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JGW Series
Ariel JGW Series User Manual
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F
OR
M
ODELS
: JGW,
JGR
AND
JGJ
S
ECTION
5 - M
AINTE
NANCE
1/01
PAGE 5 - 19
Piston and Rod - Disassembly and Reassembly
Disassembly
The Piston and Rod Clamping Fixt
ure shown in Figure 5-12: on
page 5-20 will be useful for
the piston and r
od disassembly and reassembly operat
ions. This fixture may be purchased
from Ariel.
F
IGURE
5-1
1: P
ISTON
AND
R
OD
R
EMOVAL
AND
I
NSTALLATION
Ratchet Exte
nsion
Support T
ool B-1240
Set Screw
Crosshead Nut
Crosshead
Piston Nut Spanner
A-0424 (or T
urning
T
ool A-1678)
90
92
Table of Contents
Default Chapter
3
Table of Contents
3
Design Specifications & Data
7
General
7
Specifications
7
Product Information and Safety Plates
10
Important Safety Information
11
Clearances
15
Piston Ring and Packing Ring Side Clearance, Inches (MM)
16
Fastener Tightening Torque
21
Tightening Torque Procedures
25
Ariel Bolting
27
Optional Main Bearing Temperature Instrumentation - Alarm & Shutdown
29
Amot 4103 Temperature Valve
29
Electrical Instrumentation Setting
29
Installation
31
General
31
Procedure for Setting and Aligning
31
Setting
32
Alignment
32
Vents and Drains
33
Start up
35
General
35
Start-Up Check List
36
Maximum Allowable Working Pressure
40
Relief Valve Settings
41
Filling Sump & Priming a Main Oil Lube Oil System - before Starting
42
Filling the Sump
42
Priming - Main Lube Oil System
42
Force Feed Lubricator Adjustment
42
Compressor Re-Application
43
Lubrication and Venting
45
General
45
Oil Cooler
45
Cold Starting
46
Compressor Prelube Pump
46
Petroleum Based Oils - also Referred to as Mineral Oils
46
Compounded Cylinder Oil Additives
46
Animal Fats
47
Vegetable Oils
47
Synthetic Lubricants
47
Compressor Frame Lubricants
48
Cylinder and Packing Lubrication Requirements
49
Force Feed Lubrication System - Description
55
Force Feed Lubricator Adjustment
55
Blow-Out Fittings and Rupture Disks
56
Divider Valves
57
Description
58
Standard Electronic-Lubricator Digital No-Flow Timer Switch - DNFT
58
Assembly Instructions for Divider Valves
59
Operation
59
Force Feed Lubrication System and Running Conditions
62
Force Feed Lubrication System
62
Running Conditions
62
System Design Considerations and Operating Parameters
62
Force Feed Balance Valves
63
Setting and Maintaining Balance Valves
64
Checking/Adjusting Balance Valves on Subsequent Start-Up
65
Frame Lubricating System - Description
65
Lube Oil Strainer, Filter & Filter Installation Instructions
68
Lube Oil Strainer
68
Lube Oil Filter
68
Filter Element Installation Instructions
68
Lube Oil Pump & Lube Oil Pressure
69
Description & Adjustment
69
Lube Oil Pressure
69
Low Oil Pressure Shutdown
69
Maintenance
73
General Introduction
73
Connecting Rod - Removal
74
Crank Pin Bearing & Connecting Rod Bushing Removal & Installation
75
Crank Pin Bearing
75
Connecting Rod Bushing
75
Connecting Rod - Installation
76
Crosshead - Removal
77
Crosshead - Installation
79
Crankshaft - Removal
80
Crankshaft - Oil Slinger
82
Removal
82
Installation
82
Crankshaft - Chain Sprocket
82
Installation
83
Main Bearings - Removal and Installation
83
Crankshaft - Installation
84
Chain Drive System
84
Description
84
Chain Adjustment
85
Chain and Sprocket Replacement
86
Eccentric Vernier - Chain Idler Sprocket Replacement (Self-Align Sprocket)
86
Lube Oil Pump Chain Sprocket Replacement
87
Force Feed Lubricator Chain Sprocket Replacement
88
Piston and Rod - Removal
90
Piston and Rod - Disassembly and Reassembly
91
Disassembly
91
Reassembly
92
Piston and Rod - Installation
93
Piston Rod Run out
94
Piston Rings
95
Determining Ring Wear
96
Removal
96
Wear Bands
96
Determining Wear Band Wear
96
Piston Rings - Installation
96
Wear Band - Installation
96
Piston Rod Pressure Packing - Removal
96
Piston Rod Packing - Reassembly
97
Types of Piston Rod Packing Rings
99
Type "P" Pressure Breaker
99
Type "BTR" Single Acting Seal Set
100
Type "BD" Double Acting Seal Set
101
Type "3RWS" Oil Wiper Set
102
Type "AL" Double Acting Seal Set
103
Typical Arrangement of Piston Rod Packing Rings
103
Piston Rod Packing Ring Material
104
Valves
104
Valves - Removal
104
Valves - Maintenance
105
Valves - Reassembly
105
Bolt Tightening for Valve Caps
106
VVCP - Variable Volume Clearance Pocket Head End Unloader
108
Removal
108
Disassembly
108
Maintenance
109
Adjustment
109
Water-Cooled Compressor Rod Packing
111
Re-Assembly
111
Testing
111
Ethylene Glycol Contamination
112
Cleaning Non-Lube Compressor Cylinder Components
112
Technical Assistance
115
Recommended Maintenance Intervals
115
Daily
115
Monthly (in Addition to Daily Requirements)
116
Every 6 Months or 4,000 Hours (Plus Daily/Monthly)
116
Yearly or 8,000 Hours (Plus Daily/Monthly/6 Months)
116
Every 2 Years or 16,000 Hours (Plus Daily/Monthly/6 Months/Yearly)
117
Every 4 Years or 32,000 Hours (Plus Daily/Monthly/6 Months/1/2 Years)
117
Every 6 Years or 48,000 Hours
118
Trouble Shooting
118
Appendices
121
Ariel Tools
121
Ariel Furnished Tools
121
Ariel Optional Tools
121
Minimum Hand Tools Required
122
Terms, Abbreviations and Conversion to si Metric
123
Area
123
Flow - Gas
123
Flow - Liquid
124
Force
124
Heat
124
Length
124
Mass
124
Moment or Torque
124
Power
124
Pressure or Stress
124
Speed
125
Temperature
125
Time
125
Viscosity
125
Volume
125
Other Abbreviations
125
Gas Analysis Common Abbreviations
127
Technical and Service Schools on Ariel Compressors
128
Ariel Customer Technical Bulletins (Formerly Ariel Newsletters)
128
Ariel Telephone and Fax Numbers
129
5
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Ariel JGW Series Specifications
General
Brand
Ariel
Model
JGW Series
Category
Air Compressor
Language
English
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