Professional Documents
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0 016761 3-4-13
REV DESCRIPTION REV EC DATE REV EC DATE
To prevent personal injury, verify neither driver nor compressor cylinder gas pressure
can turn the compressor crankshaft during maintenance. Follow appropriate lock out pro-
cedures. Before any maintenance or component removal, relieve all pressure from com-
pressor 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.
9. After the cap separates from the rod, remove the cap removal tool and back out the conn rod bolts
completely, but do not remove them. Do not remove the bolts and cap until step 11.
10. 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
FIGURE 2 Connecting
occur.
Rod Cap Removal
11. Rotate the rod cap around the crankshaft until the bolts are vertical. Tool
Remove bolts, then remove cap. Always remove the bolts before the
cap to prevent damage to the crankshaft.
12. Lift the cap while holding the bearing in the cap because oil causes the bearing to stick to the crank-
shaft pin.
13. Rotate the crank to inner dead center and remove the connecting rod bearing.
14. 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.
FOR JG:A:M:N:P:Q:R:J:W COMPRESSORS:
1. Remove frame top cover and all crosshead guide covers.
2. On JG:A:R:J:W frames, remove the middle frame spacer bar of the three over each pair of throws. If
replacing main and rod bearings, remove all spacer bars. 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.
3. Rotate the crankshaft to approximately 45º (see FIGURE 3).
4. Loosen all the conn rod bolts approximately 1/8 in. (3.2 mm).
5. Pry the crosshead toward the cylinder until it bottoms out. Work the
rod cap away from the rod as evenly as possible. Separating the
two parts unevenly may break the rod cap dowels or cause them to
bind in the rod dowel holes. If the two parts of the con rod do not
separate easily by hand, loosen all bolts an additional 1/8 in. (3.2
mm) and pry the crosshead again.
NOTE: Do not pry or chisel to separate cap from rod; it dam-
ages the connecting rod and can break the alignment dowel
pins.
FIGURE 3 Crank Rotation
6. Remove all bolts from the cap first, and then remove the cap. Lift
the cap while holding the bearing in the cap because oil causes the bearing to stick to the crankshaft
pin. Do not remove the cap with bolts in place.
7. Support the rod by hand while another person rotates the crank away from the rod. When the con-
necting rod is clear of the crankshaft, rest it on the crosshead guide slide.
8. Rotate the crank to inner dead center and remove the connecting rod bearing.
9. 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.
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 thrust end, use the torque procedure in the technical manual to tighten
the main bearing cap bolts to the torque listed in ER-63.
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 TABLE 1(see procedure below). Record readings on a copy of the form on page 10. If 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 ER-63.
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 lubri-
cation and to help remove foreign materials from the lube system.
10. Run the compressor according to the time intervals listed on the form on page 10. After each run,
shut down and remove the frame top cover. Measure main and connecting rod bearing cap tem-
peratures with a hand held thermocouple probe or infrared thermometer and record them on a copy
of the form on page 10. Complete the form and email or fax it to Ariel Field Service.
NOTE: Remove eye bolts, magnetic bases, dial indicators, and pry bars after meas-
urement.
Dial indicator magnetic stand placement on top of crankshaft web, and pry Use pry bar to check jack
bar inserted into eye bolt. clearance.
Dial indicator magnetic stand Dial indicator button placement. Thrust rod tight toward and away
placement. from dial indicator.
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 TABLE 1tol-
erances, 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.
Dial Indicator magnetic stand place- Button-type dial Indicator placement Pry against compressor frame to
ment on top of a main bearing cap. against the side of crankshaft web. thrust crankshaft back and forth.
After new bearing installation, if measured clearances exceed tolerances of Table B-1 in Appendix B, contact your pack-
ager or Ariel before proceeding.