Ariel Heavy Duty Balanced Opposed Compressor JGM/1

Remove crosshead guide side covers

Remove the cylinder head (or VVCP)

Turn the crankshaft to position the crosshead to near its inner dead center position

Turn the crosshead-balance nut off the piston rod

Turn the crankshaft to position the crosshead near to its outer dead center position

Turn the crankshaft to near the inner dead center position

Rotate the crosshead 90 degrees and remove it through the guide opening

Check the crosshead pin to crosshead/bushing clearance

Warning: This procedure requires trained personnel with PPE!

Crosshead pin to connecting rod bushing clearance checked and within recommended range?

Crosshead pin inspected for wear and replaced if necessary?

Existing bushing filed or sawed to reduce the tightness of the shrink fit?

New bushing installed using a hydraulic press in a qualified machine shop?

CAUTION!: DO NOT TOUCH COLD SURFACES WITHOUT PROPER INSULATION TO PREVENT INJURY. ALCOHOL IS FLAMMABLE AND SHOULD ONLY BE USED IN OPEN AIR OR A WELL VENTILATED BUILDING. AVOID SPARKS AND OPEN FLAME. AVOID ALCOHOL VAPORS WHICH MAY CAUSE INJURY TO THE TISSUES OF THE NOSE AND EYES.

AVOID EYE AND SKIN CONTACT. USE NEOPRENE OR BUTYL GLOVES, MONO-GOGGLES OR FACE-MASK AND IMPERMEABLE APRON. IT CONTAINS METHYL ALCOHOL AND IS POISONOUS IF INGESTED. SEE MANUFACTURER'S MATERIAL SAFETY DATA SHEETS FOR MORE INFORMATION. DO NOT RETURN SOLUTION TO A CLOSED CONTAINER UNTIL IT HAS REACHED ROOM TEMPERATURE OR THE CONTAINER MAY EXPLODE.

NOTE: ABSOLUTE CLEANLINESS IS REQUIRED OF BOTH THE BUSHING AND THE CONNECTING ROD TO PREVENT DIRT FROM ACCUMULATING BETWEEN THEM. ASSEMBLY MUST BE IMMEDIATE SO THAT THE BUSHING DOES NOT WARM-UP AND STICK BEFORE IT IS IN PLACE.

Bushing positioned correctly on the press table?

Remove the cap screws from the drive chain eccentric adjustment cap and rotate cap to loosen the chain.

After removing the chain from the lube sprocket, remove the sprocket set screw and sprocket. Detach all tubing to the lubricator.

Remove the four mounting bracket cap screws and remove the lubricator.

With the lubricator on the bench, remove the Woodruff Key from the shaft and file the shaft to remove any burrs raised by the cup point of the set screw. Install a new O-ring.

Install a new No. 204 Woodruff Key after first checking to make sure the key will fit into the new sprocket. If it is too thick, it can be polished with an emery cloth on a flat surface until it can easily slide into the slots for a snug fit. If the key is too high, file of the top edge for a snug fit.

After the new key has been installed and it has been determined that the new sprocket will fit, oil the new O-ring and remount the lubricator on the frame.

Put the new sprocket onto the shaft.

Check alignment to the crankshaft drive sprocket with crankshaft centered in end play, using a straight edge, to within 1/32 inch (1 mm). Tighten the set screw.

Warning: This procedure requires trained personnel with PPE!

DO NOT REUSE BEARING SHELLS. Determine bearing wear by checking actual jack and crankshaft thrust clearances against the clearance limits.

High copper content in the oil analysis may be an indication of main and/or connecting rod bearing wear, and/or chain idler, crosshead, connecting rod bushings wear.

There are notches in the frame and bearing cap for the bearing tabs in order to position and maintain the position of the bearing halves.

The old bearings halves are easily slid out, tab end first. New bearings are to be slid in (untabbed end first), and snapped into place.

On JGI models, remove the carrier bearing using a hydraulic press or jack. Remove the frame bearing using a hydraulic jack.

The bushing needs to be left 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 INSULATION TO PREVENT INJURY.

NOTE: ABSOLUTE CLEANLINESS IS REQUIRED. ASSEMBLY MUST BE IMMEDIATE SO THAT THE BEARING DOES NOT WARM-UP AND STICK BEFORE IT IS IN PLACE.

Check crosshead pin to crosshead pin bore and connecting rod bushing bore by removing crosshead pins.

Check for excessive wear in the auxiliary end drive chain tightener.

Check for excessive ring groove wear in pistons.

Sign off on the compressor maintenance