Ariel Heavy Duty Balanced Opposed Compressor JGN/1

CAUTION!: BE SURE THAT ALL PRESSURE IS RELIEVED FROM THE COMPRESSOR CYLINDERS PRIOR TO REMOVING PACKING.

Packing diaphragm and oil wiper packing removed

All tubing connections from the top of the packing flange and the primary vent tube from the bottom of the flange disconnected

Twelve point cap screws that hold the pressure packing flange to the cylinder removed

At this point do not remove the small nuts from the studs. These studs hold the entire packing case together so it can be removed as an assembly.

Pressure packing removed into the crosshead guide

CAUTION: TO PREVENT PERSONAL INJURY, BE SURE THAT COMPRESSOR CRANKSHAFT CANNOT BE TURNED BY THE DRIVER OR COMPRESSOR CYLINDER GAS PRESSURE DURING MAINTENANCE

Engine-driven compressors: Is the center coupling removed or the flywheel locked?

Electric motor-driven compressors: Is the driver switch gear locked out during maintenance?

Is the system completely vented before performing any maintenance?

Before removing a cylinder head or VVCP, are all cap screws backed off 1/8 inch (3 mm)?

Is the head loose and the cylinder or VVCP completely vented?

Follow steps 1. through 5. at “Crosshead - Removal” on page 5-11.

With the cylinder head/unloader removed and the cross-head balance nut loosened, is the piston and rod assembly screwed out of the crosshead using the piston turning/piston nut torquing tool (Ariel furnished tool) and a speed wrench?

Is the crosshead nut turned off the piston rod?

Remove the frame top cover (or chain access cover for JGI). Remove the two cap screws that hold the eccentric adjustment cap to the end cover. Rotate the eccentric cap to loosen the chain. After dropping the chain off the idler sprocket, the entire assembly can be removed from the frame.

Remove the lock nut, cap screw, sprocket, Stat-O-Seal washer and the cap O-ring. Discard these items since they must be replaced with new parts.

Reassemble all parts using a new cap screw, Stat-O-Seal washer, sprocket, and lock nut. Tighten the idler lock nut to the recommended torque given in Table 1-12 on page 1-16.

Apply oil to and install a new O-ring on the eccentric adjustment cap.

Install the assembly and adjust the chain according to the instructions given in “Chain Adjustment” on page 5-24.

Sign off on the Chain Idler Sprocket Replacement

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 new bushings are to be installed into the connecting rod by cooling the bushing in a 95 percent alcohol solution with dry ice solution.

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.

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

Warning: Ensure all power to the Unit is shut off and the Tank is drained of air pressure before servicing the Air Compressor.

After running a new compressor (or after a re-location, re-configuring or major overhaul) for the first 24 hours, shutdown, vent gas system and perform a hot alignment check at coupling within 30 minutes, while barring driver shaft to packager’s recommendations.

Realign if necessary to hold coupling hub face and rim hot alignment within 0.005 inch (0.13 mm) TIR, except for hub O.D. >17 in. (>43 cm) angular hub-face limit is increased to 0°1’ (0.0167°).

Check fastener torque on gas nozzle flange, valve cap, cylinder head, compressor rod; packing flange and, if applicable, crosshead guide to frame bolting.

If bearing temperatures increase or a visual inspection of the crankcase indicates bearing wear, check main, connecting rod and crankshaft-thrust bearing clearances.

Replace affected bearings if clearances are out of tolerances.

Check frame oil pressure. It should be 50 to 60 psig (3.5 to 4.2 barg) when at operating temperature.

Check frame oil level. It should be visible in the sight glass and approximately mid-level when running.

Check lubricator block cycle time.