)

24,000 (107)

a. Maximum Allowable Speed is the highest (potential) speed at which the frame design permits continuous operation. Compressor frame data plate "Frame Rated Speed (RPM)" is application specific, and may be low er than Maximum Allowable Speed. Do not exceed the lower of frame rated speed, lowest cylinder rated (RPM), or driver rated speed. b. Minimum Speed is the lowest frame speed needed to provide adequate oil flow to the compressor bearings. c. Average Piston Speed is based on Maximum Allowable Speed (RPM). The cylinder data-plate rated speed (RPM) or frame rated speed may be less, resulting in a lower piston speed rating. d. Flow rate at maximum rated speed and 180°F (82°C) oil.

REV: 3/17

Page C-1 of 5

Appendix C - Frame Specifications


TABLE C-2 JGE Frame Specifications Specification

JGE/2

JGE/4

Stroke, in. (mm)

4.50 (114)


1500

Minimum Speed,b RPM

750


To 1125 (5.72)

JGE/6

Horsepower, hp (kW)

1070 (798)

2140 (1596)

3210 (2394)


53 (1.35)

98 (2.49)

140 (3.56)






17 (432)




13.75 (349)

Sump Capacity, US gal. (L)

15 (57)

37 (140)

56 (212)

Oil Pump Flow Rate,d GPM (L/s)

17 (1.07)

32 (2.02)

85 (5.36)

Oil Heat Rejection BTU/hr (kW)

34,000 (10.0)

68,000 (19.9)

102,000 (29.9)


2.00 (51)


60,000 (267)

Tension, lbf. (kN)

30,000 (133)


32,000 (142)


30,000 (133)

a. Maximum Allowable Speed is the highest (potential) speed at which the frame design permits continuous operation. Compressor frame data plate "Frame Rated Speed (RPM)" is application specific, and may be lower than Maximum Allowable Speed. Do not exceed the lowe r of frame rated speed , lowe st cylind er ra ted (RPM), or d river rated speed. b. Minimum Speed is the lowest frame speed neede d to provide adequate oil flow to the compressor bearings. c. Average Piston Speed is based on Maximum Allowable Speed (RPM). The cylinder data-plate rated speed (RPM) or frame rated speed may be less, resulting in a lower piston speed rating. d. Flow rate at maximum rated speed and 180°F (82°C) oil.

Page C-2 of 5

REV: 3/17



TABLE C-3 JGK Frame Specifications Specification

JGK/2

Stroke, in. (mm)

JGK/4

JGK/6

5.50 (140) a

Maximum Allowable Speed, RPM

1200

Minimum Speed,b RPM

600


To 1100 (5.59)

Horsepower, hp (kW)

1270 (947)

2540 (1894)

3810 (2841)


53 (1.35)

98 (2.49)

140 (3.57)





Height - B ottom to C rankshaft Centerline, in. (mm)

17 (432)




13.75 (349)


15 (57)

37 (140)

56 (212)


13 (0.82)

26 (1.64)

68 (4.29)


28,000 (8.2)

56,000 (16.4)

84,000 (24.6)


2.00 (51)


74,000 (329)

Tension, lbf. (kN)

37,000 (165)


40,000 (178)


37,000 (165)

a. Maximum Allowable Speed is the highest (potential) speed at which the frame design permits continuous operation. Compressor frame data plate "Frame Rated Speed (RPM)" is application specific, and may be lower than Maximum Allowable Speed. Do not exceed the lower of frame rated speed, lowest cylinder rated (RPM), or d river rated speed. b. Minimum Speed is the lowest frame speed needed to provide adequate oil flow to the compressor bearings. c. Average Piston Speed is based on Maximum Allowable Speed (RPM). The cylinder data-plate rated speed (RPM) or frame rated speed may be less, resulting in a lower piston speed rating. d. Flow rate at maximum rated speed and 180°F (82°C) oil.

REV: 3/17

Page C-3 of 5



TABLE C-4 JGT Frame Specifications Specification

JGT/2

JGT/4

Stroke, in. (mm)

4.50 (114)


1500

Minimum Speed,b RPM

750


To 1125 (5.72)

JGT/6

Horsepower, hp (kW)

1300 (969)

2600 (1939)

3900 (2908)


53 (1.35)

98 (2.49)

140 (3.57)






17 (432)




13.75 (349)


15 (57)

37 (140)

56 (212)


17 (1.1)

32 (2.0)

84.9 (5.4)


34,000 (10.0)

68,000 (19.9)

102,000 (29.9)


2.00 (51)


74,000 (329)

Tension, lbf. (kN)

37,000 (165)


40,000 (178)


37,000 (165)

a. Maximum Allowable Speed is the highest (potential) speed at which the frame design permits continuous operation. Compressor frame data plate "Frame Rated Speed (RPM)" is application specific, and may be lower than Maximum Allowable Speed. Do not exceed the lowe r of frame rated speed , lowe st cylind er ra ted (RPM), or d river rated speed. b. Minimum Speed is the lowest frame speed neede d to provide adequate oil flow to the compressor bearings. c. Average Piston Speed is based on Maximum Allowable Speed (RPM). The cylinder data-plate rated speed (RPM) or frame rated speed may be less, resulting in a lower piston speed rating. d. Flow rate at maximum rated speed and 180°F (82°C) oil.

Page C-4 of 5

REV: 3/17



Opposed Throw - Reciprocating Weight Balancing Ariel recommends a reciprocating weight differential between opposing throws of 2.5 pounds (1.1kg) or less for JGH:E:K:T compressors. To replace a connecting rod assembly, piston, piston and rod assembly, balance nuts, or crosshead, weigh component parts on a scale calibrated to 0.1 pounds (0.05 kg) and compare to the Balancing Record in the compressor Parts Book. If the weight changes, recalculate opposing throw reciprocating weight differential. If not within recommended limits, the compressor may require new balance nuts and/or crossheads. To exchange opposing throw cylinder locations, exchange all reciprocating components to the opposite throw, except the connecting rod assemblies. Check the Balancing Record and recalculate reciprocating weight differential, including the weight of the connecting rods. If not within recommended limits, the compressor may require new crosshead balance nuts to reduce differential. If unable to balance opposing throws within recommended limits, contact the packager or Ariel. When applying or re-applying a different cylinder to a throw, recalculate opposing throw reciprocating weight differential; new balance nuts and/or crossheads may be required. The force feed oil distribution system may also need resized. Contact the packager or the Ariel Response Center for detailed information about recommended reciprocating weight differential between opposing throws. TABLE C-5 JGH:E:K:T Approximate Component Weights, Lbs (Kg) Component

Weight

Component

Weight

Main/Connecting Rod Bearing

2 (1)

Connecting Rod

91 (41)

Top Cover 2-Throw

55 (25)

Crosshead Guide

838 (380)

Top Cover 4-Throw

115 (52)

Crosshead

See Notea

Top Cover 6-Throw

172 (78)

Crosshead Pin

25 (12)

Spacer Bar

16 (7)

Lube Oil Pump 2-Throw

36 (16)

End Cover Drive End

85 (40)


36 (16)

End Cover Auxiliary End

130 (60)


124 (56)

Crankshaft 2-Throwb

580 (263)

Frame Assembly w/o Cylinders

Crankshaft 4-Throwb

1030 (468)

VVCP

Crankshaft 6-Throwb

1580 (712)

Cylinder A ssembly

Main Journal Caps

20 (9)

Piston & Rod Assembly


a. For exact weights, see Balancing Record sheet provided by Ariel in the Parts Book for each compressor. b. Crankshaft weight is without flywheel or vibration detuners.

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Appendix D - Compressor Clearance, Oil, & Temperature Record SERIAL NO. F- _______________________ MODEL _____________ Date __________________ CRANKSHAFT THRUST (END) CLEARANCE, In. (mm) Crankshaft Serial Number

Thrust Clearance, In. (mm)

CONNECTING ROD THRUST (SIDE) 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 Bearing Conn. Rod Bearing After n ew beari ng installation, if measured cl earan ces exceed tolerances in Appendix B , contact your packager or Ariel before proceeding.

OIL PRESSURE AND TEMPERATURE

Date

Time

RPM

Filter Inlet

Filter Outlet

Oil Temp.

Oil Pressure

Oil Pressure

into Frame

psig (barg)

psig (barg)

°F (°C)

Remarks

BEARING CAP TEMPERATURE, °F (°C), 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

Additional 10-15 Minutes

Full Speed

Full Speed

No Gas Load

Gas Load

Main

Rod

Main

Rod

1 2 3 4 5 6

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Appendix E - Balance Valve Log TABLE E-1 Balance Valve Maintenance Log Date

Time

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Pressure Gauge Description

Div. Block Pressure Min.

Max.

Balance Valve Set Pressure

Div. Block Cycle Time (Seconds)

Notes

Page E-1 of 1

Appendix F - ER-34.1 Cleaning, Handling, and Assembly 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 and handling will virtually eliminate oil and antiseize compounds from the cylinder interior, piston rod assembly, valve and packing case areas. In nonlubricated applications, the non-metallic rings and packings transfer some material to the metallic running surfaces. This transferred film provides a “lubricated” surface that enables the compressor to function properly. The presence of oil degrades the transferred film, forming an abrasive paste that quickly wears non-metallic elements during operation. Anti-seize compounds are oil based and also contain abrasive metallic components that cause premature component wear. This procedure applies to all non-lube compressor cylinders. Ariel cleans and protects complete nonlube cylinders to non-lube service requirements before shipping. Follow the procedure below to clean internal parts shipped loose, spare parts before installation, and contaminated surfaces during maintenance. This extends non-lube compressor component life, and ultimately, cylinder life. 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. 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. Handle all cleaned parts with new or clean “rubber” gloves or new white cotton gloves. If gloves become contaminated or dirty, dispose of them and use a new pair. 2. 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 gas passages, nozzles, etc. 3. Lubricate the threads, bolt head, and stat-o-seal of the cylinder nozzle lube bolt with very small amounts of Never-Seez, regular grade, and ensure all mating surfaces are coated. 4. Use a small amount of Loctite 577 Pipe Sealant on male threads when installing pipe plugs. 5. Very lightly oil bolt threads and head seating surfaces for valve cap, head, and packing case mounting bolts, but prevent oil penetration into the cylinder interior. 6. 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 and wear band grooves especially well. Clean piston rings and wear bands with denatured alcohol before assembling. 7. When assembling piston to rod, use very small amounts of Never-Seez, Regular Grade on the nut and collar, and ensure all mating surfaces are covered. Do not lube threads for the piston rod tensioner. Clean threads of hydraulic tensioner and all other tensioner surfaces that will contact the piston. Use very small amounts of Never-Seez, Regular Grade on piston nut set screws. After assembly, thoroughly wipe off all Never-Seez from the 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. REV: 3/17

Page F-1 of 2

Appendix F - ER-34.1


8. The manufacturer should provide packing cases cleaned, preserved, and suitable for non-lube service. Inspect packing cases for cleanliness. If they appear coated with an oil-based preservative, disassemble and clean them with denatured alcohol, then reassemble. If disassembly is required for water-cooled packing cases, re-assemble and test to Ariel Engineering Reference ER-51. Contact Ariel for latest version of ER-51. 9. Wipe down piston rod with denatured alcohol after rod installation. 10. Clean VVCP or FVCP components with denatured alcohol. Separate the unloader head from the adapter/actuator. Clean all internal surfaces with denatured alcohol including behind the unloader piston. Do not remove VVCP unloader stem seal. Clean piston ring with denatured alcohol. Do not use anti-seize compounds or oil on the steel head gaskets. Use a very thin film of oil when installing O-rings. 11. Clean crank-end head, head-end head, and steel head gaskets with denatured alcohol. Do not use anti-seize compounds or oil on the steel head gaskets. If the crank-end head uses an O-ring seal, apply a very thin film of oil to the lead-in chamfer of the cylinder seating surface to help prevent shearing of the O-ring. 12. The manufacturer should provide compressor valves cleaned, preserved, and suitable for non-lube service. Inspect valves for cleanliness. If they appear coated with an oil-based preservative, disassemble and clean them with denatured alcohol, then reassemble. If they appear clean, they require no additional cleaning provided they are sealed in their original packaging and have not been contaminated. 13. Clean valve caps, retainers, high clearance assemblies, and steel valve gaskets with denatured alcohol. Use only a very thin film of oil for valve cap O-rings. Do not use anti-seize compounds or oil on steel valve gaskets. 14. Assemble cleaned parts immediately. If cylinder will not see immediate service, see Ariel Engineering Reference ER-34 for preservation instructions. Contact Ariel for latest version of ER-34. CAUTION: Do not use Ariel non-lube compressor cylinders for oxygen service.

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Appendix G - ER-26 Hold-down Bolting to Resist Shaking Forces and Couples Requirements 1. To use the torques in the tables, the ultimate strength (Su) of the stud material must equal or exceed 100,000 psi (690 MPa); higher strength stud material is preferred. In all cases, torque the nuts to stress the stud to about 55% of the ultimate strength of the stud material. Torques shown in tables are based on 100,000 psi ultimate strength material for imperial sizes and 830 MPa ultimate strength material for metric sizes. Higher strength materials require higher torques than shown in the tables. Material strength and torque are directly proportional. Example: for 120,000 psi (830 MPa) ultimate strength Imperial bolting: 120,000 ÷ 100,000 = 1.2 x min. torque for Imperial size from table = required torque for given nut size. To use a different stud diameter, consult Ariel for feasibility and torque. 2. Compressor frame foot hold-down studs and crosshead guide support foot hold-down studs should be as long as possible. Ariel recommends a minimum 12 to 1 length to diameter ratio. NOTE: Bolting long enough to reach only through the compressor foot and a deck plate or flange of an I-beam can loosen if not provided with engineered devices to maintain bolt pre-load. 3. Tighten nuts as recommended above TABLE G-1 Crosshead Guide to Support Bolt Torques to maintain fastener pre-load during Bolting Size Bolting Torque Compressor Model operation. Ariel also recommends inch--TPI lb-ft (N•m) rolled threads and hardened spherJGH:E 7/8--9 255 (345) ical washers for hold down bolting to a JGK:T 1--8 380 (515) help compensate for fastener to frame bolt surface angular misa. For JGT compressors with ET crosshead guides, use 7/8”–9 TPI size in TABLE G-1 as the minimum torque. alignment. 4. Use grade 8 or 9 bolting to hold crosshead guides to supports. 5. Re-preserve any fasteners subject to corrosion after installation. 6. Follow lubrication guidelines and recommended procedures for torque accuracy in Appendix A . TABLE G-2 Crosshead Guide Support Foot Hold-down Bolting - Minimum Torques Imperial Size (basis 100,000 psi) Compressor Model

JGH:E:K:T

Hole Diameter inch (mm)

Recommended Stud Size inch--TPI

Minimum Nut Torque d lb-ft (N•m)

1-1/4 (32)

1-1/8--7

600 (810)

a

Metric Size (Class 8.8) b Stud Size c mm x pitch


M27x3

630 (850)

M30x3.5

850 (1150)

a. See #1, "Requirements". b. Ultimate Strength: 830 MPa (120,000 psi); Yield Strength: 660 MPa (95,700 psi). c. Where two sizes appear, the first is the preferred size, and the second is an alternate size. d. For a stud pitch other than those listed above in the same nominal diameter size, use this formula to determine required torque: Torque = (TABLE G-2 fastener torque) x (target fastener root area ÷ TABLE G-2 fastener root area).

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Appendix G - ER-26


TABLE G-3 Frame Foot H old-down Bolting - Minimum Torques a Imperial Size (basis 100,000 psi) Compressor Model

JGH:E:K:T

Hole Diameter inch (mm)

Recommended Stud Size inch--TPI


1-1/4 (32)

1-1/8--7

600 (810)

Metric Size (Class 8.8) b Stud Size c mm x pitch


M27x3

630 (850)

M30x3.5

850 (1150)

a. See #1, "Requirements". b. Ultimate Strength: 830 MPa (120,000 psi); Yield Strength: 660 MPa (95,700 psi). c. Where two sizes appear, the first is the preferred size, and the second is an alternate size. d. For a stud pitch other than those listed above in the same nominal diameter size, use this formula to determine required torque: Torque = (TABLE G-3 fastener torque) x (target fastener root area ÷ TABLE G-3 fastener root area).

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Appendix H - ER-82 Soft Foot and Top Plane Flatness Checks for Proper Main Bearing Bore Alignment in Reciprocating Compressors Main bearing bore alignment is critical to main bearing and crankshaft life. Ariel manufactures the top cover mounting surface of a compressor frame in close tolerance to a flat plane, to the main bearing bores, and to the bottom of the compressor feet. The main bearing bores align when frame feet are supported so the top cover mounting surface is flat and "in plane". Perform a soft foot check and top plane flatness measurement at these times: • Setting of a new compressor (pre and post grouting)

• Discovery of loose hold down fasteners

• Commission of a compressor in the field

• Performance of recommended scheduled maintenance inspection every 6 months or 4000 hours

• Reinstallation of a compressor • Relocation of a package

With new unit installations, Ariel recommends checking and recording initial top plane flatness before shimming the guide feet and after initial rough coupling alignment. On compressors shipped disassembled, perform the initial check before guide and cylinder assembly installation. Shim or otherwise adjust the height to bring the top cover mounting surface within the specified plane tolerance. Record subsequent readings after complete guide and cylinder installation, and again after any vessel installation and shimming. Re-adjust height if guide, cylinder, and/or vessel installation results in frame top rail measurements out of TABLE H-1 tolerances. For JGH:E:K:T frames, the soft foot check is required; the top plane flatness measurement is optional.

Soft Foot Check 1. Properly install and torque compressor frame hold down bolting. 2. Loosen each hold down bolt individually while checking the frame foot to skid deflection with a calibrated dial indicator. If there are two bolts on a foot, loosen both for this check. 3. Correct any hold down position that deflects more than 0.002 inches (0.05 mm) when released. Retorque the hold down bolt or bolts and repeat on each frame foot. See Appendix G for proper frame foot and crosshead guide bolt size and torques.

Top Plane Flatness Check 1. Remove or reposition the top cover(s) and gasket(s) to expose the frame top cover mounting surface. Verify it is clean. TABLE H-1 Top Plane Flatness Tolerances 2. Use measurement equipment with a published accuracy of ±0.001 inches (0.025 mm) over the Tolerance Compressor Frame distance required to measure the entire length of Inch (mm) both frame rails. Measure the top surface of both JGH:E:K:T/2/4 0.006 (0.15) sides of the frame rails at each anchor bolt (see JGE:K:T/6 0.008 (0.20) FIGURE H-1), or between each pair of anchor bolts for frames with pairs of anchor bolts (see FIGURE H-2). Readings between any two adjacent points must be within 0.002 in. (0.05 mm). For proper alignment, total accumulated out of plane flatness must be within TABLE H-1 tolerances.

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JGH-JGE-JGK-JGT-EN

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