8000 Hour JW Maintenance

Compressor Maintenance

• Grease VVCP stem threads at grease fittings with 2-3 pumps of cylinder compatible grease

• Turn VVCP all the way in and out to ensure threads are lubricated

• NOTE. Measure or count thread turns to return to it's original position

• Open force feed lubrication box and visually inspect pump followers, cams, gears for wear

• Pressure test distribution blocks (Manual pg 3-26)

• Remove valves and valve gaskets

• visually inspect valve pockets for damage

• Have a qualified valve shop: disassemble, inspect and refurbish valves. Insure to provide torque service guide

• Visually inspect suction valve unloader actuator for damage or wear

• Visually inspect stem seals for damage or wear, Insure actuator moves freely

• Visually inspect pneumatic clearance pockets for damage or wear

Compressor Maintenance Cont.

• Inspect cylinder bores for damage or wear

• NOTE: Replace or restore the cylinder bores if any of the following exist

• 1. Bore surfaces blemishes or gouges

• 2. Bore out of round more then 0.001 inch per inch of bore diameter (0.001 mm/mm) or tapered

• 3. Main bore is worn to counterbore or larger

• Inspect piston rings and wear-band

• Measure and log piston ring condition, end gap, side clearance, and piston groove width

• Replace rings if damaged or are outside limits listed in appendix B

• When replacing rings, re-measure and log ring side clearance to check for groove wear

• Measure and log radial projection of wear-band

• Inspect piston rods for damage or excessive wear

• Note: Replace if any of the following exist

• Gouges or scratches on the rod

• Under size more than 0.005 inch (0.13mm)

• Packing travel length out of round by more than 0.001inch (0.03mm)

• Anywhere in the packing travel area, tapered more than 0.002 inch (0.05mm)

Compressor Maintenance Cont.

• Check and re-calibrate all required instrumentation

• Clean crankcase breather filter with suitable cleaner

• Check and if needed, adjust drive chains (Manual pg 4-55)

• Visually inspect and exercise crankcase over-pressure relief valves to manufacturers recommendations

• Check fasteners torque: gas nozzle flanges, head end or unloader, valve caps, piston rods packing, frame hold downs, 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, tandem cylinder to cylinder