JG-JGA Maintenance & Repair Manual 06/29/2023

Table of Contents
General Safety for Reciprocating Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Lifting the Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Throw and Data Plate Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Other Ariel Resources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Ariel Website . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Ariel Technical and Service Schools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Ariel Contact Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Section 1 - Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Ariel Optional Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Ariel Separately Purchased Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Ariel Separately Purchased Tool Kits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Section 2 - Instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Digital No-Flow Timer (DNFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
DNFT Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Programmable DNFTs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
DNFT Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Troubleshooting DNFT’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Proximity Switch A-18255. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Proximity Switch Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Troubleshooting Proximity Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Main Bearing Temperature Alarms and Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Thermocouples - J (Iron-Constantan) or K (Chromel-Alumel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Resistance Temperature Devices (RTD). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Testing RTD’s and Thermocouples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
RTD Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Thermocouple Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Section 3 - Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Initial Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Daily Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Recommended Maintenance Intervals for Continuous Duty Operation . . . . . . . . . . . . . . . . . . . . . . . 34
Monthly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Six-Month (4,000-Hour) Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
One-Year (8,000-Hour) Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Two-Year (16,000-Hour) Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Three-Year (24,000-Hour) Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

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Four-Year (32,000-Hour) Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Six-Year (48,000-Hour) Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Frame Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Oil Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Oil Sampling Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Dry Sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Oil System Cleanliness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Frame Oil System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Oil Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Oil Pump & Regulating Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Oil Temperature Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Oil Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Oil Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Oil Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Compressor Pre-lube System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Flushing to Change to a PAG Lubricant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Recommended Flushing Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Flushing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Flushing the Force Feed Lubrication System - Common Oil Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Flushing the Force Feed Lubrication System - Independent Oil Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Cylinder and Packing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Force Feed Lubricator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Pressure Relief. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Pump Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Priming the Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Pump Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Pump Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Auto-Relief Valve (ARV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
ARV Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Force Feed Lube Blow-Out Fittings, Rupture Disks, and Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Distribution Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Distribution Block Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Divider Valve Bypass Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Balance Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Adjustment of Balance Valves Fed by a Divider Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Adjustment of Balance Valves Fed by Primary/Secondary Divider Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Subsequent Compressor Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Force Feed System Design, Operating Parameters, and Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Common Oil Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Independent Oil Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Force Feed Lubrication Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Cycle Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Under/Over Lube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Cylinder Lubrication Paper Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Coolant System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

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Section 4 - Part Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Relieving Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Depressurization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Positioning a Throw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Variable Volume Clearance Pocket (VVCP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
VVCP Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
VVCP Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
VVCP Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
VVCP Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
VVCP Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Compressor Valves - Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Required Tools and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Valve Cap Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Valve Caps on Cast Iron Cylinders or High-Pressure Caps without Spring Energized Seals . . . . . . . . . . . . . . . . 83
Removal of Valve Cap with Spring Energized Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Valve Cap Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Installation of Valve Caps on Cast Iron Cylinders or High-Pressure Caps without Spring Energized Seals . . . 87
Installation of Valve Cap with Spring Energized Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Gas Containment Fastener Torque Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Piston and Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Piston Rod Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Piston and Rod Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Piston and Rod Manual Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Piston and Rod Manual Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Piston and Rod Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Piston Rod Runout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Piston Rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Seal-Joint Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Straight-Cut Chamfered Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
High-Pressure Face-Cut Piston Rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Three-Piece Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Five-Piece Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Wear Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Piston Rod Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Piston Rod Packing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Piston Rod Packing Reassembly and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
RTV Wiper Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Reassembling and Testing Cooled Packing Cases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Long Two-Compartment Intermediate Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Types of Piston Rod Packing Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
“P” Pressure Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
“PB1” Pressure Breaker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
“UP” Pressure Breaker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
“P1U” Pressure Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

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“BTR” Single-Acting Seal Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

“BD” Double-Acting Seal Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Double "WAT" Double-Acting Seal Set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
“AL” Double-Acting Seal Set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
“BT” Single-Acting Seal Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
“BTS” Single-Acting Seal Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
“BTU” Single-Acting Seal Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
“BTUU” Single-Acting Seal Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
“CU” Single-Acting Seal Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
“CUU” Single-Acting Seal Set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
“RS3” Single-Acting Seal Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
“DS” Double-Acting Seal Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
“STU” Single-Acting Seal Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
“CR” Single-Acting Seal Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
“RTV” Oil Wiper Set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
“3RWS” Oil Wiper Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Crossheads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Crosshead Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Crosshead Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Connecting Rod Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Connecting Rod Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Crank Pin Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Connecting Rod Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Connecting Rod Bushing Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Connecting Rod Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Connecting Rod Bearing Vertical Jack Clearance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Connecting Rod Thrust (Side) Clearance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Crankshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Oil Slinger Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Main Bearing Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Main Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Crankshaft Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Crankshaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Main Bearing Vertical Jack Clearance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Crankshaft Thrust (End) Clearance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Chain Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Chain and Sprocket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Chain Idler Sprocket Replacement (Eccentric Adjustment Caps) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Lube Oil Pump Sprocket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Force Feed Lubricator Chain Sprocket Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Crankshaft Chain Sprocket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Chain Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Component Cleaning & Thread Lube for Non-Lube Compressor Cylinders . . . . . . . . . . . . . . . . . . . 142
Section 5 - Start Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Warranty Notification - Installation List Data and Start Up Check Lists for Reciprocating
Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Section 6 - Compressor Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

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Piston Rod Runout Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

Appendix A - Ariel Fasteners and Torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Recommendations for Torque Accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
JG:A Fastener Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Appendix B - Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Measuring Head End Clearance for Forged Steel Tandem Cylinders with Concentric Valves . . . 170
Appendix C - Frame Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Opposed Throw - Reciprocating Weight Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Appendix D - Compressor Clearance, Oil, & Temperature Record. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Appendix E - Balance Valve Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Appendix F - Cleaning, Handling, and Assembly Lubricants for Non-Lubricated Compressor Cylinders.
179
Appendix G - Hold-down Bolting to Resist Shaking Forces and Couples in Reciprocating Compressors.
181
Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Appendix H - Soft Foot and Top Plane Flatness Checks for Proper Main Bearing Bore Alignment in
Reciprocating Compressors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Soft Foot Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Top Plane Flatness Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Appendix I - Attachment of Wiring, Tubing, or Pipe Clamps to Ariel Compressor Cylinders . . . . . . . . 186
Alternate Attachment Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Appendix J - Recommended Maintenance Intervals for Intermittent Duty Operation . . . . . . . . . . . . . 187
400-Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
2,000-Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
4,000-Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
8,000-Hour or 22,000 Starts Maintenance (whichever occurs first) . . . . . . . . . . . . . . . . . . . . . . . . . . 189
16,000-Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
32,000-Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Latest Manual Revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
06/29/2023. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

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General Safety for Reciprocating Compressors

WARNING CAUTION

To reduce risk of injury or death, only trained personnel Noise generated by reciprocating machinery may
who have read and thoroughly understand the damage hearing. See Packager information for specific
appropriate Ariel Technical Manual and Packager recommendations. Wear hearing protection during
information should attempt any maintenance. compressor operation.
Prior to performing any maintenance activities:
• Always wear appropriate personal protection equip-
ment and follow your company safety and opera- CAUTION
tional procedures.
Where applicable, compressor installation must
• Never tighten or loosen any fastener or fitting while
conform to Zone 1 requirements. A Zone 1 environment
the unit is operating or pressurized.
requires installation of proper intrinsically safe or
• Verify neither driver nor compressor can turn during equivalent protection to fulfill electrical requirements.
maintenance.
• Follow packager instructions to completely isolate
and vent the system; call the packager for assis- CAUTION
tance.
• Verify each compressor cylinder is relieved to atmo- Hot gas temperatures (especially the cylinder
spheric pressure. To relieve residual cylinder bore discharge), 190°F (88°C) oil, and high friction areas. Wear
pressure after blowdown, open the “Kiene” valves proper protection. Shut down unit and allow to cool
on the indicator ports, if so equipped. before maintaining these areas.
WARNING: RELEASED GAS MAY BE POISONOUS
AND/OR FLAMMABLE.
Before resuming operation, purge the entire system with CAUTION
the gas being compressed to avoid a potentially Suction or discharge valves installed in improper
explosive gas/air mixture in the system. A gas/air locations may result in severe personal injury and
mixture under pressure can explode and cause severe property damage.
injury or death.

CAUTION

If applicable, do not remove the pin from the crosshead

guide to compressor cylinder mounting face. It is there
When the symbol to the left appears
to prevent installation of misapplied cylinders and avoid
on a compressor or control panel, consult the personal injury.
appropriate Ariel Maintenance and Repair
Manual for specific information before
proceeding. The Maintenance and Repair Lifting the Compressor
Manual applies to current design and build; it
may not apply to equipment built prior to the CAUTION
date on the front cover and is subject to When lifting a compressor with lifting lugs, use only
change without notice. For questions of Ariel-supplied lugs. Verify lugs are fastened with correct
grade cap screws, and properly tightened. Lifting cable
compressor safety, operation, maintenance,
spreaders are required perpendicular to the crankshaft
or repair, contact your packager or Ariel. axis and the lift point. Verify crane capacity is adequate.

• Determine compressor weight before lifting.

See the Ariel Performance Program for frame

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and cylinder weights. Also account for any • Use spreader bars or lifting beams for a
extra weight such as external and internal vertical pull on eyebolts or lifting lugs. Chains
flywheels, etc. or straps attached to eyebolts or lifting lugs
• Each compressor ships with an attached should be within 5 degrees of vertical. For
Compressor Lifting Information packet. Refer eyebolt load capacity rating or if pulling on an
to the Compressor Lifting Information docu- eyebolt in a direction other than along the
ment for each specific compressor frame threaded axis, consult ASME B18.15.
serial number. Ariel can provide the weight, • Verify lifting tackle, spreader bars, and crane
center of gravity, and lifting hook locations capacity are adequate, properly attached
for the compressor via the Ariel Performance and properly rigged for the load. Keep
software, or by contacting the Ariel Response compressor level when lifting and setting.
Center. Heavier cylinders and/or blank throws can
• If you are not experienced in lifting large significantly affect center of gravity.
compressors, Ariel recommends using quali-
fied professional riggers/movers.
• Ariel-supplied eyebolts (attached to cross-
head guides), brackets (attached to cylinder
nozzles) and lifting lugs (attached to frame
walls) are designed to lift the Ariel
compressor only, with no other equipment
such as bottles, skid, etc. Do not attempt to
lift the compressor when it is attached to the
skid, driver, or piping. Do not use these lifting
attachments on other equipment.
• On frames with lifting lugs, install lugs with
the proper Grade 8 cap screws and tighten to
the torque listed in the appropriate Ariel
Maintenance and Repair Manual or the Ariel
Torque App. If lifting lugs are already
installed, recheck bolt torque prior to lifting.
• For compressors with no lifting lugs, lift by
the eyebolts installed by Ariel at the cross-
head guides. Ariel-installed eyebolts are
locked in position with Loctite® thread locker
to help prevent turning.
• Verify eyebolts, brackets and lifting lugs are
free of any visual defects that could affect
serviceability. Remove and destroy all defec-
tive eyebolts, brackets, and lifting lugs. Use
only Ariel-supplied brackets and lifting lugs.
• Standard lifting lug and eyebolt materials can
fail when subject to shock loads at low
ambient temperatures. Follow ASME B18.15
guidelines. If necessary, eyebolts may be
replaced with forged eyebolts of materials
more suitable for low temperatures per ASME
B18.15 and ASTM F541.

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Throw and Data Plate Locations

When contacting Ariel with compressor questions, know throw locations and information on data
plates fastened to the machine. This data helps Ariel representatives answer quickly and accurately.
Contact Ariel for replacement if any data plates are missing.

Figure: Separable Guide Compressor Throw and Data Plate Locations - Typical

1 VVCP Dimension Plate 5 Cylinder Data Plate 8 Oil Filter Change Instruction
2 VVCP Data Plate 6 VVCP Serial Number, MAWP, and Plate
3 Mechanical Inspector Plate and Hydrotest Stamp 9 Force Feed Lubricator Pump Data
Frame Serial Number Stamp 7 Cylinder Serial Number, MAWP, Plate
4 Rotation Direction Plate and Hydrotest Stamp 10 Force Feed Lubricator Data Plate
11 Compressor Data Plate

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Other Ariel Resources

Ariel Website • Packager Standards provide detailed

requirements and recommendations on the
Visit www.arielcorp.com to view and print the installation of an Ariel compressor.
latest documentation, such as: • Application Manual provides detailed infor-
mation on the use of Ariel compressors in
• Customer Technical Bulletins (CTB’s)
different applications.
provide important information on changes,
corrections, or additions to Ariel products or
services. Read these bulletins before oper- Ariel Technical and Service
ating or servicing equipment.
• Engineering References (ER’s) provide stan- Schools
dard procedures and other useful informa-
Ariel schedules several in-plant schools each
tion for operation, maintenance, or repair of
Ariel compressors or components. Read and year, which include classroom and hands-on
follow these procedures for long and trouble- training. Ariel also sends representatives to
free service from your Ariel compressor. provide customized training on location. Contact
• Maintenance and Repair Manuals provide Ariel for details.
detailed maintenance and repair information
on specific Ariel compressor models.

Ariel Contact Information

Contact Telephone Fax E-Mail

Ariel Response Center 888-397-7766 (toll-free USA & 740-397-1060 [email protected]

Canada) or 740-397-3602
Ariel Parts Sales (International) 740-393-5054 [email protected]

Order Entry 740-397-3856 -

Ariel World HQ 740-397-0311 740-397-3856 [email protected]

Technical Services fieldservice@arielcorp.

com

Ariel Response Center Technicians or Emergency Service. Calls are answered by

Switchboard Operators answer telephones voice mail.
during Ariel business hours, Eastern Time - USA 2. Leave a message: caller name and telephone
or after hours by voice mail. Contact an number, serial number of equipment in ques-
authorized distributor to purchase Ariel parts. tion (frame, cylinder, unloader), and a brief
Always provide Ariel equipment serial number(s) description of the emergency.
to order parts. The after-hours Telephone
3. Your voice mail routes to an on-call represen-
Emergency System works as follows:
tative who responds as soon as possible.
1. Follow automated instructions to Technical
Services Emergency Assistance or Parts

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Section 1 - Tools
A variety of tools are required for safe and effective maintenance of Ariel compressors. Standard hand
tools are readily purchased from hardware stores or industrial supply companies. Ariel makes certain
special tools available where needed.

Ariel Optional Tools

Ariel offers an optional tool kit with every compressor. For JG:JGA compressors, it contains the tools
shown below, which are specifically designed for use on Ariel units. Clean all tools before use and verify
full tool engagement with the part being removed or installed. If the Tool Kit is missing or if a single
tool is missing, worn, or broken, call your distributor. Do not use worn or broken tools, or substitutes
for Ariel furnished tools. See Parts List for individual tool part numbers.

Figure: Optional Furnished Tools for JG:JGA Compressors

1 Tool Box
2 Main Bearing Removal Tool
3 Crank End Clearance Setting Tool
(included only for 2-3/4M, 3M, 2-3/4P-CE,
and 3-1/4P-CE class cylinders)
4 Piston Rod Entering Sleeve
5 3/8" Allen Wrench (2 provided)
6 5/16" Allen Wrench (3 provided)
7 1/4" Allen Wrench (3 provided)
8 3/16" Allen Wrench (5 provided)
9 5/32" Allen Wrench (5 provided)
10 9/64" Allen Wrench
11 1/8" Allen Wrench (10 provided)
12 3/32" Allen Wrench (10 provided)
13 Ariel Bore & Thread Gauge
14 Crank End Clearance Setting Tool
(included only for 2-1/4P-CE class cylin-
ders
15 3/4" Peg Wrench
16 2-Inch Open End Wrench
17 5/16" x 1/2" UNF Valve Tool
18 1/4" x 3/8" UNF Valve Tool
19 Piston Turning Tool for 9/16" socket
(included only for small tandem cylin-
ders)
20 Piston Nut Spanner
21 Ariel ER-63 Fastener Torque Chart (not
shown)

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Ariel Separately Purchased Tools

Figure: Ariel Separately Purchased Tools for JG:JGA Compressors
1 Piston Rod Entering Sleeve (applies only
to cylinders with part number less than D-
4500 and bore size of 2-3/4", 3", or 3-3/8")
2 Force Feed Lubricator Bearing Housing
Spanner Wrench
3 Piston and Rod Clamping Fixture
4 Force Feed Lube Hand Purge Pump

Ariel Separately Purchased • 8-1/2” breaker bar

d. 1/2" square drive wrench set, including:
Tool Kits • 14-piece, 12-point socket set, 7/16” to
1. Ariel SAE Hand Measurement Tool Kit 1-1/4” with clip rail
a. 0.0005 in. needle type dial indicator • Extensions, 1-1/2”, 5”, and 10"
b. 0.001 in. 1-inch travel dial indicator • Drive adapters: 1/2” to 3/8" and 1/2”
c. Magnet base for dial indicator to 3/4"
d. 3/8” drive calibrated torque wrench, 40 to • 1-1/4” open end crow’s foot adapter
200 in x lbs • 10-1/4” ratchet
e. 3/8” drive calibrated torque wrench, 10 to • Speed handle
100 ft x lbs • Ball type universal joint
f. 1/2” drive calibrated torque wrench, 50 to • 18” breaker bar
250 ft x lbs
• 1/2” and 5/8” hex key sockets
g. 3/4” drive calibrated torque wrench, 120
e. 3/4" square drive wrench set, including:
to 600 ft x lbs
• 18-piece, 12-point socket set, 3/4” to
2. Ariel SAE Hand Tool Kit 2”
a. 15-piece combination open/box end • Extensions, 3-1/2”, 8”, and 16”
wrench set, 5/16” to 1-1/4” • Drive adapters: 3/4” to 1/2", 3/4” to 1",
b. 8-piece slot and Phillips screwdriver set and 1” to 3/4"
c. 3/8" square drive wrench set, including: • 24” ratchet
• 12-piece, 12-point socket set, 5/16” to • 22” breaker bar
1” f. Adjustable wrenches: 12" and 18"
• 7” ratchet g. Dead blow semi-soft faced hammers: 3 lb.
• Speed handle and 6 lb
• Extensions, 1-1/2”, 3”, 6”, and 12” h. 3/4” x 36” pry bar
• Ball type universal joint i. 12” long feeler gauge set
• 3/8” to 1/2" drive adapter j. 12” machinist scale with 0.01 in. incre-
ments
• 1/4” hex key socket

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k. 13-piece Allen wrench set, 0.050 in. - 3/8”

Recommended Tools
Ariel compressor maintenance and repair
normally requires only Ariel furnished tools and
separately purchased tools and tool kits.
However, Ariel also recommends purchasing the
additional tools below. Contact Ariel for
questions about tools for Ariel units.
1. 12-point box end torque adapter extension
wrench set
2. Tape measure

3. Flashlight

4. Small mirror on a flexible extension rod

5. Small magnet on a flexible extension rod

6. Electric and/or pneumatic drill

7. Twist drill set

8. Torque multiplier

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Section 2 - Instrumentation
Several optional instruments can aid in the CAUTION
operation of an Ariel compressor. Through the
DO NOT drill holes in cylinders or other pressure
data they provide, some instruments can help containing components for any purpose. Pressure
decrease maintenance costs and downtime, and containing components include cylinders, valve caps,
help diagnose lubrication and other types of cylinder heads, unloaders, gas passage caps, and
flanges.See "Attachment of Wiring, Tubing, or Pipe
problems. The use of “alarm” instead of Clamps to Ariel Compressor Cylinders".
“shutdown” for any minimum instrumentation
requirement may result in equipment damage.
CAUTION

NOTE: Ariel recommends the use of shipboard or Any arc welding on the skid and/or associated
armored cabling as opposed to wiring in conduit to equipment and piping can permanently damage solid-
minimize nuisance shutdowns due to wire chafing state electronic equipment. Welding can cause
immediate failure or reduce electronic equipment life
and shorts. Cable in cable trays also facilitates main- and void the warranty. To protect electronic equipment
tenance access. prior to any arc welding (including repair welding),
disconnect all electrical connections including ground,
and remove batteries, or completely remove the
electronic equipment from the compressor.
It is good practice to attach the welding ground clamp as
close as possible to the area where the welding will
occur and to use the lowest practical welder output
setting. Welding must not cause a current flow across
any compressor bearing surface, including but not
limited to crankshaft and crosshead bearing surfaces.

Table: Required Instrumentation Summary

INSTRUMENT SUPPLIER SETTING/REQUIREMENT

Frame Oil System (see "Frame Oil System Components")

Oil Pressure Packager

- Start Permissive with Pre-lube Pump 30 psig (2.1 barg) for 2 minutes

- Run Permissive 45 psig (3.1 barg) within 10 seconds of start

- Alarm 50 psig (3.4 barg)

- Shutdown 45 psig (3.1 barg)

Oil Filter Differential Ariel Change at 10 psi (0.7 bar) or 6 months of operation, whichever
occurs first.

Oil Temperature Packager

- Minimum, to start-up or to load See "Viscosity" for max. oil viscosity based on frame size.

- Minimum, operating 150°F (66°C)

- Maximum, shutdown 190°F (88°C)

Crankcase Level Packager 1/2 to 2/3 sight glass level

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INSTRUMENT SUPPLIER SETTING/REQUIREMENT

- Low Level Shutdown 1/4 sight glass level

Main Bearing Temp. Ariel Recommended, but optional.

- Alarm +20°F (11°C) above normal not to exceed 220°F (104°C)

- Shutdown +30°F (17°C) above normal not to exceed 230°F (110°C)

- Differential Alarm 20°F (11°C)

- Differential Shutdown 30°F (17°C)

Packing Case Temp. Ariel Optional

- Alarm +20°F (11°C) above normal

- Shutdown +30°F (17°C) above normal

Packing Case Vent Packager Optional

- Vent Flow Alarm 2 - 4 scfm (per throw)

- Vent Flow Shutdown > 4 scfm (per throw)

Scrubber Liquid Level Packager

- High Liquid Level Control

- High Liquid Level Shutdown

Gas Conditions Packager

- Inlet Temperature Indicator, each cylinder

- Inlet Pressure Indicator, each stage

- Discharge Pressure Indicator, each stage

- Discharge Temperature Indicator, each cylinder, each nozzle on dual nozzle cylinders

- High Discharge Temperature Shutdown, each 10% above normala (Not to exceed the maximum temperatures
cylinder below)

- Lubricated Cylinders 350°F (177°C)

- Non-Lube/PRC Cylinders 325°F (163°C)

- Hydrogen Rich > 50% < 0.41 Specific Gravity 300°F (149°C)

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INSTRUMENT SUPPLIER SETTING/REQUIREMENT

- Air Not to exceed autoignition temperature of cylinder lubricant at

discharge pressure

- Relief Valve Setting above normal operating • Up to 150: 15 psig (1.0 barg)
pressure (not to exceed MAWP) • to 2500: 10%
• to 3500: 8%
• to 5000: 6%
• Over 5000: As agreed
• See "Relief Valves" in the Packager Standards Manual.

Cyl. Rod Load Protection Packager

High Vibration Shutdown Packager As close to a normal level as practical. See "Vibration
Protection" in the Packager Standards Manual.

Over Speed Packager 10% over rated speed for shutdown

a Example: Normal Discharge Temp. = 270°F; Shutdown Setting = 270 x 1.1 = 297°F.

Notes 3. Mount overhead lube oil supply tanks high

enough to provide oil flow to the level control
1. Install the compressor frame low lube oil
at all ambient temperatures.
pressure shutdown set to stop the unit if oil
pressure downstream of the filter falls below 4. On multi-nozzle cylinders, Ariel strongly
45 psig (3.1 barg). Compressor operation for recommends a temperature device in both
only a few seconds without oil pressure discharge nozzles.
causes major damage. Normal oil pressure is
5. Install the high lube oil inlet temperature
about 60 psig (4.1 barg) at full rated speed
shutdown at the filter inlet connection.
and normal operating temperature. The low
oil pressure shutdown must activate after oil 6. At a minimum, install one vibration shutdown
pressure exceeds 45 psig (3.1 barg) at start- for two and four throw frames and two for six
up. Ariel provides a 1/4 inch tubing fitting to throw frames. Mount vibration devices near
connect the low lube oil pressure shutdown the top of the frame with the sensitive axis
and ties a tag to this connection before each parallel to the piston rod axis.
compressor ships. Do not operate the
7. Install all safety shutdowns, controls, instru-
compressor for prolonged periods at less
mentation, ignition systems, electrical
than 50 psig (3.4 barg) oil pressure.
devices, and high temperature piping (gas
2. Automated pre-lube systems require a start discharge and engine exhaust) in accordance
permissive to sense minimum required pres- with good engineering practice and appli-
sure/time at oil gallery inlet.See “Compressor cable codes for the area classification at the
Pre-lube System”. Unit must shut down if the end user location. Ensure compatibility of all
system fails to achieve 45 psig (3.1 barg) oil systems for area classification.
pressure within 10 seconds after crankshaft
starts to turn.

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8. If packing vent temperature is monitored, DNFTs utilize an LED to indicate each cycle of the
confirm alarm and shutdown set points divider valve, which allows easy adjustment and
through vent flow rates. monitoring of lubrication rates. Programmable
models display total pints, cycle time of divider
valve, total cycles of divider valve, or pints per
Digital No-Flow Timer (DNFT) day pump flow rate on a liquid crystal display and
operators can adjust alarm time from 20 to 255
CAUTION
seconds.
Any arc welding on the skid and/or associated
equipment and piping can permanently damage solid-
state electronic equipment. Welding can cause
immediate failure or reduce electronic equipment life
and void the warranty. To protect electronic equipment
prior to any arc welding (including repair welding),
disconnect all electrical connections including ground,
and remove batteries, or completely remove the
electronic equipment from the compressor.
It is good practice to attach the welding ground clamp as
close as possible to the area where the welding will
occur and to use the lowest practical welder output
setting. Welding must not cause a current flow across
any compressor bearing surface, including but not
limited to crankshaft and crosshead bearing surfaces.

A DNFT is a totally enclosed electronic device,

combining the latest technology in
microprocessor and transistor components to
detect slow-flow and no-flow of divider block
lubrication systems. The DNFT uses an oscillating
crystal to accurately monitor the lubrication
system cycle time to enable precision timed
shutdown capability. The magnet assembly and
control housing mount directly to a divider valve.
Lubricant flow through a divider valve assembly
forces the piston to cycle back and forth causing
a lateral movement of the DNFT magnet linked to
the piston. The DNFT microprocessor monitors
piston movement and resets the timer, lights the
light emitting diode (LED), and allows the unit to
continue operation, indicating one complete
cycle of the lubrication system. If the
microprocessor fails to receive this cycle within a
predetermined time, a shutdown occurs. The
DNFT automatically resets the alarm circuit when
normal divider valve operation resumes.

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DNFT Installation 1. Loosen the Allen set screws on the DNFT and
remove magnet housing. Do not remove
Figure: Typical DNFT Magnet Assemblies magnet, spring, or spacer from magnet
housing.
2. Remove piston enclosure plug from the end
of desired divider valve. The DNFT installs on
any of the divider valves of the divider block.
The DNFT requires the correct magnet
assembly to match the divider valve
manufacturer.
NOTE: Do not install a DNFT on Lincoln divider valves
with cycle indicator pins.
3. If applicable, verify O-ring or metal gasket is
in place on magnet housing. Thread magnet
housing into the end of the divider valve.
Torque to 15 lbs x ft (20 N•m) maximum.
4. Slide DNFT all the way onto hex of magnet
housing. Torque Allen set screws on the hex
of magnet housing to 25 lbs x inch, (2.8 N•m)
1 Trabon Style O-ring Seal 7/16-20 maximum.
2 Trabon Metal Gasket Seal 7/16-20 (1994 or earlier) 5. The LED on the DNFT indicates each divider
3 Lincoln O-Ring Seal 7/16-20 Extended Nose valve cycle to allow lubricator pump
adjustment for Ariel recommended cycle
Figure: Typical DNFT Installation time and oil consumption. If the LED fails to
blink during compressor operation or by
manually pumping oil into the divider valve,
then the DNFT requires adjustment.
6. The divider valve must cycle during DNFT
adjustment. To cycle, either run the
compressor or manually pump oil through
the distribution block with a purge pump.
7. To adjust, slide DNFT all the way onto hex of
magnet housing. Tighten Allen set screws to
25 lbs x inch (2.8 N•m) maximum. A blinking
1 Divider Valve Piston LED indicates correct adjustment. If the LED
2 Magnet
fails to blink with divider valve cycling, slide
DNFT back on the hex of the magnet housing
3 Magnet Housing
in 1/16" increments until it does.
4 Set Screws (2)
5 LED 8. Make all conduits and connections
6 Control Housing appropriate for area classification. Insulate
7 Wire Leads unused wires from the ground, other wires,
8 O-Ring
and the case. Support conduit and fittings to
avoid bending the magnet housing.
9 Divider Valve
10 Piston Enclosure Plug

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9. After DNFT installation and before

compressor start-up, purge all air from the
divider block lubrication system with a purge
pump.
NOTE: When installing multiple DNFTs, wire each to a
separate alarm circuit of the control panel, annunci-
ator, or PLC to simplify lubrication system and DNFT
troubleshooting. Always secure the green ground
wire to "earth ground" in the control panel. Do not
ground to electrical conduit or skid. Improper
grounding can result in unreliable monitor operation.
Figure: A-10754 Programmable DNFT Wiring Connections for Unit in Operation

Figure: A-10753 and A-10772 DNFT Wiring Connections for Unit in Operation

Figure: A-20513 24 VDC Programmable DNFT Wiring Connections for Unit in Operation

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JG-JGA Maintenance & Repair Manual – 06/29/2023

Figure: A-20514 24 VDC DNFT Wiring Connections for Unit in Operation

Programmable DNFTs CAUTION

Figure: Typical Programmable DNFT Program DNFT before installing it on a divider valve. DO
NOT insert programming magnet into 1/8” recessed
opening while the compressor is operating; it causes the
DNFT to shut down the compressor. Programming
modes cannot be changed while the compressor is
operating. To program a DNFT, first remove it from the
divider valve.

To program:
1. Insert the programming magnet into the 1/8"
recessed opening on the face of the DNFT.
1 Magnet The current programming mode (1, 2, 3, or 4)
2 Magnet Housing
immediately displays on the LCD followed by
"0" 2 seconds later. "0" indicates the current
3 Allen Set Screws
mode is ready for programming.
4 LED
5 Control Housing 2. If the desired programming mode does not
6 LCD display, remove and re-insert the
7 1/8" recessed opening for programming magnet programming magnet into the recessed
8 Wire Leads
opening until it does. Leave the programming
magnet in the recessed opening when the
9 Programming Magnet
desired programming mode displays.
Programmable DNFTs come with a small liquid
3. Select one of the programming modes below:
crystal display (LCD) screen to display total
a. Mode 1 - LCD displays total divider
divider valve cycles (Mode 1), cycle time of
valve cycles; program alarm time.
divider valve in seconds (Mode 2), total pints of
• To set alarm time, press and release
oil used (Mode 3), or pump flow rate in pints per the spring-loaded magnet assembly
day (Mode 4). Operators can also adjust alarm until the desired alarm time in
time in Mode 1. seconds displays on the LCD. Set
alarm time from a minimum of 20
seconds to a maximum of 255

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JG-JGA Maintenance & Repair Manual – 06/29/2023

seconds. If not set, the device defaults Mode 1 or Mode 3, and presses the spring-
to 120 seconds. loaded magnet assembly. This action resets the
unit to zero and allows entry of a new value.
• Remove programming magnet. DNFT
displays total divider valve cycles if NOTE: Power interruption to the DNFT requires
left in this mode and alarm time is reprogramming Mode 1 and Mode 3.
now set.
b. Mode 2 - LCD displays the cycle time of
the divider valve in seconds.
DNFT Battery Replacement
• Remove programming magnet when
Mode 2 displays. LCD counts each Figure: Typical Digital No-Flow Timer Switch
divider valve cycle in seconds, (DNFT)
counting up from zero until the
divider valve completes one full cycle.
When divider valve completes one full
cycle, the LCD resets to zero and
repeats the count until another cycle
is completed. The LED blinks in all
modes to indicate each divider valve
cycle. This blink enables the operator
to set pump flow rate.
c. Mode 3 - LCD displays total pints used;
program divider valve total.
• To set divider valve total, add the sizes
1 Magnet Housing
of the divider valve sections on which
2 Magnet
the DNFT will be installed. Example:
24 + 24 + 24 = 72. 3 O-Ring
4 Control Housing
• Press and release the spring-loaded
5 Polarized Connector
magnet until the divider valve total
displays on the LCD. Maximum value: 6 Field Replaceable Battery
120. If not set, device defaults to zero 7 1/2" Pipe Plug
and prevents Mode 4 flow rate display. 8 #22 AWG 18" (0.46 m) Leads
• Remove programming magnet. The 9 Spring
DNFT displays total pints on the LCD if 10 Spacer
left in this mode. 11 Allen Set Screws

d. Mode 4 - LCD displays pump flow rate in

pints per day. The DNFT operates on a field-replaceable lithium
• Remove programming magnet with battery that should last six to ten years. If the
Mode 4 displays. LCD displays pump battery voltage drops below 2.5 VDC, the DNFT
flow rate in pints per day based upon shuts down and the compressor cannot be
the divider valve total set in Mode 3. restarted until the battery is replaced.
Mode 4 requires a minimum 4 second
cycle time.
The DNFT stores all programmed information
until the operator inserts the programming
magnet into the recessed opening, selects

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CAUTION • LED does not blink and control panel indi-

cates lube no-flow. (see also Erratic Shut-
Do not open a DNFT in an explosive gas atmosphere. down)
• ARV bypasses or rupture disk bursts and
1. Shut down the compressor. divider valve seizes after DNFT installation.
2. Disconnect DNFT wiring. • Erratic shutdown or LED blink.
Troubleshooting: DNFT Lube No-Flow

3. Use 1/8 inch Allen wrench to loosen Allen set

screws and remove control housing to a safe Problem
atmosphere.
LED does not blink and control panel indicates
4. Use 3/8 inch ratchet wrench to remove pipe lube no-flow. (see also Erratic Shutdown)
plug.
5. Remove the battery and disconnect from the
Possible Cause
polarized connector.
6. Test battery. The voltage should read 3.6 Improperly adjusted DNFT.
VDC.
Solution
7. Connect the new battery to the polarized
connector. 1. Loosen set screws, slide DNFT all the way
onto hex of magnet housing and torque to 25
8. Insert the new battery and reinstall the pipe lbs x inch (2.8 N•m) max.
plug. Apply Teflon tape to plug threads and
(Do not over tighten).
torque to 25 ft x lb (34 N•m).
2. Either pump clean oil through lubrication
9. Place DNFT control housing on the magnet
system with a purge pump or run the
housing in its original position and tighten set
compressor to cycle the divider valve.
screws. Reattach wiring and conduit.
3. If necessary, slide DNFT back in 1/16“
10. Programmable DNFTs require
increments until LED blinks with each divider
reprogramming of the alarm time (Mode 1)
valve cycle.
and divider valve total (Mode 3) after a power
interruption. See the programming section of
this document. Possible Cause
11. To verify DNFT operation, pre-lube the Broken spring or magnet in magnet housing.
system and check for LED blink.
Solution
Troubleshooting DNFT’s 1. Loosen set screws, remove DNFT from
magnet housing.
NOTE: When installing multiple DNFTs, wire each to a 2. Remove magnet housing from divider valve.
separate alarm circuit of the control panel, annunci-
3. Remove magnet, spring, and spacer and
ator, or PLC to simplify lubrication system and DNFT
check for damage.
troubleshooting. See ER-105.3.1 for DNFT bench test
procedures. 4. Replace damaged components.
5. Re-install magnet housing on divider valve
Problem: and DNFT on magnet housing.

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6. If necessary, adjust DNFT, check for LED Solution

blink.
1. Loosen set screws and remove DNFT from
7. Purge air from system with purge pump. magnet housing.
2. Check for correct magnet housing for divider
Possible Cause valve manufacturer.
Low battery voltage. 3. Remove and replace with correct magnet
housing.
Solution
4. Re-install DNFT on new magnet housing.
1. Remove battery from DNFT and test it. 5. If necessary adjust DNFT, check for LED
2. Replace battery with a factory blink.
recommended replacement lithium battery 6. Purge air from system with purge pump.
if voltage is below 2.5 VDC.

Possible Cause
Possible Cause
Air or debris in divider valve assembly.
Bent magnet housing.
Solution
Solution
1. Check system pressure to verify oil flows to
1. Loosen set screws, remove DNFT from divider valves.
magnet housing.
2. If needed, install pressure gauge to monitor
2. Check for damaged or bent magnet housing. lubrication system operation:
3. Remove magnet assembly from divider a. Loosen outlet plugs in front of valve
valve. blocks.
4. Replace magnet housing, magnet, spring, b. Purge lubrication system with a purge
and spacer. pump until clean, clear, air-free oil flows
5. Re-install new magnet housing on divider from plugs.
valve and DNFT on magnet housing. c. Loosen, but do not remove, each piston
enclosure plug individually to purge air
6. If necessary, adjust DNFT, check for LED
from behind piston. To ensure proper
blink.
lube system operation, all tubing and
7. Purge air from system with purge pump. components MUST be filled with oil and
free of air before start-up.
Troubleshooting: DNFT ARV Bypasses

Problem d. Tighten all divider valve plugs.

e. Adjust proximity switch.
ARV bypasses or rupture disk bursts and divider Troubleshooting: DNFT Erratic Shutdown

valve seizes after DNFT installation.

Problem

Possible Cause Erratic shutdown or LED blink.

Wrong magnet housing installed on divider

valve. Possible Cause

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Faulty wiring from DNFT to control panel or air in Possible Cause

system (see air in system). Overtightened divider valves
Solution Solution
Part numbers: A-10753, A-10772, and A-20513 1. Step-torque divider valves to 75 lb x in (8.5
N•m) to the backplate.
Normally Open
1. Attach ohmmeter to red wires.
2. Should read 10MΩ in operation and less than Proximity Switch A-18255
10Ω in alarm.
CAUTION
Normally Closed
Any arc welding on the skid and/or associated
1. Attach ohmmeter to orange wires. equipment and piping can permanently damage solid-
state electronic equipment. Welding can cause
2. Should read less than 10Ω in operation and immediate failure or reduce electronic equipment life
open loop in alarm. and void the warranty. To protect electronic equipment
prior to any arc welding (including repair welding),
Part number: A-10754, and A-20514 disconnect all electrical connections including ground,
and remove batteries, or completely remove the
Normally Open electronic equipment from the compressor.
It is good practice to attach the welding ground clamp as
1. Attach ohmmeter to orange wires; insulate close as possible to the area where the welding will
violet wires from each other. occur and to use the lowest practical welder output
setting. Welding must not cause a current flow across
2. Should read 10Ω or less in alarm.
any compressor bearing surface, including but not
limited to crankshaft and crosshead bearing surfaces.
Normally Closed
1. Attach ohmmeter to orange wires. A proximity switch installs into a divider valve in
2. Short violet wires together. place of a piston end plug and can be used to
3. Should read open loop in alarm. actuate any device. It consists of a reed switch
and a magnet. When installed, the magnet rests
against the divider valve piston and parallel to
Possible Cause
the reed switch. With every divider valve cycle,
Faulty lube pump. the piston moves the magnet, which opens and
closes the reed switch contacts.
Solution
The time for the proximity switch to repeat a
1. Check system pressure to verify oil flows to
contact transition (ex. from open to closed) is
pump and divider valves. If needed, install
pressure gauge to monitor lubrication known as the cycle time of the divider valve
system operation. assembly. The proximity switch must work with a
PLC or some other counter/timer device to
2. Check gauge to verify pump builds sufficient
pressure to inject oil into cylinder. Do not produce a shutdown. See "Instrumentation" in
remove tubing from check valve and pump the Ariel Packager Standards for interpretation of
oil to atmosphere to check oil flow into proximity switch pulse output.
cylinder.
3. Replace pump.

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Proximity Switch Installation Figure: Typical Proximity Switch Installation

Figure: Typical Magnet Assemblies

1 Divider Valve Piston

2 Magnet
3 Magnet Housing
4 Allen Set Screw (2)
5 Spacer
6 Spring
1 Trabon Style O-ring Seal 7/16-20 7 Switch Housing
2 Trabon Metal Gasket Seal 7/16-20 (1994 or earlier) 8 Wire Leads (yellow)
3 Lincoln O-Ring Seal 7/16-20 Extended Nose 9 Ground Wire (green)
10 O-Ring
11 Divider Valve
12 Piston End Plug

1. Loosen the Allen set screws on the proximity

switch housing and remove magnet housing.
Do not remove magnet, spring, or spacer
from magnet housing.
2. Remove piston enclosure plug from end of
desired divider valve. The proximity switch
installs on any of the divider valves of the
divider block. The proximity switch requires
the correct magnet assembly to match the
divider valve manufacturer.
NOTE: Do not install a proximity switch on Lincoln
divider valves with cycle indicator pins.
3. If applicable, verify O-ring or metal gasket is
in place on magnet housing. Thread magnet
housing into end of divider valve. Torque to
15 lbs x ft maximum.

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4. Slide proximity switch all the way onto hex of 8. Make all conduit and connections
magnet housing. Torque Allen set screws on appropriate for area classification. Support
hex of magnet housing to 25 lbs x inch, conduit and fittings to avoid bending the
maximum. magnet housing.
5. Connect an ohm meter across the two yellow 9. After proximity switch installation and before
switch leads exiting the proximity switch compressor start-up, purge all air from
housing. divider block lubrication system with a purge
6. The divider valve must cycle during proximity pump.
switch adjustment. To cycle it, either run the NOTE: When installing multiple proximity switches,
compressor or manually pump oil through wire each to a separate alarm circuit of the control
the distribution block with a purge pump. panel, annunciator, or PLC to simplify lubrication
7. To adjust, slide proximity switch all the way system and proximity switch troubleshooting. Always
onto hex of magnet housing. Tighten Allen set secure green ground wire to "earth ground" in the
screws to 25 lbs x inch maximum. The ohm control panel. Do not ground to electrical conduit.
meter showing the switch changing state as Improper grounding can result in unreliable monitor
the divider valve cycles indicates correct operation.
adjustment. If the switch state fails to
change, slide proximity switch back on the
hex of the magnet housing in 1/16"
increments until it does.
Figure: A-18255 Proximity Switch Wiring Connections for Unit in Operation

Troubleshooting Proximity • Switch does not cycle and control panel indi-
cates lube no-flow. (also see Erratic Opera-
Switches tion)
• ARV bypasses or rupture disk bursts and
NOTE: When installing multiple proximity switches, divider valve seizes after proximity switch
wire each to a separate circuit in the control panel, installation.
annunciator, or PLC to simplify lubrication system • Erratic Operation.
and proximity switch troubleshooting. Troubleshooting: Proximity Switches Lube No-Flow

Problem:

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Problem Solution

Switch does not cycle and control panel indicates 1. Loosen set screws, remove proximity switch
lube no-flow. (see also Erratic Operation) from magnet housing.
2. Check for damaged or bent magnet housing.
Possible Cause 3. Remove magnet assembly from divider
valve.
Improperly adjusted proximity switch.
4. Replace magnet housing, magnet, spring,
Solution and spacer.
1. Loosen set screws, slide proximity switch all 5. Re-install new magnet housing on divider
the way onto hex of magnet housing and valve and proximity switch on magnet
torque to 25 lbs x inch max. (Do not over housing.
tighten). 6. If necessary, adjust proximity switch and test
2. Either pump clean oil through lubrication switch functionality.
system with a purge pump or run the 7. Purge air from system with purge pump.
compressor to cycle the divider valve. Troubleshooting: Proximity Switches ARV Bypasses

3. If necessary, slide proximity switch back in Problem

1/16“ increments until the switch
opens/closes with each divider valve cycle. ARV bypasses or rupture disk bursts and divider
valve seizes after proximity switch installation.
Possible Cause
Possible Cause
Broken spring or magnet in magnet housing.
Wrong magnet housing installed on divider
Solution valve.
1. Loosen set screws, remove proximity switch
from magnet housing. Solution

2. Remove magnet housing from divider valve. 1. Loosen set screws and remove proximity
switch from magnet housing.
3. Remove magnet, spring, and spacer and
check for damage. Replace damaged 2. Check for correct magnet housing for divider
components. valve manufacturer.
4. Re-install magnet housing on divider valve 3. Remove and replace with correct magnet
and proximity switch on magnet housing. housing.
5. If necessary, adjust proximity switch and test 4. Re-install proximity switch on new magnet
switch functionality. housing.
6. Purge air from system with purge pump. 5. If necessary adjust proximity switch and test
switch functionality.

Possible Cause 6. Purge air from system with purge pump.

Bent magnet housing.

Possible Cause
Air or debris in divider valve assembly.

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Solution Solution
1. Check system pressure to verify oil flows to 1. Check system pressure to verify oil flows to
divider valves. pump and divider valves. If needed, install
pressure gauge to monitor lubrication
2. If needed, install pressure gauge to monitor
system operation.
lubrication system operation:
a. Loosen outlet plugs in front of valve 2. Check gauge to verify pump builds sufficient
blocks. pressure to inject oil into cylinder. Do not
remove tubing from check valve and pump
b. Purge lubrication system with a purge
oil to atmosphere to check oil flow into
pump until clean, clear, air-free oil flows
cylinder.
from plugs.
c. Loosen, but do not remove, each piston 3. Replace pump.
enclosure plug individually to purge air
from behind piston. To ensure proper
lube system operation, all tubing and
Main Bearing Temperature
components MUST be filled with oil and Alarms and Shutdown
free of air before start-up.
Main bearing thermocouples or RTD temperature
d. Tighten all divider valve plugs.
sensors are optional for JG:JGA frames.
e. Adjust proximity switch.
Troubleshooting: Proximity Switches Erratic Operation

Problem Thermocouples - J (Iron-

Erratic Operation.
Constantan) or K (Chromel-
Alumel)
Possible Cause A thermocouple is two dissimilar conductors
Faulty wiring from proximity switch to control joined together at one end to form a sensor that
panel or air in system (see air in system). produces a thermoelectric voltage as an accurate
function of temperature. Appropriate controls
Solution interpret the thermocouple voltage as
temperature.
1. Check electrical wiring and connections for
damage or poor contact. See Figure: A-18255
Proximity Switch Wiring Connections for
Unit in Operation.

Possible Cause
Faulty lube pump.

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Resistance Temperature Devices For main or thrust bearing temperature sensing,

(RTD) Ariel supplies dual element, six-wire, 100 Ohm (at
0°C) RTD’s. Dual element RTD’s allow rewiring
Figure: Typical Dual Element RTD Wiring instead of sensor replacement if an element fails.
Diagram Insulate unused wire ends from each other and
conduit ground.

To simplify wiring, RTD's come with two green

wires and one black for one element, and two red
wires and one white for the other. See Figure:
Typical Dual Element RTD Wiring Diagram.

A Zone 1 environment may require the

installation of proper, intrinsically safe or
equivalent protection to fulfill electrical
requirements.

Testing RTD’s and Thermocouples

Ariel uses resistive temperature devices (RTD) or
thermocouples (TC) to monitor main bearing and
packing temperatures. An RTD has either three or
six wires; a TC has two. Both types of devices are
1 Element 1 tested on the assembly floor after installation,
2 White Wire but before the run-test.
3 Red Wire
4 Element 2
RTD Testing
5 Black Wire
6 Green Wire Figure: Typical RTD/Thermocouple

An RTD is a sensor that produces electrical

resistance as an accurate function of
temperature. Appropriate controls interpret the
electrical resistance as temperature. A typical
measurement technique sends a small constant
current through the sensor and measures voltage
across the sensor with a digital voltmeter to
indicate resistance by a computer and wave-
1 Temperature Probe
fitting equations.
2 Tube Bend
3 Transition Piece
4 PTFE Insulated Foil Shield, FEP Jacket
5 Element Wires (3 or 6 for RTD; 2 for TC)

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Ariel uses two types of RTD: single and dual Thermocouple Testing
element. Single element consists of one white
Ariel uses two types of TC: Type J (-328 to 2192°F),
wire and two red wires. Dual element consists of
which has a red and a white wire, and Type K (-
one element of one white wire and two red wires,
328 to 2501°F), which has a red and a yellow wire.
and another of one black wire and two green
TC’s generate a very low voltage that is difficult to
wires.
measure with a multimeter. A digital
After RTD installation: thermometer attached to the TC measures the
1. Set multimeter to the 100 Ohms resistance voltage and converts it to a temperature reading
scale. based on the thermocouple type.
2. Touch one multimeter lead to the white After TC Installation:
element wire, and the other lead to one of the
red element wires. 1. Turn ON the digital thermometer.
• The multimeter should read between 100 2. Select the thermometer test lead with
Ohms (RTD at 32°F) to 112 Ohms (RTD at colored alligator clips that match the element
90°F). wire colors of the TC being tested.
• Test the other red wire with the white 3. Plug the test lead into the top of the
wire. Resistance should be similar for thermometer. Take care to align the blades to
both red wires. Resistance outside the the appropriate hole.
specified range indicates a damaged or
4. Press the TYPE button until “J” or “K” appears
broken element.
on the screen as appropriate. If “°C” displays,
3. For dual element RTD’s, perform step 2 with press the C/F button to change the display to
the black and two green wires. “°F”.
4. Set the multimeter to check for continuity 5. Attach the red alligator clip to the red
( ). element wire and the other alligator clip to
5. Isolate all element wires from the tube bend the remaining element wire (either white or
and transition piece. Check for continuity yellow).
between each wire and these components. • If the connections are reversed, the ther-
• The multimeter displays “1.” to indicate mometer displays inaccurate tempera-
the circuit is not continuous. ture (about 2°F less at room temperature
and 135°F less at 150°F).
• It displays a value between .001 and .010
and beeps to indicate a continuous • The temperature displayed should be
circuit. about room temperature before TC instal-
lation. If displayed temperature is not
• Only the white wire tested with either red room temperature or seems odd, verify
wire and (for dual element RTD’s) the test setup.
black wire tested with either green wire
should yield a continuous circuit. 6. Detach alligator clips from TC.
• A continuous circuit between any 7. Set the multimeter to check for
element wire and any component indi- continuity ( ).
cates a damaged RTD that needs
8. Isolate both element wires from the tube
replaced.
bend and transition piece. Check for
continuity between each wire and these
components.

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• The multimeter displays “1.” to indicate

the circuit is not continuous.
• It displays a value between .001 and .010
and beeps to indicate a continuous
circuit. Only the two TC element wires
should yield a continuous circuit.
• A continuous circuit between an element
wire and any component indicates a
damaged TC that needs replaced.

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Section 3 - Maintenance
Ariel compressors, like all industrial equipment, • Detailed records of all maintenance.
require maintenance. The severity of compressor To avoid contamination, keep all covers in place
service directly influences the frequency and where access is not required. Use paper towels
amount of maintenance needed. Below are during internal maintenance.
recommended intervals for inspections and
replacements to help determine appropriate WARNING
intervals for a given compressor application.
To reduce risk of injury or death, only trained personnel
Careful documentation of inspection results is who have read and thoroughly understand the
critical to establish whether recommended appropriate Ariel Technical Manual and Packager
information should attempt any maintenance.
intervals are adequate or require more or less
Prior to performing any maintenance activities:
frequency. • Always wear appropriate personal protection equip-
ment and follow your company safety and opera-
Continuous Duty: The compressor operates tional procedures.
continuously, 24 hours a day, shutting down only • Never tighten or loosen any fastener or fitting while
for short durations, usually for maintenance and the unit is operating or pressurized.
• Verify neither driver nor compressor can turn during
unexpected shut-downs. maintenance.
• Follow packager instructions to completely isolate
Short-Term Intermittent Duty: The compressor
and vent the system; call the packager for assis-
operates for short durations, starting and tance.
stopping perhaps several times per day, such as • Verify each compressor cylinder is relieved to atmo-
in many CNG filling station applications that spheric pressure. To relieve residual cylinder bore
pressure after blowdown, open the “Kiene” valves
require operation based on consumer demand. on the indicator ports, if so equipped.
WARNING: RELEASED GAS MAY BE POISONOUS
Long-Term Intermittent Duty: The compressor AND/OR FLAMMABLE.
operates continuously for extended durations, Before resuming operation, purge the entire system with
with extended shut-down periods, such as in the gas being compressed to avoid a potentially
explosive gas/air mixture in the system. A gas/air
some storage/withdrawal applications and fuel mixture under pressure can explode and cause severe
gas booster applications. injury or death.

Many factors affect bearing life including the

number of starts, starting conditions, and run
Initial Maintenance
hours. Consider site-specific conditions when
adjusting maintenance intervals. Comply with Ariel Packager Standards and the
compressor Start Up Check List. Adhere to all
As part of your maintenance program, Ariel
items before and after start-up.
recommends:
• Consistent adherence to safety policies, For cold alignment, account for the difference in
procedures, and equipment warning labels. thermal growth height between the compressor
• Daily operational checks. and driver. Table: Thermal Growth of JG:JGA
• Routine trending and review of operational Compressors lists compressor centerline height
parameters. change based on 6.5 x 10-6/°F (11.7 x 10-6/°C).
• Routine oil analysis and trending.

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Figure: Thermal Growth

1 HOT Centerline
2 Thermal Growth
3 COLD Centerline

Table: Thermal Growth of JG:JGA

NOTE: Thermal growth numbers were calculated
Compressors
using 170°F (77°C) as the frame operating tempera-
Initial Frame Temp. °F Thermal Growth Inch ture. Initial frame temperature is the temperature of
(°C) (mm) the frame during cold alignment. Obtain driver
0 (-18) 0.011 (0.29) thermal growth predictions from the driver manufac-
turer.
10 (-12) 0.011 (0.27)

20 (-7) 0.010 (0.26)

Figure: Angular Coupling-Hub Face Alignment
30 (-1) 0.010 (0.26) Limits
40 (4) 0.009 (0.22)

50 (10) 0.008 (0.20)

60 (16) 0.007 (0.19)

70 (21) 0.007 (0.17)

80 (27) 0.006 (0.15)

90 (32) 0.005 (0.14)

100 (38) 0.005 (0.12)

110 (43) 0.004 (0.10)

120 (49) 0.003 (0.09)

130 (54) 0.003 (0.07)

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Center the coupling between the driver and 2. Check fastener torque on gas nozzle flanges,
compressor so it does not thrust or force the valve caps, cylinder heads, piston rod
crankshaft against either thrust face. packing flanges, crosshead guide hold down,
frame hold down, crosshead guide to
To ensure parallel and concentric drive train
cylinder, and crosshead guide to frame
alignment, position connected equipment so
bolting, if applicable. See Appendix A for
misalignment is as close to zero as possible.
correct torques.
Limits for Total Indicator Reading (TIR):
• Maximum rim (outside diameter), (parallel) 3. Repeat torque check after 750 hours. Recheck
misalignment is 0.005 inch (0.13 mm). fasteners found loose in any of these intervals
• Face (angular) misalignment must be within after an additional 750 hours. If loosening
0.005 inch (0.13 mm) for hub diameters up to continues, contact your package supplier
17 inches (430 mm). For hubs greater than 17 immediately.
inches (430 mm), use the following formula:
Hub O.D. x 0.0003 = max angular misalign-
ment. See Figure: Angular Coupling-Hub Face Daily Maintenance
Alignment Limits.
1. Log and trend the following:
For laser alignment tools:
• Operating RPM, gas pressure and
• Maximum parallel misalignment is 0.0025 temperatures - determine if the unit is
inch (0.064 mm). operating within design parameters and
• Maximum angular misalignment is 0.0003 expectations.
inch/1 inch (0.03mm/100mm). NOTE: Verify high and low pressure shutdowns
are set as close as practical to normal operating
NOTE: If laser is adjusted to display TIR, use TIR limits. conditions. Set points must protect the machine
from exceeding compressor limits.
After running a new, relocated, reconfigured, or • Bearing temperatures - if the unit is
overhauled compressor for 24 hours, shut down, equipped with main bearing temperature
vent the gas system, and perform the following sensors.
maintenance: • Compressor frame oil pressure - at oper-
1. Perform a hot alignment check within 30 ating temperature (190°F (88°C) max. inlet
minutes of shutdown as described above. oil temperature), it should be 50 to 60 psig
(3.5 to 4.2 barg) at the filter gauges. If
Adjust discharge bottle supports and head
pressure falls below 50 psig (3.5 barg),
end supports, if applicable. shut down the compressor then deter-
NOTE: To avoid cylinder distortion, lift discharge mine and correct the cause.
bottles only 0.003 to 0.005 inch (0.08 to 0.13 mm) • Compressor frame inlet oil temperature.
using the supports.
• Cylinder valve cap temperatures.
• Compressor frame oil filter differential
pressure - differential pressure exceeding
the filter change value indicates a need
for a filter change. See filter information
plate on top cover or “Oil Filter” in Frame
Oil System Components for procedure.

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2. Check compressor frame oil level. It should Recommended Maintenance

be about mid-level in the sight glass and free
of foam when running. If not, determine and Intervals for Continuous Duty
correct the cause. Do not overfill. Check oil
makeup tank for sufficient oil supply. For dry
Operation
sump frames, check the package sump oil Ariel compressors, like all industrial equipment,
level. Do not add oil to the crankcase through require maintenance. The severity of compressor
the breather hole while the unit runs. This
service directly influences the frequency and
causes oil foaming and unnecessary no-flow
shutdowns in the force feed lubrication amount of maintenance needed. What follows
system. are the recommended intervals for inspections
and replacements for continuous duty
3. Check force feed lubricator box oil level. It
should be full to the overflow line. operation. This will help you determine the
appropriate intervals for a given compressor
4. Log and trend piston rod packing vent/drain
application.
temperature and check distance piece and
VVCP vents for leakage. If the piston rod
packing vent/drain temperature is trending NOTE: For intermittent duty service, see "Appendix
high, then verify leak rate before performing J".
maintenance.
5. Verify all cylinder high discharge gas NOTE: Careful documentation of inspection results is
temperature shutdowns are set to within 10% critical to establish whether recommended intervals
or as close as practical above the normal are adequate or require more or less frequency.
operating discharge temperature. Do not
exceed the maximum discharge temperature
shutdown setting for the application. Monthly Maintenance
6. Check lubricator block cycle time. See
1. Perform all Daily maintenance.
lubricator box data plate for correct cycle
time. Changes in gas composition may 2. Verify safety shutdown functionality.
require a review of cycle time. Check lube 3. Sample compressor frame oil and send it to a
sheet for units not running at the speed on reputable lubricant lab for analysis. See "Oil
the data tag. If applicable, verify auto relief Maintenance" for a list of what an oil analysis
valve indicator does not show sign of over- should provide. If analysis results indicate
pressurization. increasing levels of lead, tin, or copper
7. Check for gas, oil, and coolant leaks. particles in the oil, shut down unit. Remove
frame top cover and crosshead guide side
CAUTION
covers. Visually inspect for debris. Do not
Do not attempt to repair leaks while the unit is operating disassemble further without good reason. If
or pressurized. debris indicates, replace affected parts, then
change oil, oil filter, and clean the strainer
8. Check for unusual noises or vibrations. with a suitable solvent.
9. See packager documentation for additional NOTE: Operate the unit to bring oil temperature to a
recommended checks, i.e. scrubber liquid minimum operating temperature of 150°F (66°C) to
levels, dump valve operation, cooler louver drive off any entrained water.
positions, etc. 4. Check and log cylinder clearance devices in
use and their settings.

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JG-JGA Maintenance & Repair Manual – 06/29/2023

Six-Month (4,000-Hour) filter and clean the strainer with a suitable

solvent.
Maintenance
d. Refill compressor frame with fresh, clean
1. Perform all Daily and Monthly maintenance. oil.
2. Shut down unit and allow sufficient time for 8. Grease VVCP stem threads at grease fitting,
components to cool. with 2 to 3 pumps of cylinder lube compatible
grease using a standard manual grease
3. Inspect crankcase breather filter and clean
pump. Turn VVCP adjustment handle all the
with suitable solvent.
way in and all the way out to lubricate the
4. Drain and replace force feed lubricator box threads. Measure or count turns to return the
oil. handle to its original position.
5. Where applicable, clean sintered element in 9. Check for adequate cylinder lubrication. See
the small oil filter on the force feed “Cylinder Lubrication Paper Test” for
lubrication system now or at every main oil procedure.
filter change. Use a suitable solvent.Where
10. Re-tighten hold down fasteners to proper
applicable, replace force feed lubricator inlet
torque (compressor frame feet and
filter in independent supply system.
crosshead guide/distance piece support
6. Change compressor oil filter. See top cover feet). Inspect for frame twist or bending to
filter information plate or “Oil Filter” in Frame verify main bearing bore alignment. See
Oil System Components for procedure. Do Appendix H for flatness and soft foot
not exceed 12 month installed period for filter requirements.
element.
11. Perform a coupling alignment (see "Initial
NOTE: For replaceable element style filters, drain the
Maintenance").
canister completely before removing the element.
Inspect elements for cleanliness and damage. Do not 12. Remove and inspect inlet screens on each
install dirty or damaged elements. stage; clean if clogged with debris or replace
if damaged. Clean inlet screens regularly to
7. Change compressor oil. Extremely dirty avoid increased pressure that may collapse
environments, oil supplier them. More debris in the screen may dictate
recommendations, or oil analysis results may more frequent inspections. Inlet screens may
dictate a different oil change interval. Follow be removed if they catch little or no debris
these steps: and the gas stream is clean (optional).
a. Drain oil from frame, associated piping,
and oil cooler.
One-Year (8,000-Hour)
b. Clean oil strainer with a suitable solvent.
In dry sump applications, the strainer is Maintenance
located at the oil reservoir.
1. Perform all Daily, Monthly, and Six-Month
c. Remove frame top cover and crosshead maintenance.
guide side covers. Visually inspect for
debris. Do not disassemble further 2. Open force feed lubricator box and visually
without good reason. If debris indicates, inspect pump followers, cams, and gears for
replace affected parts, then change the oil wear.
3. Pressure test distribution blocks. See
“Divider Valve Bypass Pressure Test” for
procedure.

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JG-JGA Maintenance & Repair Manual – 06/29/2023

4. Measure, log, and trend the following: 8. If applicable, visually inspect pneumatic
• Main bearing, connecting rod bearing, clearance pockets for damage or wear
and crankshaft jack and thrust clear- (seating surface and stems/stem seals).
ances. See "Main Bearing Vertical Jack Clear- Confirm that actuator moves freely.
ance Measurement", "Connecting Rod 9. Inspect cylinder bores for damage or wear.
Bearing Vertical Jack Clearance Measure- Replace the cylinder body or restore the bore
ment", and "Crankshaft Thrust (End) Clear- if any of the following conditions exist:
ance Measurement" in Section 4.
• Bore surface blemishes or gouges.
NOTE: Clearance trends along with oil analysis
and crankcase visual inspection can indicate the • Bore out of round more than 0.001 inch
need for bearing replacement. Do not disas- per inch of bore diameter (0.001 mm/mm)
semble to check clearances. Disassemble only if or tapered.
clearance checks indicate excessive clearance. • Main bore is worn to counterbore diam-
Contact Ariel for original assembly clearances. eter or larger.
• Crosshead to guide clearances. See 10. Inspect piston rings and wearband:
“Crosshead Installation” in Section 4. a. Measure and log piston ring condition,
• Piston rod runout. See “Piston Rod end gap, side clearance, and piston
Runout” in Section 4. groove width.
If any of the above items are outside limits speci- b. Replace rings that are damaged or
fied in Appendix B, find the cause and correct it. It outside limits listed in Appendix B.
may require part replacement. c. When replacing rings, re-measure and log
5. Remove valves and valve gaskets: ring side clearance to check for groove
NOTE: If using CP/CPs/XP valves, valve maintenance wear.
may be extended to the 2 year (16,000 hour) interval. d. Measure and log radial projection of wear
a. Visually inspect valve pockets for band.
damage. Verify all old valve seat gaskets 11. Inspect piston rods for damage and excessive
are removed. wear. Replace rod if any of these conditions
b. Have a qualified valve repair shop disas- exist (see “Piston and Rod Removal” in
semble, visually inspect, and refurbish Section 4):
the valves where needed. Provide the • Gouges or scratches on the rod.
valve repair shop an Ariel torque chart • Under size more than 0.005 inch (0.13
and valve service guide. mm).
c. Visually inspect cylinder gas passages and • In the packing travel length, out of round
clean them of all debris. more than 0.001 inch (0.03 mm).
6. If applicable, remove, disassemble and • Anywhere in the packing travel area,
visually inspect the variable volume tapered more than 0.002 inch (0.05 mm).
clearance pockets (VVCP). Check for damage 12. Rebuild piston rod pressure packing cases.
or wear of all sealing components and See “Piston Rod Packing” in Section 4 for
surfaces, and repair or replace if necessary. procedure.
7. If applicable, visually inspect suction valve 13. Re-install valves, retainers, and valve caps
unloader actuator stems for damage or wear. using new valve seat gaskets and valve cap O-
Visually inspect stem seals for damage or rings/seals. See “Valve Installation” in
wear and confirm that the actuator moves Section 4. Use proper installation techniques
freely. and torque procedures for valve caps.

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JG-JGA Maintenance & Repair Manual – 06/29/2023

14. Check and re-calibrate all required 4. If applicable, use new piston and stem seals
instrumentation. to rebuild actuators on suction valve
15. Clean crankcase breather filter with suitable unloaders and fixed volume pneumatic
solvent. pockets. Replace piston stem assemblies
where stem is damaged or worn.
16. Check and, if needed, adjust drive chains. See
“Chain Adjustment” in Section 4 for 5. Check auxiliary end chain drive for undercut
procedure. sprocket teeth and chain for excessive
stretching. Replace as required.
17. If the compressor is equipped with crankcase
over-pressure relief valves, visually inspect
and exercise valves to manufacturer Three-Year (24,000-Hour)
recommendations. Maintenance
18. Check fastener torques of gas nozzle flanges,
1. Perform all Daily, Monthly, Six-Month, and
head end head or unloader, valve caps,
One-Year maintenance.
piston rod packings, crosshead pin thru-
bolts, crosshead guide to frame, frame hold 2. Replace connecting rod bearings. See
down, crosshead guide to cylinder, cylinder “Connecting Rods in Section 4”.
mounting flange to forged steel cylinder, NOTE: Main and connecting rod bearing wear and
distance piece to cylinder, distance piece to replacement intervals are heavily dependent on
crosshead guide, and tandem cylinder to many factors including speed, load, oil temperature,
cylinder. oil cleanliness, and oil quality. Depending on the
severity of service, the bearing maintenance interval
may be longer or shorter.
Two-Year (16,000-Hour)
Maintenance
Four-Year (32,000-Hour)
1. Perform all Daily, Monthly, Six-Month, and Maintenance
One-Year maintenance.
2. If using CP/CPs/XP valves, remove valves and 1. Perform all Daily, Monthly, Six-Month, One-
valve gaskets: Year, and Two-Year maintenance.
a. Visually inspect valve pockets for 2. Remove crosshead pins.
damage. Verify all old valve seat gaskets a. Measure and log crosshead pin to cross-
are removed. head pin bore and connecting rod
b. Have a qualified valve repair shop disas- bushing bore clearances.
semble, visually inspect, and refurbish b. Check crosshead pin end caps and thru-
the valves where needed. Provide the bolt for wear.
valve repair shop an Ariel torque chart c. Replace if needed.
and valve service guide.
3. Check for bushing wear in the auxiliary end
c. Visually inspect cylinder gas passages and
drive chain tightener.
clean them of all debris.
4. Check for ring groove wear in pistons.
3. Rebuild oil wiper cases.

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JG-JGA Maintenance & Repair Manual – 06/29/2023

Six-Year (48,000-Hour) Frame Oil

Maintenance
There are several oil specifications, maintenance
1. Perform all Daily, Monthly, Six-Month, One- procedures, and operating conditions which
Year, Two-Year, and Three-Year affect oil performance. For optimal performance,
maintenance. ensure the oil meets the specifications below and
2. Replace lubricator distribution blocks. is suitable for the given application, and
3. Replace crosshead bushings and connecting diligently complete maintenance procedures.
rod bushings. See “Crossheads” and
“Connecting Rods” in Section 4. Viscosity
4. Replace connecting rod bearings. See
“Connecting Rods” in Section 4. The minimum allowable viscosity of the oil
entering the frame is 16 cSt. Typically, this is the
5. Replace main bearings. See “Crankshaft” in
Section 4. viscosity of ISO 150 grade oil at about 190°F
(88°C).The maximum viscosity at this
6. Service or replace auxiliary end torsional
temperature is 60 cSt. For JG:JGA frames, the
damper, if applicable. See assembly drawing
in compressor build book for procedure. maximum viscosity to start the compressor is
3,300 cSt and the maximum viscosity to load the
compressor is 1,000 cSt. See Figure: Viscosity vs.
Temperature Graph of Different Lubricants.
Figure: Viscosity vs. Temperature Graph of Different Lubricants

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JG-JGA Maintenance & Repair Manual – 06/29/2023

Oil Pressure Oil Temperature

The factory sets normal pressure on the Maintain frame inlet oil temperature as close to
discharge side of the oil filter at 60 psig (4.1 barg) 170°F (77°C) as possible. Minimum lube oil
for compressors tested mechanically complete operating temperature is 150°F (66°C) to drive off
(inspector tag displayed). If factory tested as water vapor. Maximum allowable oil
mechanically incomplete (no inspector tag), the temperature into the compressor frame is 190°F
packager sets normal oil pressure at initial start- (88°C). Higher temperatures increase the
up to 60 psig (4.1 barg) at the lower of the frame oxidation rate of mineral oil. Every 18°F (10°C)
or cylinder rated speed, or driver speed at normal within the operating range doubles the oxidation
operating temperature. Adjust the oil pressure rate of mineral oil.
after the filter to 60 psig at minimum operating
For proper operation of the thermostatic control
speed and normal operating temperature.
valve, the maximum differential pressure
Ariel uses the pump safety relief valve to regulate between the hot oil supply line and the cooled oil
pressure into the compressor. If oil pressure into return line is 10 psid (0.7 bard).
the compressor at minimum operating speed
and normal operating temperature does not read
Oil Sampling Valve
about 60 psig (4.1 barg), adjust the pump safety
relief valve. With compressor running at Install an oil sampling valve between the oil
minimum operating speed, turn the adjustment pump and filter at an easily accessible location.
screw clockwise to increase oil pressure, or Minimize the distance between sampling valve
counter-clockwise to decrease it. The and oil circulating through the system.
compressor requires a 45 psig (3.1 barg) low oil
pressure shutdown for protection.
Dry Sump
NOTE: If oil pressure drops below 50 PSIG (3.4 barg) Compressors subject to transient motion, roll,
when crankshaft speed equals or exceeds minimum and yaw on board a ship or a floating platform
rated operating speed, find the cause and correct it.
may require a dry sump (“dry” crankcase and
separate oil reservoir). See the table for limits,
which are based on the angle where the
crankshaft/connecting rods will contact the oil
level causing foaming. The limits assume that the
running oil level is maintained between one half
and two-thirds the height of the sight glass when
the frame is level.

Table: Maximum Angle from a Horizontal Plane Allowed in Transient Motion without Dry Sump

Framea 1 or 2 Throw 4 Throw 6 Throw

JG 4° 2.5° N/A

JGA 6.5° 3.5° 2°

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JG-JGA Maintenance & Repair Manual – 06/29/2023

With a dry sump, drains are supplied at each end

NOTE: Ariel recommends not disturbing lube oil
of the compressor frame and an additional oil
piping downstream of the installed oil filter. Contam-
pump chain oiler is provided by Ariel. The inants that enter this piping or open ports flush into
packager must provide a lube oil reservoir sized the bearings causing catastrophic damage. If contam-
and located so that the oil pump has oil suction ination is suspected in the supply piping downstream
regardless of the tilt of the ship or floating of the oil filter or in the oil gallery, remove the supply
platform. An oil sump strainer must be installed piping and thoroughly clean both the piping and
in the pump suction line at the outlet of the gallery. Before performing this work, contact Ariel
Technical Service for best practices and procedures.
separate lube oil reservoir (unmounted strainer
To remove or alter piping, cover the inlets to the oil
is provided by Ariel with a new dry sump gallery, the ends of the piping, and the filter outlet so
compressor). Refer to the Ariel outline drawings no contaminants enter. Before reinstallation, chem-
for connection sizes and locations. ical and mechanical cleaning is required. Flush the
pipe in accordance with Ariel cleanliness require-
ments (see Table: Oil Flush Cleanliness Requirements
Oil System Cleanliness ).
Clean the compressor frame oil piping system
and components of all foreign matter such as Prior to start-up, flush all compressors installed
sand, rust, mill scale, metal chips, weld spatter, with an electric or pneumatic powered pre-lube
grease, and paint. Use proper cleaning pump and less than 50 feet (15 m) of oil piping as
procedures with proper cleaners, acids, and/or outlined below. Include cooler oil passages in the
mechanical cleaning to meet cleanliness flushing loop. While oil systems for compressors
requirements. Ariel recommends flushing all oil- without an electric or pneumatic powered pre-
piping systems with an electric or pneumatic lube pump and less than 50 feet (15 m) of oil
driven pump and filtered, clean production oil. piping must be clean, oil flushing is desirable, but
Ariel thoroughly cleans all compressor frame not required.
cavities prior to assembly and test runs For all compressors with oil piping systems
compressors with a filtered closed loop lube greater than 50 feet (15 m), cleaning and flushing
system. must result in a cleanliness level to ISO-4406,
Grade 13/10/9 and/or NAS-1638, Class 5 (see
Table: Oil Flush Cleanliness Requirements ), prior
to start-up.

Table: Oil Flush Cleanliness Requirements

ISO-4406 GRADE 13/10/9

Particle Size
Grade Particles
µm/ml Oil
Requirement Allowed
Sample

/13 Greater than 4 40 to 80

/10 Greater than 6 5 to 10

/9 Greater than 14 2.5 to 5

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JG-JGA Maintenance & Repair Manual – 06/29/2023

change filter limits, stop the pre-lube pump

NAS-1638 GRADE 5
and change the oil filter. To ensure system
Particle Size Range Grade 5 Maximum cleanliness, re-set time and continue flushing
µm/100ml Oil Sample Particles Allowed
until the compressor achieves a continuous
5 to 15 8,000 hour of flushing within differential pressure
15 to 25 1,424 and temperature increase limits.
25 to 50 253 See ISO-4406 "International Standard - Hydraulic
50 to 100 45 fluid power - Fluids - Method for coding level of
Over 100 8 contamination by solid particles" and/or NAS-
1638 "National Aerospace Standard, Aerospace
1. Prior to assembling lube oil piping, remove Industries Association of America, Inc. -
scale, weld slag, rust and any other matter Cleanliness Requirements for Parts Used in
that could contaminate lube oil. Confirm: Hydraulic Systems" for complete information.
• Complete and closed lube oil system. Use a competent oil lab for sample testing. To
• Crankcase filled to the correct level with flush the entire oil system see “Flushing
appropriate oil. Procedure”.
• Proper and correctly installed lube oil
filters.
• Operational and viewable oil pressure
transducer or gauge, oil filter differential-
pressure transducers or gauges, and oil
temperature RTD or indicator.
2. Start pre-lube pump. Record oil pressure, oil
filter differential-pressure, and oil tempera-
ture. Minimum oil pressure is 30 psig (2.1
barg) for effective flushing. Do not exceed 90
psig (6.2 barg).

3. Flush continuously for one hour. Oil filter

differential pressure must not increase more
than 10% of measured oil pressure into the
filter. Record the oil pressure, oil filter differ-
ential pressure, and oil temperature every 15
minutes. Oil temperature increases of more
than 10°F (5.5°C) during an hour of flushing
invalidate the system cleanliness test, due to
oil viscosity change.

4. After one hour of pre-lube flushing, if differen-

tial pressure or temperature increases
exceed the limits above, continue flushing. If
the lube oil filter differential pressure exceeds

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JG-JGA Maintenance & Repair Manual – 06/29/2023

Frame Oil System Components

Figure: Standard Frame Lube Oil Schematic

Oil Connections (see Ariel outline drawing for details) System Components
A1 Packager connection from oil pump 1 Y-Strainer
A2 Packager connection to oil filter 2 Compressor driven oil pump (with safety relief valve for
A3 Oil connection from compressor crankcase (oil sump) pressure regulation, or in models with a separate regulating
A4 Lube oil compressor inlet connection to gallery tube -Oil valve (7), for relief)
flows to crankshaft main bearings, connecting rod bearings, 3 Thermostatic control valve, 170°F (77°C) nominal rating -
crosshead pins, and bushings. required
A5 Pressure regulating valve return connection to oil sump 4 Pre-lube oil pump - required (shown with oil heating circuit,
(when applicable) when applicable), or auxiliary pump.
A6 Filter vent return connection to oil sump (when applicable 5 Optional duplex oil filter
on some models) 6 Oil filter
A7 Oil tubing connections from frame gallery tube to top and 7 Oil cooler - required
bottom of crosshead guides to lubricate crossheads. 8 Check valve
A8 Compressor crankcase oil drain (oil sump drain) 9 Heater (when applicable).
A9 Pre-lube/recirculation/heater connections (4) 10 Temperature indicator
11 Pressure indicator (dirty side)
12 Pressure indicator (clean side)
13 Pressure indicator/shutdown connection

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JG-JGA Maintenance & Repair Manual – 06/29/2023

Figure: Optional Dry Sump Frame Lube Oil Schematic - Typical

Oil Connections (see Ariel outline drawing for details) System Components
A1 Packager connection from compressor-driven oil pump 1 Separate lube oil reservoir (oil sump) - required, vent reser-
A2 Packager connection to oil filter voir to above frame height
A3 Packager connection - oil from compressor crankcase 2 Heater
A4 Lube oil compressor-inlet-connection to gallery tube and 3 Y-Strainer - required (supplied unmounted by Ariel)
bearings 4 Check valve
A5 Pressure regulating valve return connection to crankcase 5 Compressor driven oil pump (with safety relief valve for
(when applicable on some models) pressure regulation)
A6 Filter vent return connection to the crankcase (when appli- 6 Oil cooler - required
cable on some models) 7 Thermostatic control valve, 170°F (77°C) nominal rating -
A7 Oil tubing connections from frame gallery tube to top and required
bottom of crosshead guides to lubricate crossheads 8 Pre-lube oil pump - required (with oil heating circuit, when
A8 Compressor crankcase oil drain applicable), or auxiliary pump
9 Optional duplex oil filter
10 Temperature indicator
11 Pressure indicator (dirty side)
12 Oil filter
13 Pressure indicator (clean side)
14 Pressure indicator/shutdown connection

NOTE: See "Dry Sump" for further details about dry

sump lubrication systems.

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JG-JGA Maintenance & Repair Manual – 06/29/2023

Oil Strainer Oil Pump & Regulating Valve

An oil strainer installed upstream of the pump The oil pump constantly supplies oil to all journal
prevents debris from entering the pump and bearings, bushings, and crosshead sliding
damaging it. Ariel supplies a 30 mesh (595 surfaces. The crankshaft drives it by a chain and
microns) or 40 mesh (400 microns) on all frames, sprocket to provide adequate oil flow to bearings
depending on frame size. It is located on the when the compressor operates at the minimum
auxiliary end of the crankcase below oil level. speed rating (typically half of maximum rated
Remove the strainer basket and wash it in an speed).
appropriate solvent whenever lubricating oil is
changed. Figure: Typical JG:JGA Lube Oil Pump

1 Discharge
2 Safety Relief Valve
3 Dust Cap
4 Suction
Smaller compressor models have
threaded suction/discharge connections.

JG:JGA compressors maintain oil pressure with a Oil Cooler

spring-loaded safety relief valve within the pump
head (see Figure: Typical Lube Oil Pump ). With An oil cooler is required to remove heat from the
the unit running at minimum operating speed frame lube oil. When sizing an oil cooler, consider
and the frame lube oil at operating temperature, temperature and flow rate of both cooling
170°F (77°C), remove the dust cap to expose the medium and lube oil. Insufficient cooling water
safety relief valve adjustment screw and set it so flow rate is the primary cause of high oil
the pressure gauge on the clean side of the oil temperatures. Mount cooler as close to the
filter reads 60 psig (4.1 barg). compressor as possible with piping of adequate
size to minimize pressure drop of both lube oil
When installing a new oil pump on a compressor and cooling medium.
or after maintenance on an existing oil pump,
Ariel recommends priming the pump (wetting The Application Manual lists required cooling
the gears with oil) before start-up to ensure water temperature and flow rate to properly cool
proper operation. Upon compressor start-up oil with Ariel supplied coolers. The Ariel
after oil pump replacement, oil pressure should Performance Program lists oil heat rejection data
immediately reach 50-60 psi. If oil pressure fails for each frame in the frame details section
to reach 50-60 psi immediately, shut down the (contact Ariel for details).
compressor and correct the problem. Dry oil
pump gears sometimes contribute to the
problem.

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JG-JGA Maintenance & Repair Manual – 06/29/2023

Oil Temperature Control Valve

The lube oil system requires a thermostatic valve
to control compressor oil temperature. A
thermostatic valve is a three-way valve with a
temperature sensitive element. As the oil heats,
the sensing element opens the third port in the
valve.

Figure: Thermostatic Valve in Mixing Mode

Thermostatic control valve configuration may
vary from this schematic depending on valve
size. Valve connections A-B-C are marked on
the valve.
1 Lube oil from main oil pump
2 Thermostatic Control Valve
3 Lube oil to main oil filter
4 Lube Oil Cooler

Ariel recommends a thermostatic valve with a • When using a remotely mounted duplex filter,
170°F (77°C) element. Install the valve in mixing leave the frame mounted spin-on or canister
mode to more directly control oil temperature filter in place as a polishing filter. At a
into the frame (see Figure: Thermostatic Valve in minimum, leave frame mounted filters in
place until they are verified free of solid
Mixing Mode).
contaminants of any size.
JG:JGA compressors ship with simplex, spin-on,
Oil Filter non-bypassing, resin-impregnated filters as
All compressor frames require oil filters to standard. Spin-on filters carry a 5 micron
remove particle contamination that can damage nominal and 17 micron absolute rating. The Beta
equipment and oil. Contaminants that damage ratings are ß5 = 2 and ß17 = 75. Many spin-on
equipment include wear particles from filters fit an Ariel compressor, but very few meet
equipment, airborne particles such as dust or filtration ratings of Ariel filters. Do not use
sand, and particulates in new oil. Contaminants aftermarket filters.
that damage oil include oxidized oil components Pressure gauges monitor pressure drop across
and air bubbles. the filter. High differential pressure indicates a
• Ariel filters are not designed for reverse flow plugged filter. Ariel recommends lube oil filter
often caused by pumping oil out of the replacement every 6 months of operation or
compressor through the filter. This can invert when oil filter differential pressure at normal
and tear the filter media, sending dirty oil to operating temperature reaches 10 psid (0.7 bard)
crankshaft bearings.
for spin-on filters, whichever comes first. On

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JG-JGA Maintenance & Repair Manual – 06/29/2023

start-up, differential pressure may exceed the • Particle counting to the latest version of ISO
filter replacement limit until the oil reaches 4406.
operating temperature.On the same schedule, or • Spectroscopy to determine wear metals,
with every main oil filter change, clean the contaminants, and additives.
sintered element in the small oil filter of the force • FTIR (Fourier Transform Infrared Spectros-
copy) to check for oxidation, water or coolant
feed lubricator.
contamination, and additive depletion. This
is more important if the sump oil is not
Oil Maintenance consumed by the force feed system.
Proper oil maintenance is vital to the efficient Collect oil samples with the compressor running
operation of the compressor. The severity of at operating temperature. To collect an oil
compressor service affects the frequency of oil sample with an Ariel oil sampling valve:
and filter changes. 1. Remove dust cap.
2. Loosen lock ring to release button.
Oil Filter Replacement
CAUTION
Replace oil filters or elements with only genuine
Ariel parts. See parts list or name plate for part A loosened lock ring allows valve outlet rotation. Aim
outlet carefully to avoid spilling hot oil.
numbers.

CAUTION 3. Press button to purge a small amount of oil

into a waste container.
Before oil filter replacement, use the frame-mounted
pressure gauges to confirm system depressurization. Be 4. Press button to collect oil sample in a new
careful - hot oil may cause burns! Wear proper personal
protection equipment. sample bottle.

5. Tighten lock ring against button.

Oil Sampling
6. Re-install dust cap.
A consistent oil analysis program is the most
effective way to determine when to change frame
oil on the basis of need rather than a scheduled
interval. Depending on service, oil analysis can
significantly extend oil change intervals.

The packager installs an oil sampling valve on

most frames between the oil pump and filter at
an easily accessible location. Minimize dirt or
debris that can collect around it.

Collect and analyze oil samples to verify

suitability for continued service. Oil analysis
should include:
• Viscosity testing at 104°F (40°C) and 212°F
(100°C). This verifies that oil has not mixed
with cylinder oils or process gas.

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JG-JGA Maintenance & Repair Manual – 06/29/2023

Simplex Spin-on Filter Replacement Compact Duplex Filter Cartridge

Replacement
Figure: Mounted Thermostatic Valve Drain Plug
Figure: Typical Compact Duplex Filter Vessels

When filter differential pressure reaches 10 psid

(0.7 bard) or once every six months, whichever
comes first, replace oil filter with a genuine Ariel
filter. 1 Filter Vent
2 Transfer Valve Indicator
1. Remove old filter, clean filter head surfaces, 3 Filter Head
and verify old gasket is removed. 4 Filter Housing
2. Inspect new filter for damage or debris. Do 5 Filter Element
not install damaged or dirty filters. Never 6 Filter Gasket
operate a unit with a damaged or leaking 7 Drain Plug
oil filter.
3. Apply clean oil to the filter gasket and thread 1. The triangle indicator on top of the transfer
the filter with gasket onto the head. valve handle points toward the active filter.
Turn transfer valve handle until it stops to
4. Tighten the filter one turn after the filter
make the inactive filter the active filter.
gasket contacts the head. Install 1/2 inch NPT
drain plug. 2. Loosen the inactive filter vent to relieve any
pressure.
5. Use the compressor pre-lube pump to fill the
oil filter with oil and purge air from the oil 3. Drain the inactive filter housing.
system. Manually filling the filter with oil can 4. Remove the filter housing, clean and inspect.
introduce debris on the clean side of the
filter. This debris can damage the compressor 5. Remove the filter element and properly
to the point of bearing failure. dispose of.
6. After starting the unit, check for leaks, and
retighten if necessary.

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6. Inspect new filter element and place it over

the seat in the top of filter head. It requires a NOTE: The pre-lube return into the frame must be
small amount of force to seat the element upstream of the oil filter.
onto the filter head.
For on-demand compressor applications, the
7. Install drain plug in the filter housing.
pre-lube pump can circulate oil continuously
8. Inspect and replace the filter gasket if through the bearings while on standby.
damaged. Install the gasket and attach the
filter housing. Step torque the bolts to 40 Lb x Ariel requirements are based on a pre-lube pump
Ft (54 N•m). sized for 25% of frame oil pump flow to ensure oil
9. Determine unit state: flow to bearings, bushings, and oil-filled
• If unit is shut down: Crack open the clearances prior to turning or start-up (see
filter vent. Use compressor pre-lube Appendix C for frame oil pump flow rates).
pump to fill the oil filter. Close vent
once air is purged. Manually filling the The following statements depend on oil supply
filter with oil can introduce debris on and sump viscosities, which depend on oil
the clean side of the filter. Debris can temperature. Oil supply temperature at the filter
damage the compressor to the point head or frame oil gallery is not always a true
of bearing failure. representation of total oil sump temperature.
• If unit is running: Crack the vent of See Figure: Viscosity vs. Temperature Graph of
the empty vessel. Rotate transfer Different Lubricants to determine oil viscosity
valve slightly to slowly fill empty
based on temperature.
vessel. Close vent once air is purged.
Allow additional flow to the new • During a cold start of the unit when oil supply
element to push any remaining air viscosity is greater than 50 cSt, pre-lube pres-
downstream. Position transfer valve sure should be 30 psig (2.1 barg) at the oil
handle to put desired filter in service. gallery for a minimum of 2 minutes prior to
turning or starting.
10. Check for leaks.
• During a hot re-start of the unit when oil
supply viscosity is less than 50 cSt, pre-lube
Compressor Pre-lube System pressure should be 20 psig (1.4 barg) at the oil
gallery for a minimum of 2 minutes prior to
Ariel compressors must be pre-lubed anytime the turning or starting.
crankshaft is turned and prior to starting. Ariel
strongly recommends an automated pre-lube NOTE: A 10 to 15 minute pre-lube is required after:
system to extend driveline component life. • Any major drive line maintenance
• The main lube oil system is drained
Ariel requires automated pre-lube systems for • Oil filter replacement
compressors that meet any of the following
criteria: Instrumentation: Automated pre-lube systems
• Electric motor driven compressors. require a start permissive logic and
• Unattended-start compressors, regardless of instrumentation to satisfy the minimum required
driver type. pressure and duration at the oil gallery inlet.
See Figure: Standard Frame Lube Oil Schematic
for pre-lube circuit design.

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It is highly recommended that the compressor Flushing Procedure

low oil pressure shutdown be Class B. Inhibited
time shall be no longer than 10 seconds after idle Below is a general flushing procedure
speed is achieved on gas engines or start recommended to change from mineral or PAO
initiation for electric motors. oils to a synthetic PAG lubricant.

If the compressor fails to achieve 45 psig (3.1 1. Drain old oil from frame while the oil is still
warm.
barg) oil pressure within 10 seconds after
reaching engine idle speed or electric motor start 2. Drain all supply and return lines upstream of
initiation, ensure shutdown and correct the the frame lube oil filter, filter housing (if
applicable), coolers, and other peripheral
cause. Repeat pre-lube before each start
equipment in the lubricant supply loop.
attempt.
3. Remove standing oil in the frame and guide
NOTE: If a compressor fails to start or shuts down at compartment low points. Remove as much
start-up due to low oil pressure, DO NOT re-start until oil as possible with a vacuum hose. If heavy
the cause is corrected. deposits are visible, remove them as best as
possible by hand using clean, dry, lint-free
rags.
4. Install new frame lube oil filters.
Flushing to Change to a PAG
5. Remove and either clean or replace the Y-
Lubricant strainer element.
Cylinder and frame lubrication systems require 6. Reconnect oil piping and install drain plug in
flushing when changing to or from a PAG frame.
lubricant or when applying a PAG lubricant to 7. Connect a diaphragm pump upstream of the
newly installed equipment. frame mounted oil filter.
8. Feed the diaphragm pump flushing oil (see
"Recommended Flushing Oil") from a clean
Recommended Flushing Oil reservoir and prime the lube oil system.
The preferred flushing oil is soluble in both the Prime until old oil is purged from oil passages
original oil and PAG lubricant. A linear diester is and flushing oil steadily flows from all
bearings and crosshead bushings.
preferred, such as Shell Corena DE 150 or Mobil
Rarus 829. If this is unavailable, use the desired 9. Drain frame. Remove standing oil in the
PAG lubricant fill oil as the initial flushing oil. frame and guide compartment low points.
Remove as much oil as possible with a
vacuum hose.
10. Remove diaphragm pump and plug
connection upstream of frame mounted oil
filter.
11. Install drain plug in frame.
12. Refill the frame with flushing oil (see
"Recommended Flushing Oil").

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13. Circulate flushing oil for at least four hours, feed lubricator box with the same oil used to
and up to 24 hours if needed, to loosen all lubricate the compressor cylinders/packings. To
debris and existing deposits. Monitor lube oil change the lubricator box lubricant from a
filter differential pressure during flushing. mineral oil or synthetic PAO lubricant to a PAG
The filter may need to be taken off line or synthetic lubricant:
changed several times during flushing, as a. Drain old oil from lubricator box.
loosened deposits tend to plug the filter b. Rinse lubricator box with flushing oil (see
quickly. "Recommended Flushing Oil").
14. Drain the first flushing oil from the frame c. Fill lubricator box with PAG lubricant to
while the oil is still warm. Take care to also be used for the cylinders.
drain all supply and return lines, filter
housing, and other peripheral equipment in
the lubricant supply loop. If standing oil
Flushing the Force Feed
remains in the frame, remove as much as Lubrication System - Common Oil
possible with a vacuum hose. Supply
15. Refill the frame with the PAG lubricant of the
1. If installed, drain the sintered filter and clean
recommended viscosity for the application.
the element with solvent.
At this time, as much as 2-3% of the initial oil
may still remain in the system. Circulate this 2. Drain the lube line upstream of the force feed
fill for at least four hours and up to 24 hours if pump inlet.
possible. Replace filters as needed. 3. Drain tubing/manifold feeding the force feed
NOTE: If the PAG lubricant is clear and bright after pump(s).
circulating and no debris or emulsion is visible, it may
be possible to skip the final steps and simply begin 4. Remove the purge/vent connection on the
normal operation. However, a second flush is outlet of each force feed pump.
preferred (see steps 16 and 17). 5. Use a purge pump filled with clean/filtered
16. Drain second flushing (PAG lubricant) oil from flushing oil (see "Recommended Flushing
the frame while the oil is still warm. Oil") to prime each force feed pump by
forcing oil through the pump inlet and out the
17. Refill frame with PAG lubricant of the purge/vent connection.
recommended viscosity and circulate for at
least four hours. At this point, the initial oil 6. Reconnect the purge pump to the force feed
remaining in the system should be less than pump purge/vent outlet connection. If
0.5%. Sample the oil and examine it for any pumps are paired together at their outlets,
emulsion or debris. If the oil is clear and close one of the purge/vent connections.
bright (a slight haze is acceptable), then 7. For the zone fed by the force feed pump being
continue normal operation and top off as primed, disconnect lube lines at the inlet of
needed. If significant emulsion or debris the double-ball check valves.
remains, then conduct one more drain and
flush. 8. Place paper towels or suitable collection
containers beneath each disconnected lube
If the frame uses the same oil as the force-feed line to catch flushing oil during priming.
cylinder lubrication system, the overflow line on
the lubricator box can remain attached to the 9. Prime flushing oil from the force feed pump
frame auxiliary end cover. If the frame oil and purge/vent connection to downstream
cylinder oil are incompatible or of different ISO tubing, divider blocks, and check valves.
grades, disconnect overflow line on the lubricator
box (see “Independent Oil Supply”). Fill the force-

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10. Prime until no air bubbles appear in the 10. Prime until no air bubbles appear in the
flushing oil at all disconnected lube lines in flushing oil at all disconnected lube lines in
the zone. the zone.
11. Reconnect lube lines to double ball check 11. Reconnect lube lines to double ball check
valves in the primed zone. valves in the primed zone.
12. Continue to prime 2 fluid ounces of oil per 12. Continue to prime 2 fluid ounces of flushing
throw through the primed zone. oil per throw through the primed zone.
13. Repeat steps 6 thru 12 for remaining zones. 13. Disconnect the purge pump and install cap
for purge/vent connection.
Flushing the Force Feed 14. Repeat steps 6 thru 12 for remaining zones.
Lubrication System - Independent 15. Install a new oil filter.
Oil Supply 16. Reconnect lube lines between daytank and
pump inlets. Reinstall sintered filter (if
1. Drain daytank, oil filter, and lube lines provided).
upstream of the force feed pump inlet. Oil
trapped in piping can be vacuumed out or 17. Place a collection container beneath the
flushing oil can be pumped through these disconnected lube line near the force feed
lines to displace the old oil. pump inlet connection.

2. If installed, drain the sintered filter and clean 18. Add enough flushing oil to the daytank to
the element with solvent. prime the system up to the disconnected line
in step 17.
3. Drain tubing/manifold feeding the force feed
pump(s). 19. Collect oil until no air bubbles appear in the
flushing oil.
4. Remove the purge/vent connection on the
outlet of each force feed pump. 20. Reconnect feed line to force feed pump.

5. Use a purge pump filled with clean/filtered 21. Bleed trapped air by loosening tube
flushing oil (See "Recommended Flushing connections nearest each pump inlet.
Oil") to prime each force feed pump by
forcing oil through the pump inlet and out the
purge/vent connection.
Cylinder and Packing
6. Reconnect the purge pump to the force feed
Lubrication
pump purge/vent outlet connection. If The cylinder lubrication system injects
pumps are paired together at their outlets,
lubrication into cylinder bores and packings. The
close one of the purge/vent connections.
system consists of an oil supply, an oil filter, a
7. For the zone fed by the force feed pump being force feed lubricator pump, divider blocks,
primed, disconnect lube lines at the inlet of
pressure indicators, check valves, and flow
the double-ball check valves.
monitoring shutdown devices. The system is
8. Place paper towels or suitable collection progressive; each piston in the divider block
containers beneath each disconnected lube
must complete a cycle before the system cycles
line to catch flushing oil during priming.
again. This type of system offers better
9. Prime flushing oil from the force feed pump lubrication precision and eases monitoring.
purge/vent connection to downstream
tubing, divider blocks, and check valves.

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Force Feed Lubricator

The force feed lubrication system oils the
compressor cylinders and piston rod packings.
Oil flows to the suction side of the force feed
lubricator pump directly from the pressure side
of the frame lubrication system, or from an
overhead tank. A self-contained oil reservoir oils
the force feed lubricator worm gear and cam. The
force feed lubricator sight glass shows the
reservoir oil level.

Figure: Typical Force Feed Lubricator

A With Auto Relief Valve (ARV)
B With Rupture Disk
1 Auto-Relief Valve (ARV)
2 ARV Manifold
3 Priming Stem
4 Pump Plunger Stroke Adjust-
ment Screw
5 Lock Nut
6 Lubricator Oil Fill Connection
7 Sight Glass
8 Mounting Flange Capscrews
(4)
9 Drain Plug
10 Purge/Vent Connection
11 Pump Outlet to Distribution
Block
12 Inlet to ARV
13 Lubricator Overflow
14 Force Feed Lubricator
Sprocket
15 O-ring
16 Inlet Header
17 Pump Inlet from Header
18 Rupture Disk Assembly

Pressure Relief procedure before cleaning, checking, or servicing

the equipment:
This equipment stays pressurized until pressure
is manually relieved. To prevent serious injury 1. Stop lubricator pump.
from pressurized fluid, such as skin injection, 2. If installed, close oil supply valve located
splashing fluid, and moving parts, follow this upstream from pump.

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• If the supply valve cannot be closed, de- Figure: Pump Installation

energize and relieve pressure of pressur-
ized oil supplies feeding the pump.
3. Slowly crack open fluid line fittings to relieve
pressure.

Pump Installation

CAUTION

Shut down the compressor package and depressurize

cylinders before performing any work, including the
force feed lube system.

Before installation, verify the lubricator box and

lube system are sized appropriately for the
selected pressure. Verify a pressure relief device
suitable for the application is installed in the
system. Refer to Figure: Pump Installation during
installation. 1 Reservoir Cover Mounting Hole
2 Pump Mounting Hole
3 Washer
4 Mounting Bolt
5 Pump Gasket
6 Pump Body
1. Clean pump body.
2. Remove protective film from gasket and
adhere gasket to pump body.
3. Orient pump so the roller bearing on the
bottom of the pump aligns with the cam
inside the reservoir.
4. Align the pump mounting holes with the
reservoir cover mounting holes.
5. Install washers and bolts. Tighten the bolts
securely, then torque each bolt to 50 Lb x In
(5.65 N•m).

Pump Setup
Before setup, relieve all pressure from the force
feed system (see "Pressure Relief").

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The pump has an internal discharge check valve Priming the Pump
that has a cracking pressure of 55 psi (3.79 bar).
Use filtered oil when priming the pump and force
Any oil pressure greater than this cracking
feed system (minimum 5 micron nominal filter).
pressure allows unrestricted oil flow through the
Refer to Figure: Pump Priming and Adjustment
pump, even in a pump at rest or adjusted to zero
during priming.
stroke. Pumps fed 60 psig (4.13 barg) oil from the
compressor frame must pass through a 14 psi Figure: Pump Priming and Adjustment
(0.96 bar) check valve installed at the lube oil
4 5 6
gallery connection.

Specifications 3

Max. Outlet 2
Piston Dia. In. Max. Flowa In.3
Pressure psi
(mm) (cm3) 1
(bar)
3/16 (4.76) 7500 (517) 0.012 (0.196)

1/4 (6.35) 6000 (414) 0.021 (0.344)

3/8 (9.53) 3500 (241) 0.048 (0.786)

• Inlet Size: 1/4” - 18 NPTF

• Outlet Size: 1/8”- 27 NPTF
• Strokes/Minute: Max. 50; Min. 3
• Stroke Length: Max. 1/2 inch (12.7 mm)
1 O-ring
• Weight: 2.7 lbs (1.22 kg)
2 Flow Adjustment Screw Locknut
• Wetted Parts: carbon steel, stainless steel,
3 Flow Adjustment Screw
aluminum, PTFE, fluoroelastomer
4 Pump Priming Stem
• Max. allowable inlet pressure for priming: 150
5 Pump Inlet
PSI (10.34 bar)
6 Pump Outlet
• Allowable viscosity range independent of
temperature: 80-5000 SUS (16-1100 cSt) 1. Remove and discard the plastic plugs in the
pump inlet and outlet.
2. Apply thread sealant (user supplied) to inlet
and outlet line fittings.
3. Install the inlet and outlet fittings on the
pump.
4. Connect the inlet line to the inlet fitting.
5. Introduce oil into the inlet line using a clean
priming pump filled with cylinder oil
connected to the purge/vent connection. If
installed, open oil supply valve from day tank
(located upstream from pump).

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6. Wipe the pump priming stem clean and Pump Troubleshooting

lubricate with oil.
Relieve all pressure from the system before
7. Manually prime pump by using a priming
cleaning, checking, or servicing the equipment.
pump or by pressing the pump priming stem
repeatedly (if connected to a day tank) until Pump Problem:
clean, air-free oil flows from the outlet fitting.
• No flow
8. Connect outlet line to outlet fitting. • Low flow or erratic operation
9. Manually prime pump by using a priming • Low discharge pressure
pump until clean, air-free oil flows from the • Fluid flows from pump outlet when not
outlet line at the cylinder and packing lube running
points. Pump No flow

10. Connect the outlet line to the lube point. Problem

11. After start-up, adjust individual pumps to
Pump no flow.
meet required flow rates. See "Pump
Adjustment".
Possible Cause
Pump Adjustment
Stroke adjusted to zero.
The flow adjustment screw controls pump flow
rate; turning it changes the length of the piston Solution
stroke which changes the pump discharge 1. Adjust pump stroke for desired output. See
volume. Refer to "Figure: Pump Priming and "Pump Adjustment".
Adjustment" during adjustment.
1. Loosen the flow adjustment screw locknut. Possible Cause
2. Lubricate the o-ring beneath the adjustment Plugged pump outlet.
screw locknut with oil.
Solution
3. Turn the flow adjustment screw.
Counterclockwise increases flow and 1. Clean/flush pump outlet.
decreases cycle time; clockwise decreases
flow and increases cycle time.
Possible Cause
4. Check force feed lubricator data plate or Ariel
lube sheets for correct cycle time. Adjust flow Damaged outlet check valve.
until desired cycle time is achieved with the
Solution
force feed system operating.
5. Repeat Steps 2 and 3 as needed. 1. Replace pump.

6. After adjustment to the proper cycle time,

tighten the adjustment screw locknut. Possible Cause
NOTE: Inconsistent flow can occur if pump stroke is Damaged or worn inlet check ball and/or seat.
set below 20% of maximum stroke. A dust seal inside
the flow adjustment screw holds the priming stem
stationary during operation.

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Solution Problem
1. Replace pump. Low flow or erratic pump operation.

Possible Cause Possible Cause

Stuck piston. Stroke adjusted to minimal travel.
Solution Solution
1. Replace pump. 1. Adjust pump stroke for desired output. See
"Pump Adjustment".
Possible Cause
Stuck pump priming stem. Possible Cause
Damaged or worn inlet check ball and/or seat.
Solution
1. Clean and lubricate the priming stem. Solution
Replace pump if priming stem is corroded. 1. Replace pump.

Possible Cause Possible Cause

Insufficient oil supply. Damaged or worn outlet check ball and/or seat.
Solution Solution
1. Check for line and filter restrictions 1. Replace pump.
upstream of pump. Verify pump inlet is free
of debris.
Possible Cause

Possible Cause Sticking piston or priming stem.

Air bubbles in the oil. Solution

Solution 1. Replace pump.

1. Prime pump. See "Priming the Pump".

Possible Cause

Possible Cause Insufficient oil supply.

High oil viscosity. Solution

Solution 1. Check for line and filter restrictions

upstream of pump.
1. Decrease flow restrictions upstream of
pump. 2. Verify pump inlet is free of debris.

2. Heat oil to maintain viscosity ‹1100 cSt. 3. Check/inspect lube box cam gear for wear.

3. Consult oil supplier for temperature.

Low Flow or Erratic Pump Operation

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Possible Cause Solution

Air bubbles in the oil. 1. Reduce inlet pressure to below the cracking
pressure. See "Pump Setup".
Solution
1. Prime pump. See "Priming the Pump". Possible Cause
Damaged or worn outlet check ball and/or seat.
Possible Cause
Solution
High oil viscosity.
1. Replace pump.
Solution
1. Decrease flow restrictions upstream of Auto-Relief Valve (ARV)
pump. An auto-relief valve (ARV) is a mechanical valve
2. Heat oil to maintain viscosity ‹1100 cSt. that protects force-feed lubrication systems from
3. Check/inspect lube box cam gear for wear. over-pressure conditions. Unlike a rupture disk
Low Pump Discharge Pressure

assembly, the ARV is reusable and does not expel

Problem oil onto the compressor skid.

Low discharge pressure.

Possible Cause
Worn piston and bore.

Solution
1. Replace pump.

Possible Cause
Damaged or worn inlet check ball and/or seat.

Solution
1. Replace pump.
Fluid Flows From Pump Outlet

Problem
Fluid flows from pump outlet when not running.

Possible Cause
Inlet pressure exceeds cracking pressure of
pump outlet check valve.

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Figure: Auto-Relief Valve Components

1 Spring Barrel 6 Spring Piston 11 ARV Inlet

2 O-ring 7 O-ring Retainer 12 Adapter
3 Washer 8 Manifold 13 E-Clip
4 Indicator Pin 9 Pressure Pin 14 ARV Outlet (Bypass Port)
5 Spring 10 Intermediate Barrel

ARV Operation pump (Figure: ARV Operation – High Pressure).

Bypassing oil limits the pressure created by the
Figure: ARV Operation pump. The pump will operate in bypass
condition until either the divider valve no-flow
device times out due to lack of flow or pressure
downstream of the pump decreases allowing the
ARV to close (Figure: ARV Operation– Pressure
Relieved).
When the ARV begins bypassing, an indicator pin
protrudes from the top of the ARV indicating an
over-pressure condition. The indicator pin is a
“tattle tale” and remains protruding after the
ARV bypasses oil (Figure: ARV Operation–
Pressure Relieved ). Two bypass conditions are
possible:
1 Normal Pressure (pin does not protrude)
Intermittent blockage downstream of the
2 High Pressure (pin protrudes)
pump - A brief condition or one-time event that
3 Pressure Relieved (pin not reset)
prevents the shutdown device from timing out
and allows the compressor to continue to
When a force-feed pump encounters a
operate.
downstream restriction, pump discharge
pressure increases. If discharge pressure exceeds
ARV cracking pressure, the ARV bypasses excess
oil back to the low-pressure inlet side of the

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Significant blockage downstream of the pump Force Feed Lube Blow-Out Fittings,
- A condition of long enough duration to cause Rupture Disks, and Tubing
the shutdown device to timeout and shutdown
the compressor. Force feed lube pump discharge lines require
blow-out fittings and the properly rated rupture
After downstream blockage/restriction removal, disk installed. The disk color should show at the
the indicator pin can be manually reset by fitting blow-out hole. A system blockage causes
depressing the indicator pin until it is flush with pressure build-up that ruptures the disk. Venting
the ARV housing. the system through the rupture disk causes the
no-flow shutdown switch to shut down the
compressor.

Table: Blow-Out Fittings, Replacement Rupture Disks, & Tubing

Replacement Rupture Disk Standard Tubing
Blow-out
Fitting Rating
Rating psig
Ariel P/N psig Ariel P/N Color Size in. (mm) Ariel P/N
(barg)
(barg)

A-0080 3250 (224) A-0124 Purple 1/4 x 0.035 (6.4 x 0.9) 5100 (352) PT0200CB (304 SS)
wall
A-3531 3700 (255) A-3536 Yellow

A-3532 4600 (317) A-3537 Red

A-3533 5500 (379) A-3538 Orange 1/4 x 0.065 (6.4 x 1.7) 10,200 (703) PT0201CD (316 SS)
wall
A-3534 6400 (441) A-3539 Pink

A-3535 7300 (503) A-3540 Blue

Ariel force feed lube blow-out fitting rupture CAUTION

disks are color-coded to identify rupture
Use a mirror to inspect rupture disk color if force feed
pressure ratings. Some disks come with half the lube system is pressurized. A rupturing disk or high
finished face coated. If the disk color coating is pressure oil can potentially cause personal injury. Shut
less than half the face surface, the color may not down the compressor package and depressurize
cylinders before performing any work, including the
show through the small centered blow-out hole force feed lube system.
when installed in the blow-out fitting. When this
happens, a visual inspection for color coding may When installing a rupture disk, tighten the blow-
not indicate the correct disk is installed, and out hex fitting cap to 40 lb. x in. (4.5 N•m) torque.
fitting disassembly is required to confirm the Do not over tighten cap or blow-out pressure
proper disk installation. To correct this issue in may decrease, which may increase nuisance
the future, the finished face of rupture disks shutdowns.
supplied to Ariel after March 2005 are completely
coated with color. Disks need not be replaced
because of this change and existing disk stock
may be used-up.

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Distribution Blocks
Distribution blocks consist of three to seven
divider valves and an optional bypass block
fastened to a segmented baseplate. Viton O-rings
(90 Durometer) seal between the divider valves
and baseplate and between baseplate segments.
Check valves are installed at all lube port outlets.

Figure: Typical Distribution Block

1 Piston
4
3 2 Crossport Plate
3 Inlet Port
1 2 5 4 Inlet Block
5 O-Rings
6 6 Check Valve
7 Intermediate Blocks
8 Outlet Port (correct position is off-center
toward inlet block)
9 End Block
7 10 Tie Rod Nut
11 Tie Rod
12 Divider Valve
13 Valve Screw

13 12 11
10

Divider valves contain metering pistons that Single or twin valves may be externally singled or
discharge a predetermined amount of oil with cross-ported. Plug unused outlets when singling
each cycle in a single line, progressive lubrication or cross-porting.
system.

NOTE: Pistons are matched to a specific divider valve.

Do not try to place a different piston into a divider
valve.

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Bypass blocks can replace a divider valve section Divider Valve Bypass Pressure Test
to eliminate the lubrication points. Plug both
Lubricant can leak (by-pass) from a divider valve
outlets below the bypass block. A bypass block
when the divider valve piston becomes worn.
can mount in any baseplate location, but it
Pressure test or replace all divider valves every
requires at least three working divider valves in
twelve months. Testing verifies the piston fits
the block assembly (i.e. bypass blocks cannot be
tightly enough in the divider valve bore for
used on 3-section baseplates).
adequate pressure to force oil into the injection
The baseplate contains the divider valve inlet point. The supplier pressure tests all new Ariel
and outlet connections, interrelated divider valves.
passageways, and built-in check valves. All
To test distribution blocks for valve by-passing
lubricant piping to and from the distribution
requires a manual purge pump with a pressure
block connects to the baseplate. The baseplate
gauge capable of developing 5000 psig (350
consists of one inlet block, three to seven
barg). Ariel offers an optional force feed
intermediate blocks, one end block, and three tie
lubrication hand purge pump with a pressure
rods. The number of baseplate intermediate
gauge (see Section 1). Pressure test each divider
blocks determines the number of divider valves
valve one at a time, complete with pin indicators
allowed. Each distribution block requires a
installed.
minimum of three divider valves.

Distribution Block Assembly

NOTE: See specific frame Parts Book for available

divider valve assembly drawings, parts lists, and
repair kits.

1. Thread three tie rods into inlet block until the

ends flush with the top surface of the block.
2. Slide Intermediate blocks onto tie rods. Verify
all O-rings are installed and discharge ports
are off center toward the inlet block.
3. Slide end block onto tie rods.
4. Lay base plate assembly on a flat surface. Use
"Recommendations for Torque Accuracy" to
tighten the tie rod nuts to the correct torque
listed in Appendix A.
5. Mount the divider valves with O-rings onto
the base plate. Use "Recommendations for
Torque Accuracy" to tighten the tie rod nuts
to the correct torque listed in Appendix A.

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Figure: Pressure Testing Divider Valves

Distribution Block Testing “T” Testing “S”

All Outlets Open Divider Valve Block Divider Valve Block

24T 24T 24T

12S 12S 12S

12T 12T 12T

1 "S" Divider Valve - one side 3 Divider Block Inlet 6 One side Plugged to test a "T"
plugged with 1/8" NPT pipe plug 4 Base outlets open - oil flows valve - all other outlets open
2 Purge Pump freely 7 Both sides plugged to test an "S"
5 Optional Resettable Pin Indica- valve - all other outlets open
tors

1. For new divider valves, verify working piston 3. The divider block assembly should cycle at
section fastener torque is 75 lb x in (8.5 N•m). less than 300 psi (2068 kPa) while purging at a
Loosen the section fasteners, then step- steady rate. Cycle pressures above 300 psi
torque them first to 40 lb x in (4.5 N•m), and (2068 kPa) indicate inhibited piston
then to 75 lb x in (8.5 N•m). Used divider movement, possibly caused by the piston
valves can be tested “as is”, with approximate rubbing the bore, oil contamination, part
section fastener torque verified after testing. geometry, or bore distortion due to over-
2. Place the distribution block in an open tightening the section fasteners. If re-
container with all base outlets open. Connect torquing the valve section fails to improve
purge pump filled with room temperature cycle pressure, replace the divider valve
[65°F (18°C)] 10 wt. (ISO 32) mineral oil to the section. Do not attempt to alter the
divider block inlet. Pump the purge pump to piston/bore fit by polishing components
purge air from the divider block assembly. 4. For divider valves stamped with a “T” (for
Verify that oil flows freely from all outlets (see “twin”), use a 1/8 inch (3.2 mm) pipe or tubing
Figure: Pressure Testing Divider “Divider plug to plug only one base outlet when
Block All Outlets Open”). Testing with 10 wt. testing that side of the piston, and leave all
mineral oil at 65°F (18°C) simulates divider other outlets open. Plug and test each base
block operation at 120°F (49°C) with 40 wt. outlet of divider valves stamped with a “T”
(ISO 150) mineral oil. If 10 wt. (ISO 32) mineral one side at a time. See Figure: Pressure
oil is unavailable, use 40 wt. (ISO 150); Testing Divider “Testing ‘T’ Divider Valve”.
however, the pressure test will be less Individual testing of each outlet ensures both
sensitive in detecting a bypassing divider sides of the piston build adequate pressure.
valve. For all divider valves stamped with an “S” on

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the front (for “single”), plug the working Balance Valves

outlet as well to test both sides of the piston
for by-passing simultaneously. See Figure: Install balance valves on low-pressure lube lines
Pressure Testing Divider “Testing ‘S’ Divider to artificially increase lube line pressure and
Valve”. reduce differential pressure between lube points
5. Pump the purge pump until the pressure downstream of a divider block. Important
gauge indicates 3000 psi (20684 kPa). Hold considerations:
this pressure for 5 seconds, then increase it to
• Set and maintain balance valves downstream
3500 psi (24132 kPa). Stop pumping at 3500
of a divider block within 500 psi (3400kPa) of
psi (24132 kPa).
each other or less. The closer the balance
6. Start timer and monitor the pressure drop valve set pressures, the more reliable the
from 3500 psi (24132 kPa) for 30 seconds. system.
Check discharge outlet(s) plug(s) to confirm • Avoid situations in which the balance valve
no external leaks. Also check O-rings for set pressure is the greatest contributor of
external leakage. If the valve bypasses pressure to the divider block immediately
rapidly, repeat the test to ensure the bypass upstream.
wasn’t due to trapped air. New valves should • With a balanced divider block, the upstream
not exceed a 400 psi (2758 kPa) pressure drop divider block pressure gauge should exhibit
in 30 seconds. Used valves should not exceed no erratic needle movement as the divider
1000 psi (6895 kPa) pressure drop in 30 block cycles.
seconds. If pressure drops exceed these
limits, the divider valve fails the test. To maintain the force feed lube system, record
7. Repeat Steps 4 thru 6 for the remaining the maximum injection pressure indicated at
outlets on the divider block assembly. each divider block gauge, balance valve set
pressures, and divider block cycle time at least
NOTE: Test distribution blocks at higher pressures if once a day for each zone in the system. See
the application dictates higher system operating
Appendix E.
pressure.
Do not adjust balance valves prior to operating
If a divider valve fails, replace it. Discard worn the unit. Verify the tightness of all fittings and fix
divider valves. If the tested valve passes the test, any known leaks. To remove any trapped air or
relieve the pressure, move the plug to the next gas in the force feed lube system, use a high-
outlet, and repeat the test for all divider valves. pressure hand purge pump and the same oil
When all divider valves either pass this pressure recommended for the cylinder application to
test or are replaced, reassemble the distribution purge it. DO NOT USE ANY OTHER FLUIDS FOR
block, purge it with the proper force feed PURGING! Call the Ariel Response Center for
lubricant, and put it into service. details about purchasing a hand purge pump. To
prepare for balance valve adjustment:
Ariel recommends periodic tests for proper
cylinder bore lubrication rates and/or 1. Start the compressor and bring the cylinders
aftermarket devices that measure flow. up to normal operating pressure.
2. Allow operating pressures to stabilize.

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3. See the cylinder lube sheets for balance valve 5. Set balance valve(s) downstream of the
locations and proper spring type for each selected divider block to the pressure
device. calculated in step 4 by rotating the
adjustment cap clockwise to increase
pressure. Set pressure within ±50 psi (3.5 bar)
Adjustment of Balance Valves Fed by a of the calculated value.
Divider Block
6. Monitor the divider block gauge for one
Figure: Balance Valves Fed by Divider Block minute and record the minimum and
maximum pressures in Appendix E. The
difference between the minimum and
maximum should not exceed 1200 psig (82.7
barg). If it does, repeat steps 2 through 6.
7. Tighten the balance valve lock nut. DO NOT
lock wire the adjustment cap.
8. Repeat steps 2 through 7 for any remaining
divider block that feeds one or more balance
valves nearest the compressor
cylinder/packing.
1 Balance Valve 9. After setting all balance valves in the force
2 Balance Valve Pressure Gauge feed system, operate the system for 4 to 6
3 Adjustment Cap hours, then repeat step 6 for each divider
4 Lock Nut block.
5 Divider Block Pressure Gauge
6 Divider Block

1. Select one divider block that feeds one or

more balance valves nearest the compressor
cylinder/packing.
2. For each balance valve downstream of the
selected divider block, loosen the balance
valve lock nut and rotate the adjustment cap
counter-clockwise until the cap is loose.
Some residual pressure may remain on the
balance valve gauge.
3. Monitor the selected divider block gauge for
one minute and record the minimum and
maximum pressures in Appendix E.
4. Calculate the balance valve set pressure by
multiplying the maximum recorded pressure
by 0.85.

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Adjustment of Balance Valves Fed by 3. Repeat steps 1 and 2 for any remaining
Primary/Secondary Divider Blocks secondary divider blocks that feed one or
more secondary balance valves nearest the
Figure: Primary/Secondary Divider Block compressor cylinder/packing.
System 4. Select one primary divider block that feeds
one or more primary balance valves located
prior to a secondary divider block or lube
point.
5. For the selected primary divider block and
balance valves, perform steps 2 through 7 in
"Adjustment of Balance Valves Fed by a
Divider Block".
6. Repeat steps 4 and 5 for any remaining
primary divider block that feeds one or more
balance valves located prior to a secondary
divider block or lube point.
7. After setting all balance valves in the force
feed system, operate the system for 4 to 6
hours, then repeat steps 3 through 7 in
"Adjustment of Balance Valves Fed by a
Divider Block" for each primary or secondary
1 Primary Balance Valve
divider block.
2 Primary Balance Valve Pressure Gauge
3 Adjustment Cap
Subsequent Compressor Start-Up
4 Lock Nut
5 Primary Divider Block Pressure Gauge 1. Verify tightness of all fittings and fix any
6 Primary Divider Block known leaks. Purge force feed lube system.
7 Secondary Divider Block Pressure Gauge 2. If the force feed lube system has been
8 Secondary Divider Block disassembled or parts replaced since the last
9 Secondary Balance Valve start-up, purge the force feed lube system
10 Secondary Balance Valve Pressure Gauge with a high-pressure hand purge pump. When
purging the system, use the same oil that is
recommended for the cylinder application, to
NOTE: Set secondary balance valves before setting remove any trapped air or gas in the system.
primary balance valves. If the system contains no DO NOT USE ANY OTHER FLUIDS FOR
secondary balance valves downstream of a PURGING! Call the Ariel Response Center for
secondary divider block, proceed to step 4. details about purchasing a hand purge pump.
3. Start the compressor and bring up to normal
1. Select one secondary divider block that feeds operating pressure.
one or more secondary balance valves
nearest the compressor cylinder/packing.
2. For the selected secondary divider block and
secondary balance valves, perform steps 2
through 7 in "Adjustment of Balance Valves
Fed by a Divider Block".

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4. Operate the unit for 2 to 3 hours to allow the 2. Multiple pumps may be manifolded to
operating pressures to stabilize. DO NOT achieve required lubrication rates.
adjust the balancing valves immediately after
start-up. It is possible that some lube point 3. Do not operate pumps below 20% of full
injection pressures will fluctuate after a short stroke or they become inconsistent. When
period of run time and the system pressures two or more pumps are manifolded to feed
will stabilize as components increase in one distribution block, adjust them equally.
temperature. Start with pumps wide open, and adjust them
5. See the cylinder lube sheets for balance valve together so that when break-in cycle time is
locations and proper spring type for each set, the pumps stroke about the same. After
device. break-in period, adjust the pumps in the
6. Select one divider block that feeds one or same manner, provided the final pump
more balance valves. stroke is not too short. Try to keep the stroke
7. Monitor the selected divider block gauge for greater than 20% of maximum; a shorter
one minute and record the minimum and stroke produces unreliable pump output. If
maximum pressures in Appendix E. needed, close one pump to stop its flow and
8. See "Balance Valves" if any of the conditions open the other(s) to make the “normal” cycle
below occur: time, and maintain a stroke greater than 20%
a. The difference between the maximum in the functioning pump(s).
and minimum recorded divider block
pressures exceeds 1200 psig (82.7 barg). 4. In some applications, one divider valve
delivers lubrication to both a packing and a
b. The maximum recorded balance valve
pressure exceeds 85% of the maximum cylinder to optimize lubrication system oper-
recorded divider block pressure. ation. In some applications, cross-ported
c. The divider block gauge exhibits erratic divider valves deliver the proper proportion
needle movement as the divider block of lubricant to a given point.
cycles.
5. During operation, verify oil fills the lubricator
reservoir sight glass to the overflow line.
Force Feed System Design, Reservoir oil lubricates the worm gear and
Operating Parameters, and cam; it does not flow through the system. The
reservoir also catches force feed lube pump
Conditions leakage. Add oil only if needed to raise reser-
voir oil level. See Table: Force Feed Lubri-
See specific packager data to confirm designed
cator Reservoir Oil Capacity.
gas composition, operating pressures, and
speed. If operating outside design conditions,
system may need to be reviewed. To optimize
force-feed lubrication system operation, Ariel
uses these general guidelines:
1. Maintain lube rates within prescribed limits
and cycle times as low as possible (normally
10 sec minimum) to lubricate each point as
frequently as possible.

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Table: Force Feed Lubricator Reservoir Oil

Capacity
Lubricator Type Ariel
US Gallons (Liters)
Designs

Single Pump 0.25 (1)

Dual Pump 0.5 (1.75)

Four Pump 0.8 (3)

6. Ariel primes the force feed system with

mineral oil. If tubing is missing, or if the
system is drained, fill and prime the system
through a 1/8 inch plug on the discharge end
of the force feed lubricator pump.

7. Prime the force feed lubrication system with

a proper priming pump just prior to starting
the compressor (see "Force Feed Lubricator"
for pump illustration). Use clean force feed
lubricating oil of same type and grade as used
in service. Do not use any other fluid type or
grade to prime.

8. For recently overhauled units, adjust force

feed cycle time for maximum delivery.
Loosen adjusting screw locknut. Turn
plunger stroke adjustment screw to the full
up position. Tighten adjusting screw locknut.
After two hours of operation or before leaving
site, reset to “normal” cycle time.

Common Oil Supply

Figure: Force Feed Lubrication System Common
Oil Supply shows the force feed lube system
installation when compressor frame lube oil is
also used for cylinder and packing lubrication.

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Figure: Force Feed Lubrication System Common Oil Supply

A To other cylinders and pack-
ings
B Drain to crankcase
1 Frame Oil Gallery
2 Single Ball Check Valve
3 Sintered Bronze Filter (if
applicable)
4 Force Feed Lubricator Pump
5 ARV or Rupture Disk
6 Pressure Gauge
7 Divider Valves/Distribution
Block
8 Fluid Flow Monitor No-Flow
Timer Shutdown Switch
9 Double Ball Check Valve
10 Top Cylinder Injection Point
11 Bottom Cylinder Injection
Point
12 Packing Injection Point

Independent Oil Supply Independent force feed lube systems require oil
with a viscosity below 1100 cSt at the lubricator
When cylinders and packing require oil different pump inlet (e.g. ISO 320 at 73°F (23°C), contact
from frame oil, the force feed lubricator system lube supplier about specific lubricants). Possible
requires an independent oil supply system (see ways to ensure force feed pump is fed oil during
Figure: Force Feed Lubrication System suction stroke:
Independent Oil Supply). An elevated tank must
• Increase pipe and fitting size from tank to
supply pressurized force feed lube oil at a force feed pump.
minimum of 1 psig (0.07 barg) to the force feed • Heat the oil.
pump inlet manifold. • Heat trace and insulate the line from the tank.
To prevent force feed oil from contaminating • Pressurize the supply tank (tank must be
compressor frame oil, disconnect lubricator box designed for pressure).
overflow tubing from compressor frame and
direct it to a suitable drain system.

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Figure: Force Feed Lubrication System Independent Oil Supply

A NOTE: System must provide
positive pressure to force
feed lubricator pump.
B 1/4-inch NPT (female) over-
flow. Pipe or tube to appro-
priate isolated customer
connection. Do not drain to
crank case.
1 Oil Supply Tank
2 Oil Filter (max. 5 micron)
3 System Inlet 1/4-inch NPT
(female) customer connec-
tion
4 Sintered Bronze Filter (if
applicable)
5 Force Feed Lubricator Pump
6 ARV or Rupture Disk
7 Pressure Gauge
8 Divider Valves Distribution
Block
9 Fluid Flow Monitor No-Flow
Timer Shutdown Switch

Force Feed Lubrication Cycle Time

Conditions Lubricant flow rates are measured in seconds per
cycle of the distribution block. The calculated
CAUTION break-in and normal cycle times are stamped on
To prevent personal injury, verify driver or compressor the lubricator box data plate. These cycle times
cylinder gas pressure cannot turn compressor are calculated based on the gas analysis,
crankshaft during maintenance. Before any
maintenance or component removal, relieve all pressure operating conditions, and applied speed
from compressor cylinders. See Packager’s instructions specified in the compressor order. If gas
to completely vent the system. After maintenance, purge conditions were not supplied with the
the entire system with gas prior to operation to avoid a
potentially explosive air/gas mixture. compressor order, the data plate/lube sheet
rates default to clean, dry, 0.65 specific gravity,
sweet gas and cylinder MAWP. If the applied

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speed is not specified, the cycle time is based on To set proper force-feed lubricator pump flow
maximum rated speed of the frame or cylinders, rate, read or measure the cycle time from the
whichever is less. The lube sheets in the Ariel installed device. For a magnetic cycle indicator
Parts Book state gas conditions and list the base assembly, time the cycle from initial indicator pin
rate multiplier at each lube point. movement at the fully retracted position to the
time when the pin returns to the fully retracted
Break-in Rate - Set the break-in lube rate about
position and just begins initial movement out
twice the recommended daily rate (150%
again. Adjust the lubricator pump to provide the
minimum); i.e. set the break-in cycle time about
required cycle time.
half the normal cycle time (67% max.) to increase
lube rate. Maintain break-in rate for 200 hours of NOTE: Pump output can become inconsistent if flow
operation for new equipment. Contact Ariel if rate is set too low. See “Force Feed System Design,
existing pump is incapable of minimum flow rate Operating Parameters, and Conditions”.
required.

Lube Rate and Speed - Recommended lube Changes in operating conditions (such as gas
rates for break-in or normal operation, in properties or pressures, temperatures, flow
seconds per cycle, are calculated at the frame requirements, or cylinder re-configuration)
rated speed (RPM) stamped on the frame data require lubrication rate re-calculation and
plate or the cylinder rated RPM stamped on the possible force-feed lubrication system
cylinder data plate, whichever is lower. Lube rate alteration. Consult the Ariel Packager Standards,
decreases with speed, (as compressor actual the Packager, and/or Ariel.
running speed decreases, cycle time increases,
reducing lube rate): Under/Over Lube
(RPMmax ÷ RPMactual) x cycle time seconds from Inadequate lubrication causes premature wear
lube plate = cycle time seconds at actual running of piston and packing ring materials. Indications
speed. of under lubrication are black, gummy deposits
in the distance piece, packing case, cylinder, and
See the Ariel Parts Book Lubrication Sheets for
valves. When symptoms indicate under
the Cycle Time (seconds) vs. RPM (compressor
lubrication:
speed) table at various running speeds at stated
gas operating conditions and lubricant. • Verify proper operation of force feed lubri-
cator pumps.
Adjusting the cycle time changes the lubrication • Confirm distribution block cycle time
rate for all the compressor cylinders and matches the lube sheet or force feed lubri-
packings supplied by a particular pump. To cator data plate.
change the lubrication rate for only one cylinder • Verify all tubing and fitting tightness; check
or packing requires individual divider valve for leakage. Check fittings inside cylinder gas
passages.
changes. Contact your packager or Ariel for
• Pressure test or replace divider valves to
information.
ensure they do not bypass.

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Over lubrication can result in excessive oil Coolant System Requirements

carryover into the gas stream, and increased
valve and gas passage deposits. Valve plate Coolant flow = number of packing cases x 1 US
breakage and packing failure may also indicate gallon per minute (gpm), minimum for each inch
over-lubrication. of piston rod diameter (No. cases x 0.149 l/min for
each mm of piston rod diameter). Based on using
a solution of 50/50 treated water/glycol solution.
Cylinder Lubrication Paper Test See Figure: Typical Packing Cooling System.
1. Remove head end head and position piston
for the desired cylinder at inner dead center.
2. Using light pressure, wipe the cylinder bore
with two layers of regular unwaxed cigarette
paper together. Begin at the top and wipe
downward about 20° along the bore
circumference. The paper against the bore
surface should be stained (wetted with oil),
but the second paper should not be soaked
through.
3. Repeat the test at both sides of the bore at
about 90° from the top, using two clean
papers for each side. Paper against the bore
surface not stained through may indicate
under-lubrication; both papers stained
through may indicate over-lubrication. In
either case, Ariel normally recommends
changing lubrication rate accordingly and
repeating all paper tests until passed.
4. Repeat this procedure for all cylinders. If the
test indicates a lubrication rate reduction or
increase for a cylinder, change in 5%
increments by adjusting cycle time at the
force feed lube pump (see "Pump
Adjustment"). Repeat oil film testing, for
affected cylinders, after 24 hours of
operation. For a formal lube rate reduction
program, see Ariel ER-125.
NOTE: The paper test indicates only oil film quantity.
Aftermarket devices exist that measure flow. Neither
method indicates viscosity quality. Oils diluted with
water, hydrocarbons, or other constituents may
appear to produce an adequate film or flow, but dilu-
tion will reduce lubricant effectiveness below require-
ments.

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Figure: Typical Packing Cooling System

PI Pressure Indicator
TI Temperature Indicator
FI Flow Indicator
LG Level Gauge
1 Packing Case
2 Throttling Valve
3 Isolation Valve
4 Surge Tank
5 Strainer
6 Water Pump
7 Cooler

Example: JGK/2 with 2.0 inch (50.8 mm) diameter

piston rod.
• 2 packing cases x 1 gpm per inch of rod diam-
eter x 2.0 inch rod diameter = 4 gpm
• (2 packing cases x 0.149 l/min per mm of rod
diameter x 50.8 mm rod diameter = 15.1
l/min)
Cooler size = number of cases x 70
BTU/minute/inch of rod diameter (number of
cases x 0.05 kW/mm of rod diameter). Pressure
drop depends on several factors including flow
rate and fluid, but should generally be 10-30 psi
(0.7-2.1 bar). Coolant into the packing must not
exceed 130°F maximum (54°C max.). Lower
coolant temperature increases heat transfer
from the packing and may be required in high-
pressure applications.

Coolant inlet pressure should be 40-80 psig (2.8-

5.5 barg). 300 psig (20.7 barg) is the maximum to
preserve the o-ring seal between the cups.

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Section 4 - Part Replacement

Major frame assembly components include the Relieving Gas Pressure
crankcase, crankshaft and bearings, connecting
rods, chain drive system, crossheads, and Before conducting maintenance on the
guides/distance pieces. Removable end covers, compressor, it is vital to ensure the cylinders
an aluminum top cover, and crosshead guide contain no gas pressure. During maintenance,
side covers provide easy access to internal unrelieved gas pressure could cause equipment
components. Below are general guidelines to damage, personal injury, or even death.
follow during maintenance.
1. Cleanliness during part replacement: Isolation
• Use lint-free wiping cloths.
Isolate the compression system from all energy
• When not working on a frame with access
sources prior to any maintenance. To ensure the
covers removed, cover it to protect the
interior from rain, dust, and other system remains isolated during maintenance, a
airborne debris. lock out procedure is required. This is a
• Place removed components in a safe requirement of most corporate policies and
place away from work area to prevent occupational safety regulatory agencies. The
damage. Take precautions to keep parts extent of the isolation depends on the system.
from rusting.
2. Gasket maintenance:
Depressurization
• When dismantling the machine, carefully
inspect gaskets at non-pressure loca- Fully depressurize the compression system prior
tions. If damaged, replace them. to any maintenance. If the application involves a
• Always replace pressure-retaining corrosive or poisonous gas, purging is necessary
gaskets. to remove the hazard. There are many different
• Always apply an anti-seize lubricant to configurations of compression systems, so refer
both sides of metallic gaskets. to the information provided by the system
3. For major overhauls, drain and flush the provider for depressurization. In general, the
crankcase. following steps are required:

If replacing a connecting rod assembly, piston, 1. Isolate inlet gas from entering the system.
piston and rod assembly, crosshead-balance 2. Isolate discharge gas from entering the
nuts, or crosshead, weigh component parts and system.
compare to the Compressor Balancing Record 3. Vent and isolate scrubber dump lines, vent
included in the parts manual with each and drain lines, flare vent lines, and any
compressor. If there are weight changes, common blow-down lines to prevent back-
recalculate opposing throw reciprocating weight flow into the system.
differential. See "Opposed Throw - Reciprocating
Weight Balancing” in Appendix C. 4. Open the system blow-down line and reduce
the system pressure to atmospheric.

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5. If so equipped, open the indicator valves on crossheads slide toward the crankcase as far as
the individual cylinders to remove any possible. In the outer dead center position, the
residual pressure in the cylinder(s). crossheads slide away from the crankcase as far
as possible (see figure below). Some procedures
require a dial indicator with magnetic base to
WARNING locate the precise inner or outer dead center. At
Process gas from these valves can be under high other times, a procedure may require turning the
pressure if the system is not depressurized properly and crankshaft so a throw occupies its highest or
can be flammable and/or poisonous depending on the lowest position. In the figure below, the throw on
application.
the left is in its highest position and the throw on
the right is in its lowest position.
Positioning a Throw
WARNING

To reduce risk of injury or death, only trained personnel

who have read and thoroughly understand the
appropriate Ariel Technical Manual and Packager
information should attempt any maintenance.
Prior to performing any maintenance activities:
• Always wear appropriate personal protection equip-
ment and follow your company safety and opera-
tional procedures.
• Never tighten or loosen any fastener or fitting while
the unit is operating or pressurized.
• Verify neither driver nor compressor can turn during
maintenance.
• Follow packager instructions to completely isolate
and vent the system; call the packager for assis-
tance.
• Verify each compressor cylinder is relieved to atmo-
spheric pressure. To relieve residual cylinder bore
pressure after blowdown, open the “Kiene” valves
on the indicator ports, if so equipped.
WARNING: RELEASED GAS MAY BE POISONOUS
AND/OR FLAMMABLE.
Before resuming operation, purge the entire system with
the gas being compressed to avoid a potentially
explosive gas/air mixture in the system. A gas/air
mixture under pressure can explode and cause severe
injury or death.

Component replacement often requires

manually turning the crankshaft to position a
throw in one of two positions: inner dead center
or outer dead center. During normal operation,
crossheads slide back and forth in the crosshead
guides. In the inner dead center position, the

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Figure: Throw Positioning

1 Inner Dead Center Position 2 Outer Dead Center Position 3 Highest/Lowest Throw Position

Variable Volume Clearance

Pocket (VVCP)
A VVCP changes the clearance volume of the
head end of a cylinder. The amount of clearance
depends on the position of the clearance pocket
piston. Users turn the piston/stem assembly
counterclockwise to increase clearance, and
clockwise to decrease it. In the event that gas
begins to leak from the VVCP vent, replace the V-
packing or seal within the VVCP.

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VVCP Removal
WARNING

To reduce risk of injury or death, only trained personnel

who have read and thoroughly understand the
appropriate Ariel Technical Manual and Packager
information should attempt any maintenance.
Prior to performing any maintenance activities:
• Always wear appropriate personal protection equip-
ment and follow your company safety and opera-
tional procedures.
• Never tighten or loosen any fastener or fitting while
the unit is operating or pressurized.
• Verify neither driver nor compressor can turn during
maintenance.
• Follow packager instructions to completely isolate
and vent the system; call the packager for assis-
tance.
• Verify each compressor cylinder is relieved to atmo-
spheric pressure. To relieve residual cylinder bore
pressure after blowdown, open the “Kiene” valves
on the indicator ports, if so equipped.
WARNING: RELEASED GAS MAY BE POISONOUS
AND/OR FLAMMABLE.
Before resuming operation, purge the entire system with
the gas being compressed to avoid a potentially
explosive gas/air mixture in the system. A gas/air
mixture under pressure can explode and cause severe
injury or death.

Figure: Typical VVCP with Bellows or Metal Thread Protector

1 Cylinder
2 Eyebolt
3 VVCP Vent
4 Locking Handle
5 Adjustment Handle
6 Flange Bolts
7 Bellows Thread Protector
8 Piston Stem
9 Metal Thread Protector
10 Adjustment Locknut

1. For VVCP with a bellows thread protector: with a metal thread protector: After venting
After venting the cylinder, loosen the locking the cylinder, unscrew the metal thread
handle so the adjustment handle can turn protector. Loosen the locking handle or
freely. Turn the adjustment handle. For VVCP adjustment locknut so the piston stem can

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turn freely. With a wrench, turn the piston VVCP Disassembly

stem.
The VVCP piston ring is not gas-tight to allow a
CAUTION
nearly balanced gas pressure, which eases VVCP
A hard to turn adjustment handle or piston stem may adjustment with the cylinder pressurized. Gas
indicate pressurized gas trapped within the VVCP. See
VVCP Disassembly caution. pressure behind the VVCP piston normally vents
when the cylinder vents. Process debris or rust
2. Tighten the locking handle or adjustment around the piston ring can form a seal that traps
locknut. gas within the VVCP assembly, sometimes at
3. Disconnect the VVCP vent. substantial pressure.
4. Remove plastic plug from eyebolt hole and CAUTION
thread an eyebolt into the eyebolt hole.
Trapped gas pressure can present a personal safety
5. Use the Ariel supplied eyebolt to support the hazard when servicing the VVCP. Work in a well-
weight of the VVCP. ventilated, non-sparking area, particularly with sour gas
applications. Do not breathe gas emission from VVCP
6. Remove all flange bolts and slide the VVCP when venting trapped gas.
out from the cylinder. The Ariel Performance
Program contains approximate VVCP
weights.
If the VVCP does not slide out easily, loosen the
valve cap bolts. If it still does not slide out easily:
a. Remove head end valves.
b. Clean the area between the VVCP head
and the cylinder.
c. Loosen discharge bottle supports.
7. Discard the head gasket and transport the
VVCP to a suitable work area for disassembly.

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Figure: VVCP Disassembly/Assembly

A V-Packing Seal 5 Locking Handle 12 Piston 19 Backup Ring

B Spring Engerized Seal 6 Grease Fitting 13 Piston Ring 20 V-Packing or Seal
C See Note 1 7 Adapter 14 O-Ring (see Note 2) 21 Seal
1 Locknut 8 Match Mark 15 Retaining Plate 22 Seal Carrier
2 Adjustment Handle 9 Piston Stem 16 Snap Ring 23 O-Ring
3 Adjustment Handle Lip 10 Socket Head Bolt 17 Spring Retainer
4 Bellows Thread 11 Head 18 Compression Spring
Protector

1. Place the VVCP on a table, adapter up. 5. Thread the locking handle or adjustment
NOTE: Steps 2-4 apply only to VVCP's with a bellows locknut off of the piston stem. Leave the
thread protector. bellows thread protector attached to the
locking handle, if applicable.
2. The bellows thread protector grips a lip on
the adjustment handle. Use pliers to pull the 6. Depending on size, a VVCP may have two to
bellows from the adjustment handle lip. Do four socket head bolts. Use a marker to draw
not tear the bellows. match marks on the side of the VVCP where
the adapter and head join at each socket
3. Remove locknut.
head bolt location. Loosen the socket head
4. Remove adjustment handle. The adjustment bolts evenly and incrementally to release any
handle is a tapered fit onto the piston stem; potentially high-pressure gas. Do not
use a soft hammer or puller to break the fit. breathe gas emission from VVCP.

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7. Remove socket head bolts and turn the vii) Remove nut from threaded rod.
adapter counterclockwise to thread it off of Remove threaded rod and
the piston stem. Place adapter flange up next washers from adapter main
to the head. bore.
8. Remove the piston stem and piston assembly Figure: Spring Compression for Snap Ring
from the head. The piston stem and piston Removal
are permanently joined; do not attempt to
disassemble them.
9. Remove the piston ring from the piston.
10. Depending on VVCP size, Ariel machines a
groove for the o-ring into either the face of
the head or the base of the adapter. Remove
and discard the o-ring.
NOTE: Steps 11-13 apply only to VVCP's with a V-
packing seal.
11. Some adapters use a bolted retaining plate
while others use a snap ring and spring
retainer:
• Retaining Plate - Remove retaining plate
bolts and retaining plate.
• Snap Ring and Spring Retainer 1 Washer
i) Thread a nut onto a threaded 2 Snap Ring
rod that is a few inches longer 3 Threaded Rod
than the adapter height. 4 Nut
ii) Slide a washer wider than the 5 Backup Ring
main bore of the adapter down 6 Spring Retainer
to the nut. 7 Compression Spring
iii) Insert the threaded rod end with 8 V-Packing or Seal
no nut into the main bore of the
12. Remove spring retainer, compression spring,
adapter until it protrudes from
and backup ring from the adapter
the base of the adapter.
counterbore.
iv) Slide a washer wide enough to
overlap spring retainer but less 13. Remove V-packing or seal from adapter
wide than the snap ring onto the counterbore. Find a strong, foot-long metal
protruding threaded rod. 3/16 inch rod or pipe and bend about .75 inch
at 90°. Insert the rod into the adapter
v) Thread a nut onto the threaded
counterbore and slide the .75 inch beneath
rod protruding from the base.
the V-packing or seal. Pull up on the rod or
Tighten nut until compression
pipe to pull the V-packing or seal from the
spring compresses enough to
adapter counterbore.
separate spring retainer from
snap ring. NOTE: Steps 14-15 apply only to VVCP's with a spring
energized seal.
vi) Use snap ring pliers to remove
snap ring.

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14. Using an appropriate puller tool, remove the 9. Some adapters use a bolted retaining plate
first seal from the seal carrier bore. Be careful while others use a snap ring and spring
not to damage the seal housing surfaces. retainer:
15. Remove the four socket head bolts, seal • Retaining Plate
carrier, and second seal from the adapter i) Place the retaining plate on top
bore. Remove the O-ring from the seal carrier. of the spring retainer and press
down to compress the compres-
sion spring.
VVCP Reassembly
ii) Install retaining plate bolts
Clean all VVCP parts of all debris, rust, etc. through the retaining plate and
Replace worn or damaged parts. Rebuild kits are into the adapter.
available through your Ariel Parts Distributor. iii) Tighten the retaining plate bolts
hand tight.
1. With flange up, place the head on a table.
With flange up, place the adapter beside the • Snap Ring and Spring Retainer
head. i) Compress the compression
spring (see Figure: Spring
2. Depending on VVCP size, Ariel machines a
Compression for Snap Ring
groove for the O-ring into either the face of
Removal).
the head or the base of adapter. Oil and insert
a new O-ring into O-ring groove. ii) Use snap ring pliers to install the
snap ring above the spring
3. Install the piston ring onto the piston. retainer.
4. Oil the head bore, then insert stem and piston iii) Remove the nut from the
assembly into the head cavity. threaded rod, then remove the
NOTE: Steps 5-9 apply only to VVCP's with a V-packing threaded rod and washers from
seal. the main bore of the adapter.
5. Oil the adapter counterbore and insert V-
packing or seal. The V-packing or seal NOTE: Steps 10-12 apply only to VVCP's with a spring
consists of five partitions; insert V-packing or energized seal.
seal into the counterbore with the thickest
partition down and the thinnest partition up. 10. Lightly oil and install a new seal in the VVCP
NOTE: When properly installed, a V-packing gives adapter bore with the spring facing up.
resistance when the stem is inserted. If there is no Lightly oil and install a new O-ring on the seal
resistance, remove the stem and use a solid cylinder carrier.
of wood or metal to tap the V-packing or seal two or 11. Install the seal carrier in the VVCP adapter,
three times into the counterbore to ensure proper tightening the four socket-head bolts to the
seating. torque listed in Appendix A
6. Insert backup ring into adapter counterbore. 12. Lightly oil and install a new seal in the seal
7. Insert compression spring into adapter carrier with the spring facing up.
counterbore. 13. Grease piston stem threads and install
8. Place spring retainer on top of the adapter onto piston stem. Install adapter as
compression spring. far as possible on the piston stem, then turn
the adapter counter-clockwise to align the
socket head bolt match marks on the adapter
flange with the match marks on the head.

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14. Install the socket head bolts. Tighten socket 18. For VVCP with an adjustment handle, install
head bolts to the torque listed in Appendix A. the locknut onto the piston stem and tighten
15. Install locking handle or adjustment locknut it to prevent the adjustment handle from
onto the piston stem, but do not lock it. For loosening.
VVCP with bellows thread protector, 19. Bellows thread protector: Slide thread
assemble the locking handle with the protector bellows onto the adjustment
protector facing up. handle lip and verify that it grips securely.
16. For VVCP with an adjustment handle, slide Metal thread protection: Thread protector
the adjustment handle onto the piston stem over the piston stem.
and use a soft hammer to ensure full 20. Apply 3-4 pumps of all-purpose petroleum
engagement of the tapered fit. grease with a grease pump at the grease
17. Use the adjustment handle or piston stem fitting.
hex to turn the piston stem counter-
clockwise to tighten the seal between the VVCP Installation
adapter and head, then lock the locking
handle or adjustment locknut. Install the VVCP prior to installing valves and
torqueing valve caps. Use the Ariel supplied
eyebolt to support the weight of the VVCP.

Figure: VVCP Installation

1 Cylinder
2 Head Gasket
3 Eyebolt
4 VVCP Vent
5 Flange Bolts

1. Apply an anti-sieze lubricant to both the new 3. Lubricate and torque flange bolts per
head gasket and the cylinder seating surface. Appendix A.
Stick the new head gasket to the cylinder
seating surface.
2. Slide the VVCP into the cylinder and align the
adapter flange bolt holes with the cylinder
bolt holes.

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4. Reconnect VVCP vent. Verify piston end 5. Add the step 4 result to the fully closed
clearances. See Appendix B. dimension.
5. Install valves and torque the valve caps. See 6. Turn the adjustment handle or piston stem
"Compressor Valves - Removal and until the measurement from the base of the
Installation". locking handle or adjustment locknut, when
locked, to the top of the adjustment handle or
piston stem equals the step 5 result.
VVCP Adjustment
Users may change VVCP clearance volume with
Compressor Valves - Removal
the compressor running or stopped. The
expected change in compressor flow and and Installation
absorbed power depends on compression ratio
Before servicing any valve, see the correct valve
and properties of the compressed gas. Consult
assembly drawing, parts list, and service
packager instructions regarding where to set the
literature in the Ariel Parts Book. The cylinder
VVCP. Also see the VVCP data sheet in the Ariel
cover sheet in the Ariel Parts Book lists the valve
Parts Book. To open VVCP to a desired
originally supplied with each cylinder. Changes
percentage:
in operating pressures, temperatures, RPM, or
Figure: VVCP Dimension Plate gas composition may require alternate valve
configuration including springing and lift.
ARIEL CORPORATION A-12927

Contact your Packager and/or Ariel for help in

FULLY CLOSED A =
FULLY OPEN A = valve selection.
A A VVCP S.N.
REMOVE ALUMINUM THREAD PROTECTOR WHERE APPLICABLE

1. For VVCP with a bellows thread protector: Required Tools and Materials
Loosen the locking handle so the adjustment
handle can turn freely. For VVCP with a • Appropriate Ariel parts list
metal thread protector: Unscrew the metal • Appropriate Ariel Maintenance and Repair
thread protector.Loosen the locking handle manual
or adjustment locknut so the piston stem can • Calibrated torque wrench with the appro-
turn freely. priate range for target values
2. Find the VVCP dimension plate. • Lubricant specified in Appendix A
3. Subtract fully closed dimension from fully • Appropriate personal protection equipment
open dimension. The Ariel Performance • Bottle brush
program also lists these dimensions if the • Pressurized liquid solvent
VVCP dimension plate is missing. • Valve Tool
4. Multiply the step 3 result by the desired
percentage expressed as a decimal.

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Valve Cap Removal Cast Iron Cylinder

Valve Caps on Cast Iron Cylinders or

High-Pressure Caps without Spring
Energized Seals

WARNING

To reduce risk of injury or death, only trained personnel

who have read and thoroughly understand the
appropriate Ariel Technical Manual and Packager
information should attempt any maintenance.
Prior to performing any maintenance activities:
• Always wear appropriate personal protection equip-
ment and follow your company safety and opera-
tional procedures.
• Never tighten or loosen any fastener or fitting while 1 Cap Screw
the unit is operating or pressurized. 2 Valve Cap
• Verify neither driver nor compressor can turn during
3 O-Ring
maintenance.
• Follow packager instructions to completely isolate 4 Valve Retainer
and vent the system; call the packager for assis- 5 Valve Assembly
tance. 6 Valve Seat Gasket
• Verify each compressor cylinder is relieved to atmo-
spheric pressure. To relieve residual cylinder bore High-Pressure without Spring Energized Seal
pressure after blowdown, open the “Kiene” valves
on the indicator ports, if so equipped.
WARNING: RELEASED GAS MAY BE POISONOUS
AND/OR FLAMMABLE.
Before resuming operation, purge the entire system with
the gas being compressed to avoid a potentially
explosive gas/air mixture in the system. A gas/air
mixture under pressure can explode and cause severe
injury or death.

Figure: Valve Cap Assembly

1 Valve Cap
2 Valve Retainer
3 Valve Assembly
4 Valve Seat Gasket
5 Metallic Wire Gasket
1. Slightly loosen all valve cap fasteners in steps
and evenly; the cap should stay in its original
position. If it pushes outward, STOP!
Completely vent the cylinder. See Warning
above.

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2. Continue to turn the cap screws out, for a

total of three complete 360° turns. Pry the
valve cap out, observing cap movement to
ensure there is no gas pressure. Perform
steps 1 and 2 for a suction and discharge
valve cap on each acting end of the cylinder.

3. Remove cap screws and valve cap. Take care

to prevent damage to fasteners.

WARNING

Even with the above precautions, the cylinder bore

could still be pressurized if the valve assemblies are
fouled with deposits from the gas stream. Continue to
use caution until at least one complete valve assembly
has been removed from each acting end of the cylinder,
which completely assures there is no gas pressure.

CAUTION

Valve cap, retainer, and valve may fall out of bottom

pockets if not supported. Support them after cap screw
removal to prevent personal injury.

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Removal of Valve Cap with Spring 7 Valve Gasket

Energized Seal 8 Keeper Bolt
9 2-Piece Wedge Lock Washer
WARNING 10 Spring Energized Seal

To reduce risk of injury or death, only trained personnel 1. Remove cap nuts from long studs.
who have read and thoroughly understand the 2. Slightly loosen all hex nuts on each valve cap
appropriate Ariel Technical Manual and Packager
information should attempt any maintenance.
in steps and evenly. With all the nuts loose,
Prior to performing any maintenance activities: the cap should stay in its original position. If it
• Always wear appropriate personal protection equip- pushes out of its own accord, STOP!
ment and follow your company safety and opera- Completely vent the cylinder. See Warning
tional procedures. above.
• Never tighten or loosen any fastener or fitting while
the unit is operating or pressurized. 3. After the above safety checks and with hex
• Verify neither driver nor compressor can turn during nuts still in place but loosened, remove hex
maintenance. nuts from short studs.
• Follow packager instructions to completely isolate
and vent the system; call the packager for assis-
4. Evenly back off hex nuts on long studs while
tance. pulling the valve cap from the cylinder. Use a
• Verify each compressor cylinder is relieved to atmo- pair of pry bars, one on each side of the cap,
spheric pressure. To relieve residual cylinder bore to remove the cap. Ensure the spring
pressure after blowdown, open the “Kiene” valves energized seal completely disengages from
on the indicator ports, if so equipped. the cylinder before removing the hex nuts
WARNING: RELEASED GAS MAY BE POISONOUS from long studs.
AND/OR FLAMMABLE.
Before resuming operation, purge the entire system with
NOTE: Long studs are assembled with thread locker
the gas being compressed to avoid a potentially to eliminate the possibility of the studs backing out of
explosive gas/air mixture in the system. A gas/air the cylinder while the hex nut is removed.
mixture under pressure can explode and cause severe
injury or death. 5. Remove long stud hex nuts and valve cap.
6. Inspect seal for damage. If undamaged, the
Figure: High-Pressure Valve Cap Assembly with spring energized seal is re-usable.
Spring Energized Seal
CAUTION

Valve cap, retainer, and/or valve may fall out of bottom

pockets if not supported. Support them carefully after
removing hex nuts to prevent personal injury.

Valve Removal
1. With the valve cap removed and the valve
retainer still in place, install a valve tool onto
the valve center bolt or threaded washer. See
1 Hex Nut Section 1 for an illustration of the tool.
2 Cap Nut
3 Valve Cap
2. It may be necessary to loosen the plastic
thumb screws in the valve retainers. In some
4 Seal Keeper
cylinder classes, the discharge valve retainer
5 Retainer
is held in place with an O-ring - simply pull the
6 Valve
retainer out to remove it.

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3. For high pressure applications that use a 5. In most cases, the flat metal gasket remains
metallic wire gasket seal under the valve cap, in the pocket. It is difficult to see. A flashlight
the cylinder vents upon loosening the cap and a small mirror on an adjustable rod are
screws. Use the valve tool to unseat the the best tools to see the gasket clearly. On
metallic wire gasket. cylinders with horizontal valves, the gasket
4. Remove the valve and retainer together. may fall into the gas passage. Use a small
magnet on a flexible extension rod to remove
gasket from cylinder.
6. Head end tandem cylinders may require
removal of suction and discharge piping and
the cylinder head to access the concentric
valve. A concentric valve combines suction
and discharge valves in one assembly.

Valve Installation
Figure: Typical Valve Assemblies
A Suction Valve
B Discharge Valve
C 1/8" (3mm)
1 12-Point Capscrew (Center Bolt)
2 Threaded Washer
3 Valve Retainer
4 Seat
5 Guard
6 Valve
7 Cylinder Bore
8 Valve Seat Gasket
9 Valve Cap Bolt
10 Retainer-Keeper (Thumbscrew)
11 Valve Cap O-Ring
12 Valve Cap

1. Coat valve seat gasket with Never Seez. Either cylinder bore (see Item 1, Figure: Typical
insert it into the valve pocket or stick it on the Valve Assemblies). If a valve is not marked for
valve. In either case, do not allow the gasket suction or discharge, manually depress the
to fall into the gas passage. Replace valve valve plate to verify the type. Preferably, use
seat gaskets anytime a valve is removed from a tool softer than the valve plate material or
a cylinder, if the unit has been in service. exercise care to prevent damage to the plate.
2. Install suction valves only in suction pockets A suction valve plate may be depressed only
and discharge valves only in discharge from the valve fastener (bolting) side of the
pockets. The valve pockets have valve; a discharge valve plate may be
identification plates. Install all valves with depressed only from the side of the valve that
valve fastener(s) positioned away from the faces the cylinder bore.

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3. Use the valve tool to insert the valve and See Appendix A for critical information on torque
retainer into the pocket together (see tools accuracy. Valve cap bolt failures can occur if the
for your compressor model in Section 1). cap is torqued improperly. Draw bolting to full
Verify the valve seats properly in the pocket. torque in even, gradual steps, without bias on
When installed correctly, the valve rotates
one bolt or cocking the valve cap in the bore.
freely by hand.
Such bias or cocking can unevenly crush the
4. Plastic thumbscrews or o-rings hold valve gasket, which may cause leakage and/or bolt
retainers in position in bottom valve pockets.
failure. In correct assemblies with new valves, the
Tighten thumbscrews just enough to provide
friction so retainers and valves in bottom distance from the underside of the cap to the
pockets stay in position during valve cap surface of the cylinder is a uniform 1/8 inch (3
installation. Do not replace plastic mm). The distance is slightly less with re-worked
thumbscrews with metal. valves. Proper tightening of gas containment
5. Lubricate a new O-ring with oil and install it in fasteners is critical to ensure safe and reliable
the groove on the valve cap nose. Some high operation.
pressure cylinders use a soft metallic wire
gasket or spring-energized seal in lieu of the CAUTION
O-ring. Continue to "Valve Cap Installation".
Severe personal injury and property damage may result
from improperly torqued valve cap bolts. See Appendix
Valve Cap Installation A for correct torque and detailed recommendations.

Depending on the application, Ariel compressor Installation of Valve Caps on Cast Iron
cylinders utilize different styles of valve caps. Cylinders or High-Pressure Caps
Cast iron cylinders utilize valve caps in which an
without Spring Energized Seals
O-ring on the valve cap seals gas within the
cylinder.Forged steel cylinders utilize a valve cap 1. Install valve assembly (and high clearance
with either a spring-energized seal or a round spacer, if applicable), with the valve seat
gasket and valve retainer in the valve pocket.
metallic gasket to seal gas within the cylinder.
See "Valve Installation".
The valve cap presses the round metallic gasket
into a triangular cross section during the torque 2. For high-pressure valve caps only: Place a
new, round, metallic wire gasket. Always use
procedure.
a new wire gasket when installing a high-
Ensure all threads are clean and free of debris or pressure valve cap; gaskets are not re-
burrs. Use a bottle brush and pressurized liquid useable.
solvent to clean threaded holes thoroughly. 3. Oil and install a new O-ring on the valve cap.
Avoid sending debris into cylinder gas passage. Install the valve cap.
Bolts should thread into hole and bottom out on 4. For standard fasteners in iron cylinders,
the valve cap by hand without resistance or use lubricate threads and bolt seating surfaces
of a wrench. If bolts do not thread into hole with mineral oil. For stainless steel fasteners
freely, contact ARC for thread repair instructions. or in steel cylinders, lubricate threads and
bolt seating surfaces with Never Seez regular
grade. Do not use Never Seez on standard
fasteners. See Appendix A for correct valve
cap bolt torque.

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5. For high-pressure applications, the valve cap

joint design requires pressing a round
metallic wire gasket into a triangular cross
section (see Figure: Gasket Crush). This
requires multiple passes in a crisscross
pattern with the torque wrench. See
Appendix A

Figure: Gasket Crush

A Before Torque
B After Torque
1 Cylinder
2 Valve Cap
3 Metallic Wire Gasket
4 Valve Retainer

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Installation of Valve Cap with Spring Energized Seal

Figure: High-Pressure Valve Cap Assembly with Spring-Energized Seal
1 Valve Gasket
2 Valve
3 Retainer (openings aligned with gas
passage)
4 Thumb Screws
5 Roll Pins
6 Seal Keeper
7 Spring Energized Seal
8 Valve Cap
9 Hex Nut
10 Cap Nut

1. Install valve assembly with valve seat gasket 6. Continue to torque the valve cap at 100%
and valve retainer in the valve pocket. See torque value until no bolt movement is
"Valve Installation". Verify valve retainer observed. Even minute bolt movement
openings are aligned with the cylinder gas warrants another pass around the valve cap
passage. Re-tighten thumb screws, if in a crisscross pattern.
applicable.
7. Tighten cap nuts on long studs, hand wrench
2. Inspect and lightly lubricate spring energized tight.
seal with petroleum oil.
3. Install valve cap so the roll pins engage the
clearance slots in the seal keeper. Be careful
not to gouge the bore, or distort or damage
the gasket.
4. Liberally coat the valve cap stud threads and
hex nut seating surface with Never-Seez.
5. See Appendix A for correct valve cap fastener
torque.

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Gas Containment Fastener Torque Piston and Rod Removal

Checks
WARNING
Per Per Section 5 (start-up checklists) and
To reduce risk of injury or death, only trained personnel
Section 3 (Recommended Maintenance
who have read and thoroughly understand the
Intervals), Ariel recommends checking all gas appropriate Ariel Technical Manual and Packager
containment fastener torques by the schedule information should attempt any maintenance.
Prior to performing any maintenance activities:
below. Gas containment components include
• Always wear appropriate personal protection equip-
cylinders, valve caps, cylinder heads, unloaders, ment and follow your company safety and opera-
gas passage caps, flanges, and packings. Include tional procedures.
this schedule in your computerized maintenance • Never tighten or loosen any fastener or fitting while
the unit is operating or pressurized.
management system (CMMS): • Verify neither driver nor compressor can turn during
1. Prior to start-up maintenance.
• Follow packager instructions to completely isolate
2. 24 hours after start-up and vent the system; call the packager for assis-
tance.
3. 750 hours after start-up • Verify each compressor cylinder is relieved to atmo-
spheric pressure. To relieve residual cylinder bore
4. Every 8,000 hours after start-up pressure after blowdown, open the “Kiene” valves
on the indicator ports, if so equipped.
Per Section 3, re-check any fasteners found loose
WARNING: RELEASED GAS MAY BE POISONOUS
in any of these intervals after an additional 750 AND/OR FLAMMABLE.
hours. If loosening continues, contact your Before resuming operation, purge the entire system with
packager immediately. the gas being compressed to avoid a potentially
explosive gas/air mixture in the system. A gas/air
mixture under pressure can explode and cause severe
injury or death.
Piston and Rod
Most piston and rod assemblies consist of NOTE: See Section 1 for illustrations of tools
separable pistons that attach to the piston rod mentioned below. For non-lube cylinders, see
with a crank-end collar and a head-end nut. Appendix F.
Some cylinder classes require other designs,
including one-piece (integral) piston/piston rods, 1. Loosen cylinder head bolts. Remove cylinder
and there are some multi-piece assemblies that head and all crosshead guide side covers.
do not use a crank-end collar. 2. Move crosshead to inner dead center. Back
off, but do not remove, the crosshead
balance nut set screws. Loosen crosshead
Piston Rod Inspection balance nut with the special slugging wrench.
Use the open end wrench for hex nuts or the
At the specified recommended maintenance
peg wrench for round nuts.
interval, inspect piston rods for damage and
excessive wear.
• For condemning limits, see Section 3.

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3. In tandem cylinders, where the outboard Handle all piston rings carefully with clean
cylinder bore is smaller than the inboard tools and hands to protect them from nicks,
bore, remove the outboard cylinder. Support marring, and bending. Despite their
such cylinders during removal and toughness in service, some rings are fragile
installation, to avoid excessive weight on the when removed.
piston and rod assembly that may bend
8. The weight of the piston and rod assembly is
them.See ER-118 for outboard cylinders with
stamped on the head end. Support the piston
removable liners.
either manually or with a crane as
4. If the piston uses a wear band, measure appropriate as it slides from the cylinder
piston to cylinder clearance at bottom of bore. The piston rod must remain parallel
piston with a feeler gauge. See Appendix B for with the bore until it leaves the bore
tolerances. If out of tolerance, replace completely. Take care not to ding any
wearband. surfaces.
5. Move crosshead to outer dead center, then
use the piston nut spanner to turn the piston Piston and Rod Manual
and rod assembly out of the crosshead. The
two dowels on the tool fit the piston nut
Disassembly
holes. Remove the crosshead nut from the Figure: Clamping Fixture with Clamping Rings
piston rod. (Ariel P/N D-0961)
6. Slide the piston rod entering sleeve over the
piston rod threads. With extreme care, slowly
slide piston rod through packing so as not to
damage wiper or packing rings.
7. For one-piece piston rings, slide the piston
rod assembly from the cylinder, then
carefully remove the piston rings. For two-
piece piston rings (in high pressure
applications), slide the piston rod assembly
out of cylinder until a fraction of the first ring
clears the cylinder. Hold the first ring in the
piston groove by hand, or use a band for
larger sizes, until the ring clears the cylinder,
then carefully remove the ring. This prevents
the ring from popping out of the groove and Nom. Piston Rod Clamping Force
damaging the ring. Remove succeeding two- Diameter Inches (mm) Required Ton (kN)
piece rings and wear band in the same way. 1.125 (29) 8.67 (19.3)

CAUTION

Trapped gas pressure in hollow pistons can present a

personal safety hazard when servicing the piston and
rod assembly. Work in a well-ventilated, non-sparking
area. Do not breathe gas emitted from pistons when
venting trapped gas.

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3. Clamp the piston and rod assembly in an

NOTE: Ariel offers a clamping fixture for 1.125 to 2 appropriate clamping fixture using the
inch (29 to 51 mm) diameter piston rods. appropriate clamping ring for the rod size.
Clamp it as close to the collar as possible
1. Securely bolt clamping fixture to a base to without fixture interference with the piston.
prevent it from turning with the piston rod. Torque the four fixture cap screws to 345 lb x
Place it at a height of about three feet (0.9 m). ft (465 N•m) to prevent the rod from turning.
2. Verify the clamping fixture saddle where the The fixture properly holds the piston rod to
clamping ring seats, the clamping ring, and prevent damage to the parts and promote
the piston rod are clean, dry, and free of any safety during disassembly and reassembly.
oil. Even a small amount of oil can cause the
piston rod to turn in the fixture during
torquing, and a small amount of debris
clamped under high force can damage a
piston rod.

Figure: Piston and Rod Clamping Fixture

1 Allen Wrench (for piston nut setscrews)
2 Torque Multiplier
3 Clamping Fixture
4 Spanner (bolts to piston nut)
5 Torque Wrench

4. Remove piston nut using piston nut spanner. 2. Inspect collar (or collar area on rod, when
collar is integral and not separable), piston,
5. After piston nut removal, slip the piston and
and piston nut for nicks, burrs, or scratches.
collar off the end of the piston rod.
Replace if surfaces are damaged, worn, or
galled. Inspect piston ring grooves. If
Piston and Rod Manual damaged, or ring groove width is out of
Reassembly tolerance, replace the piston (see Appendix B
for tolerances). Dress surfaces with a fine grit
1. Clean all piston and rod assembly parts stone as required. Fit collar and nut into
thoroughly.Verify piston is internally clean piston to verify the outside diameter fits and
and dry. turns freely by hand in the piston.
NOTE: Any reassembly of used parts requires re-
cleaning and re-lubrication of threads and seating
surfaces.

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3. Inspect piston rod threads and collar 9. Use the piston nut spanner and clamping
shoulder. Clean and de-burr threads. Install fixture to torque piston nut to the torque
collar and nut onto piston rod to verify inside listed in Appendix A. A torque multiplier may
diameter fits and rotates freely. Turn piston be necessary to achieve required torque.
nut until rod threads protrude to verify Loosen the piston nut without disassembling
freedom of thread engagement. Remove nut and re-tighten to required torque. Repeating
and collar. the torque properly seats components and
4. Verify the clamping fixture saddle where the enhances the integrity of the assembly.
clamping ring seats, the clamping ring, and NOTE: To calculate torque wrench setting when using
the piston rod are clean, dry, and free of any a torque multiplier, divide desired fastener torque by
oil. Even a small amount of oil can cause the the multiplier actual mechanical advantage, not
piston rod to turn in the fixture during design mechanical advantage. Example: A multiplier
torquing, and a small amount of debris with a design mechanical advantage of 4.0, but an
clamped under high force can damage a actual mechanical advantage of 3.6 requires 442 lb x
piston rod. ft (599 N•m) of applied torque to achieve a 1590 lb x ft
(2156 N•m) torque.
5. Clamp the piston and rod assembly in an
appropriate clamping fixture using the 10. After tightening, the piston rod should not
appropriate clamping ring for the rod size. protrude more than 0.010 inch (0.25 mm)
Clamp it as close to the collar as possible past the piston face. If it does, contact your
without fixture interference with the piston. packager and/or Ariel.
Torque the four fixture cap screws to 345 lb x 11. Apply a thin coat of Never-Seez Regular Grade
ft (465 N•m) to prevent the rod from turning. to two new Allen set screws. To install a set
The fixture properly holds the piston rod to screw, tighten it 15° past the Allen wrench
prevent damage to the parts and promote yield point. Discard the deformed Allen
safety during disassembly and reassembly. wrench, and use a new Allen wrench to
6. Apply a thin coat of Never-Seez Regular Grade tighten the other set screw in the same way. If
to piston rod shoulder, rod collar locating Allen wrenches are unavailable, use the
band, and collar face in contact with piston, torques in Appendix A.
then slide collar onto rod. Figure: Staking a Set Screw
7. Apply a thin coat of Never-Seez Regular Grade
to piston rod threads at the piston end, then
slide piston onto rod and collar.
NOTE: If one end of the piston has an undercut, and 12. Use a punch within 1/16 inch (1.5 mm) of set
the piston has the same number of piston ring screw threads to deform the threads and
grooves on each side of the wearband, assemble with stake set screws in place (see Figure: Staking
the undercut toward the head end. For pistons with a a Set Screw).
different number of piston ring grooves on each side
of the wearband, assemble with the side of fewer 13. Use a calibrated scale to weigh piston rod
piston ring grooves toward the head end. assembly with piston rings and wear band.
Stamp weight on piston head end. Flatten
8. Apply a thin coat of Never-Seez Regular Grade any raised lips to avoid clearance
to piston nut threads and piston mating face. measurement errors. Record weight on a new
Install nut and hand tighten to make up the balance sheet and send to Ariel. See
piston rod assembly. “Opposed Throw - Reciprocating Weight
Balancing” in Appendix C for approximate
component weights.

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Piston and Rod Installation

Figure: Typical Piston and Rod Installation
1 Crosshead
2 Crosshead Nut
3 Set Screw
4 Piston Nut Spanner

1. Install piston rings in cylinder main bore 5. Verify the balance nut and crosshead mating
without piston to measure end gaps. Ariel surfaces are flat and free from dings or other
recommends replacing piston rings when the disparities. If necessary use a flat stone to
end gap equals three times its original smooth the surfaces.
specification. See Appendix B for
6. Lubricate piston rod and crosshead threads
specification.
with Never-Seez Regular Grade. Apply a thin
2. Except for non-lube cylinders, liberally coat of oil to either the balance nut or
lubricate the cylinder bore, piston rod, piston crosshead mating surface. Do not apply
rings, wearbands and piston with compatible Never-Seez to the mating surfaces. Install
cylinder oil. Install rings on piston with ring crosshead-balance nut on piston rod. Turn
gaps staggered. the piston rod into the crosshead. Visually
a. For cylinders requiring two-piece piston center the packing flange around the piston
rings or wear bands, verify that they are a rod and torque packing bolts per Appendix A.
set by the match marks. Two-piece rings 7. Set piston end clearance (see Appendix B):
use dots as match marks - verify the dots
a. Using the piston nut spanner, turn the
face the pressure side of cylinder. Two-
piston rod into the crosshead.
piece piston rings and wear bands are
manufactured as matched sets; mixing b. Place a long feeler gauge equal to the
ring halves may result in incorrect end crank end clearance required in the crank
gaps. end top valve pocket between the piston
and the crank end head.For 13 in. (330
b. For all other rings, see "Piston Rings".
3. Slide the piston rod entering sleeve over the
piston rod threads. Slide piston rod with
piston rings and wear band into cylinder
bore. Damage to the packing rings is likely if
an entry sleeve is not used.
4. Using a dial indicator, position the crosshead
at the inner dead center position.

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mm) and larger cylinders, insert feeler Piston Rod Runout

gauge through a bottom valve pocket.
c. Tighten piston against the feeler gauge so Table: JG:JGA Max. Piston Rod Runout, Inch
the feeler gauge cannot be pulled out. (mm)a
d. Tighten the crosshead nut against the
Vertical 0.0010 (0.025)
crosshead.
Horizontal 0.0005 (0.013)
e. Tighten the crosshead nut by the slugging
method. See "Crosshead Installation" for a Machines with readings falling outside the limits
hydraulic torquing device. require disposition by Ariel.
f. Tighten the balance nut set screws and be
sure to remove the piston nut spanner. Check piston rod runout after new unit
8. See "Crosshead Installation" for details to re- installation, unit relocation, or maintenance that
attach piston rod to crosshead, check piston may affect rod runout.
end clearance, piston rod runout and
Position the stem of a 0.0001 inch (0.001 mm)
crosshead clearances, and re-assemble to
close cylinder and crosshead guide. See increment calibrated dial indicator against the
Appendix B and "Piston Rod Runout". piston rod, close to the packing case. Set the
indicator to zero with the piston toward the
CAUTION
crank end. Bar over crankshaft and record
Ariel recommends leaving distance piece covers off after indicator readings with the piston at mid-stroke
any piston rod or rod packing ring maintenance. Verify
no ignition sources exist in the area, pressurize the unit,
and H. E. positions, in both vertical and
and check for gas leaks before distance piece cover horizontal directions. Record upward vertical rod
installation. This protects against crosshead guide over- movement as positive and downward as
pressure and possible ignition due to incorrect
installation of packing case or components. When
negative. Record horizontal rod movement
checking for leaks, take proper precautions in process toward the auxiliary end of the frame as positive
gas applications, such as H2S. and toward the drive end as negative. Copy the
table below to record readings and compare to
Table: JG:JGA Max. Piston Rod Runout, Inch
(mm) values.

Table: Piston Rod Runout, Inches

Throw 1 2 3 4 5 6

Vertical (0°) Piston @ C. E. 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000

Mid-Stroke

Piston @ H. E.

Horizontal (0°) Piston @ C. E. 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000

Mid-Stroke

Piston @ H. E.

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If a vertical reading is greater than the are within 0.0003 inch of the original runout
maximum acceptable, use this procedure to readings above, the rod is acceptable - break the
determine component acceptability: Break the balance nut loose. Re-set C.E. clearance and re-
balance nut loose. Looking from the head end, torque the balance nut. If rod runout is not within
turn the piston 90º counter-clockwise, and re- 0.0003 inch of the original reading above, contact
torque the balance nut. Record both vertical and Ariel.
horizontal readings in the table below. If readings

Table: Alternate Piston Rod Runout, Inches

Throw 1 2 3 4 5 6

Vertical (90°) Piston @ C. E. 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000

Mid-Stroke

Piston @ H. E.

Horizontal (90°) Piston @ C. E. 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000

Mid-Stroke

Piston @ H. E.

Vert. Runout Differencea

Horiz. Runout Differencea

a Piston @ H. E., original minus alternate.

Piston Rings NOTE: On tandem cylinders with a combination of

seal-joint rings and other ring styles, always position
Most cylinders use one-piece angle-cut filled
the seal-joint rings farthest from the pressure side.
PTFE piston rings. High-pressure cylinders use See Figure: Seal-Joint, Straight-Cut, and Angle-Cut
two-piece thermoplastic rings. Ariel Piston Ring Installation Orientation.
recommends replacing rings when the end gap
increases to three times the new dimension. To
measure end gaps, insert rings in the cylinders Straight-Cut Chamfered Piston
without pistons (see Appendix B for minimum Rings
end gap dimensions).
Straight-cut chamfered piston rings are
directional and require correct installation.
Seal-Joint Piston Rings
Install them with chamfers or dots toward the
Seal-joint piston rings are directional and require pressure and with the end gaps staggered.
correct installation.

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Figure: Seal-Joint, Straight-Cut, and Angle-Cut Piston Ring Installation Orientation

1 Frame Side
2 Pressure
3 Seal-Joint Ring
4 Chamfers or Match Marks
toward Pressure, End Gaps
Staggered
5 Match Mark Side toward
Pressure
6 Typical for Tandem Cylinder
7 Angle Cut or Straight Cut
Rings
8 Typical for Double Acting
Cylinder - with or without
Wearband

High-Pressure Face-Cut Piston Gas pressure in the wear band area escapes past
Rings the piston rings via the face cuts during the
suction stroke to prevent loading the wear band
Face-cut piston rings are typically used in and increase service life. Also, do not align the
cylinders with 2500 psi MAWP or higher, and ring end gaps; stagger them to minimize gas
generally with notched and fluted wear bands. leakage.
The rings install with the face cuts toward the
highest pressure, or toward the nearest head.

Figure: High-Pressure Face-Cut Piston Ring Orientation

1 Piston Rod
2 Crank End
3 Piston
4 Piston Rings
5 Wear Band
6 Head End
7 Notches
8 Staggered End Gaps
9 Frame Side
10 Pressure

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Three-Piece Piston Rings with expander chamfer facing the nearest head
or highest pressure (see Figure: Three-Piece
This ring style consists of two “outer” rings Piston Ring Installation Orientation). Install outer
installed over an “inner” ring. The first outer ring rings with match marks facing the nearest head
has double match marks and the second outer or highest pressure and end gaps staggered to
ring has single match marks. The inner ring rests prevent leakage.
in the bottom of the piston ring groove; install

Figure: Three-Piece Piston Ring Installation Orientation

1 Double Match Marks 4 Second Outer Ring 7 Inner Ring

2 Staggered End Gaps 5 Single Match Marks 8 Match Marks toward Pressure
3 Pressure 6 First Outer Ring 9 Frame Side

Five-Piece Piston Rings

A five-piece ring set consists of two outer rings
cut in half and an inner ring with a single cut. In
the five-piece design, Ariel uses two different
styles: face-cut (notched) and non-face-cut. Ring
orientation is critical to proper function.

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Figure: Five-Piece Piston Ring Installation Orientation

Non-Face-Cut Rings Face-Cut Rings Piston Rod Assembly

1 Inner Ring 5 Second Outer Ring 9 Face-Cut
2 Chamfer (where applicable) 6 Staggered End Gaps 10 Frame Side
3 First Outer Ring 7 Single Match Marks 11 Match Marks toward Pressure
4 Double Match Marks 8 Pressure

Face-Cut (Notched) Rings: When the inner ring Wear Bands

is chamfered, the chamfer faces the nearest head
or highest pressure. The first outer ring has no Most cylinders use one-piece angle-cut filled
face-cut (notch) and double match marks, and PTFE wear bands. High-pressure cylinders use
the second outer ring has a face-cut (notch) and two-piece thermoplastic bands (see Figure: High-
single match marks. Install both outer rings with Pressure Face-Cut Piston Ring Orientation).
match marks facing the nearest head or highest During installation, check and record wear band
pressure. When the match marks are correct, the end gap and projection. To measure end gap,
end gaps of the outer rings do not align. insert one or two-piece wear band into cylinder
Non-Face-Cut Rings: When the inner ring is without the piston then measure the total gap
chamfered, the chamfer faces the nearest head while the band maintains full contact with the
or highest pressure. The first outer ring has cylinder bore. See Appendix B for end gap
double match marks and the second outer ring dimensions.
has single match marks. Install both outer rings To measure wear band projection, install the
with match marks facing the nearest head or entire piston assembly or remove the head to
highest pressure. When the match marks are check during maintenance. Measure the gap
correct, the end gaps of the outer rings do not between the piston and cylinder bore at the
align. bottom of the cylinder. Compare the wear band
projection to the as-new condition (recorded at
new wear band installation or found in Appendix
B). Replace the bands if there is any indication
the next planned run time may fully degrade the
wear band and allow the piston to contact the
cylinder bore.

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Piston Rod Packing 4. Typically, the small nuts are not removed
from the studs as they hold the packing case
The piston rod packing prevents gas from together for removal as an assembly.
entering the crosshead guide. Piston rod rings However, some packings are too big to fit
within the packing wear over time and need through the distance piece or crosshead
guide doors, so removal of the small nuts and
replacement.
the packing flange is necessary. For certain
longer, higher pressure rating packing cases,
Piston Rod Packing Removal knurled nuts hold the remaining packing
assembly together to assist with installation
and removal.
WARNING
5. Remove the pressure packing and take it to a
To reduce risk of injury or death, only trained personnel
who have read and thoroughly understand the clean place for disassembly.
appropriate Ariel Technical Manual and Packager 6. Set pressure packing on a clean surface on its
information should attempt any maintenance.
nose cup or cylinder end. Usually, packing
Prior to performing any maintenance activities:
• Always wear appropriate personal protection equip-
cups are marked to represent the assembly
ment and follow your company safety and opera- order starting with the cup closest to the
tional procedures. cylinder as number 1. If the cups are not
• Never tighten or loosen any fastener or fitting while matchmarked, then match mark the outside
the unit is operating or pressurized. diameter of the cups and flange for proper
• Verify neither driver nor compressor can turn during reassembly. Long tie studs hold the pressure
maintenance. packing together. The stud holes are
• Follow packager instructions to completely isolate
unequally spaced to prevent misalignment of
and vent the system; call the packager for assis-
tance. the stack of parts. Remove the nuts and
• Verify each compressor cylinder is relieved to atmo- unstack the pressure packing. Replace these
spheric pressure. To relieve residual cylinder bore nuts each time the pressure packing is
pressure after blowdown, open the “Kiene” valves serviced.
on the indicator ports, if so equipped.
WARNING: RELEASED GAS MAY BE POISONOUS
7. To check ring wear, place assembled rings
AND/OR FLAMMABLE. (note match-marks) on the piston rod. Check
Before resuming operation, purge the entire system with end gap clearance. If the ends butt, or nearly
the gas being compressed to avoid a potentially butt, replace the rings. See "Types of Piston
explosive gas/air mixture in the system. A gas/air Rod Packing Rings" for correct ring
mixture under pressure can explode and cause severe orientation.
injury or death.
8. Pry loose the metal or spiral-wound gasket
1. Remove piston and piston rod. See "Piston on the end cup with a sharp awl. Do not
and Rod Removal". scratch the sides of the gasket groove.
Discard the used gasket.
2. Remove packing diaphragm (if applicable)
and oil wiper packing. 9. Before reassembly, clean all parts
thoroughly.
3. Disconnect all tubing and instrumentation (if
applicable) from packing flange. Ensure there
is no debris in the tubing between the check
valve and packing flange. Remove the twelve-
point cap screws that hold the pressure
packing gland to the crank end of the
cylinder/head.

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Piston Rod Packing Reassembly and Installation

Figure: Piston Rod Packing Case Lube Cups
1 Lube cup identification axial
groove (after 2005).
2 1/4 in. (6mm)

1. Refer to the pressure packing assembly in 5. Verify proper position of each rod ring and
your parts book. Ariel supplies parts books cup and, unless non-lube, coat rings liberally
with each unit. Contact your distributor to with new, clean lubricant before reassembly.
obtain a parts book. Each pressure packing Use only the same lubricant in the force feed
re-build kit includes a pressure packing lube system. If non-lube cylinders, see
assembly drawing. Appendix F.Ensure tie studs are completely
2. Take care not to scratch mating surfaces of threaded into end cup. Examine all parts for
the cups. Cup surfaces must be clean and dry unusual nicks or burrs which may interfere
for re-assembly. with the free floating of the rod rings in the
cups. Take particular care with rod rings
3. To install a new set of rod rings in an existing made of soft materials, such as bronze or
packing case, inspect case parts for wear. PTFE. It is extremely important to handle and
Cups should be smooth and flat on the back install wiper rings carefully to prevent
side where the rod rings must seal. If cups or damage to scraping edges. If packing case is
grooves are concave or tapered, regrind or cooled, see “Reassembling and Testing
relap them. Contact Ariel for appropriate Cooled Packing Cases”.
rework thickness dimensions. It is rarely
necessary to alter the crosshead side of cups, 6. Lay out parts on a work bench for progressive
but if necessary, take care not to destroy the installation, with each part in its correct
correct side clearance for the renewal rings. position and the rod rings with their proper
faces toward the pressure. Long tie studs
NOTE: If premature wear is suspected, see “Force
hold the pressure packing together. The stud
Feed Lubrication Conditions”.
holes are unequally spaced to prevent
4. Before a packing case installation, misalignment of the stack of parts. Note that
disassemble and thoroughly clean it in an all rod ring segments are carefully lettered;
appropriate solvent for the intended service. assemble them accordingly. This is most
important for proper sealing. Center side-
loaded WAT and AL rings prior to tightening

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tie stud nuts. Install tie stud nuts and tighten 10. Reinstall packing diaphragm (if applicable)
to the torques in Appendix A. Manually verify and wiper packing.
all rings move freely, radially, in their
11. Reinstall piston and rod. See "Piston and Rod
grooves. Side-loaded rings are tight, but
Installation".
should still move manually. Center these
rings. 12. After tightening the crosshead nut, visually
Packing reassembly: align the packing, to maintain a uniform
clearance between the packing case bore and
a. With no gasket installed, install the studs the piston rod.Tighten rod packing bolts
into the end cup (cup # 1). evenly in a criss-cross pattern to the
b. Using cylinder oil, lubricate the cup and recommended torque in Appendix A. This
the pressure breaker ring or ring set, then procedure squares the pressure packing on
install them into cup (see pressure its nose gasket. Rod packing bolt tightening
packing assembly drawing for correct on high pressure cylinders requires a torque
orientation). multiplier.
c. Install cup # 2 and repeat Step b for the NOTE: Repeat final torque for rod packing bolts until
seal ring sets. the bolts no longer turn. Re-check torque on these
fasteners at the next service interval.
d. Repeat steps above for cups #3, #4, etc,
until packing case is reassembled per the 13. Retighten tie stud nuts. Reinstall tubing
pressure packing assembly drawing. connections and instruments (if applicable).
e. Using a clean oil pump filled with cylinder Take care not to cross-thread tubing nuts.
oil, squirt oil into the lube fitting(s). If the Tubing nuts must be tight.
packing is assembled correctly, the oil will NOTE: After pressure packing installation, see “Force
come out the lube cup. If not, disassemble Feed Lubricator” in Section 3 to prime the force feed
the packing and correct the error. lube system and obtain recommended lubrication
rates for new machine break-in. Priming may be
f. Using pressurized air, repeat the above
necessary after extended down time. Break-in lube
process for vent and purge lines.
rates are approximately twice the normal rates, or
g. For cooled packings the cooling circuit half the normal cycle time.
must be pressure tested (see "Testing").
CAUTION
7. For new installations, carefully clean all
accumulated dirt in the lines and Ariel recommends leaving distance piece covers off after
compressor. Any foreign material lodges in any piston rod or rod packing ring maintenance. Verify
the packing and becomes destructively no ignition sources exist in the area, pressurize the unit,
and check for gas leaks before distance piece cover
abrasive.
installation. This protects against crosshead guide over-
8. Verify the gasket surface in the packing pressure and possible ignition due to incorrect
counter bore on the crank end of the installation of packing case or components. When
checking for leaks, take proper precautions in process
cylinder/head is clean and not scratched.
gas applications, such as H2S.
Install a new end cup gasket. Round wire
gaskets will fit tightly in the gasket
groove.Spiral-wound or other gasket styles
require application of grease (or adhesive for
non-lube applications) to hold them in place.
9. Reinstall complete packing case assembly
with oil supply point on top. Use rod packing
bolts to pull packing into place.

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RTV Wiper Installation 3. The installation plug is tapered on the inside

to receive an entering sleeve. Install the ring
1. The RTV comes with an installation plug to with the wider plug opening toward the
center the assembly in the cup and ensure cylinder.
proper orientation. Install RTV with an
4. When the piston rod is installed, the entering
installation plug in the cup.
sleeve pushes the installation plug out, and
2. Ensure cup depth is correct for the ring the RTV slides onto the rod. See Figure: RTV
assembly. The ring is tight in the groove when Wiper Installation below.
the cup is bolted down.

Figure: RTV Wiper Installation

1 RTV Wiper 2 Installation Plug 3 Entering Sleeve

Reassembling and Testing Cooled

Packing Cases
In the event of disassembly, the procedures
below detail the reassembly of cooled rod
packing cases and testing for proper assembly.
See also "Piston Rod Packing Reassembly and
Installation" and "Types of Piston Rod Packing
Rings".

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Reassembly 4. Repeat step 3 to assemble remaining parts in

consecutive order per the packing case
Figure: Cooled Packing Turnaround Cups drawing.
5. Install tie stud nuts. Tighten 10-24 nuts to 20
Lb x In (2.3 N•m), 1/4-20 to 72 Lb x In (8.1 N•m),
and 5/16-18 to 144 Lb x In (16 N•m). Verify all
rings move freely, radially, in the grooves.
Side loaded WAT and AL rings are snug, but
should move manually.

Testing
1. Verify 100% function for all internal passages.
Blow dry, oil-free compressed air through the
connection taps on the flange and verify that
air exits at the proper holes. Air applied to the
connection tap stamped “Coolant In” should
exit the connection tap stamped “Coolant
Out”. Air applied to the tap stamped “Lube”
should exit the appropriate cup on the inside
1 Coolant turnaround cup circumferential identifica-
tion groove (all - beginning 2006)
diameter of the case.
2 O-Ring Grove 2. Pressure leak test packing cases as follows:
a. Plug the “Coolant Out” connection.
See pressure packing assembly in the parts book b. Apply 60 to 100 psig dry, oil-free
supplied with the unit. Contact the distributor to compressed air to the “Coolant In”
obtain a parts book. A pressure packing assembly connection through a ball valve with a
drawing comes with each pressure packing re- calibrated pressure gauge located
build kit. between the ball valve and packing case.
c. Close the ball valve and disconnect the air
Cooled cases are lapped. Take special care not to supply. There should be no pressure drop
scratch cup mating surfaces; it can cause for 5 minutes, minimum.
significant problems. Cup surfaces must be clean
3. Disassemble, inspect, correct, re-assemble,
and dry for reassembly. and re-test any case that fails testing. To aid
1. The cups are numbered on the outside sealing, bolt a packing case into place in a
diameter. Assemble them in consecutive cylinder head with properly torqued original
order, starting with the end cup. The offset packing retention bolts.
studs allow the cups to fit only one way.
2. Ensure the tie studs thread completely into
the end cup. Install the proper ring facing the
proper direction in the groove. Do not scratch
lapped faces when sliding parts onto tie
studs.
3. Install next cup. Install the rings and verify
installation of the two (2) small O-rings
around the coolant holes.

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Long Two-Compartment Figure: “P” Pressure Breaker

Intermediate Packing
Compressors supplied with long two-
compartment distance pieces include an
intermediate packing assembly that seals
around the rod between the outboard and
inboard distance pieces. This packing assembly
includes a single AL ring set.

For lubricated service, the force feed lube oils the

top of the ring set at a very low rate because this
ring set is not subject to cylinder pressures and
temperatures. The end-to-end seal in the cup
and the low lube rate of AL ring sets, ensures 1 Pressure
newly installed rings run virtually dry for the first
few hours of operation. To avoid damage to the “PB1” Pressure Breaker
rings and rod, copiously oil the ring set during
installation, before rod installation. Use only the This single ring is cut radially into three equal
same lubricant in the force feed lube system. If segments. It breaks down or slows gas flow
non-lube, see Appendix F. without sealing it completely. This ring uses a
solid wire spring.
Figure: “PB1” Pressure Breaker
Types of Piston Rod Packing Rings
There are several types of piston rod packing
rings depending on the application. Below are
those used in Ariel JG:JGA compressors.

“P” Pressure Breaker

This single ring is cut radially into three equal
segments. It breaks down or slows gas flow
without sealing it completely.

1 Pressure

“UP” Pressure Breaker

This single solid ring breaks down or slows gas
flow without sealing it completely.

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Figure: “UP” Pressure Breaker “BTR” Single-Acting Seal Set

This three-ring set seals in one direction only. The
first ring (pressure side) is radially cut. The
second ring is tangentially step cut and made of
the same material as the first ring. These two
rings are doweled to stagger the cuts from one
ring to the other. The third ring is called a back-
up ring. It is radially cut and has a bore larger
than the rod diameter. This allows the radial
joints to form a tight gas seal. This ring needs no
dowel.
Figure: “BTR” Single-Acting Seal Set

1 Pressure

“P1U” Pressure Breaker

This two-ring set allows controlled leakage in one
direction only and installs in the first or second
packing cup (closest to the piston). The first ring
(pressure side) is one-piece with a single radial
cut; the second ring is solid and has a bore larger 1 Pressure
than the rod diameter.
Figure: “P1U” Pressure Breaker “BD” Double-Acting Seal Set
This two-ring set consists of tangentially step cut
rings doweled to stagger the tangential cuts from
one ring to the other. This double acting set seals
in either direction. In cylinders operating near
atmospheric pressure, it prevents air from
entering the cylinder. Install with the match mark
letters facing towards the cylinder.

1 Pressure

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Figure: “BD” Double-Acting Seal Set Figure: “AL” Double-Acting Seal Set

1 Pressure

“BT” Single-Acting Seal Set

1 Pressure
This two-ring set seals in one direction only. The
Double "WAT" Double-Acting Seal Set first ring (pressure side) is radially cut; the second
is tangentially step cut. The rings are doweled to
In this three-ring PTFE set, the first two rings stagger the cuts from one ring to the other and
(pressure side) are radially cut; the third is form a tight gas seal.
tangentially step cut. The last two rings are
doweled to stagger the cuts from one ring to the Figure: “BT” Single-Acting Seal Set
other. The first ring, along with the center ring,
forms a wedge that overcomes rod friction and
holds the ring set against both groove faces
during either direction of rod travel. Use this ring
set primarily for low pressure applications. WAT
rings must be centered when installed in the
packing case.
Figure: Double "WAT" Double-Acting Seal Set

1 Pressure

“BTS” Single-Acting Seal Set

This three-ring set seals in one direction only. The
first ring (pressure side) is radially cut. The
second ring is tangentially step cut. These first
1 Pressure two rings are doweled to stagger the cuts from
one ring to the other. The third ring is called a
“AL” Double-Acting Seal Set back-up ring. It is an uncut one-piece ring with
This five-ring PTFE set functions like a double- clearance over the rod. It allows the joints of the
ended “WAT” ring set. AL rings must be centered first two rings to form a gas-tight seal and
when installed in the packing case. prevents extrusion of the tangent ring.

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Figure: “BTS” Single-Acting Seal Set “BTUU” Single-Acting Seal Set

This four-ring set seals in one direction only. The
first ring (pressure side) is radially cut; the second
is tangentially step cut. These rings are doweled
to stagger the cuts from one ring to the other. The
third and fourth are uncut one-piece rings with
clearance over the rod, allowing the joints of the
first two rings to form a gas-tight seal. In many
applications, the uncut rings will deflect under
1 Pressure
pressure and seal against the piston rod.
“BTU” Single-Acting Seal Set Figure: “BTUU” Single-Acting Seal Set
This three-ring set seals in one direction only. The
first ring (pressure side) is radially cut. The
second is tangentially step cut. These first two
rings are doweled to stagger the cuts from one
ring to the other. The third ring is called a back-
up ring. It is an uncut one-piece ring with
clearance over the rod, allowing the joints of the
first two rings to form a gas-tight seal. In many 1 Pressure

applications, the uncut ring will deflect under

pressure and seal against the piston rod.
“CU” Single-Acting Seal Set

Figure: “BTU” Single-Acting Seal Set This three-ring set seals in one direction only. The
first ring (pressure side) is radially cut. The
second ring is tangentially cut. The first two rings
are doweled to stagger the cuts from one ring to
the other. The third ring is a solid back-up ring
and has a bore larger than the rod diameter,
allowing radial joints of the first two rings to form
a tight gas seal.
Figure: “CU” Single-Acting Seal Set

1 Pressure

1 Pressure

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“CUU” Single-Acting Seal Set “DS” Double-Acting Seal Set

This four-ring set seals in one direction only. The This two-ring set consists of tangentially step cut
first ring (pressure side) is radially cut; the second rings doweled to stagger the tangential cuts from
is tangentially cut. These rings are doweled to one ring to the other. This double acting set seals
stagger the cuts from one ring to the other. The in either direction. In cylinders operating near
third and fourth rings are solid and have bores atmospheric pressure, it prevents air from
larger than the rod diameter, allowing the radial entering the cylinder. Install with the match mark
joints of the first two rings to form a tight gas seal. letters facing towards the cylinder.
Figure: “CUU” Single-Acting Seal Set Figure: “DS” Double-Acting Seal Set

1 Pressure

“RS3” Single-Acting Seal Set

1 Pressure
This three-ring set seals in one direction only. The
first ring (pressure side) is radially cut. The “STU” Single-Acting Seal Set
second ring is tangentially step cut. These first
This three-ring set seals in one direction only. The
two rings are doweled to stagger the cuts from
first ring (pressure side) is solid, with radial
one ring to the other. The third ring is called a
grooves on the pressure side. The second ring is
back-up ring. It is a solid one-piece ring with
tangentially cut. The third ring is solid.
clearance over the rod. It holds the first two rings
perpendicular to the rod, allows their joints to Figure: “STU” Single-Acting Seal Set
form a seal, and prevents extrusion of the
tangent ring.
Figure: “RS3” Single-Acting Seal Set

1 Pressure

1 Pressure

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“CR” Single-Acting Seal Set “3RWS” Oil Wiper Set

This three-ring set seals in one direction only. The The three rings in this set are radially cut and
first ring (pressure side) is radially cut. The doweled to stagger the cuts from one ring to the
second ring is tangentially cut. The first two rings other. They keep crankcase oil out of the packing
are doweled to stagger the cuts from one ring to and cylinder. Assemble with the blank face
the other. The third ring is called a back-up ring. towards the oil (crankcase) and the slotted side
It is radially cut and has a bore larger than the rod towards the pressure packing.
diameter to allow the radial joints to form a tight
Figure: “3RWS” Oil Wiper Set
gas seal.
Figure: “CR” Single-Acting Seal Set

1 Oil Side

1 Pressure
Crossheads
“RTV” Oil Wiper Set The crosshead assembly consists of the
This three-ring set is doweled to stagger the end crosshead and crosshead pin bushings, where
gaps from one ring to the other. The first ring required. Most crossheads use a layer of soft
(toward oil side) is PEEK and tangentially step cut babbitt material on the shoes, which are the
with radial drains. The center ring is also PEEK surfaces that slide in the crosshead guide bore.
and radially cut with axially loaded inside
diameter groove and radial holes. The third ring NOTE: Some small-line and JGH crossheads do not
use a bushing or babbitt.
is PTFE and tangentially step cut.
Figure: “RTV” Oil Wiper Set Take care during maintenance to avoid
damaging the babbitt or the bushings.

1 Oil Side

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Crosshead Removal
WARNING

To reduce risk of injury or death, only trained personnel

who have read and thoroughly understand the
appropriate Ariel Technical Manual and Packager
information should attempt any maintenance.
Prior to performing any maintenance activities:
• Always wear appropriate personal protection equip-
ment and follow your company safety and opera-
tional procedures.
• Never tighten or loosen any fastener or fitting while
the unit is operating or pressurized.
• Verify neither driver nor compressor can turn during
maintenance.
• Follow packager instructions to completely isolate
and vent the system; call the packager for assis-
tance.
• Verify each compressor cylinder is relieved to atmo-
spheric pressure. To relieve residual cylinder bore
pressure after blowdown, open the “Kiene” valves
on the indicator ports, if so equipped.
WARNING: RELEASED GAS MAY BE POISONOUS
AND/OR FLAMMABLE.
Before resuming operation, purge the entire system with
the gas being compressed to avoid a potentially
explosive gas/air mixture in the system. A gas/air
mixture under pressure can explode and cause severe
injury or death.

Figure: Typical Crosshead

1 Shoe Area
2 Bushing
3 Crosshead Pin
4 End Plate
5 Thru Bolt Lock Nut
6 Crosshead Nut
7 Roll Pin
8 Thru Bolt
9 Set Screw (loosen before
turning nut)

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Figure: Crosshead Bushing Replacement

NOTE: See Section 1 for illustrations of tools
mentioned below.

1. Remove crosshead guide side covers and

head end cylinder head or unloader.
2. Move crosshead to its inner dead center
position. Back off, but do not remove, the
crosshead nut set screws.
3. Loosen crosshead nut with the special
slugging peg or open end wrench (depending
on nut type).
4. Use the piston nut spanner to turn the piston
rod out of the crosshead. The two dowels on
the spanner fit holes in the piston nut.
Remove crosshead nut from piston rod.
Install the piston rod entry sleeve and push
the rod end forward towards the cylinder
until the rod end clears the wiper packing 1 Crosshead
assembly. 2 About 3 Tons (27kN) Force Required
5. With crosshead in its outer dead center 3 Bushing
position, remove crosshead pin thru-bolt, 4 Support Here
lock nut, end-plates and pin. Discard old lock
nut. 10. Slide crosshead out of crosshead guide.
6. Turn crankshaft to its inner dead center 11. Check crosshead pin to bushing clearance
position. (see Appendix B). Determine pin wear by
7. Remove oil wiper packing from crosshead inspection.
guide diaphragm. 12. Replace pin, if necessary.To replace
8. Move crosshead to its outer dead center bushings, hacksaw or file to within 1/32
position, free of the connecting rod. Support inches (1 mm) of their thickness, then drift
connecting rod so it does not drop and them out.
damage the crosshead guide surface. 13. New bushing installation requires a press. To
9. Rotate crosshead 90°.Support the crosshead install a bushing in the crosshead, cool the
by hand. bushing in 95% alcohol with dry ice solution.
Leave the bushing in the solution long
enough to reach the same temperature as the
solution, about -110°F (-80°C). An alternate

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method of cooling is to submerge the bushing 3. Turn crankshaft to its outer dead center
in liquid nitrogen. When the nitrogen stops position to locate the connecting rod in
bubbling, the temperature has reached position and insert crosshead pin. Oil
equilibrium, and the bushing is ready to crosshead pin, crosshead, and connecting
install. rod bushing prior to installation. Install
crosshead pin end-plates (be careful to align
CAUTION
roll pins with holes in the end plates), thru-
Do not touch cold surfaces without proper protection. bolt, and a new lock nut. Tighten thru-bolt
Alcohol is flammable; use it only in open air or well- and lock nut to the torque listed in Appendix
ventilated buildings. Avoid sparks and open flame. Avoid A.
alcohol vapors which may cause injury to nose and eye
tissue. Do not return solution to a closed container until 4. Reposition throw to inner dead center and
it reaches room temperature or container may explode. push the piston rod assembly toward the
crosshead far enough to remove piston rod
NOTE: Directly support the crosshead side entry sleeve.
receiving the new bushing to prevent the press
5. Lubricate piston rod threads with Never-Seez
from possibly crushing the crosshead (see Figure:
regular grade. Apply a thin coat of oil to either
Crosshead Bushing Replacement). Thoroughly
the balance nut or crosshead mating surface.
clean bushing and crosshead to prevent dirt accu-
Do not apply Never-Seez to the mating
mulation between bushing and crosshead bore.
surfaces. Install crosshead-balance nut on
14. Where applicable, verify oil holes in the piston rod.
bushing line up with the holes in the
6. Push the rod into the crosshead and turn the
crosshead.
piston rod assembly until the required crank
15. Inspect shoe surfaces. Except for light end piston clearance is reached.
polishing, there should be no wear or de- NOTE: At this point, set piston end clearance or
lamination. serious damage may occur. See required piston crank
end clearance on cylinder data plate or Appendix B.
Crosshead Installation 7. Insert a feeler gauge, equal to the required
crank end clearance, through an open valve
pocket. For 13 in. (330 mm) and larger
NOTE: Return crossheads to their original throw loca-
cylinders, insert feeler gauge through a
tion. Use frame oil for lubrication where needed.
bottom valve pocket. Place the feeler gauge
as close to the piston rod as possible. Tighten
1. Oil crosshead and guide surfaces and push the piston rod into the crosshead until piston
crosshead into position. is tight against the feeler gauge, and the
2. Rotate crosshead 90°.If crosshead becomes feeler gauge cannot be easily removed.
wedged, do not force it; it will damage the 8. Tighten crosshead-balance nut:Strike the
crosshead shoe surface. Use a box end special slugging peg or open end wrench with
wrench on the connecting rod bolt to lever a dead blow semi-soft faced hammer until an
the small end of the connecting rod into the audible difference can be heard or the
centered position, then slide the crosshead wrench “bounces” indicating a tight
into the guide under the connecting rod. Be nut.Some mechanics obtain desired
careful not to damage crosshead shoe or tightness in 3 to 4 strikes; others may require
crosshead slide surfaces during installation. more.

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9. For all cylinders except tandem:With the Connecting Rod Removal

head end head or unloader properly installed
(closed position) and fasteners tightened, WARNING
rotate crankshaft 180° to outer dead center
position of throw. Remove a top head end To reduce risk of injury or death, only trained personnel
who have read and thoroughly understand the
valve.Determine required piston head end
appropriate Ariel Technical Manual and Packager
clearance limits from cylinder data plate or information should attempt any maintenance.
Appendix B.Measure head end clearance at Prior to performing any maintenance activities:
the top of the head end, using feeler gauges • Always wear appropriate personal protection equip-
through the open valve pocket. Determine if ment and follow your company safety and opera-
measured clearance is within tolerance. tional procedures.
Tighten the crosshead-balance nut set • Never tighten or loosen any fastener or fitting while
the unit is operating or pressurized.
screws. Re-install valve assemblies and
• Verify neither driver nor compressor can turn during
properly tighten fasteners.See "Valve maintenance.
Installation".For tandem cylinders: Set • Follow packager instructions to completely isolate
piston head end clearance. See "Measuring and vent the system; call the packager for assis-
Head End Clearance for Forged Steel Tandem tance.
Cylinders with Concentric Valves" in • Verify each compressor cylinder is relieved to atmo-
Appendix B. spheric pressure. To relieve residual cylinder bore
pressure after blowdown, open the “Kiene” valves
10. Check piston rod runout and crosshead on the indicator ports, if so equipped.
clearances upon re-assembly, any time a WARNING: RELEASED GAS MAY BE POISONOUS
piston rod is removed. Check crosshead AND/OR FLAMMABLE.
guide to crosshead clearance at the top by Before resuming operation, purge the entire system with
inserting a standard 0.5 inch (13 mm) wide the gas being compressed to avoid a potentially
explosive gas/air mixture in the system. A gas/air
feeler stock from one side edge of the mixture under pressure can explode and cause severe
crosshead across to the opposite side - do injury or death.
this at both ends. Check bottom clearance
with 0.0015 inch (0.038 mm) feeler stock at
1. Remove top cover from crankcase and side
the four corners. If the feeler at the bottom
covers from crosshead guides.
inserts more than 0.5 inch (13 mm), the
assembly is not acceptable.See Appendix B 2. Remove the middle frame spacer bar of the
for crosshead clearances. three over the desired pair of throws. Spacer
bars are compressor and throw dependent.
11. Examine top cover and side cover seals. If
They are match-marked with the throw
there is doubt about their condition, replace
position and machined with a tight fit. After
them. Apply Never-seez Regular Grade to
bolt removal, spacer bars should remove
both sides of the gasket to ease future
easily by hand with maybe a slight resistance.
removal. Replace top cover and crosshead
A very loose or tight fit indicates an unlevel
guide side covers. Tighten all cap screws
frame, softfoot, incorrect crosshead guide
hand wrench tight.
shimming, improperly adjusted discharge
bottle wedges, or pipe stress affecting the
Connecting Rods cylinder flange fit. Correct any of these
conditions before returning the compressor
A connecting rod assembly consists of a rod with to service. If a spacer bar is tight and will not
bushing, a rod cap, rod cap bolts (4), and two half easily come out, it may help to loosen one
bolt on each spacer bar above the nearest
bearing shells. The bearing shells join together to
main bearing caps.
form the connecting rod bearing.

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3. Move throw to outer dead center position.

4. Remove crosshead as described in
"Crosshead Removal".
5. Turn the crankshaft until the throw is at its
highest point.
6. Loosen all connecting rod fasteners
approximately 1/8 in. (3.2 mm).
7. Pry or manually pull the small end of the
connecting rod towards the cylinder until cap
and rod separate.
NOTE: Do not pry on any machined running
surfaces. Work rod cap away from rod as evenly as
possible. Separating the two parts unevenly may
break rod cap dowels or cause them to bind in the rod
dowel holes. If the two parts of the connecting rod do
not separate easily by hand, loosen all bolts an addi-
tional 1/8 in. (3.2 mm) and pry the connecting rod
again.
NOTE: Do not pry or chisel at joint of
connecting rod cap/rod to separate cap from
rod; it damages the connecting rod and can
break alignment dowel pins. Skip to Step Care-
fully remove the connecting rod through the
crosshead compartment window..
8. Completely loosen the connecting rod
fasteners while holding the rod and cap in
position. Slide fasteners back to clear the rod.
Use fasteners as a handle to hold cap in
position.
9. While supporting the cap and fasteners, slide
the rod toward the cylinder. When the rod is
clear of the crankshaft, carefully rest it in the
guide.
10. Rotate the cap up and remove all fasteners,
then remove the rod cap and bearing. Hold
the bearing in the cap while lifting it off the
pin. Do not remove cap with fasteners in
place.
11. Carefully remove the connecting rod through
the crosshead compartment window.

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Connecting Rod Bearing Removal 1. Remove frame top cover and all crosshead
guide covers.
WARNING 2. Remove all head end heads.
To reduce risk of injury or death, only trained personnel 3. Remove spacer bars as needed to access
who have read and thoroughly understand the connecting rods. If a spacer bar will not easily
appropriate Ariel Technical Manual and Packager
come out, it may help to loosen one bolt on
information should attempt any maintenance.
Prior to performing any maintenance activities: each adjacent spacer bar. Spacer bars are
• Always wear appropriate personal protection equip- compressor and throw dependent. They are
ment and follow your company safety and opera- match-marked with the throw position and
tional procedures. machined with a close-tolerance fit. After bolt
• Never tighten or loosen any fastener or fitting while removal, spacer bars should remove easily by
the unit is operating or pressurized. hand with maybe a slight resistance. A very
• Verify neither driver nor compressor can turn during loose or tight fit indicates an unlevel frame,
maintenance.
softfoot, incorrect crosshead guide
• Follow packager instructions to completely isolate
and vent the system; call the packager for assis- shimming, improperly adjusted discharge
tance. bottle wedges, or pipe stress affecting the
• Verify each compressor cylinder is relieved to atmo- cylinder flange fit. Correct any of these
spheric pressure. To relieve residual cylinder bore conditions before returning the compressor
pressure after blowdown, open the “Kiene” valves to service.
on the indicator ports, if so equipped.
WARNING: RELEASED GAS MAY BE POISONOUS 4. Rotate crankshaft to approximately 45º (see
AND/OR FLAMMABLE. Figure: Crank Rotation)
Before resuming operation, purge the entire system with
the gas being compressed to avoid a potentially
Figure: Crank Rotation
explosive gas/air mixture in the system. A gas/air
mixture under pressure can explode and cause severe
injury or death.

Figure: Rod/Rod Cap Separation

5. Loosen all connecting rod bolts about 1/8 in.

(3.2 mm).
6. Pry crosshead toward the cylinder until it
bottoms out.

1 Top Face
2 Connecting Rod Bolts
3 Rod Cap
4 Rod

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NOTE: Do not pry on any machined running 8. Rotate the cap up and remove all bolts, then
surfaces. Work rod cap away from rod as evenly as remove the rod cap and bearing. Hold the
possible. Separating the two parts unevenly may bearing in the cap while lifting it off the pin.
break rod cap dowels or cause them to bind in the rod Do not remove cap with bolts in place.
dowel holes. If the two parts of the conrod do not
9. After removing bearings, clean any coking or
separate easily by hand, loosen all bolts an additional
debris from both the rod and rod cap surfaces
1/8 in. (3.2 mm) and pry the crosshead again.
with a non-metallic Scotch-Brite or similar
Figure: Prying Behind Crosshead scouring pad and solvent. Check for raised
edges on machined surfaces. All surfaces
should be as clean and dry as possible.

Crank Pin Assessment

Inspect bearings after removal. If bearings
indicate scratches or dings on pin, inspect crank
pin, and if needed, carefully stone the pin using
an Arkansas stone (Ariel part number A-19676).
Lightly slide the stone around the circumference
of the crank pin surface to remove any high spots;
do not slide it back and forth over the length of
the pin. If the pin is scored around the
circumference, use 600 grit emery cloth to
remove high spots. After dressing, ensure crank
pin is clean and dry. Use only lint-free, clean
paper towels to clean crankshaft pin of any
debris after dressing.

NOTE: Do not pry or chisel at joint of connecting

rod cap/rod to separate cap from rod; it damages
the connecting rod and can break the alignment
dowel pins. Do not pry on machined running
surfaces when separating the cap from the rod.
Separate caps by backing out all 4 bolts no more
than 1/4 inch and prying behind the crosshead
(see Figure: Prying Behind Crosshead)
7. Support rod and cap by hand while another
person pries the crosshead toward the
cylinder as much as possible. When the rod is
clear of the crankshaft, carefully rest it in the
guide.

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Connecting Rod Bearing 2. Apply clean, new lube oil liberally to the crank
pin. Verify oil is compatible with the oil used
Installation in the frame.
Figure: Connecting Rod Bearing Installation 3. Fit the tab of the other bearing shell into the
rod cap notch.
4. Use the following steps to attach the rod cap
to the rod:
a. Support the connecting rod by hand while
another person rotates the crank towards
the rod. Stop rotating the crank at about a
45º angle (see Figure below).
Figure: Attaching Rod to Crankshaft

A Apply lube oil liberally to this surface.

1 Rod
2 Rod Bushing
b. Carefully lower the connecting rod cap
3 Dowel Holes
(WITHOUT BOLTS!) onto the crank pin.
4 Rod Notch
Verify rod bolts are undamaged and free
5 Bearing Shell of dirt. Lubricate them per Appendix A,
6 Bearing Shell Tab then place all four bolts into the rod cap.
7 Dowels NOTE: Ensure notches on both the connecting rod
8 Rod Cap Notch and connecting rod cap match. Install with both
9 Rod Cap notches on top, in the upward position.
c. Keep supporting the connecting rod by
1. Check new bearing shells for handling hand while the second person pries the
damage, scratches, burrs, and loose material crosshead towards the crank until the rod
at the tabs. DO NOT RUB BEARING SURFACE bottoms out on the crankshaft.
WITH FINGERNAIL. New bearing shells and
crankshaft crank pin bearing surfaces must d. After ensuring the rod cap seats properly
be absolutely clean. Clean new bearings with on the rod, tighten all connecting rod
appropriate solvent and clean paper towel. bolts to the torque listed in Appendix A.
Paper towels do not leave lint behind 5. Repeat steps 1-4 for all remaining connecting
compared to rags. Fit the tab of a new, dry rods.
half bearing shell into the rod notch.
6. Measure each connecting rod bearing jack
NOTE: Where bearings are identified with an ink
and thrust clearance as detailed in this
pictograph, connecting rod bearings and main bear-
document. If clearance readings are not
ings are not interchangeable. DO NOT put main bear-
within tolerances of Appendix B, contact your
ings in a connecting rod. Do not mix part numbers on
packager or Ariel before proceeding.
an individual main or connecting rod. Both bearing
half shells must have the same part number.

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NOTE: If replacing main bearings, continue to "Main Connecting Rod Bushing Removal
Bearing Removal". If not replacing main bearings,
continue to Step Install spacer bars so the match
and Installation
mark is up and next to the spacer bar boss with the
1. Check crosshead pin to bushing clearance
same mark. Tighten all spacer-bar cap screws to the
(see Appendix B). Determine pin wear by
torque listed in Appendix A..
inspection. Replace pin, if necessary.
7. Install spacer bars so the match mark is up 2. To replace a bushing, file or hacksaw the
and next to the spacer bar boss with the same existing bushing to reduce the tightness of
mark. Tighten all spacer-bar cap screws to the shrink fit. From the inside diameter, file or
the torque listed in Appendix A. saw across the length of the bushing to within
8. Account for all tools, equipment, supplies, 1/32 inches (1 mm) of its radial thickness. It
and parts to ensure none are left inside the can then be easily drifted out. DO NOT file or
crankcase. saw into the connecting rod; any bore
damage renders the rod useless and
9. Examine top cover and side cover seals. If
requires rod replacement.
there is doubt about their condition, replace
them. For O-ring seals, oil the O-ring and 3. Use a hydraulic press in a qualified machine
apply a light coating of corrosion inhibitor or shop to install the new bushing. Do not
marine grease to mating surface. Replace top hammer bushing into place; it will distort the
cover and crosshead guide side covers. bushing bore.
Tighten all cap screws hand wrench tight. 4. Before installation, cool new bushing in a
10. Reverse lockout procedures. 95% alcohol and dry ice solution. Leave
bushing in solution long enough to reach the
11. After replacing bearings, it is recommended
solution temperature, about -110°F (-80°C).
to pre-lube compressor for at least 10-15
An alternate method of cooling is to
minutes at 30 psi (2.1 barg) to ensure bearing
submerge the bushing in liquid nitrogen.
lubrication and to help remove foreign
When the nitrogen stops bubbling, the
materials from the lube system.
temperature has reached equilibrium, and
12. Run the compressor according to the time the bushing is ready to install.
intervals listed on the form in Appendix D.
CAUTION
After each run, shut down and remove the
frame top cover. Measure main and Do not touch cold surfaces without proper protection.
connecting rod bearing cap temperatures Alcohol is flammable; use it only in open air or well-
with a hand held thermocouple probe or ventilated buildings. Avoid sparks and open flame. Avoid
alcohol vapors which may cause injury to nose and eye
infrared thermometer and record them on a
tissue. Do not return solution to a closed container until
copy of the form in Appendix D. Complete the it reaches room temperature or container may explode.
form and file it in the unit records for future
reference.
13. After each shutdown, visually inspect the
crankcase for signs of excessive heat in
bearing areas, and babbitt or other debris. If
any are found, find and correct the problem
before continuing.

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NOTE: Thoroughly clean bushing and connecting be absolutely clean. Snap a new, dry half
rod to prevent dirt accumulation between them. bearing shell into the rod and rod cap with
Immediately assemble them so the bushing does the bearing tabs properly located in the rod
not warm and stick before it is in place. If the and cap notches. Turn the connecting rod pin
bushing sticks, remove it by notching as in step 2 to the vertical position and oil crankshaft
above. connecting rod pin bearing surfaces with new
5. Position connecting rod on the press table so clean lubricating oil, the same type used in
the chamfered edge of the rod bushing bore the frame. Carefully lower the connecting rod
is on top. Press bushing into rod bore.Align cap (without bolts) onto the pin.
bushing oil hole with connecting rod oil NOTE: Connecting rod bearings and main bearings
passage (if applicable) before pressing are not interchangeable. Connecting rod bearings
bushing in. The bushing has an annular have a narrower groove or no groove at all. DO NOT
groove around its outside diameter aligned put main bearings in connecting rod bearing loca-
with the oil hole; if the bushing shifts in the tions.
connecting rod during operation, oil still NOTE: Caps and rods are numbered by throw
travels to the bushing inside diameter and to beginning with number one at the drive end. For
the crosshead pin. However, a new bushing throw numbering sequence, see Plate Locations.
installation should cover no more than 1/3 of Always install rods with numbers up. Protect
the rod oil passage hole. crank pin at all times. Be sure both bearing tabs
are on top.
Connecting Rod Installation 3. Verify rod bolts are undamaged and free of
dirt, then lubricate them per Appendix A and
1. To install a new connecting rod, stamp match insert all bolts into rod cap. Rotate the cap
mark numbers matching the throw location and fit the connecting rod to the rod pin and
on the tops of the connecting rod and bearing snug the bolts, pulling the cap and rod
cap (with bearing notches up). See Figure: together evenly.
Typical Connecting Rod.
4. Reconnect rod and crosshead with pin. Install
2. Check new bearing shells for handling end plates, thru-bolt, and new lock nut.
damage, scratches, burrs, and loose material Tighten lock nut to the torque listed in the
at the tabs. DO NOT RUB BEARING SURFACE Appendix A.
WITH FINGERNAIL. New bearing shells and
crankshaft crank pin bearing surfaces must

Figure: Typical Connecting Rod

1 Correct rod orientation is
with bearing notches on top
joint. NOTE: Install joint
match marks up.

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5. Follow the "Recommendations for Torque 7. Reinstall spacer bars. All spacer bars are
Accuracy" in Appendix A to tighten match-marked for proper location; reinstall
connecting rod cap screws to the them in their original location. Tighten all
recommended torque. spacer bar bolts to the torque listed in
6. Measure each connecting rod bearing to Appendix A.
crankshaft jack clearance and connecting rod 8. Examine top cover and side cover seals. If
thrust (side) clearance (see "Connecting Rod there is doubt about their condition, replace
Bearing Vertical Jack Clearance them.Apply Never-seez Regular Grade to
Measurement" and "Connecting Rod Thrust both sides of the gasket to ease future
(Side) Clearance Measurement"). Record removal. Replace top cover and crosshead
measurements on a copy of the form in guide side covers. Tighten all cap screws
Appendix D. If measurements are out of hand wrench tight.
tolerance after installing new bearings,
contact your packager or Ariel before
proceeding.

Connecting Rod Bearing Vertical Jack Clearance Measurement

Figure: Typical Connecting Rod Vertical Jack
Clearance Measurement

Dial indicator placement on connecting rod.

Magnetic stand placement on top of adjacent

crankshaft web.

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3. Zero the dial indicator. Insert a pry bar into

the eye bolt and pry against the frame to
force the connecting rod up until the dial
indicator needle stops moving.For JG:JGA
models, pry against the top conrod bolts.
While maintaining upward pressure, note the
reading.
NOTE: Too much force when prying on the
connecting rod eyebolt may lift the crankshaft
resulting in incorrect readings.
4. Release upward pressure and push
downward on the rod until the indicator
reads zero again. If a zero reading cannot be
obtained, zero the indicator again and repeat
Use pry bar to check jack clearance. steps 3 and 4. Repeat the measurement
1. Turn the crankshaft pin of the desired throw process until the measurement returns to
to its highest position. zero twice in a row to verify accuracy.
2. To ensure measurement of only vertical 5. Repeat measurement process for every rod. If
movement between the crankshaft and a reading is outside the tolerances of
connecting rod, attach the dial indicator Appendix B, contact your packager or Ariel.
magnetic base to the crankshaft web NOTE: Remove eye bolts, magnetic bases, dial indica-
adjacent to the measured connecting rod. tors, and pry bars after measurement.

Connecting Rod Thrust (Side) Clearance Measurement

Figure: Typical Connecting Rod Thrust (Side)
Clearance Measurement

Dial indicator placement.

Dial indicator magnetic stand placement.

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Crankshafts
The crankshaft is the heart of the compressor.
With proper maintenance, it should provide
years of trouble-free service. If replacing a
crankshaft fitted with torsional detuners, contact
the Ariel Response Center with the frame and
crankshaft serial numbers and the part numbers
and quantity of detuners to ensure compatibility.

Oil Slinger Replacement

Thrust rod tight toward and away from dial indicator. CAUTION

1. Turn the crankshaft pin of the desired throw Do not touch hot surfaces without proper protection.
to its highest position.
Although the slinger should last indefinitely with
2. Attach the magnetic base of a dial indicator to
the crankshaft web adjacent to the proper care, it may become nicked.
connecting rod. Place the button of the dial 1. Suspend the crankshaft as detailed in
indicator against the thrust surface of the "Crankshaft Removal" and heat the slinger to
connecting rod (see Figure: Typical about 400°F (204°C). When it expands, it is
Connecting Rod Thrust (Side) Clearance easily removed.
Measurement).
2. Slide a minimum ½-inch (13mm) diameter
3. Use a pry bar to pry gently against the rod through the new slinger. Do not mar
crankshaft web and thrust the connecting rod slinger surfaces, and be careful of its sharp
tight toward the dial indicator (do not pry on outer edge. Suspend the slinger and heat it
rod cap). Release pressure and zero the dial with a small torch. When it reaches about
indicator. 400°F (204°C), slip it over the drive end of the
4. Thrust the connecting rod tight in the crankshaft. Hold the slinger in place with high
opposite direction until the dial indicator temperature gloves or two pieces of clean
needle stops moving. Release pressure and wood. Rotate it slightly to ensure squareness,
note reading. Gently pry connecting rod in until it cools enough to shrink onto the
opposite direction to ensure the dial returns crankshaft.
to zero.
5. Repeat the measurement process for every
rod. If a reading is outside the tolerances in
Appendix B, contact your packager or Ariel.
NOTE: Remove magnetic bases, dial indicators, and
pry bars after measurement.

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Main Bearing Removal NOTE: Support cap, bearing, and thrust plates to
ensure nothing drops into the frame or damages the
WARNING
crankshaft.

To reduce risk of injury or death, only trained personnel

who have read and thoroughly understand the
appropriate Ariel Technical Manual and Packager
information should attempt any maintenance.
Prior to performing any maintenance activities:
• Always wear appropriate personal protection equip-
ment and follow your company safety and opera-
tional procedures.
• Never tighten or loosen any fastener or fitting while
the unit is operating or pressurized.
• Verify neither driver nor compressor can turn during
maintenance.
• Follow packager instructions to completely isolate
and vent the system; call the packager for assis-
tance.
• Verify each compressor cylinder is relieved to atmo-
spheric pressure. To relieve residual cylinder bore
pressure after blowdown, open the “Kiene” valves
on the indicator ports, if so equipped.
WARNING: RELEASED GAS MAY BE POISONOUS
AND/OR FLAMMABLE.
Before resuming operation, purge the entire system with
the gas being compressed to avoid a potentially
explosive gas/air mixture in the system. A gas/air
mixture under pressure can explode and cause severe
injury or death.

1. Remove top cover and spacer bars. Spacer

bars are compressor and throw dependent.
They are match-marked with the throw
position and machined with a tight fit. After
bolt removal, spacer bars should remove
easily by hand with maybe a slight resistance.
A very loose or tight fit indicates an unlevel
frame, softfoot, incorrect crosshead guide
shimming, improperly adjusted discharge
bottle wedges, or pipe stress affecting the
cylinder flange fit. Correct any of these
conditions before returning the compressor
to service.
2. Remove the four main (journal) bearing cap
screws. Pull caps straight up using bearing
cap puller to prevent damage to the dowel fit
(see Figure: Main Bearing Cap Puller) Remove
shells from main bearing caps.

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Figure: Main Bearing Cap Puller

1 Puller Nut - turn to pull bearing cap
straight up.
2 Rectangular Steel Bar Clearance Hole: 5/8
in. (16 mm) Length: 16 in. (406 mm)
3 Drill Hole
4 Threaded Rod Nominal Size: 1/2 in. - 13
Length:10 in. (254 mm)
5 Lock Nut
6 Puller Hole
7 Crankshaft

3. Inspect bearings. If bearings indicate easier removal. To remove, rotate shell under
scratches or dings on pin, inspect crankshaft the crankshaft tab side out first, by pushing or
journal, and if needed, carefully stone the tapping with a non-metallic tool on the
journal using an Arkansas stone (Ariel part opposite side. Ariel provides an optional tool
number A-19676). Lightly slide the stone (B-3340) to push the shell out. Do not damage
around the circumference of the journal crankshaft bearing surfaces. Replace with
surface to remove any high spots; do not slide new bearing shell, before rotating out the
it back and forth over the length of the next main bearing shell.
journal. If the crank is scored around the
5. If any coked oil is observed on bearing cap or
circumference, use 600 grit emery cloth to
frame saddle surfaces, contact Ariel for
remove high spots. After dressing, ensure
instructions. Check for raised edges on
crank pin is clean and dry. Use only lint-free,
machined surfaces. Verify all surfaces are
clean paper towels to clean crankshaft
clean and dry as possible and no bolting is
journal of any debris after dressing. Rotate
damaged.
the crankshaft 180° to expose the other half of
the journal and repeat.
4. To limit debris entering the system, work on Main Bearing Installation
only one main bearing at a time. Remove 1. Clean new bearings with appropriate solvent
main journal bearing shells from under the and clean paper towel. Paper towels do not
crankshaft one at a time. If needed, attach leave lint behind compared to rags. Check
clean nylon straps around the crankshaft and new bearing shells for damage, scratches,
lift it 0.003 - 0.005 inch (0.076 - 0.127 mm) to burrs, and loose material at the tab. DO NOT
lessen weight on the bearings and allow

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RUB BEARING SURFACE WITH FINGERNAIL. 5. Install spacer bars so the match mark is up
Keep the backs of shells dry and clean; and next to the same match mark on the
installation requires perfectly clean bearing frame rail. Tighten all spacer-bar cap screws
shells. Install bearing shells in caps, and to the torque listed in Appendix A.
frame journals, properly located in the tab
6. Account for all tools, equipment, supplies,
notch, (rotate in the un-tabbed end
and parts to ensure none are left inside the
first).JG:JGA units use a thrust bearing, where
crankcase. Examine top cover and side cover
the thrust plate is integral to one bearing
seals. If there is doubt about their condition,
shell, and the other shell has no thrust plate.
replace them. For O-ring seals, oil the O-ring
Install the bearing shell with the integral
and apply a light coating of corrosion
thrust plate into the #1 main bearing cap.
inhibitor or marine grease to mating surface.
NOTE: Where bearings are identified with an ink Replace top cover and crosshead guide side
pictograph, main and connecting rod bearings are covers. Tighten all cap screws hand wrench
not interchangeable. Do not put connecting rod bear- tight. Bar compressor over 360° to ensure free
ings in main bearing locations. Do not mix part rotation.
numbers on an individual main or connecting rod.
Both bearing half shells must have the same part 7. Reverse lockout procedures.
number except for frames with integrated thrust 8. After replacing bearings, it is recommended
bearings (JG:A:M:P:N:Q and KB100). to pre-lube compressor for 10-15 minutes at
2. Apply clean, new lube oil liberally to the crank 30 psi (2.1 barg) to ensure bearing lubrication
journal. Verify oil is compatible with oil used and to help remove foreign materials from
in the frame. the lube system.
3. Main bearing caps have position match- 9. Run the compressor according to the time
marks corresponding with frame spacer bars intervals listed on the form in Appendix D.
and spacer bar bosses. Install main bearing After each run, shut down and remove the
caps with new bearing shells in their correct frame top cover. After each shutdown,
locations. Verify proper alignment of main visually inspect the crankcase for signs of
bearing cap dowels with the holes in the excessive heat in bearing areas, and babbitt
crankcase base.A set screw on top of each or other debris. If any are found, find and
dowel prevents it from backing out. Seat the correct the problem before continuing.
cap by tapping it with the handle of a hammer Measure main and connecting rod bearing
or screwdriver. It is a machined fit, not a press cap temperatures with a hand held
fit, and the cap should not rock in the jaw fit thermocouple probe or infrared
when it seats. Do not use bolting to force the thermometer and record them on a copy of
cap to seat. Tighten the cap screws. Tighten the form in Appendix D. Complete the form
the main bearing cap bolts in the pattern and and file it in the unit records for future
torque listed in Appendix A. reference.
4. Check crankshaft journal bearing jack
clearances and crankshaft thrust clearance to
values in Appendix B (see procedure below).
Record readings on a copy of the form
Appendix D. If readings are out of tolerance
after new bearing installation, contact your
packager or Ariel before proceeding.

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Crankshaft Removal
WARNING

To reduce risk of injury or death, only trained personnel

who have read and thoroughly understand the
appropriate Ariel Technical Manual and Packager
information should attempt any maintenance.
Prior to performing any maintenance activities:
• Always wear appropriate personal protection equip-
ment and follow your company safety and opera-
tional procedures.
• Never tighten or loosen any fastener or fitting while
the unit is operating or pressurized.
• Verify neither driver nor compressor can turn during
maintenance.
• Follow packager instructions to completely isolate
and vent the system; call the packager for assis-
tance.
• Verify each compressor cylinder is relieved to atmo-
spheric pressure. To relieve residual cylinder bore
pressure after blowdown, open the “Kiene” valves
on the indicator ports, if so equipped.
WARNING: RELEASED GAS MAY BE POISONOUS
AND/OR FLAMMABLE.
Before resuming operation, purge the entire system with
the gas being compressed to avoid a potentially
explosive gas/air mixture in the system. A gas/air
mixture under pressure can explode and cause severe
injury or death.

Figure: Typical Crankshaft

1 Oil Slinger
2 Main Bearing Journals
3 Chain Sprocket
4 Crank Pins
5 Counterweights

1. Remove coupling disk pack.The coupling hub crankshaft. Remove all drive end cover
may be removed now, but it may be easier mounting bolts. Remove the two tapered
after crankshaft removal. If the hub is not dowel pins from the drive end cover.
removed, the drive end cover cannot be
2. Remove top cover and spacer bars.
removed and must lift out with the

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3. Do not damage the sharp corners on each grip, to avoid cuts from the slinger, and to
end of the crankcase top. They form a avoid marring the running surface. As the
junction between the end covers, top cover, shaft slowly raises, lift the drive and auxiliary
and base; keep them sharp and unmarred to ends at the same rate. Carefully guide the
prevent oil leaks. crankshaft to avoid marring its surfaces.
4. Detach connecting rods and move them to
their full outer position.See "Connecting Rod Crankshaft Installation
Bearing Removal".
1. Thoroughly clean the oil gallery that runs
5. Remove chain eccentric adjustment
from the drive end to the auxiliary end of the
capscrews. Turn the eccentric to loosen the
crankcase and the vertical and horizontal
chain and slip it off the crankshaft sprocket.
intersecting oil passages that lube the main
For more clearance while lifting the
bearings and crosshead guides. Any debris
crankshaft, remove the force feed lubricator
left in the oil gallery or intersecting
drive sprocket.
passageways could cause bearing or
6. Remove main bearing caps. See "Main crosshead failure. Deburr and clean main
Bearing Removal". bearing caps to prepare for installation.
7. Before removing the crankshaft, prepare 2. Thoroughly clean new main bearing half
wooden saddles or blocks of wood with sides shells and install them in the frame saddles.
high enough to prevent the webs or oil slinger Cover bearings with clean paper towels to
from touching the floor to store the prevent debris contamination.
crankshaft during maintenance - even if for
3. Remove towels just before seating the crank
only a short time. Also, protect the crankshaft
in the saddles. Lubricate bearing surfaces
from above so dropped tools or equipment
with clean crankcase oil.
cannot mar pin and journal surfaces.
4. Move connecting rods to full outer position if
8. Turn the crankshaft so that sling lifting points
not already there.
are above the shaft center of gravity to
prevent rotation when lifted. Lift straight up 5. Install the crankshaft. While the crankshaft
with the crankshaft ends parallel to the lowers very slowly into the crankcase
frame. The crankshaft weight requires two (suspended by a crane with clean nylon
men and a crane to safely remove it. Use slings), one man wearing clean gloves should
appropriate sized nylon slings to prevent grasp the drive end and slowly maneuver the
marring the crankshaft running surface. drive end and auxiliary end straight down
NOTE: Lower half bearing shells sometimes stick to into the crankcase. Both drive end and
the shaft journals. After lifting the shaft about ¼ inch auxiliary end journals should touch the
(6mm) clear of the saddles, verify the lower half bottom bearing shells at the same time.
bearing shells remain on the saddles. If not, tap them 6. Before connecting rod installation, measure
back onto the saddles before lifting the shaft further. each crankshaft journal bearing jack
9. While one person raises the crane very slowly, clearance with a dial indicator (see procedure
the second person must grasp the crankshaft on "Main Bearing Vertical Jack Clearance
at the drive end with one hand on the Measurement" and allowable clearances in
counterweight or one of the throws and the Appendix B).
other on the shaft end to keep the crankshaft 7. Reattach connecting rods (See "Connecting
level. It may be necessary to lower the crank Rod Installation"), packing diaphragms, and
and reposition the straps to achieve a unloaders/head end heads.
balanced lift. Wear clean gloves for a good

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8. Reinstall chain drive. (See “Chain Drive 11. Use a knife to trim excess from end cover
System”). gaskets flush to the compressor frame top
9. Replace spacer bars. Locate spacer bar match cover rail.
mark. Install spacer bar so the match mark is 12. Examine top cover and side cover seals. If
up and next to the spacer bar boss with the there is doubt about their condition, replace
same marking. them.Apply Never-seez Regular Grade to
10. Install drive end cover with new gasket using both sides of the gasket to ease future
the tapered dowel pins to properly align the removal. Replace top cover and crosshead
cover. Verify at least 0.008 inch (0.2 mm) guide side covers. Tighten all cap screws
clearance exists between the dust seal hand wrench tight.
housing and crankshaft. Then install a new
dust seal.

Main Bearing Vertical Jack Clearance Measurement

Figure: Typical Crankshaft Journal Bearing
Vertical Jack Clearance Measurement

Dial indicator placement.

Dial Indicator magnetic stand placement.

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6. In some instances, a heavy drive end flywheel

can distort the crankshaft enough to lift it
from the bottom main bearing, causing low
main bearing jack clearance readings at
certain main bearing locations.

Place lifting strap around crankshaft web - attach

strap to crane.
1. Turn the crankshaft until the web adjacent to
the desired main bearing is vertical (see
Figure: Typical Crankshaft Journal Bearing
Vertical Jack Clearance Measurement).
2. Loop a clean, appropriately sized, and rated
lifting strap around the crankshaft web
adjacent to the main bearing and attach the
strap to a crane.
NOTE: If the crane has no fine adjustment, attach a
chain hoist to the crane lifting hook to prevent exces-
sive force on the crankshaft and crane.
3. Attach the magnetic base of a dial indicator to
any stable frame surface. Place the point of
the dial indicator against the top of the web
adjacent to the measured bearing and zero
the indicator.
4. GENTLY lift the crankshaft. The dial indicator
needle moves steadily until the crane/hoist
overcomes the crankshaft oil stiction; at this
point, the needle jumps a little. Stop lifting
immediately at this point, and note the
reading.
5. Release crane/hoist pressure and verify
indicator returns to zero. Repeat step 4 to
verify the measurement.

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Figure: Crankshaft Distortion

Four-Throw Compressor Detail A

1 Main Jack Clearance before Lifting

Flywheel
1 Flywheel Lifting Point 2 Bottom Journal Clearance before Lifting
2 Crankshaft Centerline Flywheel
3 First Web 3 Main Jack Clearance after Lifting
Flywheel
4 Crankshaft Distortion
4 Bottom Journal Clearance after Lifting
Flywheel

If heavy drive end flywheel affects measured When the indicator stops and begins
values on a 4- or 6-throw compressor, follow moving in the positive direction, stop
these steps: lifting and maintain the current lifting
a. Roll the crankshaft so the first web is device position. This position relieves
vertical. flywheel weight for accurate bearing
b. Set up a dial indicator on the first web to clearance measurement.
measure vertical movement. d. Measure main bearing clearances per
c. Slowly lift the flywheel from underneath. step 2-5 above.
Initially, the indicator moves in the nega- For two-throw compressors with a heavy drive
tive direction during flywheel lifting. end flywheel:

Figure: 2-Throw Compressor with Crankshaft Distortion

1 Flywheel Lifting Point
2 Crankshaft Centerline
3 Drive End Main Bearing
4 Crankshaft Distortion
5 Non-Drive End Counterweight

a. Mount a dial indicator on the crankshaft b. Slowly lift the flywheel from underneath
counterweight on the non-drive end and until the dial indicator stops moving,
zero it. which indicates the crankshaft sits in the

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bottom of the non-drive end main bearing 7. Repeat the measurement process for each
shell. main bearing. If reading is outside tolerances
c. Record reading from Step 2 as the main in Appendix B, contact your packager or Ariel.
bearing clearance for the non-drive end. NOTE: Remove magnetic bases, dial indicators, and
lifting strap after measurement.
d. Place another dial indicator on the drive
end main bearing and zero it.
e. Lift the flywheel until the indicator stops
moving.
f. Record reading from Step 5 as the main
bearing clearance for the drive end.

Crankshaft Thrust (End) Clearance Measurement

Figure: Typical Crankshaft Thrust Clearance
Measurement

Dial indicator placement against the side of

crankshaft web.

Dial indicator magnetic stand placement on main

bearing cap.

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3. Thrust the crankshaft tight in the opposite

direction until the dial indicator needle stops
moving, then release pressure. Note reading.
Repeat steps 2 and 3 to verify measurement
accuracy.
4. If the measurement is outside the tolerances
in Appendix B, contact your packager or Ariel.
NOTE: Remove magnetic bases, dial indicators, and
pry bar after measurement.

Chain Drive System

The chain drive system is crankshaft-driven at
Pry against compressor frame to thrust crankshaft
the auxiliary end of the frame. For JG:JGA
back and forth.
compressors, a single chain runs the lube oil
1. Attach the magnetic base of a dial indicator to pump and force feed lubricator. An idler
any stable frame surface. Place the button of
sprocket attached to the eccentric adjustment
the dial indicator against the side of the
adjacent crankshaft web (see Figure: Typical cap controls chain tightness. The chain dips into
Crankshaft Thrust Clearance Measurement). the crankcase oil for constant lubrication. In dry
NOTE: Do NOT place magnetic base on end cover- it sump applications, an oil sprayer lubricates the
can flex if pried against, resulting in inaccurate read- chain.
ings.
A separate idler sprocket for each chain, each
2. Use a pry bar to pry against the compressor attached to its own eccentric adjustment cap,
frame and thrust the crankshaft tight toward
controls chain tightness. The lube oil pump chain
the dial indicator. Release pressure and zero
the dial indicator. dips into the crankcase oil and splash action oils
the force feed lubricator chain as well. In dry
sump applications, an oil sprayer lubricates the
chains.

Figure: JG:JGA Chain Drive Systems

A Standard Rotation
B Reverse Rotation
1 Force Feed Lubricator
Sprocket
2 Crankshaft Sprocket
3 Eccentric Adjustment
4 Cap Screw
5 Dust Plug
6 Chain
7 Oil Pump Sprocket

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Chain and Sprocket Replacement pitches (X) to a measurement between the inside
of the same rollers (Y), and then divide by two.
WARNING Replace the chain if the result exceeds 3.834
To reduce risk of injury or death, only trained personnel inches (97.4 mm).This number applies to either
who have read and thoroughly understand the one-row or two-row chains.
appropriate Ariel Technical Manual and Packager
information should attempt any maintenance. Replace sprockets showing any undercutting or
Prior to performing any maintenance activities: other damage.
• Always wear appropriate personal protection equip-
ment and follow your company safety and opera-
tional procedures.
• Never tighten or loosen any fastener or fitting while
the unit is operating or pressurized.
• Verify neither driver nor compressor can turn during
maintenance.
• Follow packager instructions to completely isolate
and vent the system; call the packager for assis-
tance.
• Verify each compressor cylinder is relieved to atmo-
spheric pressure. To relieve residual cylinder bore
pressure after blowdown, open the “Kiene” valves
on the indicator ports, if so equipped.
WARNING: RELEASED GAS MAY BE POISONOUS
AND/OR FLAMMABLE.
Before resuming operation, purge the entire system with
the gas being compressed to avoid a potentially
explosive gas/air mixture in the system. A gas/air
mixture under pressure can explode and cause severe
injury or death.

Figure: Measuring to Check Chain Elongation

1 X- Measure outside rollers at 10 pitches

2 Y - Measure inside rollers at 10 pitches

Replace chain(s) if elongation exceeds 0.084

inches (2.13 mm) over a 10 pitch length. Measure
the section of chain with vernier calipers while it
is stretched tight in position in the compressor.
Add a measurement outside the rollers at 10

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Chain Idler Sprocket Replacement

(Eccentric Adjustment Caps)
WARNING

To reduce risk of injury or death, only trained personnel

who have read and thoroughly understand the
appropriate Ariel Technical Manual and Packager
information should attempt any maintenance.
Prior to performing any maintenance activities:
• Always wear appropriate personal protection equip-
ment and follow your company safety and opera-
tional procedures.
• Never tighten or loosen any fastener or fitting while
the unit is operating or pressurized.
• Verify neither driver nor compressor can turn during
maintenance.
• Follow packager instructions to completely isolate
and vent the system; call the packager for assis-
tance.
• Verify each compressor cylinder is relieved to atmo-
spheric pressure. To relieve residual cylinder bore
pressure after blowdown, open the “Kiene” valves
on the indicator ports, if so equipped.
WARNING: RELEASED GAS MAY BE POISONOUS
AND/OR FLAMMABLE.
Before resuming operation, purge the entire system with
the gas being compressed to avoid a potentially
explosive gas/air mixture in the system. A gas/air
mixture under pressure can explode and cause severe
injury or death.

Figure: Typical Chain Idler Sprockets (Eccentrics)

A Oil O-ring before assembly.
1 Dust Plug
2 Cap Screw
3 Stat-O-Seal
4 Self-Lock Nut
5 Washer
6 Sprocket
7 Thru Bolt

1. Remove frame top cover. the idler sprocket and remove entire
2. Remove all dust plugs from the eccentric cap assembly from the end cover.
and all cap screws holding the eccentric cap NOTE: Chain idler sprocket location varies for stan-
to the end cover. Rotate eccentric cap to dard versus reverse rotation.
loosen chain for removal. Drop the chain off

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3. Remove and discard lock nut, hex cap screw,

stat-o-seal, washer, and cap O-ring.
4. Reassemble new cap screw, stat-o-seal,
washer, sprocket, and lock nut. Tighten idler
lock nut to recommended torque in Appendix
A.
5. Apply oil and install a new O-ring. Install
assembly and chain.
6. Take care when measuring and adjusting the
force feed idler sprocket; it is thinner than the
force feed lubricator and drive sprockets. To
center the idler sprockets in the chain,
subtract the force feed idler sprocket
thickness from the drive sprocket thickness
and divide the difference by 2. Add this value
to the measurement from the inside face of
the auxiliary end cover to the outside face of
the force feed idler sprocket. Adjust driven
sprockets to the drive sprocket
measurements, aligned within 1/32 inch (1
mm). Non-alignment may require
disassembly and shimming eccentrics.
7. Adjust chain according to "Chain
Adjustment".

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Lube Oil Pump Sprocket

Replacement
WARNING

To reduce risk of injury or death, only trained personnel

who have read and thoroughly understand the
appropriate Ariel Technical Manual and Packager
information should attempt any maintenance.
Prior to performing any maintenance activities:
• Always wear appropriate personal protection equip-
ment and follow your company safety and opera-
tional procedures.
• Never tighten or loosen any fastener or fitting while
the unit is operating or pressurized.
• Verify neither driver nor compressor can turn during
maintenance.
• Follow packager instructions to completely isolate
and vent the system; call the packager for assis-
tance.
• Verify each compressor cylinder is relieved to atmo-
spheric pressure. To relieve residual cylinder bore
pressure after blowdown, open the “Kiene” valves
on the indicator ports, if so equipped.
WARNING: RELEASED GAS MAY BE POISONOUS
AND/OR FLAMMABLE.
Before resuming operation, purge the entire system with
the gas being compressed to avoid a potentially
explosive gas/air mixture in the system. A gas/air
mixture under pressure can explode and cause severe
injury or death.

Figure: Typical Lube Oil Pump Chain Sprocket

1 Gaskets
2 Key
3 Set Screws
4 Sprocket
5 Adapter
6 Pump

1. Remove all pump piping. Remove fasteners from pump mounting flange. After chain

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removal, the pump with sprocket comes free

through the end cover hole.
2. To position the new sprocket, use a machinist
rule to measure the exact distance from
sprocket drive face to pump mounting flange
face (X). Note this measurement for future
reference.
3. With the oil pump on a bench, use an Allen
wrench to remove the sprocket set screws,
then pull the sprocket from the shaft.
4. Remove the key from the shaft and file the
shaft to smooth burrs raised by the set screw
cup point.
5. Install a new key (see build book for type and
dimensions). First verify it fits into the new
sprocket. If too thick, polish the key with
emery cloth on a flat surface until it easily
slides into the notch. The top edge may also
require a little polishing.
6. Install new sprocket to the original
measurement between the sprocket drive
face and the pump mounting flange face.
When in position, tighten set screws.
7. Lubricate both sides of gaskets with anti-
seize lubricant or multi-purpose grease to
ease future removal. Install new gaskets.
8. Reinstall pump onto end cover. Using a
straight edge, to within 1/32 inch (1 mm),
check alignment to crankshaft drive sprocket
with crankshaft centered in end play. If
misaligned, adjust sprocket position as
needed.
9. Adjust chain according to "Chain
Adjustment".
10. Reinstall all piping to pump.

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Force Feed Lubricator Chain Figure: Force Feed Lubricator Chain Sprocket
Sprocket Replacement
WARNING

To reduce risk of injury or death, only trained personnel

who have read and thoroughly understand the
appropriate Ariel Technical Manual and Packager
information should attempt any maintenance.
Prior to performing any maintenance activities:
• Always wear appropriate personal protection equip-
ment and follow your company safety and opera-
tional procedures.
• Never tighten or loosen any fastener or fitting while
the unit is operating or pressurized.
• Verify neither driver nor compressor can turn during
maintenance.
• Follow packager instructions to completely isolate
and vent the system; call the packager for assis- 1 Mounting Bracket Cap Screws (4)
tance.
2 Auxiliary End Cover
• Verify each compressor cylinder is relieved to atmo-
spheric pressure. To relieve residual cylinder bore 3 O-Ring
pressure after blowdown, open the “Kiene” valves 4 Shaft Oil Seal
on the indicator ports, if so equipped. 5 Key
WARNING: RELEASED GAS MAY BE POISONOUS 6 Set Screw
AND/OR FLAMMABLE.
Before resuming operation, purge the entire system with 7 Sprocket
the gas being compressed to avoid a potentially
explosive gas/air mixture in the system. A gas/air 1. With a good machinist rule, measure exact
mixture under pressure can explode and cause severe distance from inside face of auxiliary end
injury or death.
cover to near face of lubricator sprocket.
Note measurement for proper positioning of
new sprocket. Remove chain.
2. Remove sprocket set screw and sprocket.
Detach all tubing from lubricator.
3. Remove mounting bracket cap screws and
lubricator.
4. With the lubricator on the bench, remove key
from shaft and file shaft to remove burrs
raised by set screw cup point. Oil and install a
new O-ring.
5. Dig out the shaft oil seal with an awl and
install a new one.

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6. Install a new key. Verify it fits into the new Crankshaft Chain Sprocket
sprocket (see build book for key type and
dimensions). If too thick, polish it with emery
Replacement
cloth on a flat surface until it easily slides into
the notch. The top edge may also require a WARNING
little polishing. To reduce risk of injury or death, only trained personnel
who have read and thoroughly understand the
7. After new key installation, verify the new appropriate Ariel Technical Manual and Packager
sprocket fits, oil the new O-ring, and remount information should attempt any maintenance.
lubricator to the end cover. Prior to performing any maintenance activities:
• Always wear appropriate personal protection equip-
8. Slide new sprocket onto the shaft and set to
ment and follow your company safety and opera-
dimension measured in step 1. Tighten set tional procedures.
screw. • Never tighten or loosen any fastener or fitting while
9. Using a straight edge, to within 1/32 inch (1 the unit is operating or pressurized.
• Verify neither driver nor compressor can turn during
mm), check alignment to crankshaft drive
maintenance.
sprocket with crankshaft centered in end • Follow packager instructions to completely isolate
play. When aligning this sprocket with the and vent the system; call the packager for assis-
idler sprocket, take into account that the idler tance.
sprocket is thinner than the other sprockets. • Verify each compressor cylinder is relieved to atmo-
If misaligned, adjust sprocket position as spheric pressure. To relieve residual cylinder bore
needed. pressure after blowdown, open the “Kiene” valves
on the indicator ports, if so equipped.
10. Install chain and adjust according to "Chain WARNING: RELEASED GAS MAY BE POISONOUS
Adjustment". AND/OR FLAMMABLE.
Before resuming operation, purge the entire system with
11. Re-attach all tubing to lubricator. the gas being compressed to avoid a potentially
explosive gas/air mixture in the system. A gas/air
mixture under pressure can explode and cause severe
injury or death.

CAUTION

Do not touch hot surfaces without proper protection.

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Figure: Crankshaft Sprocket Removal Chain Adjustment

Figure: Typical Chain Deflection Measurement

1 Strike here with chisel.

1 Finger Pressure
Examine sprocket carefully for wear; sprockets 2 Machinist's Scale
operating for five years or more may require 3 Straight Edge
replacement. To replace a sprocket on a 4 Span Length
JG:JGA:
1. Roll the crankshaft to the tightest position of
1. Drill a hole in the sprocket hub parallel to the
the chain. This prevents snugging the chain at
shaft centerline and big enough to remove
a slack position and breaking rollers, or
most of the hub cross section (see figure to
ruining the pump and lubricator bearings
the right). Multiple smaller holes may be
when the chain goes through its tightest
required. DO NOT touch shaft with drill. Mark
position.
the drill with tape to avoid drilling through
the sprocket and into the crankshaft face. The 2. Use a tape measure to measure the longest
hole relieves most of the shrink, and a few most easily accessible span from sprocket
radial strikes with a hammer and chisel opens center to sprocket center, where the
the sprocket enough for easy removal. deflection will be gauged. Determine
allowable deflection limits for the measured
2. Suspend the new sprocket with a wire and
span as defined by the shaded area in Figure:
heat it with a small torch to about 400°F
Allowable Chain Deflection.
(204°C), then slip it over the auxiliary end of
the crankshaft. Hold the sprocket in place 3. Measure chain deflection from a straight edge
and rotate it slightly to ensure squareness held on the chain rollers where it wraps over
until it cools enough to shrink onto the the two sprockets of the span (see Figure:
crankshaft Typical Chain Deflection Measurement).
Using a machinist’s rule with 0.01 inch or (1.0

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mm) increments, apply finger pressure to 5. Replace and tighten the two cap screws hand
measure the distance from the straight edge wrench tight.
to a chain roller at the center of the span.
CAUTION
Record the measurement and check to see if
it is in tolerance. Over tightening may result in bent shafts.

4. If adjustment is required, remove the cap

screws and plastic plugs from the eccentric 6. Roll the crankshaft to check tightness in
cap. Rotate the cap clockwise to line up the several positions. At its tightest position, the
first two new cap screw holes. If this tightens chain should deflect within the shaded limits
the chain too much, turn the cap in Figure: Allowable Chain Deflection.
counterclockwise for a different hole Replace plastic caps to keep the holes clean.
alignment.

Figure: Allowable Chain Deflection, Inches (mm)

A Deflection B Length of 1 Maximum 2 Minimum Deflec- 3 Allowable

Measured Span Deflection tion Deflection

Component Cleaning & Thread contaminated internal surfaces, and repair parts
prior to installation, to extend the life of rings and
Lube for Non-Lube non-lube compressors.
Compressor Cylinders
Ariel cleans and protects complete non-lube
cylinders to non-lube service requirements.
Clean all internal parts shipped loose,

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Clean cylinder bore thoroughly with denatured Clean the head end head or unloader
alcohol until a clean, alcohol-soaked, white components with denatured alcohol. Use
paper towel removes no more debris. This minimal amounts of oil for the bolt-holes to
includes all surfaces of the bore, counter bore, ensure oil does not run into the cylinder. Also
valve pockets, etc. Do not use Never-Seez on install the head end steel gasket without Never-
steel gaskets. Apply a light film of oil to cylinder Seez.
seating surfaces to seal o-rings.
Disassemble and clean the valves with denatured
CAUTION alcohol, then re-assemble, wipe them again, and
install. Clean retainers and high clearance
Denatured alcohol presents health and safety hazards. It
contains methyl alcohol and is poisonous if ingested. assemblies with denatured alcohol. Use only a
Avoid eye and skin contact. Keep alcohol away from thin film of oil for the valve cap O-rings and bolt-
heat, sparks, flame, and all other ignition sources. Use holes.
adequate ventilation, neoprene or butyl gloves, mono-
goggles or face-mask, and impermeable apron. Properly Assemble cleaned parts immediately to avoid
handle and dispose of materials resulting from clean-up.
See manufacturer's material safety data sheets for more contamination and corrosion. If cylinder will not
details. commence immediate service, contact Ariel for
preservation instructions to ER-34.
Do not use any lubricants or anti-seize
compounds on parts that may contact the gas
stream.

Use very small amounts of Never-Seez regular

grade on nut and collar when assembling piston
assembly. Thoroughly clean piston (especially
the ring grooves) with denatured alcohol until a
clean, alcohol-soaked towel removes no more
debris.

Disassemble packing case. Wipe all surfaces

clean with denatured alcohol. Re-
assemble.When the packing case is water cooled,
re-assemble and test to "Testing". Handle
cleaned parts with new or clean "rubber" or new
white cotton gloves.

Before piston rod installation, wipe it with

denatured alcohol. Be careful not to leave
fingerprints on the rod before it contacts the
packing rings. Wipe the rod with denatured
alcohol after installation.

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Section 5 - Start Up

Warranty Notification - Installation List Data and Start Up Check

Lists for Reciprocating Compressors
Download the Installation List Data and Start Up Check Lists forms, which is designed to ensure a
successful start-up of Ariel reciprocating compressors. Ariel warranty coverage requires these
completed forms be sent to:

Administrative Assistant - Sales, Ariel Corporation

35 Blackjack Road
Mount Vernon, Ohio 43050 USA
Phone: 740-397-0311 FAX: 740-397-3856
Email: [email protected]

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Section 6 - Compressor Troubleshooting

Expect minor problems during routine operation of an Ariel compressor. These troubles most often
trace to liquid, dirt, improper adjustment, or operators unfamiliar with Ariel compressors. These
difficulties can usually be corrected by cleaning, proper adjustment, elimination of an adverse
condition, part replacement, or proper training.

Major problems usually trace to long periods of operation with unsuitable lubrication, careless
operation, lack of routine maintenance, or using the compressor for purposes not intended.

Recording inter-stage pressures and temperatures on multistage units is valuable. Any variation when
operating at a given load point indicates trouble in one of the stages. Normally, a decrease in inter-
stage pressure indicates trouble in the lower pressure cylinder. An increase usually indicates trouble
in the higher pressure cylinder. Below is a list of common problems and possible causes.

Problem Possible Causes

Low Oil Pressure • Oil pump pressure regulating valve set too low or
sticking.
• Oil pump or oil pump drive failure.
• Oil foaming from counterweights striking oil
surface (oil level in sight glass too high), or from
vortex at strainer inlet (oil level in sight glass too
low), or from leaks in pump suction line.
• Cold oil.
• Dirty oil filter.
• Interior frame oil leaks.
• Excessive leakage at bearings.
• Improper low oil pressure switch setting.
• Oil pump relief valve set too low.
• Defective pressure gauge.
• Plugged oil sump strainer.
• Improper end clearance in oil pump.
High/Low Suction Pressure • Suction control valve malfunction.
• Faulty pressure gauges.
• Frozen/plugged inlet line.
• Plugged intake screen or filter.
• Scrubber dump valve stuck open.
• Recycle malfunction.
• Site production equipment problems.

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Problem Possible Causes

High/Low Inter-Stage Pressure • Faulty valves or rings.

• Gas leak.
• Frozen cooler section or tubing to panel.
• Faulty pressure gauges.
• Scrubber dump valve stuck open.
• Load change.
Noise in Cylinder • Loose piston.
• Piston hitting cylinder head end head or crank
end head.
• Loose crosshead balance nut.
• Broken or leaking valve(s).
• Worn or broken piston rings or wear bands.
• Valve improperly seated or damaged seat gasket.
• Liquids in cylinder.
Frame Knocks • Loose crosshead pin or pin caps.
• Loose or worn main, crankpin, or crosshead
bearings.
• Low oil pressure.
• Cold oil.
• Incorrect oil.
• Knock is actually from cylinder end.
• Low fluid level in damper.
Excessive Carbon on Valves • Excessive lube oil.
• Improper lube oil.
• Oil carry-over from inlet system or previous
stage.
• Broken or leaking valves causing high tempera-
ture.
• Excessive temperature due to high pressure ratio
across cylinders.
Relief Valve Popping • Faulty relief valve.
• Leaking suction valves or rings on next higher
stage.
• Obstruction, closed or faulty valve in discharge
line.
High Discharge Temperature • Excessive ratio across cylinder due to leaking
inlet valves or rings on next higher stage.
• Fouled inter-cooler piping.
• Leaking discharge valves or piston rings.
• High inlet temperature.
• Improper lube oil and/or lube rate.

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Problem Possible Causes

High Frame Oil Temperature • Faulty temperature gauge.

• Dirty oil filters.
• High oil level.
• Faulty thermostatic element.
• Faulty thermostatic control valve.
• Clogged or blocked oil cooler.
• Binding or tightness in the compressor.
Packing Over Heating • Lubrication failure.
• Improper lube oil and/or insufficient lube rate.
• Worn packing rings.
• Dirt in packing.
• Improper ring side or end gap clearance.
• Scored, tapered or out of round piston rod.
• Excessive piston rod runout.
Excessive Packing Leakage • Worn packing rings.
• Improper lube oil and or insufficient lube rate.
• Dirt in packing.
• Packing rings assembled incorrectly.
• Improper ring side or end gap clearance.
• Plugged packing vent system.
• Scored, tapered or out of round piston rod.
• Excessive piston rod runout.
• Packing not seated or properly run in.
Drive End of Crankshaft Oil Leaks • Clogged vent or vent piping.
• Excessive cylinder packing leakage.
Piston Rod Oil Wiper Leaks • Worn wiper rings.
• Wipers incorrectly assembled.
• Worn/scored rod.
• Improper fit of rings to rod/side clearance.
Force Feed Lubrication Shutdown • Force feed pump or lubricator block failure.
• Loss of oil supply to force feed pump.
• Lubricator drive failure.
• DNFT not programmed correctly.
• DNFT battery failure or power loss.
• Loose or grounded control wiring.
• Pin assembly not completely pushed into the
DNFT housing.

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Problem Possible Causes

Oil Leaks at Pipe Threaded Connections • Joint not tight.

• Pipe sealant was omitted.
• Defective or damaged pipe threads.
• NPTF Dryseal threads not being used.
• Pressure too high for pipe threaded connection
use.
• Pipe thread sealant incompatible with the
synthetic oil used.
• Cracked pipe or fittings.
Vibration Shutdown • Short in wire to panel.
• Incorrectly positioned vibration switch.
• Loose mounting bolts.
• High scrubber level (liquid carry-over).
• Broken valve, piston, or piston rod.
• Main drive-line or coupling failure.

Piston Rod Runout Correction

Figure: Piston Rod Runout Measurement

Piston rod runout may be either positive or rod runout tolerance requires correction for safe,
negative. A positive reading indicates the piston efficient compressor operation (see Appendix B).
drops as it moves to the head end of the cylinder Piston rod runout correction first requires
due to the clearance in the bore. As the piston verification (and correction, if needed) of the
drops, the rod rises, yielding a positive reading crosshead clearance. See flowcharts below.
on the indicator. If the cylinder is not supported
properly, it could droop causing the piston to
drop as it moves to the head end of the cylinder.
A negative reading indicates the piston climbs as
it moves to the head end of the cylinder. When
the piston climbs, the rod drops, yielding a
negative reading. Any reading outside the Ariel

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Figure: Crosshead Clearance Verification/Correction Flowchart

NOTE: Review all steps before troubleshooting. If

issues persist, contact the Ariel Response Center.

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Figure: Piston Rod Runout Verification/Correction Flowchart

NOTE: Verify crosshead clearance is within Ariel specs

per the manual before checking piston rod runout.

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Appendix A - Ariel Fasteners and Torques

This document lists fastener lubrication and standard cap screws, contact your packager
torque requirements for proper assembly of or Ariel.
JG:JGA reciprocating compressors. For older • Clean and de-burr all threads.
units with lower specified torque values, do not • Do not use molybdenum disulfide lubricants.
assume higher values without consulting the • Do not use Never-Seez for fastener lubrica-
packager and/or Ariel. tion unless specified or excessive stresses
may result with specified torques. See Table:
• Use only Ariel specified fasteners tightened to Fastener Thread & Seating Surface Lubrica-
the correct torque. tion.
• Connecting rod, valve cap, and • Use anti-seize lubricants sparingly; excessive
suction/discharge nozzle (Ariel supplied amounts cause oil analysis to indicate
flange) fasteners are modified to prevent contamination and may unnecessarily
fatigue; do not replace them with standard increase maintenance costs.
cap screws. To replace other fasteners with
• Re-preserve any fasteners subject to corro-
sion after installation.

Table: Fastener Thread & Seating Surface Lubrication

NOTE:Lubricate all fasteners both under the head and on the threads.

Application Lubricant

Forged Steel Cylinders: valve cap, cylinder mounting Never-Seez Regular Grade
flange to cylinder body, packing, crank end and head end
head, gas passage

Cast Cylinders: valve cap, tandem cylinder mounting, Mineral oil (ISO 100-150)
packing, crank end and head end head

Frame: jack screws Never-Seez Regular Grade

Pistons: piston nuts, set screws, piston collar, crosshead
threads, tandem piston to piston rod
All stainless steel fasteners except valve fasteners
listed in Table: Hoerbiger Valve Assembly Fastener
Torques

Connecting rod cap Lubriplate 630-AA

Crosshead balance nut, frame to spacer bar Under the head or mating surface: Mineral oil (ISO 100-
150).
On the threads: Never-Seez Regular Grade.

All pipe threads Loctite 567

Fasteners specified with Loctite on threads Loctite only with no additional lube

All other fasteners, all O-rings and stat-o-seals Mineral oil (ISO 100-150)

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Figure: Bolt Head Grade and Material Identification

CAUTION 5. Always apply a steady, slow force to a torque

wrench, and stop immediately when the
To replace a fastener, see parts list for fastener grade
and part number. Do not use a lesser or greater material wrench clicks. Do not bounce, jerk, or double
grade. Use Ariel parts to replace special fasteners and tap the wrench – it significantly increases the
fasteners with reduced body diameter for fatigue applied torque. Perform final tightening with
resistance. Do not torque fasteners with compressor
running or pressurized. Read technical manual safety a torque wrench.
warnings.
6. Do not break fasteners loose with a torque
wrench - it may overload the wrench and
Recommendations for Torque affect its accuracy.

Accuracy 7. Determine torque wrench accuracy range

before using - most are not accurate at the
1. Critical bolted joints require accurate
extreme lower and higher ends of their range.
fastener pre-stress to ensure safe and reliable
operation. On Ariel compressors, these joints 8. Clean and de-burr all threads before
have specified torque or other engineered assembly. Ensure no oil or debris is in the
tightening methods. Only mechanics prop- bottom of the bolt hole when installing bolts.
erly trained in bolted flange joint assembly Apply oil only to fasteners, not in the bolt
should maintain these joints. hole.
2. When torque is specified for a fastener, use a 9. Inspect all joint mating surfaces for
properly calibrated torque wrench to torque scratches, nicks, gouges, burrs, corrosion and
the fasteners correctly. flatness. This includes the fastener and the
3. Use the correct lubricant on the fastener (see fastener contact area on the bolted part.
Table: Fastener Thread & Seating Surface Address any findings before proceeding.
Lubrication). Figure: Main Bearing Cap or Connecting Rod Cap
Torque Sequence
4. Always turn fasteners in by hand until they
are finger tight and drawn down evenly.
Using a wrench, turn fasteners to draw o-
rings into their bores. Using pneumatic, elec-
tric, or hydraulic drivers and runners can
result in uneven tightening and over-stressed
fasteners. If there is significant resistance,
remove the fastener to determine and correct
the cause.

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10. For main bearing cap and connecting rod After 100% torque is reached, continue
cap fasteners: If the bearing cap is stamped passes until all fasteners stop moving.
with torque sequence numbers, tighten • Inspect the gap under the bolted flange (if
fasteners in that sequence. If not stamped, visible) after each pass to ensure a consis-
follow the Figure: Main Bearing Cap or tent gap all around. If the gap is not
consistent, the assembly is cocked –
Connecting Rod Cap Torque Sequence.
disassemble and inspect to determine the
• Where torque and turn IS NOT SPECI- cause, and re-assemble after the cause is
FIED: Apply 50% of specified torque in the corrected.
sequence shown to close joint. Once
closed, apply 100% of specified torque in
the same sequence. Repeat 100% torque
in the same sequence until all fasteners
stop moving.
• Where torque and turn IS SPECIFIED:
Apply 100% of pre-torque in the sequence
shown to close joint. Repeat 100% torque
in the sequence until all fasteners stop
moving. Finally, apply the full turn value
to each fastener one time in the same
sequence.
11. For Ariel pressure containing components,
see Figure:Pressure Containing Joint
Recommended Torque Sequences for
recommended torque sequences (includes
cylinders, valve caps, cylinder heads,
unloaders, gas passage caps, flanges, and
packings):

• Refer to ASME PCC-1 “Guidelines for Pres-

sure Boundary Bolted Joint Flange
Assembly” for commonly accepted prac-
tices.
• Install a new gasket or O-ring.
• For 3-bolt valve caps, tighten in this
sequence: 1-2-3, 2-3-1, 3-1-2. Use the
sequence to close the joint without
exceeding 25% of full torque. Repeat the
three-pass sequence for 25%, 50%, 75%,
and 100% of full torque. Repeat 100%
torque in a circular pattern until all
fasteners stop moving.
• For other pressure containing joints,
tighten the fasteners in four passes using
the appropriate sequence for 25%, 50%,
75% and 100% of the specified torque.

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Figure: Pressure Containing Joint Recommended Torque Sequences

A 3 Fasteners E 7 Fasteners I 11 Fasteners M 18 Fasteners Q Obround Flange

B 4 Fasteners F 8 Fasteners J 12 Fasteners N 20 Fasteners R 40-Fastener
C 5 Fasteners G 9 Fasteners K 14 Fasteners O 22 Fasteners Peanut Flange
D 6 Fasteners H 10 Fasteners L 16 Fasteners P 24 Fasteners S 24-Fastener
Peanut Flange

12. When finished, reset torque wrench to its 13. To determine the torque wrench setting
lowest setting to relax the spring. A torque when using a torque multiplier, divide the
wrench left in a high setting stresses the desired fastener torque by the multiplier
spring and decreases accuracy with time. actual mechanical advantage, not the design
mechanical advantage. See manufacturer
documentation for multiplier.

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Figure: Torque Wrench with Angled Adapter Tw = Ta x [L ÷ (L + A)]

Tw = Torque wrench setting, Lb x Ft or N·m.
Ta = Torque required at fastener, Lb x Ft or N·m.
L = Length of wrench, ft or m (from square drive end to
center point of force on handle).
A = Wrench length added by adapter, ft or m (measured
to end of adapter on a line parallel to wrench center
line).
14. If using an offset adapter with a torque
wrench, the torque setting is not the actual
torque applied, unless the adapter is 90° to
the torque wrench. To determine the correct
torque setting:

Table: Hoerbiger Valve Assembly Fastener Torques

Type Torque
Nominal Size
Fastener Lb x Ft (N·m), unless Lb x Ft (N·m), unless
Inch - TPI
specified specified

Center Cap Screwa 5/16 - 24 12 Point - Steel Grade 5 14 (19)

Material Parts: SPL3 & 4
3/8 - 24 24 (33)

7/16 - 20 35 (48)

5/16 - 24 12 Point - Steel Grade 5 22 (30)

Material Parts: SPL or SPL5
3/8 - 24 40 (54)

7/16 - 20 65 (88)

5/16 - 24 12 Point - Stainless Steel 14 (19)

Grade B
3/8 - 24 8M Material Parts: SPL6 24 (33)

7/16 - 20 35 (48)

Peripheral Cap Screw #10 - 32 Hex Socket Head 25 Lb x In (2.8)

#12 - 28 43 Lb x In (4.9)

1/4 - 20 110 Lb x In (12)

5/16 - 18 176 Lb x In (20)

3/8 - 16 21 (28)

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Type Torque
Nominal Size
Fastener Lb x Ft (N·m), unless Lb x Ft (N·m), unless
Inch - TPI
specified specified

Single-piece Lock Nuts Nominal Size Torque Lb x Ft (N·m), unless specified

(Greer, Flexloc, Selflock)
Inch - TPI SPLb Other

#12 - 28 96 Lb x In. (11)c -

b
(Microlock, Spiralock )
5/16 - 24 15 (20) 109 Lb x In (12)

3/8 - 24 26 (35) 17 (23)

7/16 - 20 48 (65) 26 (35)

1/2 - 20 67 (91) 41 (55)

5/8 - 18 110 (150) 82 (110)

3/4 - 16 195 (265) 145 (195)

7/8 - 14 295 (400) 230 (310)

Center Stud Drake 2-Piece Inch - TPI Bottom Half Top Half
Beam Lock Nut
1/4 - 28 103 Lb x In (12) 66 Lb x In (7.5)

5/16 - 24 168 Lb x In (19) 96 Lb x In (11)

3/8 - 24 16 (22) 96 Lb x In (11)

1/2 - 20 36 (49)d 20 (27)

5/8 - 18 73 (99) 40 (54)

3/4 - 16 130 (175) 70 (95)

7/8 - 14 210 (285) 115 (155)

a Center cap screw valve assemblies have Spiralock® (SPL) threads to prevent loosening. See bottom of valve
assembly for SPL material parts number (3, 4, 5 or 6) and select proper torque from the table. Lubricate both threads
and seating surfaces with mineral oil (ISO 100-150) ONLY. If using older valve assemblies not covered in the table,
see the original torque chart provided in the compressor tool box, or contact Ariel for instructions. Spiralock®
threads cannot be dressed with a standard tap. Clean center cap screws in valve assemblies not marked SPL with
Loctite safety solvent and lock them with one or two drops of Loctite #272 thread locking compound. DO NOT use
petroleum lubricants.
b Microlock and Spiralock nuts are marked "SPL" on one of the flats.
c Use this torque only with a 17-4PH 900H material center stud.
d Use 29 (39) for 1/2 - 20 bottom half Drake lock nut with non-metallic valve plates in liftwasher valves.

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JG:A Fastener Torques

Torque
Fastener Nom. Size, Inch - tpi Type Lb x Ft (N·m), unless
specified

Main Bearing Cap - Cap 1/2 - 13 12 Point - Grade 8 58 (79)

Screw

Connecting Rod Cap - Cap 1/2 - 20 12 Point - Grade 8 67 (91)

Screw

Torsional Vibration 1/2 - 20 12 Point - Grade 8 61 (83)

Detuner - Cap Screw

Crosshead Pin Thru Bolt - 3/8 - 24 Hex - Nylon Insert 25 (34)

Lock Nut

Frame to Spacer Bar - Cap 5/8 - 18 Hex Grade 8 or 9 or 12 Point 92 (125)

Screw - Grade 8

Crosshead Guide to Frame 1/2 - 13 12 Point or Hex Grade 8 48 (65)

or to Cylinder; Unloader
Actuator to Valve Cap - Cap
Screw
Distance Piece to 1/2 - 13 12 Point 57 (77)
Crosshead Guide - Cap
Screw

Distance Piece to Cylinder 3/8 - 16 Socket Head 18 (24)

(11JG) - Cap Screw

Eccentric Vernier Cap - Cap 5/16 - 18 12 Point or Hex Grade 8 Hand Wrench Tight
Screw

Idler Sprocket Thru Bolt - 1/2 - 20 Hex - Prevailing 41 (55)

Lock Nut

Force Feed Lube Box - 1-3/8 - 20 LH Bearing Housing 70 (95)

Bearing Housing

Force Feed Lube Box - Jam 1" - 14 Hex 75 (100)

Nut

Force Feed Lube Pump 1/4 - 20 Hex - Grade 5 50 Lb x In. (5.6)

Mounting

Auto Relief Valve 1/2e Ariel Design 75 Lb x In. (8.5)

Auto Relief Valve Manifold #10 - 24 Ariel Design 50 Lb x In. (5.6)

Plug
1/4 NPT Hex Hand Wrench Tight

Rod Packing - Cap Screwf 1/2 - 13 12 Point - Grade 8 35 (48)

9/16 - 12 12 Point - Grade 8 51 (69)

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Torque
Fastener Nom. Size, Inch - tpi Type Lb x Ft (N·m), unless
specified

Packing Tie Stud Nut #10 - 24 Hex 20 Lb x In. (2.3)

1/4 - 20 72 Lb x In. (8.1)

5/16 - 18 12 Point Flange 144 Lb x In. (16)

Piston Nutg 7/8 - 12 Ariel Design 220 (300)

Piston Nut Set Screw #10 - 32 Socket Head 36 Lb x In. (4.1)h

Crosshead Balance Nut 1” - 12 Ariel Design Slugging Method

Piston Rod Oil Slinger Bolt - 1/4 - 28 Hex Jam-Prevailing 95 Lb x In. (11)
Lock Nut

Rupture Disk - Blow-Out 1/4 Nom. Tube Hex - Tube Fitting 40 Lb x In. (4.5)
Fitting Cap

Frame Foot Hold Down 3/4 - 10 Hex Nut 175 (235) i

Crosshead Guide Support 5/8 - 11 Hex Nut 100 (140) i
Foot Hold Down

Crosshead Guide to 5/8 - 11 12 Point - Grade 8 90 (120)

Support

Ariel Supplied Companion 1/2 - 13 12 Point - Grade 8 or 17- 40 (54)

Flange Except "Peanut" 4PH
Dual Nozzlei
1/2 - 20 Hex Nut 12 Point - Grade 8 46 (62)
or 17-4PH

ANSI Flange to Cylinder See Cylinder Outline Provided by Packager See ER-127.
Nozzle

Taper-Lok Flangej 1/2 - 13 Hex Nut on Grade 8 Stud or 40 (54)

17-4 stud
1/2 - 20 46 (62)

5/8 -11 79 (105)

5/8 -18 92 (125)

3/4 - 16 160 (215)

Tandem Piston to Piston 5/16 - 24 Dog Pt. Stud 17-4PH 18 (24)k

Rod

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Torque
Fastener Nom. Size, Inch - tpi Type Lb x Ft (N·m), unless
specified

Cap Screwl 5/16 - 18 Hex - Grade 8 or 9, 12 Point 108 Lb x In. (12)

- Grade B7M or 8 or 17-4PH,
• Valve Cap 3/8 - 16 193 Lb x In. (22)
or Socket Head
• Cylinder Head
7/16 - 14 26 (35)
• Gas Passage
• VVCP or eVCP 1/2 - 13 40 (54)
m
Adapter to Head 9/16 - 12 57 (77)
• VVCP Seal Carrier
5/8 -11 79 (105)

5/8 - 18 92 (125)

3/4 - 10 140 (190)

3/4 - 16 160 (215)

7/8 - 9 230 (310)

7/8 -14 260 (350)

1” - 8 345 (465)

1” - 14 395 (535)

VVCP, FVCP, or eVCP to 1/2 - 13 12 Point - Grade 8 or 17- 40 (54)

Cylinder 4PH
5/8 - 11 79 (105)

Tandem Cylinder to 1/2 - 13 Hex - Grade 8 or 9 or 12 44 (60)

Cylinder - Cap Screwl Point - Grade 8
5/8 - 11 88 (120)

3/4 - 10 160 (215)

1” - 14 440 (595)

Stud Seating 3/8 - 16 Dog Point Grade 8 or 17- 107 Lb x In. (12)
In valve cap assemblies 4PH
with a spring energized 7/16 - 14 172 Lb x In. (19)
seal, install longer studs 1/2 - 13 22 (30)
with Loctite 242.
9/16 - 12 32 (43)

5/8 - 11 44 (60)

3/4 - 10 79 (105)

3/4 - 16 90 (120)

7/8 - 9 130 (175)

7/8 - 14 145 (195)

1” - 8 200 (270)

Distribution Block Tie Rod - 1/4 - 28 Dog Point Grade 8 or 17- 68 Lb x In. (7.7)
Nut 4PH

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Torque
Fastener Nom. Size, Inch - tpi Type Lb x Ft (N·m), unless
specified

Distribution Block Divider 1/4 - 28 Hex 75 Lb x In. (8.5)n

Valve - Screw

Grade 5 - Hex Cap Screw All Socket Head Hand Wrench Tight

Valve Cap Assembly - Cap 3/4 - 16 Hex - Grade 5 Hand Wrench Tight
Nut

Valve Cap Seal Keeper - 5/16 - 18 Cap Nut 120 Lb x In. (14)
Cap Screw
3/8 - 24 12 Point - 17-4PH 21 (28)

e "1/2" indicates the wrench size. Auto relief valve can swivel in the manifold once torqued. See assembly drawing.
f Repeat final torque for rod packing bolts until they no longer turn before the torque wrench clicks.
g Tighten, loosen, then re-tighten to ensure proper torque.
h Or tighten set screw 15° past the Allen wrench yield point. Discard deformed wrench, and use a new Allen wrench to
tighten the other set screw. Stake set screws per manual after tightening.
i Minimum torque to stress recommended hold-down stud to 55,000 psi (380 MPa). Use studs with an ultimate
strength of 100,000 psi (690 MPa) or greater. If greater, increase torque stress to about 55% of ultimate strength, as
specified by packager.
j See ER-136 for Taper-Lok installation instructions.
k Tighten, loosen, then re-tighten to ensure proper torque.
l For studs specified for cylinder applications, tighten nuts to the same torque as cap screws in similar applications.
m Excludes socket head cap screws, which are installed hand wrench tight.
n Step-torque first to 40 Lb x In. (4.5 N•m), and then to 75 Lb x In. (8.5 N•m).

Table: Straight Thread SAE O-Ring Connections into Steel, Cast Iron, or Aluminum: Positionable
Lock Nuts, Plugs, & Non-Positionable Fitting Torques
Nominal Fitting Size SAE Number Thread Size Wrench Size Torque
Inch Size Inch – TPI Inch Lb x Ft (N·m)

1/4 -4 7/16 – 20 9/16 160 Lb x In (18)

3/8 -6 9/16 – 18 11/16 22 (30)

1/2 -8 3/4 – 16 7/8 37 (50)

5/8 -10 7/8 – 14 1" 44 (60)

3/4 -12 1-1/16 - 12 1-1/4 70 (95)

1" -16 1-5/16 – 12 1-1/2 110 (150)

1-1/4 -20 1-5/8 – 12 1-7/8 150 (205)

1-1/2 -24 1-7/8 – 12 2-1/8 155 (210)

2 -32 2-1/2 – 12 2-3/4 220 (300)

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Appendix B - Clearances
Table: JG:JGA Frame and Running Gear Clearances, in. (mm)
Description Clearance

Crankshaft Journal Bearing (Jack) 0.0005 to 0.0035 (0.013 to 0.089)

Crankshaft Thrust (End) 0.0035 to 0.011 (0.089 to 0.279)

Connecting Rod Bearing (Jack) 0.0015 to 0.0040 (0.038 to 0.102)

Connecting Rod Thrust (Side) 0.007 to 0.016 (0.178 to 0.406)

Crosshead to Guide (Babbitted Ductile Iron with 0.004 to 0.008 (0.10 to 0.20) (Feeler Gauge)
bushings)

Crosshead to Guide (Babbitted Bronze, no bushings) 0.006 to 0.010 (0.15 to 0.25) (Feeler Gauge)

Crosshead Pin to Connecting Rod Bushing 0.0014 to 0.0031 (0.036 to 0.079)

Crosshead Pin to Crosshead Bushings 0.0014 to 0.0036 (0.036 to 0.091)

Crosshead Pin to Crosshead (Bronze, no bushings) 0.0015 to 0.0025 (0.038 to 0.064)

Shaft Seal Housing, Centered on Crankshaft 0.008 (0.20) (Feeler Gauge All Around)

Table: JG:JGA Piston End Clearances, in. (mm)a, b

Description Clearance

Total Piston End Clearance - Double Acting 0.090 to 0.145 (2.29 to 3.68)

Piston End Clearance - Crank End - Double Acting 0.035 (0.89)

Piston End Clearance - Head End - Double Acting 0.055 to 0.110 (1.40 to 2.79)

Total Piston End Clearance - Tandemc 0.090 to 0.180 (2.29 to 4.57)

Piston End Clearance - Crank End Tandemc 0.035 (0.89)

Piston End Clearance - Head End Tandemc 0.055 to 0.145 (1.40 to 3.68)

a Measured clearances may not agree due to oil films, wear, etc. Do not use plastigages, solder, etc.
b If total piston end clearance (crank end + head end) is not within table tolerance, contact Packager or Ariel.
c For 2-1/4P-CE cylinders, it is not practical to use the CE clearance tool to set piston clearance.

Table: JG:JGA Max. Acceptable Piston Rod Runout, in. (mm)

Description Runout

Vertical Runout 0.0010 (0.0254)

Horizontal Runout 0.0005 (0.0127)

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Table: New Uncut Packing Ring Side Table: New Wiper Ring Side Clearance, in.
Clearance, in. (mm), (mm)
(BTUU/CUU/BTU/CU/STU) Wiper Ring Type Side Clearance
Actual Groove Width Side Clearance 2RWS, 2RUG 0.004 to 0.006 (0.010 to
0.447 to 0.449 (11.35 to 0.013 to 0.018 (0.33 to 0.015)
11.40) 0.46) 3RWS, 3RUG 0.006 to 0.009 (0.15 to
0.572 to 0.574 (14.53 to 0.023 to 0.028 (0.58 to 0.23)
14.58) 0.71) RTV 0.000
0.625 to 0.627 (15.88 to 0.025 to 0.030 (0.64 to
15.93) 0.76) Table: Piston/Rider Ring Side Clearance, in.
0.750 to 0.752 (19.05 to 0.030 to 0.035 (0.76 to (mm)
19.10) 0.89)
Actual Groove Width Side Clearance

Table: New Pressure Breaker and Segmented 0.188 to 0.190 (4.78 to 0.008 to 0.013 (0.20 to
4.83) 0.33)
Packing Ring Side Clearance, in. (mm),
(BTR/BTS/CR/BD/BT/TR/P/UP/P1U) 0.250 to 0.252 (6.35 to
6.40)
Actual Groove Width Side Clearance
0.312 to 0.314 (7.92 to
0.375 to 0.377 (9.53 to 0.011 to 0.015 (0.28 to 7.98)
9.58) 0.38)
0.375 to 0.377 (9.53 to
0.447 to 0.449 (11.35 to 0.013 to 0.018 (0.33 to 9.58)
11.40) 0.46)
0.500 to 0.502 (12.70 to
0.572 to 0.574 (14.53 to 0.017 to 0.022 (0.43 to 12.75)
14.58) 0.56)
0.625 to 0.627 (15.88 to
0.625 to 0.627 (15.88 to 0.019 to 0.024 (0.48 to 15.93)
15.93) 0.61)
0.750 to 0.752 (19.05 to
19.10)

Table: Piston Ring Side Clearances, in. (mm)

Actual Groove Width PTFE PEEK

0.188 to 0.190 (4.78 to 4.83) 0.003 to 0.008 (0.08 to 0.20) 0.002 to 0.007 (0.05 to 0.18)

0.250 to 0.252 (6.35 to 6.40) 0.005 to 0.010 (0.13 to 0.25) 0.003 to 0.008 (0.08 to 0.20)

0.312 to 0.314 (7.92 to 7.98) 0.006 to 0.011 (0.15 to 0.28)

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Actual Groove Width PTFE PEEK

0.375 to 0.377 (9.53 to 9.58) 0.007 to 0.012 (0.18 to 0.30) 0.004 to 0.009 (0.10 to 0.23)

0.438 to 0.440 (11.13 to 11.18) 0.008 to 0.013 (0.20 to 0.33)

0.500 to 0.502 (12.70 to 12.75) 0.009 to 0.014 (0.23 to 0.36) 0.005 to 0.010 (0.13 to 0.25)

0.563 to 0.565 (14.30 to 14.35) 0.010 to 0.015 (0.25 to 0.38) 0.006 to 0.011 (0.15 to 0.28)

0.625 to 0.627 (15.88 to 15.93) 0.011 to 0.016 (0.28 to 0.41)

0.688 to 0.690 (17.48 to 17.53) 0.012 to 0.017 (0.30 to 0.43) 0.007 to 0.012 (0.18 to 0.30)

0.750 to 0.752 (19.05 to 19.10) 0.014 to 0.019 (0.36 to 0.48) 0.008 to 0.013 (0.20 to 0.33)

Table: Wearband Side Clearances, in. (mm)

Actual Groove Width PTFE PEEK

0.500 to 0.502 (12.70 to 12.75) 0.006 to 0.011 (0.15 to 0.28) 0.004 to 0.009 (0.10 to 0.23)

0.750 to 0.752 (19.05 to 19.10) 0.009 to 0.014 (0.23 to 0.36) 0.005 to 0.010 (0.13 to 0.25)

0.875 to 0.877 (22.23 to 22.28) 0.011 to 0.016 (0.28 to 0.41) 0.006 to 0.011 (0.15 to 0.28)

1.000 to 1.002 (25.40 to 25.45) 0.012 to 0.017 (0.30 to 0.43) 0.007 to 0.012 (0.18 to 0.30)

1.250 to 1.252 (31.75 to 31.80) 0.015 to 0.020 (0.38 to 0.51) 0.009 to 0.014 (0.23 to 0.36)

Table: Wear Band (new) Clearance Specifications - Lubricated 1-3/4JG-FS-HE and 7-1/2JG (with
Heavy Piston) Class, in. (mm)

Bore Diameter Minimum End Gap Radial Projectiona

1.25 (32) 0.039 (0.99) 0.005 to 0.012 (0.13 to 0.30)

1.5 (38) 0.049 (1.24) 0.0075 to 0.0145 (0.19 to 0.37)

1.625 (41) 0.052 (1.32) 0.0075 to 0.0135 (0.19 to 0.34)

1.75 (44) 0.058 (1.47) 0.0075 to 0.0145 (0.19 to 0.37)

7.5 (191) 0.170 (4.32) 0.028 to 0.039 (0.71 to 0.99)

a Replace wear band before piston contacts the cylinder bore.

Table: Wear Band (new) Clearance Specifications - Non-Lube, in. (mm)

Bore Diameter Minimum End Gap Radial Projectiona

2.75 (70) 0.088 (2.24) 0.036 to 0.050 (0.91 to 1.27)

3.375 (86) 0.085 (2.16) 0.027 to 0.034 (0.69 to 0.86)

6.125 (156) 0.201 (5.11) 0.028 to 0.039 (0.71 to 0.99)

7.5 (191) 0.164 (4.17) 0.028 to 0.039 (0.71 to 0.99)

a Replace wear band before piston contacts the cylinder bore.

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Table: Piston to Bore Clearance and Conventional Piston Ring End Gap - Non-Lube JG Class
Cylinders, in. (mm)

Piston to Bore Diametral PISTON RING END GAP - NON-METALLIC

Bore Diametera Clearance New Maximum

3.375 (86) 0.075 to 0.083 (1.91 to 2.11) 0.044 to 0.056 (1.12 to 1.42) 0.224 (5.68)

6.125 (156) 0.084 to 0.097 (2.13 to 2.46) 0.073 to 0.093 (1.85 to 2.36) 0.373 (9.47)

7.5 (191) 0.085 to 0.098 (2.16 to 2.49) 0.098 to 0.118 (2.49 to 3.00) 0.472 (11.99)

Table: Piston to Bore Clearance and Piston/Rider Ring End Gap (Seal-Joint a), in. (mm) -
Lubricated JG Class Cylinders

Piston to Bore Diametral PISTON RING END GAP - NON-METALLIC

Bore Diametera Clearance New Maximum

2.75 (70) 0.090 to 0.096 (2.29 to 2.44) 0.047 to 0.059 (1.19 to 1.50) 0.177 (4.50)

3 (76) 0.090 to 0.096 (2.29 to 2.44) 0.051 to 0.063 (1.30 to 1.60) 0.189 (4.80)

a Seal-Joint piston rings are standard for JG Class high-pressure tandem cylinders.

Table: Piston to Bore Clearance and Conventional Piston Ring End Gap - Lubricated M, P and SP
Class Cylinders, in. (mm)

Piston to Bore Diametral PISTON RING END GAP - NON-METALLIC

Bore Diametera Clearance New Maximum

2.0625 (52) 0.007 to 0.011 (0.18 to 0.28) 0.025 to 0.030 (0.64 to 0.76) 0.120 (3.05)

2.25 (57) 0.027 to 0.032 (0.69 to 0.81) 0.128 (3.25)

2.5 (64) 0.030 to 0.036 (0.76 to 0.91) 0.144 (3.66)

2.75 (70) 0.033 to 0.040 (0.84 to 1.02) 0.160 (4.06)

3 (76) 0.036 to 0.044 (0.91 to 1.12) 0.176 (4.47)

3.25 (83) 0.009 to 0.013 (0.23 to 0.33) 0.039 to 0.047 (0.99 to 1.19) 0.188 (4.78)

3.5 (89) 0.042 to 0.052 (1.07 to 1.32) 0.208 (5.28)

3.75 (95) 0.010 to 0.014 (0.25 to 0.36) 0.046 to 0.056 (0.17 to 1.42) 0.224 (5.69)

3.875 (98) 0.047 to 0.057 (0.19 to 1.45) 0.228 (5.79)

4.125 (105) 0.049 to 0.060 (1.24 to 1.52) 0.240 (6.10)

4.375 (111) 0.011 to 0.015 (0.28 to 0.38) 0.052 to 0.064 (1.32 to 1.63) 0.255 (6.48)

4.75 (121) 0.012 to 0.017 (0.30 to 0.43) 0.057 to 0.077 (1.45 to 1.96) 0.308 (7.82)

5.125 (130) 0.061 to 0.081 (1.55 to 2.06) 0.324 (8.23)

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Piston to Bore Diametral PISTON RING END GAP - NON-METALLIC

Bore Diametera Clearance New Maximum

5.5 (140) 0.013 to 0.018 (0.33 to 0.46) 0.065 to 0.085 (1.65 to 2.16) 0.340 (8.64)

5.75 (146) 0.068 to 0.088 (1.73 to 2.24) 0.352 (8.94)

6.125 (156) 0.014 to 0.020 (0.36 to 0.51) 0.073 to 0.093 (1.85 to 2.36) 0.372 (9.45)

6.5 (165) 0.077 to 0.097 (1.96 to 2.46) 0.388 (9.86)

7.5 (191) 0.016 to 0.022 (0.41 to 0.56) 0.089 to 0.109 (2.26 to 2.77) 0.430 (10.92)

8 (203) 0.095 to 0.115 (2.41 to 2.92) 0.460 (11.68)

a Conventional piston rings are standard for all M, P and SP Class Cylinders, except for 1-3/4M-FS Class Cylinder with
bore diameters of 1.625” (41) and 1.75” (44) where piston/rider rings are standard. Piston/rider rings are optional
for all other lubricated M, P and SP class cylinders. See Table: Piston to Bore Clearance and Piston/Rider Ring End
Gap, in. (mm) - Lubricated M, P and SP Class Cylinders.

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Table: Piston to Bore Clearance and Piston/Rider Ring End Gap, in. (mm) - Lubricated M, P and
SP Class Cylinders

Piston to Bore Diametral PISTON RING END GAP - NON-METALLIC

Bore Diametera Clearance New Maximum

1.625 (41) 0.090 to 0.096 (2.29 to 2.44) 0.016 to 0.032 (0.41 to 0.81) 0.128 (3.25)

1.75 (44)

2.0625 (52) 0.020 to 0.036 (0.51 to 0.91) 0.144 (3.66)

2.25 (57) 0.023 to 0.039 (0.58 to 0.99) 0.156 (3.96)

2.5 (64) 0.044 to 0.060 (1.12 to 1.52) 0.240 (6.10)

2.75 (70)

3 (76)

3.25 (83)

3.5 (89)

3.75 (95)

3.875 (98) 0.045 to 0.061 (1.14 to 1.55) 0.244 (6.20)

4.125 (105) 0.049 to 0.065 (1.24 to 1.65) 0.260 (6.60)

4.375 (111) 0.052 to 0.068 (1.32 to 1.73) 0.272 (6.91)

4.75 (121) 0.057 to 0.073 (1.45 to 1.85) 0.292 (7.42)

5.125 (130) 0.062 to 0.078 (1.57 to 1.98) 0.312 (7.92)

5.5 (140) 0.068 to 0.084 (1.73 to 2.13) 0.336 (8.53)

5.75 (146) 0.071 to 0.087 (1.80 to 2.21) 0.348 (8.84)

6.125 (156) 0.069 to 0.099 (1.75 to 2.51) 0.396 (10.06)

6.5 (165) 0.074 to 0.104 (1.88 to 2.64) 0.416 (10.57)

7.5 (191) See Noteb See Noteb

8 (203) See Noteb See Noteb

a Conventional piston rings are standard for all M, P and SP Class Cylinders, except for 1-3/4M-FS Class Cylinder with
bore diameters of 1.625” (41) and 1.75” (44) where piston/rider rings are standard. Piston/rider rings are optional
for all other lubricated M, P and SP class cylinders.
b 8M x 3-1/2 (89) stroke & 8SP-HE with 7.5 (191) bore: new - 0.099 to 0.129 (2.51 to 3.28), max. - 0.516 (13.11).
8M x 3” (76) stroke with 7.5” (191) bore: new - 0.088 to 0.118 (2.24 to 3.00), max. - 0.472 (11.99).

8M x 3-1/2 (89) stroke & 8SP-HE with 8” (203) bore: new - 0.106 to 0.136 (2.69 to 3.45), max. - 0.544 (13.82).

8M x 3” (76) stroke with 8” (203) bore: new - 0.095 to 0.125 (2.41 to 3.18), max. - 0.500 (12.70).

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Table: Piston to Bore Clearance and Conventional Piston Ring End Gap (Angular-Cut & Seal-
Joint), in. (mm) - Lubricated JG Class Cylinders

Piston to Bore Diametral PISTON RING END GAP - NON-METALLICb

Diametera Clearance
New Maximum

1.25 (32)c 0.025 to 0.033 (0.64 to 0.84) 0.018 to 0.028 (0.46 to 0.71) 0.112 (2.84)

1.5 (38)b 0.030 to 0.038 (0.76 to 0.97) 0.021 to 0.031 (0.53 to 0.79) 0.124 (3.15)

1.625 (41)b 0.023 to 0.033 (0.58 to 0.84) 0.132 (3.35)

1.75 (44)b 0.025 to 0.035 (0.64 to 0.89) 0.140 (3.56)

2 (51) 0.020 to 0.027 (0.51 to 0.69) 0.108 (2.74)

2.25 (57) 0.007 to 0.016 (0.18 to 0.41) 0.064 (1.63)

2.5 (64) 0.011 to 0.019 (0.28 to 0.48) 0.076 (1.93)

2.75 (70) 0.009 to 0.014 (0.23 to 0.36) 0.028 to 0.040 (0.71 to 1.02) 0.160 (4.06)

3 (76) 0.030 to 0.036 (0.76 to 0.91) 0.144 (3.66)

3.375 (86) 0.010 to 0.015 (0.25 to 0.38) 0.034 to 0.041 (0.86 to 1.04) 0.164 (4.17)

3.625 (92) 0.036 to 0.044 (0.91 to 1.12) 0.176 (4.47)

3.875 (98) 0.011 to 0.016 (0.28 to 0.41) 0.039 to 0.057 (0.99 to 1.45) 0.228 (5.79)

4.125 (105) 0.041 to 0.050 (1.04 to 1.27) 0.200 (5.08)

4.75 (121) 0.012 to 0.018 (0.30 to 0.46) 0.057 to 0.077 (1.45 to 1.96) 0.308 (7.82)

5.125 (130) 0.061 to 0.081 (1.55 to 2.06) 0.324 (8.23)

6.125 (156) 0.013 to 0.019 (0.33 to 0.48) 0.073 to 0.093 (1.85 to 2.36) 0.372 (9.45)

6.5 (165) 0.014 to 0.020 (0.36 to 0.51) 0.077 to 0.097 (1.96 to 2.46) 0.388 (9.86)

7.125 (181) 0.015 to 0.021 (0.38 to 0.53) 0.085 to 0.105 (2.16 to 2.67) 0.409 (10.39)

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Piston to Bore Diametral PISTON RING END GAP - NON-METALLICb

Diametera Clearance
New Maximum

7.5 (191) 0.015 to 0.021 (0.38 to 0.089 to 0.109 (2.26 to 2.77) 0.430 (10.92)
0.53)d

8.5 (216) 0.017 to 0.023 (0.43 to 0.58) 0.102 to 0.122 (2.59 to 3.10) 0.488 (12.40)

8.875 (225) 0.018 to 0.024 (0.46 to 0.61) 0.106 to 0.126 (2.69 to 3.20) 0.504 (12.80)

10.5 (267) 0.022 to 0.027 (0.56 to 0.69) 0.125 to 0.145 (3.18 to 3.68) 0.580 (14.73)

11 (279) 0.022 to 0.028 (0.56 to 0.71) 0.131 to 0.151 (3.33 to 3.84) 0.604 (15.34)

a Conventional piston rings are standard for JG class cylinders, except 2-1/2JG-FS-HE class cylinders with bore diam-
eters of 2.25 (57) and 2.5 (64); 3JG-CE, 2.75 (70) and 3 (76); 3-5/8JG-CE, 3.375 (86) and 3.625 (92); and 13-12JG, 13
(330) and 13.5 (343), which use piston/rider rings. Piston/rider rings are optional for other lubricated JG Cylinders,
except for the 1-3/4JG-FS-HE class, which uses conventional rings, but with seal-joint and wear band.
b Seal-Joint piston rings are standard for JG class high-pressure tandem cylinders.
c The 1-3/4JG-FS-HE class bore diameters use conventional seal-ring piston rings and wear band (see Table: Wear
Band (new) Clearance Specifications - Lubricated 1-3/4JG-FS-HE and 7-1/2JG (with Heavy Piston) Class, in. (mm)).
d For 7.5” (191) bore with a heavy piston, piston to bore clearance is 0.085 to 0.098 (2.16 to 2.49).

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Table: Piston to Bore Clearance and Piston/Rider Ring End Gap (Angular-Cut), in. (mm) -
Lubricated JG Class Cylinders

Piston to Bore Diametral PISTON RING END GAP - NON-METALLIC

Bore Diametera Clearance New Maximum

2.25 (57) 0.090 to 0.096 (2.29 to 2.44) 0.023 to 0.039 (0.58 to 0.99) 0.156 (3.96)

2.5 (64) 0.030 to 0.046 (0.76 to 1.17) 0.184 (4.67)

2.75 (70) 0.044 to 0.060 (1.12 to 1.52) 0.240 (6.10)

3 (76)

3.375 (86)

3.625 (92)

3.875 (98) 0.051 to 0.067 (1.30 to 1.70) 0.268 (6.81)

4.125 (105) 0.055 to 0.071 (1.40 to 1.80) 0.284 (7.21)

4.75 (121) 0.057 to 0.073 (1.45 to 1.85) 0.292 (7.42)

5.125 (130) 0.062 to 0.078 (1.57 to 1.98) 0.312 (7.92)

6.125 (156) 0.069 to 0.099 (1.75 to 2.51) 0.396 (10.06)

6.5 (165) 0.074 to 0.104 (1.88 to 2.64) 0.416 (10.57)

7.125 (181) 0.083 to 0.113 (2.11 to 2.87) 0.452 (11.48)

7.5 (191) 0.088 to 0.118 (2.24 to 3.00) 0.472 (11.99)

8.5 (216) 0.114 to 0.144 (2.90 to 3.66) 0.576 (14.63)

8.875 (225) 0.120 to 0.150 (3.05 to 3.81) 0.600 (15.24)

10.5 (267) 0.144 to 0.174 (3.66 to 4.42) 0.696 (17.68)

11 (279) 0.152 to 0.182 (3.86 to 4.62) 0.728 (18.49)

13 (330) 0.182 to 0.212 (4.62 to 5.38) 0.848 (21.54)

13.5 (343) 0.190 to 0.220 (4.83 to 5.59) 0.880 (22.35)

a Conventional piston rings are standard for JG cylinders, except 2-1/2JG-FS-HE with bore diameters of 2.25 (57) and
2.5 (64); 3JG-CE, 2.75 (70) and 3” (76); 3-5/8JG-CE, 3.375 (86) and 3.625 (92); and 13-12JG, 13” (330) and 13.5 (343),
which use piston/rider rings. Piston/rider rings are optional for other lubricated JG cylinders, except for the 1-3/4JG-
FS-HE class, which uses conventional type seal-joint rings and wear band.

Table: Piston to Bore Clearance and Conventional Piston Ring End Gap, in. (mm) - Non-Lube
(with wear bands) M and P Class Cylinders

Piston to Bore Diametral PISTON RING END GAP - NON-METALLIC

Bore Diameter
Clearance New Maximum

2.75 (70) 0.057 to 0.064 (1.45 to 1.63) 0.033 to 0.045 (0.84 to 1.14) 0.180 (4.57)

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Measuring Head End Clearance outer face, with the cylinder near to outer
dead center. Manually turn crankshaft to find
for Forged Steel Tandem the 0.010 inch (0.25 mm) position, before and
Cylinders with Concentric after outer dead center. Then turn crankshaft
to position piston at outer dead center (see
Valves Figure: Position Piston At Outer Dead Center).
3. Dimension A: Measure from cylinder head
Figure: Position Piston At Outer Dead Center end to piston head end to the nearest
thousandth inch and record. See illustration.
4. Dimension B: With gasket removed, measure
from head end cylinder face to the gasket
seat and record.

1 Button Dial Indicator

2 Mirror

CAUTION

Completely vent compressor to relieve ALL gas pressure

and remove coupling spacer prior to removing access
covers for compressor internal maintenance. For electric
drive motors, lock out the breaker. Failure to follow
these steps can result in serious personal injury or death.

1. Set crank end piston clearance to the proper

feeler gauge specification stamped on the
cylinder data plate or printed in the Ariel
Technical manual.
2. With head end components removed,
position the piston for the desired cylinder at
outer dead center. Position a dial indicator to
index off of the crosshead or crosshead nut

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5. Dimension C: 7. Compare calculated head end piston

clearance to clearance tolerances stamped
Norm. Thickness Use
on the cylinder data plate or printed in the
.030 .028 Ariel Technical manual. If tolerances are
unavailable or if calculated clearance is
.060 .055
outside tolerance, contact your packager
.060 .070* or Ariel before proceeding.
* Use when the cylinder has a removable liner with a 8. Measure head end piston clearance prior to
metallic tapered seat gasket between it and the new start up, as required by recommended
cylinder body (see ER-118).
maintenance intervals in Section 3, or after
installation, removal, or replacement of any
6. Calculate Head End Clearance: A - B + C = one of the following:
Head End Clearance
• Crankshaft
A _______________
• Connecting Rod
- B _______________
• Crosshead Guide
+ C _______________
• Piston and/or Piston Rod
= _______________
• Either Tandem Cylinder Body

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• Crosshead and/or Crosshead Nut

9. Re-assemble all components according to
the Ariel Maintenance and Repair Manual
supplied with your compressor. Verify
installation of all gaskets and manually bar
over the compressor to confirm the
crankshaft rotates freely.

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Appendix C - Frame Specifications

For more information, see the Ariel Performance Program.

Table: JG:JGA Frame Specifications

Specification JG/2 JG/4 JGA/2 JGA/4 JGA/6

Stroke, in. (mm) 3.5 (89) 3 (76)

Maximum 1500 1800

Allowable Speed
a
, RPM

Minimum Speed 750 900

b, RPM

Maximum N/A 1200

Lubricated PRC
Speed, RPM

Minimum N/A 750

Lubricated PRC
Speed, RPM

Maximum Non- N/A 1200

Lubricated
Speed, RPM

Minimum Non- N/A 750

Lubricated
Speed, RPM

Piston Speed c, To 875 (4.45) To 900 (4.57)

FPM (m/s)

Horsepower (kW) 252 (188) 504 (376) 280 (209) 560 (418) 840 (626)
Maximum 33 (0.84) 58 (1.47) 33 (0.84) 58 (1.47) 85 (2.16)
Length, in. (m)

Maximum 18 (0.46) to top of aluminum cover

Overall Height,
in. (m)

Maximum Width See appropriate frame, guide, and cylinder outline drawings.

Height - Bottom 10.25 (260)

to Crankshaft
Centerline, in.
(mm)

Approximate See Ariel Performance Program.

Weight with
Cylinders

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Specification JG/2 JG/4 JGA/2 JGA/4 JGA/6

Connecting Rod 8.25 (210)

Centerline to
Centerline, in.
(mm)

Sump Capacity 4 (15) 10 (38) 4 (15) 10 (38) 16 (61)

US gallons (L)

Oil Pump Flow 4.0 (0.25) 8.0 (0.50) 5.0 (0.32) 9.0 (0.57) 14 (0.88)
Rate d, GPM (L/s)
Oil Heat 8400 (2.5) 16800 (4.9) 16800 (4.9) 34000 (9.9) 51000 (14.9)
Rejection
BTU/hr. (kW)

Piston Rod 1.125 (29)

Diameter, in.
(mm)

Internal Rod Load - Double Acting

Compression + 18,000 (80) 20,000 (89)

Tension, lbf. (kN)

Tension, lbf. k(N) 9000 (40) 10,000 (44)

Compression, 10,000 (44) 11,000 (49)

lbf. (kN)

Internal Rod Load - Single Acting

Tension, lbf. (kN) 9000 (40) 10,000 (44)

a Maximum Allowable Speed is the highest (potential) speed at which the frame design permits continuous opera-
tion. Compressor frame data plate "Frame Rated Speed (RPM)" is application specific, and may be lower than
Maximum Allowable Speed. Do not exceed the lower of frame rated speed, lowest cylinder rated (RPM), or driver
rated speed.
b Minimum Speed is the lowest frame speed needed to provide adequate oil flow to the compressor bearings.
c Average Piston Speed is based on Maximum Allowable Speed (RPM). The cylinder data-plate rated speed (RPM) or
frame rated speed may be less, resulting in a lower piston speed rating.
d Flow rate at maximum rated speed and 180°F (82°C) oil.

Opposed Throw - To replace a connecting rod assembly, piston,

piston and rod assembly, balance nuts, or
Reciprocating Weight crosshead, weigh component parts on a scale
Balancing calibrated to 0.1 pound (0.05 kg) and compare to
the Balancing Record in the compressor Parts
Ariel recommends a reciprocating weight Book. If the weight changes, recalculate
differential between opposing throws of 1.0 opposing throw reciprocating weight
pound (0.45 kg) or less for JG:JGA compressors. differential. If not within recommended limits,
the compressor may require new balance nuts
and/or crossheads.

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To exchange opposing throw cylinder locations, If unable to balance opposing throws within
exchange all reciprocating components to the recommended limits, contact the packager or
opposite throw, except the connecting rod Ariel.When applying or re-applying a different
assemblies. Check the Balancing Record and cylinder to a throw, recalculate opposing throw
recalculate reciprocating weight differential, reciprocating weight differential; new balance
including the weight of the connecting rods. If nuts and/or crossheads may be required. The
not within recommended limits, the compressor force feed oil distribution system may also need
may require new crosshead balance nuts to resized. Contact the packager or the Ariel
reduce differential. Response Center for detailed information about
recommended reciprocating weight differential
between opposing throws.

Table: JG:JGA Approximate Component Weights, Lbs (Kg)

Component Weight Component Weight

Main/Connecting Rod 0.5 (0.2) Crosshead Guide (close 96 (44)

Bearing coupled)

Top Cover 2-Throw 21 (10) Crosshead Guide (long 137 (62)

single)

Top Cover 4-Throw 43 (20) Crosshead Guide (short 147 (67)

two)

Top Cover 6-Throw 64 (29) Crosshead Guide (long 260 (118)

two)

Spacer Bar 3 (1) Crosshead See Note a

End Cover Drive End 30 (14) Crosshead Pin 4 (2)

End Cover Auxiliary End 42 (19) Lube Oil Pump 2-Throw 7 (3)

Crankshaft 2-Throw b 100 (45) Lube Oil Pump 4-Throw 16 (7)

Crankshaft 4-Throw b 200 (91) Lube Oil Pump 6-Throw 36 (16)

Crankshaft 6-Throw b 280 (127) Frame Assembly w/o See Ariel Performance
Cylinders Program.
Main Journal Caps 6 (3) VVCP
Cylinder Assembly
Connecting Rod 13 (6)
Piston & Rod Assembly a

a For exact weights, see Balancing Record sheet provided by Ariel in the Parts Book for each compressor.
b Crankshaft weight is without flywheel, or vibration detuners.

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Appendix D - Compressor Clearance, Oil, & Temperature

Record

SERIAL NO. F- MODEL DATE

CRANKSHAFT THRUST (END) CLEARANCE, In. (mm)

Crankshaft Serial Number Thrust Clearance, In. (mm)

CONNECTING ROD THRUST (SIDE) CLEARANCE, In. (mm)

Throw 1 Throw 2 Throw 3 Throw 4 Throw 5 Throw 6

JACK CLEARANCES, In. (mm)

Throw # 1 2 3 4 5 6

Main Bearing

Conn. Rod
Bearing

After new bearing installation, if measured clearances exceed tolerances in Appendix B, contact your
packager or Ariel before proceeding.

OIL PRESSURE AND TEMPERATURE

Date Time RPM Filter Inlet Oil Filter Outlet Oil Temp. into Remarks
Pressure psig Oil Pressure Frame °F (°C)
(barg) psig (barg)

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Throw BEARING CAP TEMPERATURE, °F (°C), AFTER RUN TIME OF a:

3 Minutes Idle Speed (engine, Additional 3-5 Minutes Additional 10-15 Minutes
VFD) Full Speed, No Gas Load Full Speed, Gas Load
1 Minute (single speed motor)
No Gas Load

Main Rod Main Rod Main Rod

a These minimum recommended test intervals may change based on driver restrictions. Regularly inspect running
gear for any debris or signs of abnormality. Bearing cap temperature should not be more than 10°F from each other
(compare mains and rods separately).

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Appendix E - Balance Valve Maintenance Log

Table: Balance Valve Maintenance Log
Div. Block Balance Div. Block
Pressure Gauge Pressure
Date Time Valve Set Cycle Time Notes
Description
Min. Max. Pressure (Seconds)

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Appendix F - Cleaning, Handling, and Assembly Lubricants

for Non-Lubricated Compressor Cylinders
Cleaning and handling are critical to prevent
NOTE: Clean all table surfaces and tools that will
premature wear and failure of non-metallic rings
come in contact with the cylinder, cylinder compo-
and packings in non-lube compressor cylinders. nents, or piston components
Proper cleaning and handling will virtually
eliminate oil and anti-seize compounds from the 1. Handle all cleaned parts with new or clean
cylinder interior, piston rod assembly, valve and “rubber” gloves or new white cotton gloves. If
packing case areas. In non-lubricated gloves become contaminated or dirty,
applications, the non-metallic rings and dispose of them and use a new pair.
packings transfer some material to the metallic 2. Clean cylinder interior surfaces thoroughly
running surfaces. This transferred film provides a with denatured alcohol until a clean, alcohol
“lubricated” surface that enables the soaked, white paper towel or lint-free rag
compressor to function properly. The presence removes no more debris. This includes all
of oil degrades the transferred film, forming an surfaces of the bore, counter bore, valve
pockets, suction and discharge gas passages,
abrasive paste that quickly wears non-metallic
nozzles, etc.
elements during operation. Anti-seize
compounds are oil based and also contain 3. Lubricate the threads, bolt head, and stat-o-
seal of the cylinder nozzle lube bolt with very
abrasive metallic components that cause
small amounts of Never-Seez, regular grade,
premature component wear. and ensure all mating surfaces are coated.
This procedure applies to all non-lube 4. Use a small amount of Loctite 567 Pipe
compressor cylinders. Ariel cleans and protects Sealant on male threads when installing pipe
complete non-lube cylinders to non-lube service plugs.
requirements before shipping. Follow the 5. Very lightly oil bolt threads and head seating
procedure below to clean internal parts shipped surfaces for valve cap, head, and packing
loose, replacement parts before installation, and case mounting bolts, but prevent oil
contaminated surfaces during maintenance. This penetration into the cylinder interior.
extends non-lube compressor component life, 6. Thoroughly clean piston, collar, rod, and nut
and ultimately, cylinder life. with denatured alcohol until a clean, alcohol
soaked paper towel or lint-free rag removes
CAUTION no more debris. Clean piston ring grooves
and wear band grooves especially well. Clean
Denatured alcohol presents health and safety hazards. piston rings and wear bands with denatured
Keep away from heat, sparks, flame and all other
alcohol before assembling.
ignition sources. Use adequate ventilation, neoprene or
butyl gloves, mono-goggles or face-mask, and 7. When assembling piston to rod, use very
impermeable apron. Contains methyl alcohol; small amounts of Never-Seez, Regular Grade
poisonous if ingested. Avoid eye and skin contact.
on the nut and collar, and ensure all mating
Properly handle and dispose of materials resulting from
clean-up. See manufacturer Material Safety Data Sheets surfaces are covered. Do not lube threads for
for details. the piston rod tensioner. Clean threads of
hydraulic tensioner and all other tensioner
surfaces that will contact the piston. Use very

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small amounts of Never-Seez, Regular Grade clean them with denatured alcohol, then
on piston nut set screws. After assembly, reassemble. If they appear clean, they require
thoroughly wipe off all Never-Seez from the no additional cleaning provided they are
piston rod assembly exterior in the collar and sealed in their original packaging and have
nut areas with denatured alcohol until a not been contaminated.
clean, alcohol soaked, white paper towel or
13. Clean valve caps, retainers, high clearance
lint-free rag removes no more debris.
assemblies, and steel valve gaskets with
8. The manufacturer should provide packing denatured alcohol. Use only a very thin film of
cases cleaned, preserved, and suitable for oil for valve cap O-rings. Do not use anti-seize
non-lube service. Inspect packing cases for compounds or oil on steel valve gaskets.
cleanliness. If they appear coated with an oil- 14. Assemble cleaned parts immediately. If
based preservative, disassemble and clean cylinder will not see immediate service, see
them with denatured alcohol, then Ariel Engineering Reference ER-34 for
reassemble. If disassembly is required for preservation instructions. Contact Ariel for
water-cooled packing cases, re-assemble and latest version of ER-34.
test to Ariel Engineering Reference ER-51.
Contact Ariel for latest version of ER-51. CAUTION

9. Wipe down piston rod with denatured Do not use Ariel non-lube compressor cylinders for
alcohol after rod installation. oxygen service.

10. Clean VVCP or FVCP components with

denatured alcohol. Separate the unloader
head from the adapter/actuator. Clean all
internal surfaces with denatured alcohol
including behind the unloader piston. Do not
remove VVCP unloader stem seal. Clean
piston ring with denatured alcohol. Do not
use anti-seize compounds or oil on the steel
head gaskets. Use a very thin film of oil when
installing O-rings.
11. Clean crank-end head, head-end head, and
steel head gaskets with denatured alcohol.
Do not use anti-seize compounds or oil on the
steel head gaskets. If the crank-end head uses
an O-ring seal, apply a very thin film of oil to
the lead-in chamfer of the cylinder seating
surface to help prevent shearing of the O-
ring.
12. The manufacturer should provide
compressor valves cleaned, preserved, and
suitable for non-lube service. Inspect valves
for cleanliness. If they appear coated with an
oil-based preservative, disassemble and

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Appendix G - Hold-down Bolting to Resist Shaking Forces

and Couples in Reciprocating Compressors

Requirements
Figure: Hold-down Fasteners
1 Crosshead Guide-to-Support
Fastener(see Table: Crosshead Guide-to-
Support Fastener Torques)
2 Crosshead Guide Support Foot and
Frame Foot Hold Down Fastener (see
Table: Crosshead Guide Support Foot &
Frame Foot Hold-down Fasteners)

1. The torque values provided will achieve the 2. The torque values in Table: Crosshead Guide-
minimum clamp load necessary for opera- to-Support Fastener Torques achieve 50,000
tion. psi (345 MPa) prestress in the fasteners. Use
grade 8 or 9 bolting to hold crosshead guides
to supports.

Table: Crosshead Guide-to-Support Fastener Torquesa

Compressor Model Size inch - TPI Torque lb-ft (N•m)

JG:A b 5/8 - 11 90 (120)

a Guide supports purchased from Ariel ship with guide-to-support fasteners.

b Crosshead guide supports do not apply to JGM:P:N:Q and KB100 frames. Use this torque for guide-hold-down
fasteners.

3. To use the torques in Table: Crosshead Guide imperial sizes and 830 MPa ultimate strength
Support Foot & Frame Foot Hold-down material for metric sizes to meet the
Fasteners, the ultimate strength (Su) of the minimum clamp load necessary for opera-
stud material must equal or exceed 100,000 tion. Higher strength materials require higher
psi (690 MPa); higher strength stud material is torques than shown in the tables for added
preferred. In all cases, torque the nuts to fastener stretch and preload. Material
stress the stud to about 55% of the ultimate strength and torque are directly propor-
strength of the stud material. Torques shown tional. Example: for 120,000 psi (830 MPa)
in Table: Crosshead Guide Support Foot & ultimate strength Imperial bolting: 120,000 ÷
Frame Foot Hold-down Fasteners are based
on 100,000 psi ultimate strength material for

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100,000 = 1.2 x min. torque for Imperial size

from table = required torque for given nut
size. To use a different stud diameter, consult
Ariel for feasibility and torque.

Table: Crosshead Guide Support Foot & Frame Foot Hold-down Fasteners - Min. Torquesa

Foot Hold- Imperial (basis 100,000 psi) Metric (Class 8.8)c

down Hole
Compressor Min. Nut Recom. Stud Min. Nut
Fastener Diameter
Model Recom. Stud
inch (mm)
Size inch--TPI Torquee lb-ft Sized mm x Torqued lb-ft
Applicationb
(N•m) pitch (N•m)

JG:A Guide 3/4 (19) 5/8 - 11 100 (140) M16x2 125 (170)
Support

JG:A Framef 7/8 (22) 3/4 - 10 175 (235) M18x2.5 175 (235)

M20x2.5 250 (340)

a See #1, "Requirements".

b Crosshead guide support feet and frame feet with counterbored holes are designed to accept 12-point fasteners. To
use hex head fasteners or studs and nuts instead, a washer thick enough to clear the counterbore is required to
provide adequate clearance for the fastener and any tooling used for installation. A washer is also recommended
for feet with holes that are milled flat.
c Ultimate Strength: 830 MPa (120,000 psi); Yield Strength: 660 MPa (95,700 psi).
d Where two sizes appear, the first is the preferred size, and the second is an alternate size.
e For a stud pitch other than those listed above in the same nominal diameter size, use this formula to determine
required torque: Torque = ( Table: Crosshead Guide-to-Support Fastener Torquesa fastener torque) x (target
fastener root area ÷ Table: Crosshead Guide Support Foot & Frame Foot Hold-down Fasteners - Min. Torquesa
fastener root area).

4. Compressor frame foot hold-down studs and 5. Tighten nuts as recommended in step 3 to
crosshead guide support foot hold-down maintain fastener pre-load during operation.
studs listed in Table: Crosshead Guide Ariel also recommends rolled threads and
Support Foot & Frame Foot Hold-down hardened spherical washers for hold down
Fasteners should be as long as possible. Ariel fasteners to help compensate for fastener-to-
recommends a minimum 12 to 1 length to frame surface angular misalignment.
diameter ratio.
6. Re-preserve any fasteners subject to corro-
NOTE: Fasteners long enough to reach only sion after installation.
through the compressor foot and a deck plate or
flange of an I-beam can loosen if not provided 7. Follow lubrication guidelines and recom-
with engineered devices to maintain fastener pre- mended procedures for torque accuracy in
load. Appendix A.

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Appendix H - Soft Foot and Top Plane Flatness Checks for

Proper Main Bearing Bore Alignment in Reciprocating
Compressors
Main bearing bore alignment is critical to main can then be extended to 12 months or 8000
bearing and crankshaft life. Ariel manufactures hours.
the top cover mounting surface of a compressor
NOTE: If at any time frame hold down fasteners are
frame in close tolerance to a flat plane, to the loose, perform soft foot check and top plane flatness
main bearing bores, and to the bottom of the measurement. If a crankcase is damaged, top plane
compressor feet. The main bearing bores align flatness must be within tolerance prior to any
when frame feet are supported so the top cover machining in the shop or on site.
mounting surface is flat within a plane created by
two measurement points on one top rail and one
measurement point on the opposite top rail. Soft Foot Check
After establishing the plane, adjust frame feet to
1. Properly install and torque compressor frame
within acceptable limits. Frame flatness ensures
hold down bolting. See Appendix G for proper
the main bore is straight and not distorted. Level
frame foot and crosshead guide bolt size and
the compressor before flatness adjustment. For
torques.
leveling limits, see Appendix H in the Packagers
2. Loosen each hold down bolt individually
Standards Manual.
while checking the frame foot to skid deflec-
A best practice is to install and use reference tion with a calibrated dial indicator. If there
pads to measure level and flatness during skid are two bolts on a foot, loosen both for this
fabrication. Verify skid level and flatness is check.
satisfactory on site using the pads. When
3. Correct any hold down position that deflects
documented properly and duplicated, this
more than 0.002 inches (0.05 mm) when
practice reduces labor to re-establish major
released. Re-torque the hold down bolt or
component alignment.
bolts and repeat on each frame foot.
For JG:JGA frames, the soft foot check is
required; the top plane flatness measurement is
optional. Top Plane Flatness Check
1. Remove or reposition the top cover(s) and
Soft foot checks and top plane flatness
gasket(s) to expose the frame top cover
measurements are required:
mounting surface. Verify it is clean.
• On new installations or if a unit is relocated. 2. Use measurement equipment with a
Perform measurements both prior to skid
published accuracy of ±0.001 inches (0.025
grouting and at final shaft alignment prior to
initial startup. mm) over the distance required to measure
• At 6 months or 4000 hours to ensure skid the entire length of both frame rails. Measure
stability. If no changes are found, the interval the top surface of both sides of the frame rails

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based on the frame type as shown in figures 4. Frame temperature can greatly affect flat-
below. For proper alignment, readings ness readings. Factors such as direct sunlight
between any two adjacent points must be on a portion of the frame or cooling after unit
within 0.002 in. (0.05 mm). shut down can cause measurement inaccu-
racy. Ensure frame temperature is consistent
3. The ER-82 software tool determines if read-
throughout the measurement process. Ariel
ings meet ER-82 specifications, and if not,
recommends flatness measurement while
provides recommendations for shim correc-
the frame is at ambient temperatures to mini-
tions as well. Contact Ariel Technical Service
mize the effects of thermal expansion.
for the latest version of this tool.

NOTE: If the unit will not be restarted immediately,

re-preserve the unit in a manner appropriate to the
time duration until restart.

Figure: Flatness Measurement Locations for Frames with Single Anchor Bolts

Figure: Flatness Measurement Locations for Frames with Pairs of Anchor Bolts

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Figure: Flatness Measurement Locations for KBE:K:T:C:D:F Frames

1 Loosen both when taking soft foot.

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Appendix I - Attachment of Wiring, Tubing, or Pipe Clamps

to Ariel Compressor Cylinders
DO NOT drill holes to mount wiring, tubing, Newer Ariel cylinder designs include 1/4-20 UNC
instrumentation, or pipe clamps to any pressure tapped holes to the milled pad that contains the
containing component. Pressure containing cylinder indicator port holes (see Figure: Typical
components include cylinders, valve caps, Cylinder Plugs and Tapped Holes). These extra
cylinder heads, unloaders, gas passage caps, and tapped holes will provide additional
flanges. DO NOT use pressure containment accommodation to clamp unloader tubing or
fasteners to mount brackets or other structural instrumentation lines.
attachments. These practices can compromise
the integrity of pressure containing components.
Alternate Attachment Method
CAUTION
An alternate method to attach clamps to
Do not drill holes in any pressure containing compressor cylinders is to use an epoxy resin.
components for any reason.
Ariel recommends Loctite 331 or Loctite 332
applied to clean, unpainted metal. Follow all
Figure: Typical Cylinder Plugs and Tapped Holes
manufacturer instructions and
recommendations to prepare the area for the
adhesive. The clamp and unpainted surface can
be painted after the adhesive cures. This clamp
attachment method does not compromise
cylinder integrity.

1 Standard Plug
2 Plug A-28373
3 New 1/4-20 UNC Tapped Holes

Ariel offers a 1/2-inch NPT pipe plug with a 1/4-20

UNC tapped hole to accommodate a tubing
clamp or bracket (see Figure: Typical Cylinder
Plugs and Tapped Holes). Installing this plug in
cylinder indicator ports provides locations to
secure unloader tubing or instrumentation lines.
The plug is designed for high pressure and will
not affect existing Ariel cylinder MAWP in any
application. Also, standard cylinder plugs may be
replaced with this plug without a hydrotest.
Packagers may purchase this plug (A-28373)
through Ariel Parts Sales.

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Appendix J - Recommended Maintenance Intervals for

Intermittent Duty Operation
Ariel compressors, like all industrial equipment, 2,000-Hour Maintenance
require maintenance. The severity of compressor
service directly influences the frequency and 1. Perform Daily and 400-Hour maintenance.
amount of maintenance needed. What follows 2. Drain and replace force feed lubricator box
are the recommended intervals for inspections oil.
and replacements for intermittent duty 3. Where applicable, clean sintered element in
operation. This will help you determine the the small oil filter on the force feed
appropriate intervals for a given compressor lubrication system now or at every main oil
application. filter change. Use a suitable solvent. Where
applicable, replace force feed lubricator inlet
NOTE: For continuous duty service, see "Recom- filter in independent supply system.
mended Maintenance Intervals for Continuous Duty 4. Change compressor oil filter. See top cover
Operation". filter information plate or “Oil Filter” in Frame
Oil System Components for procedure. Do
not exceed 12 month installed period for filter
NOTE: Careful documentation of inspection results is
element.
critical to establish whether recommended intervals
NOTE: For replaceable element style filters, drain the
are adequate or require more or less frequency.
canister completely before removing the element.
Inspect elements for cleanliness and damage. Do not
install dirty or damaged elements.
400-Hour Maintenance 5. Change compressor oil. Extremely dirty
1. Perform Daily maintenance. environments, oil supplier
recommendations, or oil analysis may dictate
2. Sample frame oil and send to a reputable a different oil change interval. Follow these
lubricant lab for analysis. See "Oil Sampling" steps:
for a list of what an oil analysis should
a. Drain oil from frame, associated piping,
provide.
and oil cooler.
• If analysis results indicate increasing
levels of lead, tin, or copper particles in b. Clean oil strainer with a suitable solvent.
the oil, shut down unit. Remove frame top In dry sump applications, the strainer is
cover and crosshead guide side covers. located at the oil reservoir.
Visually inspect for debris. Do not disas- c. Remove frame top cover and crosshead
semble further without good reason. guide side covers. Visually inspect for
• If debris indicates, replace affected parts, debris. Do not disassemble further
then change oil, oil filter, and clean the without good reason. If debris indicates,
strainer with a suitable solvent. replace affected parts, then change the oil
filter and clean the strainer with a suitable
NOTE: Operate the unit to bring oil temperature to a solvent.
minimum operating temperature of 150°F (66°C) to d. Refill frame with fresh, clean oil.
drive off any entrained water
e. Visually inspect the crankcase for debris
or other foreign material. Disassembly is

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not recommended unless a reason is Measurement", and "Crankshaft Thrust

found to do so. (End) Clearance Measurement".
f. Check for adequate cylinder lubrication. NOTE: Clearance trends along with oil analysis and
See “Cylinder Lubrication Paper Test” for crankcase visual inspection can indicate the need for
procedure. bearing replacement. Do not disassemble to check
clearances. Disassemble only if clearance checks indi-
6. Grease VVCP stem threads at grease fitting, cate excessive clearance. Contact Ariel for original
with 2 to 3 pumps of cylinder lube compatible assembly clearances.
grease using a standard manual grease
pump. Turn VVCP adjustment handle all the b. Crosshead to guide clearances. See
way in and all the way out to lubricate the “Crosshead Installation” in Section 4.
threads. Measure or count turns to return the c. Piston rod runout. See “Piston Rod
handle to its original position. Runout” in Section 4.
If any of the above items are outside limits , find
the cause and correct it. It may require part
4,000-Hour Maintenance replacement.
1. Perform Daily, 400-Hour, and 2,000-Hour 7. Remove valves and valve gaskets:
maintenance. NOTE: If using CP/CPs/XP valves, valve maintenance
2. Verify safety shutdown functionality. may be extended to the 8,000 hour or 22,000 starts
interval.
3. Inspect crankcase breather filter and clean
with suitable solvent. a. Visually inspect valve pockets for
damage. Verify all old valve seat gaskets
4. Open force feed lubricator box and visually are removed.
inspect pump followers, cams, and gears for
wear. b. Have a qualified valve repair shop disas-
semble, visually inspect, and refurbish
5. Pressure test distribution blocks. See the valves where needed. Provide the
“Distribution Block Assembly” for procedure. valve repair shop an Ariel torque chart
6. Measure, log, and trend the following: and valve service guide.
a. Main bearing, connecting rod bearing, c. Visually inspect cylinder gas passages and
and crankshaft jack and thrust clear- clean them of all debris.
ances. See "Main Bearing Vertical Jack 8. If applicable, visually inspect suction valve
Clearance Measurement", "Connecting unloader actuator stems for damage or wear.
Rod Bearing Vertical Jack Clearance Visually inspect stem seals for damage or
wear and confirm that the actuator moves
freely.
9. If applicable, visually inspect pneumatic
clearance pockets for damage or wear
(seating surface and stems/stem seals).
Confirm that actuator moves freely.
10. Inspect cylinder bores for damage or wear.
Replace the cylinder body or restore the bore
if any of the following conditions exist:
• Bore surface blemishes or gouges.

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• Bore out of round more than 0.001 inch 17. Check and re-calibrate all required
per inch of bore diameter (0.001 mm/mm) instrumentation.
or tapered.
18. If the compressor is equipped with crankcase
• Main bore is worn to counterbore diam- over-pressure relief valves, visually inspect
eter or larger. and exercise valves to manufacturer
11. Inspect piston rings and wear bands: recommendations.
• Measure and log piston ring condition, 19. Check auxiliary end chain drive for undercut
end gap, side clearance, and piston ring sprocket teeth and chain for excessive
groove width. stretching. Replace as required. See “Chain
• Replace rings that are damaged or Adjustment” in Section 4 for procedure.
outside limits listed in Appendix B. 20. Check fastener torques of gas nozzle flange,
• When replacing rings, re-measure and log head end head, valve cap, piston rod packing,
ring side clearance to check for groove crosshead pin through bolt, frame hold
wear. down, crosshead guide to cylinder, distance
• Measure and log radial projection of wear piece to cylinder, and tandem cylinder to
band. cylinder.
12. Inspect piston rods for damage and excessive
wear. Replace rod if any of these conditions 8,000-Hour or 22,000 Starts
exist (see "Piston Rod Inspection"):
• Gouges or scratches on the rod.
Maintenance (whichever
• Under size more than 0.005 inch (0.13 occurs first)
mm).
1. Perform Daily, 400-Hour, 2,000-Hour, and
• In the packing travel length, out of round 4,000-Hour maintenance.
more than 0.001 inch (0.03 mm).
• Anywhere in the packing travel area, 2. Replace crankshaft main and connecting rod
tapered more than 0.002 inch (0.05 mm). bearing shells if no replacement has occurred
in the past 8,000 hours or 22,000 starts.
13. Re-tighten hold down fasteners to proper
torque. Visually inspect cylinder gas passages 3. If using CP/CPs/XP valves, remove valves and
and clean them of all debris. Inspect for frame valve gaskets:
twist or bending to verify main bearing bore a. Visually inspect valve pockets for
alignment. See Appendix E for flatness and damage. Verify all old valve seat gaskets
soft foot requirements. are removed.
14. Perform a coupling alignment (see "Initial b. Have a qualified valve repair shop disas-
Maintenance"). semble, visually inspect, and refurbish
the valves where needed. Provide the
15. Rebuild piston rod pressure packing cases valve repair shop an Ariel torque chart
and oil wiper cases. See “Piston Rod Packing” and valve service guide.
in Section 4 for procedure.
c. Visually inspect cylinder gas passages and
16. Re-install valves, retainers, and valve caps clean them of all debris.
using new valve gaskets and valve cap o-
rings/seals. Use proper installation
techniques and torque procedures for valve
caps. See “Valve Installation” in Section 4.

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16,000-Hour Maintenance
1. Perform Daily, 400-Hour, 2,000-Hour, 4,000-
Hour, and 8,000-Hour maintenance.
2. Remove crosshead pins.
a. Measure and log crosshead pin to cross-
head pin bore and connecting rod
bushing bore clearances.
b. Check the crosshead pin end caps and
through bolt for wear.
c. Replace if needed.
3. Check for bushing wear in the auxiliary end
drive chain tensioner.

32,000-Hour Maintenance
1. Perform Daily, 400-Hour, 2,000-Hour, 4,000-
Hour, 8,000-Hour, and 16,000-Hour
maintenance.
2. Replace lubricator distribution blocks.
3. Replace crosshead and connecting rod
bushings. See “Crossheads” in Section 4 and
“Connecting Rods” in Section 4.

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Latest Manual Revisions

06/29/2023
Topic Change Description

Frame Specifications Figure: Pressure Containing Joint Recommended Torque Sequences: added
sequences for peanut flanges. Hoerbiger Valve Assembly Fastener Torques,
Drake Lock Nut, 5/16-24: '168 Lb x in (19)' WAS '120 Lb x in (14)', '96 Lb x in (11)'
WAS '66 Lb x in (7.5)'.

JG:A Fastener Torques Changed table footnotes to sequential lettering A-N.

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