Documente Academic
Documente Profesional
Documente Cultură
Heavy Duty
Balanced Opposed
Compressors
OPERATOR'S MANUAL
For Models:
JG, JGA, JGM, JGP
WORLD HEADQUARTERS:
ARIEL CORPORATION
35 BLACKJACK ROAD
MOUNT VERNON, OHIO 43050
TELEPHONE: 614-397-0311
FAX: 614-397-3856
WORLD WIDE WEB: www.arielcorp.com
CAUTION
CAUTION
CAUTION
CAUTION
CAUTION
CAUTION
Contents
Table of Contents
Section 1 - Reference Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Specifications - JG/2, JG/4, JGA/2, JGA/4 & JGA/6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Specifications - JGM/1 & JGP/1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Specifications - JGM/2 & JGP/2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Identification and Information Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Force Feed Lubricator Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cylinder Identification Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Ariel Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Other Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Piston Ring Side Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Piston Ring End Gaps - JG & JGT Model Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Piston Ring End Gaps - JGM & JGP Model Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Ariel Bolting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Bolt Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Installation- Dog Point Type Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Models: JG, JGA, JGM & JGP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Required Torques - JG, JGA, JGM and JGP Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Valve Center Bolt or Center Stud Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Section 2 - Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Start-Up Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Maximum Allowable Working Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Main Oil Lube Oil System - Before Starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Filling Sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Force Feed Lubrication System - Running Conditions and Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Before Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Running Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Frame Lubricating System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Lube Oil System - Schematic JG, JGA, JGM & JGP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Lube Oil Strainer, Lube Oil Filter
& Filter Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Lube Oil Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Lube Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Spin-On Type Filter - Filter Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Replaceable Element Type Filter (Reusable Canister) - Servicing . . . . . . . . . . . . . . . . . . . . . . 27
Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Lube Oil Pump & Lube Oil Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Description & Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Lube Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
i
Contents
Low Oil Pressure Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Force Feed Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Force Feed Lubricator Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Force Feed Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Packing Tubing and Distance Piece Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Packing Lubrication and Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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Contents
Section 4 - Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Piston and Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Determining Ring Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Piston Rod Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Packing Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Identification of Rings and Arrangements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Type P Pressure Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Type TR Single Acting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Type BD Double Acting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Type 3RWS Oil Wiper Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Arrangement of Packing Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Packing Ring Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
iii
Contents
iv
JG/2
Stroke, inches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
RPM
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . to 1400
Piston speed, fpm . . . . . . . . . . . . . . . . . . . . . . . . . . . to 817
Number of throws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . to 200
Weight (approximate.), lbs. (without cylinders) . . . . 2,000
Oil pump capacity, gpm . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Oil heat rejection, btu/hr . . . . . . . . . . . . . . . . . . . . . . 4,000
Sump capacity, gallons. . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Internal rod loads
Double acting
Compression + tension . . . . . . . . . . . 18,000 lbs.
Tension. . . . . . . . . . . . . . . . . . . . . . . . . 9,000 lbs.
Compression . . . . . . . . . . . . . . . . . . . 10,000 lbs.
Single acting
Tension. . . . . . . . . . . . . . . . . . . . . . . . . 9,000 lbs.
JG/4
Stroke, inches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . to 1400
Piston speed, fpm . . . . . . . . . . . . . . . . . . . . . . . . . . . to 817
Number of throws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . to 400
Weight (approximate.), lbs. (without cylinders) . . . . 4,000
Oil pump capacity, gpm . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Oil heat rejection, btu/hr . . . . . . . . . . . . . . . . . . . . . . 7,000
Sump capacity, gallons. . . . . . . . . . . . . . . . . . . . . . . . . . 10
Internal rod loads
Double acting
Compression + tension . . . . . . . . . . . 18,000 lbs.
Tension. . . . . . . . . . . . . . . . . . . . . . . . . 9.000 lbs.
Compression . . . . . . . . . . . . . . . . . . . 10,000 lbs.
Single acting
Tension. . . . . . . . . . . . . . . . . . . . . . . . . 9,000 lbs.
JGA/2
Stroke, inches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
RPM
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .to 1800
Piston speed, fpm . . . . . . . . . . . . . . . . . . . . . . . . . . .to 900
Number of throws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .to 200
Weight (approximate.), lbs. (without cylinders) . . . . 2,000
Oil pump capacity, gpm . . . . . . . . . . . . . . . . . . . . . . . . . .4
Oil heat rejection, btu/hr . . . . . . . . . . . . . . . . . . . . . . 5,000
Sump capacity, gallons . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Internal rod loads
Double acting
Compression + tension . . . . . . . . . . . . 18,000 lbs.
Tension . . . . . . . . . . . . . . . . . . . . . . . . . 9,000 lbs.
Compression . . . . . . . . . . . . . . . . . . . . 10,000 lbs.
Single acting
Tension . . . . . . . . . . . . . . . . . . . . . . . . . 9,000 lbs.
JGA/4
Stroke, inches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
RPM
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .to 1800
Piston speed, fpm . . . . . . . . . . . . . . . . . . . . . . . . . . .to 900
Number of throws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .to 400
Weight (approximate.), lbs. (without cylinders) . . . . 4,000
Oil pump capacity, gpm . . . . . . . . . . . . . . . . . . . . . . . . . .8
Oil heat rejection, btu/hr . . . . . . . . . . . . . . . . . . . . . . 5,000
Sump capacity, gallons . . . . . . . . . . . . . . . . . . . . . . . . . .10
Internal rod loads
Double acting
Compression + tension . . . . . . . . . . . . 18,000 lbs.
Tension . . . . . . . . . . . . . . . . . . . . . . . . . 9,000 lbs.
Compression . . . . . . . . . . . . . . . . . . . . 10,000 lbs.
Single acting
Tension . . . . . . . . . . . . . . . . . . . . . . . . . 9,000 lbs.
JGM/1
Stroke, inches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
RPM
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . to 1400
Piston speed, fpm . . . . . . . . . . . . . . . . . . . . . . . . . . . to 817
Number of throws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .to 62.5
Weight (approximate.), lbs. (without cylinders) . . . . 1200
Oil pump capacity, gpm . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Oil heat rejection, btu/hr . . . . . . . . . . . . . . . . . . . . . . 4.000
Sump capacity, gallons. . . . . . . . . . . . . . . . . . . . . . . . 2-1/2
Internal rod loads
Double acting
Compression + tension . . . . . . . . . . . 12,000 lbs.
Tension. . . . . . . . . . . . . . . . . . . . . . . . . 6,000 lbs.
Compression . . . . . . . . . . . . . . . . . . . . 7,000 lbs.
Single acting
Tension. . . . . . . . . . . . . . . . . . . . . . . . . 6,000 lbs.
JGP/1
Stroke, inches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
RPM
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .to 1800
Piston speed, fpm . . . . . . . . . . . . . . . . . . . . . . . . . . .to 900
Number of throws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . to 62.5
Weight (approximate.), lbs. (without cylinders) . . . . .1200
Oil pump capacity, gpm . . . . . . . . . . . . . . . . . . . . . . . . . .4
Oil heat rejection, btu/hr . . . . . . . . . . . . . . . . . . . . . . 5,000
Sump capacity, gallons . . . . . . . . . . . . . . . . . . . . . . . 2-1/2
Internal rod loads
Double acting
Compression + tension . . . . . . . . . . . . 12,000 lbs.
Tension . . . . . . . . . . . . . . . . . . . . . . . . . 6,000 lbs.
Compression . . . . . . . . . . . . . . . . . . . . . 7,000 lbs.
Single acting
Tension . . . . . . . . . . . . . . . . . . . . . . . . . 6,000 lbs.
JGM/2
Stroke, inches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
RPM
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .to 1400
Piston speed, fpm . . . . . . . . . . . . . . . . . . . . . . . . . . .to 817
Number of throws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .to 125
Weight (approximate.), lbs. (without cylinders) . . . . .1500
Oil pump capacity, gpm . . . . . . . . . . . . . . . . . . . . . . . . . .4
Oil heat rejection, btu/hr . . . . . . . . . . . . . . . . . . . . . . 4.000
Sump capacity, gallons . . . . . . . . . . . . . . . . . . . . . . . 2-1/2
Internal rod loads
Double acting
Compression + tension . . . . . . . . . . . . 12,000 lbs.
Tension . . . . . . . . . . . . . . . . . . . . . . . . . 6,000 lbs.
Compression . . . . . . . . . . . . . . . . . . . . . 7,000 lbs.
Single acting
Tension . . . . . . . . . . . . . . . . . . . . . . . . . 6,000 lbs.
JGP/2
Stroke, inches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
RPM
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . to 1800
Piston speed, fpm . . . . . . . . . . . . . . . . . . . . . . . . . . . to 900
Number of throws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . to 125
Weight (approximate.), lbs. (without cylinders). . . . . 1500
Oil pump capacity, gpm . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Oil heat rejection, btu/hr. . . . . . . . . . . . . . . . . . . . . . .5,000
Sump capacity, gallons . . . . . . . . . . . . . . . . . . . . . . . . 2-1/2
Internal rod loads
Double acting
Compression + tension. . . . . . . . . . . . 12,000 lbs.
Tension . . . . . . . . . . . . . . . . . . . . . . . . . 6,000 lbs.
Compression. . . . . . . . . . . . . . . . . . . . . 7,000 lbs.
Single acting
Tension . . . . . . . . . . . . . . . . . . . . . . . . . 6,000 lbs.
Nameplate
IMPORTANT
WARNING PLATES
The Force Feed Lubricator provides oil to the piston rod packing and the compressor pistons. The Lubricator
Plate gives directions for adjusting the flow of oil. If this plate is missing, please call Ariel, Mount Vernon,
for a replacement or for specific directions.
See Section 3 - Frame and Parts for maintenance instructions.
See page 24 for force feed lubricator operating instructions.
Serial number
stamped on
end of cylinder
Cylinder Identification Plates appear on each cylinder. The serial number is also stamped on the end of each
cylinder, as illustrated above. If any plate is missing, please call Ariel, Mount Vernon, for replacement or for
specific directions.
NOTE:
Tools
Ariel Tools
Ariel provides those tools identified below free of charge. Please contact your Distributor if you do not have
these tools.
These tools are specifically designed for use on Ariel Units. Clean all tools before use. Make sure the tool is
clean and held snug with the part being removed or installed. If a tool is worn or broken, please call your distributor for a replacement. Do not use worn or broken tools.
Valve Tools
A-409
A-135
A-409
A-135
Tools
Other Tools
The following tools are normally all that is required to work on an Ariel Compressor. These are in addition to
the Ariel Tools listed on page 8. Please contact Ariel if you have questions about tools used on Ariel Units.
3/8" Square Drive Ratchet Wrench
3/8" Square Drive Breaker Bar
2" and 6" Extensions for above Ratchet
3/8" Square Drive Universal Joint
3/8" Square Drive Torque Wrench 30 Ft. Lb. to 150 Ft. Lb.
7/16", 1/2", 9/16", 3/4", 15/16", 3/8" Square Drive Sockets
3/8" Hex Key and 1/4" Hex Key (Allen) for 3/8" Square Drive
1/2" X 9/16" Open End Wrench
3/8" X 7/16" Open End Wrench
5/64", 3/32", 1/8", 9/64", 5/32", 3/16", 7/32", 1/4", and 3/8" Allen Wrenches
12" Crescent Wrench
2 Medium Size Screw Drivers
1 Feeler Gauge Pack
1 Awl
Babbitt or Plastic Faced Slugging Hammer
Clearances
All clearances are listed in inches.
.005 - .001"
.005 - .010"
.0015 - .0045"
.0015 - .0045"
.010" - .015"
.010" - .015"
Crankpin Bearing
.0014" - .0039
.0014" - .0039"
.0015" - .0035"
.0015" - .0035"
.0015" - .0035"
.0015" - .0035"
Crosshead to guide
Babbitt
.006" - .010"
Bronze
.010: - .014"
Cast Iron
.010" - .014"
.008" - .012"
NOTE:
Crank end
1/3 of total
1/3 of total
Head end
2/3 of total
2/3 of total
10
Clearances
Piston Ring Side Clearance
The standard side clearance for piston rings when new is as follows:
Nominal Width
Teflon
3/16"
.0035 - .0075"
1/4"
.005 - .009"
3/8"
.008 - .012"
3/4"
.016 - .022"
.010 - .012
Piston-to-Cylinder Clearance
Bore
Diameter
Clearance
(inches)
Bore
Diameter
Clearance
(inches)
Bore
Diameter
Clearance
(inches)
3-3/4" JG
.009 - .014
2-1/2" P
.007 - .011
2-1/2" M
.007 - .011
3" JG
.009 - .014
2.75" P
.007 - .011
2.75" P
.007 - .011
3-3/8" JG
.010 - .015
3" P
.007 - .011
3" M
.007 - .011
3-5/8" JG
.010 - .015
3-1/4" P
.007 - .011
3-1/4" M
.009 - .013
3-7/8" JG
.011 - .016
3-1/2" P
.009 - .013
3-1/2" M
.009 - .013
4-1/8" JG
.011 - .016
3-3/4" P
.010 - .014
3-7/8" M
.010 - .014
4-3/4" JG
.012 - .018
4-1/8" P
.010 - .014
4-1/8" M
.010 - .014
5-1/8" JG
.012 - .018
4-3/8" P
.011 - .015
4-3/4" M
.012 - .017
6-1/8" JG
.013 - .019
4-3/4" P
.013 - .018
5-1/8" M
.012 - .017
6-1/2" JG
.014 - .020
5-1/8"
.013 - .018
5-1/2" M
.013 - .018
7-1/8" JG
.015 - .021
5-1/2" P
.013 - .018
5-3/4" M
.013 - .018
7-1/2" JG
.015 - .021"
5-3/4" P
.013 - .018
6-1/8"
.014 - .020
8-1/2" JG
.017 - .023
6-1/8" P
.014 - .020
6-1/2" M
.014 - .020
8-7/8" JG
.018 - .024
6-1/2" P
.014 - .020
7-1/2" M
.016 - .022
10-1/2"JG
.021 - .027
7-1/2"
.016 - .022
8" M
.016 - .022
11" JG
.022 - .028
8" P
.016 - .022
13" JG
.026 - .032
13-1/2" JG
02027 - .033
11
Bronze 2-pc.
Diameter
New
Max.
2.75
.0041 - .0083
.0045 - .0090
Max.
New
Max.
Teflon
New
Max.
.332
.027 - .033
.132
.0360
.030 - .036
.144
3.375
.012 - .022
.088
.034 - .041
.164
3.625
.014 - .024
.096
.036 - .044
.176
3.875
.014 - .024
.096
.039 - .047
.188
4.125
.016 - .026
.104
.041 - .050
.200
4.75
.021 - .031
.124
.057 - .077
.308
5.125
.023 - .033
.132
.061 - .081
.324
6.125
.027 - .037
.148
.073 - .093
.372
6.5
.030 - .040
.160
.077 - .097
.388
7.125
.032 - .042
.168
.085 - .105
.409
7.5
.034 - .044
.176
.089 - .109
.430
8.5
.102 - .122
.488
8.875
.106 - .126
.504
1.5
.125 - .145
.580
11
.131 - .151
.604
13
.155 - .075
.700
13.5
.162 - .182
.728
12
Clearances
Piston Ring End Gaps - JGM & JGP Model Cylinders
Piston
Diameter
2.062 P
2.25 P
2.5 P
2.75 P
3P
3.25 P
3.5 SP
3.75 SP
4.125 P/SP
4.375 P/SP
4.75 P
5.125 P
5.5 P
5.75 P
6.125 SP
6.5 SP
7.5 SP
8 SP
2.5 M
2.75 M
3M
3.25 M
3.5 M
3.875 M
4.124 M
4.75 M
5.124
5.5 M
5.75 M
6.125 M
6.5 M
7.5 M
8M
8.5 M
8.875 M
10.5 M
11 M
Bronze 1-pc.
New
Max.
.012-.022
.012-.022
.014-.024
.088
.088
.096
.021-.031
.023-.033
.026-.036
.026-.036
.124
.132
.144
.144
.012-.022
.012-.022
.014-.024
.088
.088
.096
.021-.031
.023-.033
.026-.036
.026-.036
.124
.132
.144
.144
Teflon
New
Max.
.025-.030
.027-.032
.030-.036
.033-.040
.036-.044
.039-.047
.042-.052
.046-.056
.049-.060
.052-.064
.057-.077
.061-.081
.065-.085
.068-.088
.073-.093
.077-.097
.089-.109
.095-.115
.030-.036
.033-.040
.036-.044
.039-.047
.042-.052
.046-.056
.049-.060
.057-.077
.061-.081
.065-.085
.068-.088
.073-.093
.077-.97
.089-.109
.095-.115
.102-.122
.106-.126
.125-.145
.131-.151
.120
.130
.144
.160
.176
.188
.208
.224
.240
.255
.308
.324
.340
.352
.372
.388
.436
.460
.144
.160
.176
.188
.208
.244
.240
.308
.324
.340
.352
.372
.388
.436
.460
.488
.504
.580
.604
13
Ariel Bolting
NOTE:
Ariel has selected bolting that meets strength, elongation, sealing, and locking
requirements. Proper bolting must be used and torqued to the values. See
Required Torques - JG, JGA, JGM and JGP Units tables starting on page 16.
Bolt Identification
See page 16 for Required Torques - JG, JGA, JGM and JGP Units and page 17 for Valve Center Bolt or
Center Stud Torques.
14
15
Grade 5 bolts
Size
Type
Torque (Ft.xLbs.)
1/2 - 12 UNC
1/2 - 13 UNC
3/8 - 24 UNF
5/8 - 18 UNF
1/2 - 13 UNC
1/2 - 13 UNC
1/2 - 13 UNC
58
58
21
92
58
58
58
3/8 - 16 UNC
Hex Socket
18
1/2 - 13 UNC
5/16 - 18 UNC
1/2 - 13 UNC
7/8 - 12
1 - 12
3/8 - 16 UNC
3/8 - 16 UNC
7/16 - 14 UNC
1/2 - 14 UNC
5/8 - 11 UNC
1/4 - 20 UNC
1/4 - 28 UNF
5/16 - 18 UNC
3/8 - 16 UNC
1/2 - 20 UNF
12 Point
Hex head grade 8
12 point
Ariel design
Ariel design
Hex head grade 8
Hex socket (DE Hd 8" JGM)
Hex head grade 8
Hex head grade 8
Hex head grade 8
Hex head grade 5
Hex head grade 5
Hex head grade 5
Hex head grade 5
Hex head grade 5
58
12
33
222
300
18
18
29
44
79
46 (In Lbs)
54 (In Lbs)
8
14
41
NOTE:
Torques listed are for clean, oiled threads only.
When an application requires the use of an adapter with a torque wrench (to reach not readily accessible nuts
or bolts) the torque on the wrench scale may not be the actual torque applied to the fasteners.1
The ratio of actual torque at the fastener with that on the wrench scale is a function of the adapter's length and
its position in relation to the torque wrench beam and the location on that beam at which the force is applied.
L+A
T a = T w -------------
L
L
T a = T w -------------
L+A
Fig. 1
Force
Fig. 2
1.
16
Force
The exception is when the adapter is at 90 degrees to the torque wrench. The torque will be the same as on wrench scale (see Fig. 2
above).
Type
Size
Torque
Greer/
1/4 - 28 UNF
Spiralock
5/16 - 24 UNF
Fastener
Type
Size
Torque
Drake
Lock Nut
Bottom Half
Torque
Top Half
Torque
1/4 - 28 UNF
66 In. Lbs.
5/16 - 24 UNF
96 In. Lbs.
3/8 - 24 UNF
16 Ft. Lbs.
8 Ft. Lbs.
1/2 - 20 UNF
36 Ft. Lbs.
20 Ft. Lbs.
5/8 - 18 UNF
73 Ft. Lbs.
40 Ft. Lbs.
3/4 - 16 UNF
70 Ft. Lbs.
17
Section 2 - Operation
Section 2 - Operation
18
Start-Up Checklist
Start-Up Checklist
Compressor Model __________________________ Serial No. F-_________________________
Cylinder Serial No. C-________, C-_________, C-_________, C-_________, C-____________.
Driver__________________________________ Rated Speed__________________________
Packager________________________________ Packager Unit #_______________________
Date Packager Shipped_____________________ Start Up Date ________________________
Serviceman_______________________________ Customer____________________________
Location_________________________________ Field Contact_________________________
Field Telephone Number____________________ Unit Location_________________________
Make and Grade of Oil______________________ Unit Location________________________
Prior to Starting
YES
NO
1.
Do you have a parts book, instruction manual, special tools, and spares?
_____
_____
2.
Have you checked the design limitations for the compressor model such as rod load,
maximum and minimum speed, discharge temperature?
_____
_____
3.
_____
_____
4.
Have the compressor feet and crosshead guide support been shimmed so the machine
is not twisted or bent?
_____
_____
_____
_____
5.
Have the piping and supports been checked to be sure they do not bend compressor?
_____
_____
6.
_____
_____
_____
_____
_____
_____
7.
19
Section 2 - Operation
Start-Up Checklist
7a. Have the piston end clearances been checked?
Throw # 1
Throw # 2
Throw # 3
HE_______
HE_______
HE_______
CE_______
CE_______
CE_______
YES
NO
_____
_____
Throw # 4
HE_______
CE_______
8.
Has the crankcase been filled with oil to the proper level?
_____
_____
9.
Has proper oil been installed if extreme ambient conditions exist or special gases are
compressed?
_____
_____
10. Is the compressor crankcase oil level control working, set to proper level and supply
valve open?
_____
_____
_____
_____
_____
_____
12. Are the oil filter element and all lube oil piping primed with oil?
_____
_____
13. Is the low oil pressure shutdown installed and tubed correctly to the downstream side
of the filter?
_____
_____
_____
_____
_____
_____
_____
_____
_____
_____
_____
_____
_____
_____
19. Is the force feed lubrication system no flow shutdown installed and working?
_____
_____
20. Is the force feed blow out assembly installed? Check disc for color? Blue is standard.
_____
_____
21. Have you checked the lubricator instruction plate or the instruction book for proper
lube feed rate?
_____
_____
_____
_____
23. Are the primary and secondary packing vents and the distance piece vents open, and
when necessary, tubed off of the skid or out of the building?
_____
_____
_____
_____
25. Are the suction pressure, interstage pressure and discharge pressure shutdowns set and
working?
_____
_____
26. Are the safety valves installed and working to protect cylinders and piping for each
stage of compression?
_____
_____
20
Start-Up Checklist
Start-Up Checklist
YES
NO
27. Are the discharge temperature shutdowns installed, set and working?
_____
_____
28. Have the gas suction lines been blown out to remove water, slag, dirt, etc.?
_____
_____
29. For gas starting units, have you rolled the machine with the starter to make sure it is
free? The oil pressure should come up noticeably while rolling on the starter.
_____
_____
For electric driven units, compressor must have prelube pump. Did you prelube compressor prior to starting? Does the motor rotation arrow match that of the compressor?
_____
_____
30. For other drivers, have you barred the machine over by hand to assure it is rolling free?
_____
_____
31. For machines compressing a combustible gas, have the piping and compressor been
purged to remove all air?
_____
_____
32. Packagers Start-Up and Operating Instructions for the unit shall be reviewed by the
packagers representative with the unit operator.
_____
_____
After Starting
YES
NO
1.
_____
_____
2.
_____
_____
3.
_____
_____
4.
_____
_____
5.
Are the high discharge gas temperature shutdowns set at approximately 25 above dis- _____ _____
charge temperature?
6.
Is the distribution block indicator pin moving, and have you set lubricator for proper
brake-in rate?
_____
_____
7.
_____
_____
8.
_____
_____
9.
_____
_____
_____
_____
_____
_____
_____
_____
13. Have all safety functions been tested to assure shutdown of unit upon malfunction?
_____
_____
14. Have start-up instructions for other package equipment been followed?
_____
_____
21
Section 2 - Operation
Before starting a new compressor, be sure you have filled out and checked off the
items on the Start Up Check List beginning on page 19. This list is designed to
provide maximum safety in operating your compressor.
WARNING
API Standard 618, Third Edition, February 1986, Paragraph 1.4.8, defines
Maximum Allowable Working Pressure as follows:
Maximum Allowable Working Pressure is the maximum continuous pressure
for which the manufacturer has designed the equipment (or any part to which the
term is referred), when handling the specified fluid at the specified temperature.
All Ariel Compressor Cylinders have a Maximum Allowable Working Pressure
(MAWP). The MAWP, the hydrostatic test pressure, and the test date are
stamped on the end of every Ariel Cylinder. (See page 5 for illustration.)
It is the responsibility of the packager to provide relief valves for every stage of compression in compliance
with API 618, Paragraph 3.6.4.4.2, as follows:
Relief valves shall be set to operate at not more than the maximum allowable working pressures
but not less than the values listed in Table 2.
Table 2 - Maximum Relief Valve Settings
Rated Discharge Pressure
Psig
Bar Effective
-14.7 to 150
-1 to 10
15 psi (1 bar)
151 to 2500
10+ to 170
10 percent
2501 to 3500
170+ to 240
8 percent
3501 to 5000a
240+ to 345
6 percent
a. For rated discharge pressures above 5000 psig (345 bar effective), the relief valve setting shall be agreed upon between the purchaser and the vendor.
22
Priming
WARNING
Make sure the oil system from the lube oil pump to the cooler and back to the
compressor filter is filled with oil.
Compressors that are not equipped with a priming pump must be primed by hand. This can be done by either
one of two methods. Ariel recommends a manual charge pump be attached to the system's priming point
(a 1/8, 1/4 or 1/2 [on later models] pipe plug on discharge side of the lube oil pump). If a hand pump is
unavailable, a clean hose or pipe can be attached to the priming point. Use enough piping to achieve two or
three feet of head. Pour in sufficient oil to fill all oil piping and tubing. With either method, turn the machine
over slowly to get oil in the bearings. Make sure oil system from lube oil pump to cooler and back to compressor filter is filled with oil.
23
Section 2 - Operation
2.
3.
Check sight glass on lubricator reservoir to make sure it is properly filled with oil. The
oil in the reservoir is used only to lubricate the worn gear and cam; it does not flow
through the system. Therefore, oil must be added if it becomes necessary to raise the
reservoir oil level.
Adjust the oil lubricator for maximum delivery by screwing the feed regulator on the
reservoir cover completely up and locking it into place. Proper feed rate may be set
after the machine is started.
The system has been filled with oil at the factory and, unless the piping has been disturbed, ready for operation. If piping has been removed, or if the system has been
drained, it can be filled and primed through a 1/8" plug on the discharge end of the
lubricator. Priming the force feed lubrication system requires the use of a priming
pump.
Running Conditions
After running for an hour, adjust the force feed lubricator to the break-in rate shown on the force feed lubricator plate. (See page 6.) An indicator pin on the distribution block shows the rate at which the block is cycling.
To adjust, screw down the feed regulator until the indicator pin strokes at the proper rate. Run at this setting
for one week. The lubricator adjustment may then be reduced to the normal operating rate. (See page 6.)
When the machine is running, make sure that the oil level in the sump is at least one-half way up the sight
level, but does not exceed two-thirds.
See your packagers specific data to determine the normal operating conditions, the cylinder working pressure, and the rated speed.
Stopping
Consult compressor packagers instructions for stopping procedures.
24
25
Section 2 - Operation
26
Lube Oil Strainer, Lube Oil Filter & Filter Installation Instructions
27
Section 2 - Operation
Lubrication
CAUTION
1.
2.
3.
4.
5.
NOTE
28
Normal Pressure on the discharge side of the lube oil filter is set at the factory at
60 PSI when crankshaft speed is 600 RPM or more. If oil pressure drops below 50
PSI, the reason should be found.
29
Section 2 - Operation
4.
1.
30
NOTE: Ariel recommends a cooling means be provided that maintains lube oil temperature out of the unit between 170F - 190F,
except for two hours out of every twenty-four when a maximum temperature of 200F is permissible.
The force feed lubricator must have a blow-out disc between the force feed lubricator
pump and the no-flow shutdown.
The force feed system must have a working no-flow shutdown. This shutdown must be
set to actuate within three to five minutes after interruption of the lubricator oil flow.
31
Section 2 - Operation
Diagrams
Force Feed Lubrication System
32
Diagrams
Packing Tubing and Distance Piece Venting
33
Section 2 - Operation
Packing Lubrication and Venting
34
General Introduction
On engine-driven compressors, remove the center coupling to make sure that the
compressor cannot turn over during maintenance. On electric motor-driven compressors, if it is inconvenient to detach the driver from the compressor, the driver
must be switched off and the switch locked in that position during maintenance.
DANGER
Before starting any maintenance or removing any components, relieve all pressure from the compressor cylinders. (See packagers instructions for completely
venting the system.)
35
Connecting Rods
Removal
Step 1
Step 2
Step 3
Step 4
Step 5
36
Remove the top cover from the crankcase and the side covers from the crosshead
guides.
Remove the middle spacer bar on a 2-throw frame and the middle bar of each set of
three on a 4-throw frame. (JG & JGA only)
Move the throw to the outer dead center position and remove the locknut, bolt, end
plates, and crosshead pin from the crosshead.
Turn the crankshaft until the throw is at its highest point. Remove the connecting rod
bolts and the rod bearing cap.
Turn the crankshaft until the rod can be taken out through the top opening of the crankcase.
Absolute cleanliness is required of both the bushing and the connecting rod so
that dirt cannot cause excessive wear between the bushing and connecting rod.
37
The caps and rods are numbered by throw beginning with number one at the
drive end. Always install rods with the numbers up. (See page 36.)
Step 1
Step 2
NOTE
Step 6
38
Snap the half bearing shell into the rod with the bearing tap properly located in the
notch on the rod. With the crankcase top cover off, turn the throw to inner dead center
position and slide the rod into the crosshead guide space.
Fit the connecting rod to the crank pin and turn to the highest position. Replace the
cap, the half bearing shell properly located in the notch, and the bolt. Snug up all the
bolts.
Reconnect the rod and the crosshead with the pin. Install the end plates, the bolt and
nut. Tighten the bolt to the value listed on page 16.
Tighten the connecting rod bolts in small increments to full torque in a crisscross pattern. (See page 16.)
Reinstall the spacer bars with new Stato-seal washers. All spacer bars are matchmarked for proper location. They must be reinstalled in their original location. Tighten
all spacer bar bolts to the value listed on page 16. (JG & JGA only)
Examine the removed top cover and side cover gaskets. If there is any doubt, that they
are not in good usable condition, install new gaskets. Before installing old or new gaskets, apply an anti-seize lubricant to both sides to aid in their easy removal at a later
date. Replace the top cover and crosshead guide cover. Tighten all capscrews.
Crosshead
Crosshead
Crosshead
Removal
Step 1
DANGER
Step 2
NOTE
Step 3
Step 4
Step 5
Step 6
Step 7
CAUTION
Use the Piston Nut Torquing Adaptor shown on page 8 to screw the piston rod out of
the crosshead. The two dowels on the Adaptor fit holes in the piston nut. Turn the
crosshead nut off the piston rod. Push the rod end forward to the edge of the packing to
provide a clearance for crosshead removal.
With the crosshead in dead center position, remove the crosshead pin lock nut, bolt,
end plates, and pin.
Turn the crankshaft to its inner dead center position. Move the crosshead to its outer
dead center position to be free of the connecting rod. Make sure the connecting rod
does not drop and damage the crosshead guide surface.
Roll the crosshead 90 degrees and remove it through the guide opening.
Check the crosshead pin to bushing clearance. (See page 10.) Wear on the pin can be
determined by a visual inspection. Replace the pin if necessary. If the bushings need to
be replaced, hacksaw or file to within 1/32" of their thickness. They can be easily
drifted out. A press will be needed to install new bushings. (JG & JGA only)
The side of the crosshead receiving the new bushing should be supported directly
to prevent possible crushing of the crosshead by the press. (See illustration
below.)
39
Visually inspect the shoe surfaces for scoring. Since they are constantly lubricated
under pressure during operation, there is virtually no wear.
Installation
NOTE
Step 2
Step 3
CAUTION
Step 4
Step 5
40
With the crosshead on its side, slip it into the crosshead guide. Once inside it can be
rolled upright. Make sure it does not become cocked. Should the crosshead become
wedged, do not force it. Ease it off and start again. Be careful not to damage the crosshead shoe surface during installation. (See page 39.)
Turn the crankshaft to its outer dead center position to locate the connecting rod in
position and insert the pin. Install the bolt, lock nut, and end plates. Tighten the locknut to the value listed on page 16.
Reinstall the crosshead nut on the piston rod. Be sure to have set screw cup points on
the crosshead side of the nut. Screw the piston rod in the crosshead using the Torquing
Adaptor. Make sure all threads are well lubricated with clean, fresh oil to assure a
smooth installation.
Piston end clearance must now be set or serious damage could occur. See Piston
Rings Installation on page 54. (Crank end - 1/3 of total; Head end - 2/3 of total.)
Before installing the side covers, apply an anti-seize lubricant to the gaskets. This will
aid in their easy removal at a later date.
Replace the crosshead guide side covers; tighten all capscrews.
Step 1
Step 2
NOTE
Step 3
Step 4
Detach the connecting rods. (See Removal on page 36.) Move the rods to their full
outer position.
Remove the capscrews on the chain adjustment cap. Turn the cap to loosen the chain.
Slip the chain off the crankshaft sprocket. (See illustration above.)
41
Step 5
Step 6
Step 7
42
Remove the capscrews from the bearing caps. Pull the caps straight up to prevent damage to the dowel fit. If the cap is tight, use the Bearing Cap Puller illustrated.
Before removing the crankshaft from the crankcase, wooden saddles or a notched
wooden crate with sides high enough to prevent the webs or oil slinger from touching
bottom should be prepared in order to store the crankshaft during maintenance- even
though it may be out only for a short time. In addition, the crankshaft should be adequately protected from above so that dropped tools or equipment cannot burr the surface of pins and journals.
Remove crankshaft from the crankcase. For JGM and JGP, see 2-Throw Crankshaft
on page 43. For JG/4 or JGA/4, see 4-Throw Crankshaft on page 44.
Turn the shaft so that the drive end counterweight is straight up. Since it weighs only
100 pounds with oil slinger and chain sprocket, it can be lifted out by one or two men.
(If necessary, the shaft can be lifted out with a crane using nylon ropes.) Great care
must be taken since the shaft could bind and become damaged. The lower half bearing
shells sometimes have a tendency to stick to the shaft journals because of the close fitting oily surface of the two parts. When the shaft has been lifted clear of the saddles
1/4" or so, check to make sure that the lower half bearing shells have not come out
with it. If so, they should be tapped back onto the saddles before lifting the shaft any
further. The shaft can then be removed from the frame. See illustration below for
method of removing JGM & JGP Crankshaft.
43
2. The lower half bearing shells sometimes have a tendency to stick to the shaft journals because of the close fitting oily surfaces of two parts. When the shaft has been
lifted clear of the saddles 1/4" or so, check to make sure that the lower half bearing
shells have not come out with it. If so, they should be tapped back on the saddles
before lifting the shaft any further.
3. While one man operates the crane, raising it very slowly, the second man must
grasp the crankshaft at the drive end with one hand on the counterweight and the
other hand on the end of the shaft. Wear gloves to avoid being cut by the slinger
and to achieve a good grip. As with everything else, the gloves should be absolutely clean. As the shaft is being raised inch by inch, the drive end must be lifted
at a slightly faster rate while being twisted counterclockwise in order for the webs
to clear the ribs of the crankcase. When the drive end is clear, it must be held clear
while the crane slowly lifts the auxiliary end. While that end is being inched up,
the shaft must now be twisted in a clockwise direction so that it too can clear the
ribs of the frame.
44
Oil Slinger
Oil Slinger
Removal
Although the slinger should last indefinitely with proper care, it might become nicked. Should it
need replacing, suspend the crankshaft (using a nylon sling attached to the auxiliary end), and
heat the slinger to 400F. When it has expanded, it should fall by itself.
Installation
Encircle the slinger with wire. (Special care should be exercised when handling the slinger, not
only to keep its surface unmarred, but also to avoid being cut by the outer sharp edge.) Suspend
the slinger from the wire and heat it with a small propane torch. When it has attained a yellow
glow (approximately 400F) it can be slipped over the drive end of the crankshaft. Hold the
slinger in position with asbestos gloves or two pieces of clean wood, rotating it slightly to make
sure it is square, until it has cooled enough to shrink on the crankshaft.
Chain Sprocket
Removal
Examine the sprocket carefully for signs of wear. If it has been in operation for five years or more,
it may need to be replaced once the crankshaft has been removed from the frame.
Step 1
Drill a hole in the sprocket hub. This hole should be parallel to the shaft centerline and
big enough that it removes most of the hub cross section. (See illustration below.) Be
careful not to touch the fit diameter of the shaft with the drill. Mark the drill with tape
so you do not drill through the sprocket and into the crankshaft face.
Step 2
The drilled hole will relieve most of the shrink, and a couple of good radial hits with a
hammer and chisel will open the sprocket enough so it can be easily removed.
Installation
Encircle the sprocket with wire. Suspend the sprocket from the wire and heat it with a small propane torch. When it has attained a yellow glow (approximately 400F) it can be slipped over the
auxiliary end of the crankshaft. Hold the sprocket in position with asbestos gloves or two pieces
of clean wood, rotating it slightly to make sure it is square, until it has cooled enough to shrink on
the crankshaft.
45
Bearings
Removal
Bearing must be replaced if they show signs of wear or scoring. Wear will be indicated by the
bronze showing through the babbitt surface.
If replacement bearings are needed, the old bearings can easily be slid in (untabbed end first), and
snapped into place. Locate tabs in the notches in the bearing saddles and bearing caps.
Crankshaft - Installation
2-Throw Crankshaft Installation:
With the connecting rods in their full outer position, carefully set the crankshaftwith drive end
counterweight straight upon bearing saddles. See illustration on page 43 for method of inserting JGM and JGP crankshaft.
4-Throw Crankshaft
Step 1
Step 2
NOTE
Be sure the dowels in the bearing caps are aligned with the holes in the crankcase
base. A set screw on top of each dowel prevents it from backing out.
Step 3
Step 4
Step 5
Step 6
Step 7
46
Move the connecting rods to their full outer position. While the crankshaft is being
lowered very slowly into the crankcase, (suspended by a crane with a nylon sling), one
man should grasp the drive end (wearing clean gloves as during removal) and tilt the
shaft so that the auxiliary end journal is practically touching the lower bearing surface.
Then the shaft must be twisted clockwise so that the webs clear the ribs of the crankcase. As the shaft is inched slowly down, and after two auxiliary end webs are within
the crankcase, the shaft must be twisted counterclockwise to allow the drive end webs
to clear.
When the crankshaft is resting on the bearing saddles, attach the bearing caps with
capscrews slightly snugged. Then starting at the thrust end, tighten the bolts in a crisscross pattern in small increments to the recommended torque value on page 16. Bearing caps are match-marked to correspond with the spacer bar and spacer bar bosses on
the frame.
Adjustment
Step 1
Step 2
Step 3
Step 4
Roll machine to the tightest position of the chain. This prevents snugging up on the
chain at a slack position and breaking rollers or ruining the pump and lubricator bearings when the chain goes through its tightest position.
Remove the two capscrews and eight plugs from the eccentric cap. Rotate the cap 6
degrees counterclockwise to line up the two new capscrew holes. If this makes the
chain too tight, try turning the cap around in a clockwise direction for a different hole
line-up.
Tighten the two capscrews and roll the machine to check the tightness in a number of
positions. At its tightest position, the chain should have very little slack, but should not
feel dead tight.
Replace the plugs in the eccentric adjustment cap to keep dirt out of the unused holes
in the end cover.
47
Step 2
Step 3
Step 4
Step 5
Step 6
Step 7
48
Remove the frame top cover. Remove the two capscrews that hold the eccentric adjustment cap to the end cover. Rotate the eccentric cap to loosen the chain for removal.
After dropping the chain off the idler sprocket, the entire assembly can be removed
from the end cover.
Measure the exact distance from the outer edge of the sprocket to the outer edge of the
cap. Note the measurement for the proper positioning of the new sprocket.
Drift the roll pin from the idler nut. Remove the nut, capscrew, and Stato-seal washer.
Discard all four items since they must be replaced by new equipment. Remove and
discard the cap O-ring.
Reassemble all parts using a new capscrew, Stato-seal washer, sprocket, and nut. Compare the sprocket and cap measurement to the measurement previously taken. If necessary, shim with automobile valve lifter shims (or standard shim stock) between the cap
and the idler space.
Install the assembly on the end cover. Do not install the chain. First check the alignment with the other sprockets using a straight edge.
If the alignment is correct, remove the entire assembly again. Tighten the idler nut to
the recommended torque on page 16 and drill a 1/8" hole through the nut. Tap in the
roll pin.
Install a new O-ring and oil it. Install the assembly and adjust the chain according to
the instructions given.
Step 3
Step 4
Step 5
Step 6
Step 7
Step 8
Step 9
Remove all piping on the pump. Remove the mounting plate and the sprocket will
come free through the hole in the end cover after the removal of the chain.
Measure the exact distance from the outer edge of the sprocket to the outer edge of the
mounting plate in order to position the new sprocket. Note this measurement for future
references.
With the oil pump on a bench, use an Allen Wrench to remove the sprocket set screw;
then, pull the sprocket from its shaft.
Remove the No.1 Woodruff Key from the shaft and file the shaft to smooth out any
burrs raised by the cup point of the set screw.
Install a new No.1 Woodruff Key after first checking to make sure the key will fit into
the new sprocket. If the key is too thick, it can be polished with an emery cloth on a
flat surface until it can easily slide into the notch. It may also be a little high and
require filling of the top edge.
Install a new sprocket and compare the distance between the sprocket and the mounting plate outer surface with previous measurement. When it is positioned exactly right,
tighten the set screw.
Examine the mounting plate gasket. If there is any doubt that it is not in good usable
condition, install a new gasket. Before installing a new pump, apply an anti-seize
lubricant to the gasket surfaces. This will aid in its easy removal at a later date.
Reinstall the pump onto the end cover and check the alignment with the other sprockets using a straight edge.
Adjust the chain according to the instructions.
49
Lubricator Sprocket
Replacement
Step 1
Step 2
Step 3
Step 4
Step 5
Step 6
Step 7
50
Remove the sprocket set screw and sprocket. Detach all tubing to the lubricator.
Remove the four mounting bracket capscrews 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 No.1 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 notch. It may also be a little high and require filing
on the top edge.
After the new key has been installed and it has been determined that the new sprocket
will fit, install and oil a new O-ring and remount the lubricator to the end cover.
Put the new sprocket onto the shaft and align it with the other sprockets using a
straight edge. Tighten the set screw.
Adjust the chain using the instructions given.
Section 4 - Cylinders
Piston and Rod
Removal
DANGER
DANGER
On engine-driven compressors, remove the center coupling to make sure that the
compressor cannot turn over during maintenance. On electric motor-driven compressors, if it is inconvenient to detach the driver from the compressor, the driver
must be switched off and the switch locked in that position during maintenance.
Step 1
Step 2
Step 3
NOTE
Remove the crosshead guide side covers and the cylinder head. It has already been
loosened per the instruction above.
Move the crosshead to its inner dead center position and back off, but do not remove
the crosshead nut set screws. Loosen the crosshead nut with the special slugging
wrench. (See page 8.) Use the open-end wrench for hex nuts and the peg wrench for
round nuts.
Use the Piston Nut Torquing Adaptor to screw the piston rod out of the crosshead. (See
page 8.) The two dowels on the tool fit the holes in the piston nut. Turn the crosshead
nut off the Piston Rod.
As the piston leaves the cylinder, be careful in handling the piston rings. Despite
their toughness in service, rings are fragile with regard to removal. Always handle them with clean tools and hands-protecting the rings from nicks, marring,
and bending. Move the piston out of the cylinder until a fraction of the first ring
clears the cylinder. Encircle the ring by hand until it is clear and remove it. Use
this same procedure to remove the succeeding rings.
Step 4
Slide the piston rod out of the head end. The threaded crosshead end of the rod is 1/8"
smaller in diameter than the inside diameter of the packing. Using extreme care,
slowly slide the piston rod through the packing so as not to damage the rod threads or
the packing rings.
51
Section 4 - Cylinders
Disassembly
Step 1
Step 2
NOTE
A small amount of pressure may have built up within the piston during operation. This will vent when the piston nut is loosened.
Step 3
NOTE
52
Remove the set screws from the piston nut. Even though the piston nut has been prickpunched to lock in the set screws, they can be forced with an Allen Wrench past the
small lip that has formed.
Ariel recommends exclusive use of its Piston Torque Fixture (P/N D-961), shown
below, for disassembly and reassembly of the piston from a piston rod. This fixture
can be purchased from Ariel, Mount Vernon. This fixture will prevent bending the piston rod during disassembly and reassembly. The Piston Torque Fixture must be
securely bolted down to prevent its turning with the piston. It should be at a convenient
height, (around three feet).
After the piston nut has been removed, the piston and collar will slip off the end of the
rod.
Ariel recommends exclusive use of the special tools illustrated on page 8.
Step 2
Step 3
Step 4
Secure the piston rod into the holding device. See page 51. Tighten the piston nut to
recommended torque found on page 16.
Install the set screws and prick-punch the piston nut to lock them in.
The set screws should be so tight that the Allen Wrench is slightly deformed (twisted)
after tightening.
Installation
Step 1
Step 2
Step 3
Step 4
Step 5
Install the piston/rod assembly and piston rings in the cylinder. See page 54. Since the
threaded crosshead end of the rod is 1/8" smaller than the diameter of the packing, it
will not be necessary to use an entering sleeve over the end if reasonable care is taken.
Replace the crosshead nut on the rod and use the Piston Torquing Adaptor illustrated
on page 8 to screw the rod in the crosshead.
Remove a crank end suction valve. With the crosshead at its inner dead center position, screw the piston rod in the crosshead far enough to give the approximate recommended clearance at the crank end head. Measure the clearance with the crosshead nut
well snugged up. To readjust, loosen the crosshead nut and screw the piston in or out
in order to have the clearance conform with that recommended on page 10. (Crank
end - 1/3 of total; Head end - 2/3 of total - See page 40.) Tighten and torque the crosshead nut to the value given on page 16. To double-check clearance, remove head end
suction valve and check head end clearance.
Tighten the crosshead nut set screws and replace the cylinder head and gasket. Tighten
all capscrews evenly to the proper torque value listed on page 16.
Replace the valves, tighten all capscrews evenly to the proper torque value listed on
page 16, and replace the crosshead guide side covers.
53
Section 4 - Cylinders
Piston Rings
Materials
There have been three materials of rings used in Ariel Compressors: Bronze, Teflon and Cast Iron.
Teflon is standard in all cylinders today.
Removal
See NOTE on page 51 for piston ring removal.
Installation
NOTE
Ring gaps should be staggered around the piston, rather than lined up.
Step 1
Step 2
Step 3
CAUTION
54
Insert the piston/rod assembly in the cylinder up to the crank end ring groove. Place
the inner ring in the groove (with the two piece ring match marks in the proper relative
positions).
With the rings fully compressed in the grooves, insert the rod and piston into the cylinder. Make sure the one-piece rings stay in place while inserting the piston and rod.
Follow the installation steps under Piston and Rod on page 53.
Whenever installing a piston in a cylinder, since the threads on the end of the piston rod are 1" in diameter, an entering sleeve is not necessary. However, you
should reach into the packing with a finger, from the crankshaft side, and guide
the rings on the piston rod. Follow this procedure so that the end of the piston rod
does not bang into the edge of a packing ring and bend it.
Step 3
Step 4
Step 5
Step 6
Step 7
Step 8
Step 9
Remove the piston and piston rod. See page 51. Set crosshead at inner dead center.
Disconnect the lube oil U-tube from the top of the packing gland and the primary vent
U-tube from the bottom of the gland. Remove the four twelve point capscrews that
hold the packing gland to the cylinder.
At this point do not remove the small nuts from the studs in the wiper cup. These studs
hold the entire packing case together so it can be removed as an assembly.
Screw two short 3/8-16 NC capscrews into the two tapped holes provided in the crank
end face of the gland. A screwdriver or pry bar under the heads of these capscrews can
be used to pull the entire packing out into the crosshead guide. It will then come out
through the side opening of the guide. The packing may now be taken to a clean place
for disassembly.
Set the packing on a clean surface on its nose cup or cylinder end. Three long tie studs
hold the packing together. The stud holes are not equally spaced. This prevents the
stack of parts from being aligned incorrectly. Remove the stud nuts and the packing
can be unstacked. Replace these nuts each time the packing is serviced.
Ring wear can be determined by placing the assembled rings, (note match-marks), on
the piston rod. Check end gap clearance. If the ends butt, or nearly butt, they should be
replaced by new rings.
Fins or wire edges on the rings due to wear should be carefully filed off so that all
matching edges will be square.
The metal gasket on the end cup can be pried loose with a sharp awl. Be careful not to
scratch the sides of the gasket groove.
Before reassembly be certain all parts are perfectly clean.
55
Section 4 - Cylinders
Reassembly
CAUTION
Step 1
CAUTION
Step 2
Step 3
Step 4
CAUTION
56
Be sure to refer to the packing assembly in your parts book. Ariel supplies four parts
books with each unit. Please contact your distributor if you do not have a parts book.
Install a new end gasket. Restack the assembly, taking special care that the oil cup is in
its proper location and that the rings are installed with the correct side toward the pressure. After the stud nuts are tightened, all rings should be free to float radially in
each cup. Be sure to use clean, fresh oil in parts to be assembled.
Before installing the packing into the cylinder, be sure the gasket surface in the
packing counter bore on the crank end of the cylinder is clean and not scratched.
Put a new O-ring on the gland and oil it liberally. Reinstall the complete assembly with
the oil supply point on top. Using the four capscrews, pull the packing into place.
Tighten the four capscrews evenly to the recommended torque on page 16. This procedure will ensure that the packing comes up square on its nose gasket.
Retighten the small tie stud nuts. Reinstall the U-tubes for the oil supply and primary
vent. Take care not to cross-thread the tubing nuts. Tubing nuts must be tight.
Follow the installation steps under Piston and Rod on page 53.
After installing the new packing rings, refer to page 31 for instructions for priming the force feed lube system. Follow instructions on page 6 for lubrication rates
that are recommended for break-in of a new machine. Break-in lube rates are
twice the normal operating rates, or one-half the normal indicator pin cycle time.
Packing Rings
Packing Rings
Identification of Rings and Arrangements
Type P Pressure Breaker
This is a single ring. It is cut radially into three equal segments. It may be installed with either
face toward the cylinder. This ring breaks down or slows the gas flow without sealing it completely. See illustration below.
57
Section 4 - Cylinders
Type TR Single Acting
This set is made up of a pair of rings. It seals in one direction only. The first ring (pressure side) is
tangentially cut and made of Teflon. The second ring is called a back-up ring and is radially cut.
The bore in this ring is larger than the rod diameter. This allows the radial joints to be tight
together forming a gas seal. No dowel is necessary. See illustration below.
58
Packing Rings
Type BD Double Acting
This set consists of two tangentially cut rings. The rings are doweled so the tangential cuts are
staggered from one ring to the other. The set is double acting in that it will seal in either direction.
It is used in cylinders operating near atmospheric pressure to prevent air entering the cylinder. See
illustration below.
MATERIAL: TEFLON
59
Section 4 - Cylinders
Type 3RWS Oil Wiper Set
This set uses three radial cut rings. They are doweled to provide a staggered arrangement. Their
purpose is to keep crankcase oil out of the packing and cylinder(s).
Assemble with the blank face towards the oil (crankcase) and the slotted side towards the packing.
See illustration below.
60
Packing Rings
Arrangement of Packing Rings
Ariel supplies packing in three pressure ratings. Ring, oil supply, and vent locations are illustrated in the following chart, starting from the pressure side:
NOTE
B - 69
0 - 350 PSIG
B - 20
350 - 1250 PSIG
B - 38
350 - 2000 PSIG
Pressure side
Pressure side
Pressure side
Pressure breaker
Pressure breaker
Oil Supply
Oil Supply
Oil Supply
Primary vent
Primary vent
Primary vent
Secondary vent
Secondary vent
Secondary vent
Wiper set
Wiper set
Wiper set
Crankcase side
Crankcase side
Crankcase side
Refer to packing assembly in your parts book. See Diagrams - page 33 for Packing Tubing and Distance Piece Venting and page 34 for Packing Lubrication and
Venting.
Another arrangement has been devised for moderately wet gas service. It is called Washout Resistant. A typical packing arrangement would be:
A Bronze pressure breaker, Teflon/Cast Iron single acting rings, all Teflon double acting rings, and a Bronze
wiper set.
61
Section 4 - Cylinders
Valves
Removal
DANGER
Step 1
Step 2
Before attempting to remove any valve cap, be very certain that all pressure has
been vented from the cylinder. Pressure must be completely vented from both the
suction and the discharge passages of the cylinder. (See IMPORTANT WARNING PLATES on page 5.)
A typical valve assembly is shown on page 64. On each valve cap loosen all of the
bolts slightly. With all the bolts loose, the cap should stay in its original position. If it
pushes out on its own accord-stop!! Take steps to completely vent the cylinder. See
DANGER above.
a. After all the above safety checks, remove the valve bolts. A pair of screwdrivers,
one on each side of the cap, will help pry it loose. With the retainer still in place,
screw a valve tool over the valve center bolt. (See page 8.) Now the valve and
retainer can be pulled out together.
In most cases the flat metal gasket will remain 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.
A small magnet on a flexible extension rod will help fish it out. This gasket should be
replaced after several uses.
Maintenance
Ariel uses valves manufactured by Hoerbiger Corporation. Before servicing any valve refer to the correct
valve assembly drawing and parts list and Hoerbigers literature in the Parts Book. On the valve assembly
drawing you will notice that valves have different springing for different pressure levels. The valve group
sheet in the Parts Book shows the valve originally supplied with the unit and its selected pressure range. If
different operating pressures are encountered, then different springs may be required.
The suction valve must be selected on the basis of operating suction pressure and the discharge valve for
operating discharge pressure. Proper valve spring selection is also based upon the operating speed (RPM) and
gas specific gravity. The pressure ranges shown on the valve assembly drawing are based on rated speed
(1400 RPM for JG & JGM units, and 1800 RPM for JGA & JGP units) and a gas specific gravity of 0.65.
Valves are not selected on the basis of the maximum working pressure of the cylinder. If the operating pressure falls between the recommended pressure ranges, then select the valve for the higher range.
Some valve assemblies may not have the pressure ranges stated. Contact Ariel, Mount Vernon, for assistance
in valve selection.
NOTE
62
When rebuilding any valve, always use a new locknut on the center bolt. See page
17 for the recommended valve torques.
Valves
Reassembly
NOTE
Be certain all parts, gasket faces, and mating surfaces are absolutely clean.
Step 1
Step 2
Step 3
Step 4
CAUTION
The 1/32" thick metal gasket should be coated with an anti-seize lubricant. It can then
be either inserted into the valve pocket or stuck on the valve. In either case, care must
be taken to keep this gasket from falling into the gas passage.
The retainer keeper is a piece of Viton O-ring stock in a threaded hole. This should be
screwed out just far enough to provide friction so that bottom retainers will not fall out
while the cap is being installed.
Using the valve tool illustrated on page 8, the valve and retainer may be inserted into
the pocket together. When installed correctly, the distance from the outer retainer face
to the surface of the valve boss on the cylinder will be 1/8" shorter than the length of
the nose on the valve cap.
Inspect the valve cap O-ring for cuts or gashes and replace it if necessary. Lubricate
the O-ring and the nose of the valve cap. Insert the cap and tighten the bolts evenly to
the recommended torque on page 16. If the assembly is correct, the distance from the
underside of the cap to the valve boss surface on the cylinder will be 1/8".
Always use clean, fresh oil on the threads before reinstalling bolts.
63
Section 4 - Cylinders
Valve Assembly
See illustration below of a typical valve assembly.
64