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NEWSLETTER

January 31, 1997 No. 41

PISTON TO ROD REASSEMBLY PROCEDURE


Ariel is responding to field inquiries for an Ariel approved procedure that can be used in the field. This procedure for the reassembly and torquing of piston rod assemblies should be used with both new and used components. The goal is to provide information for consistent assembly techniques that minimize piston rod assembly failures. Ariel provides the following procedure to assist in field compressor repairs, but realizes you may have additional questions concerning specific repairs. You are encouraged to contact Ariel's Field Service group if you have questions or require additional information concerning this procedure. 1. Clean all piston rod assembly parts thoroughly. Be sure piston is internally clean and dry.

NOTE: Any reassembly of used parts requires the recleaning and re-lubricating of threads and seating surfaces. 2. Inspect collar (or collar area on rod, when collar is integral and not separable), piston and piston nut for nicks, burrs or scratches. Dress surfaces with a fine grit stone as required. Fit collar and nut into piston to verify the outside diameter fits, turn freely by hand in the piston. Inspect piston rod threads and collar shoulder. Threads are to be clean and free of burrs. Install collar and nut onto piston rod to verify inside diameter fits, rotate freely. Run piston nut down by hand until piston threads protrude to verify freedom of thread engagement. Remove nut and collar. Install piston rings in cylinder bore without piston to measure end gaps. Ariel recommends replacing piston rings when end gap is increased three times its original amount. If piston has wear band, install and place piston in cylinder bore and measure piston to cylinder clearance at bottom of piston. Replace the wear band before it has worn enough to allow the piston to touch the cylinder bore. Wear band clearance can be measured before piston rod assembly is removed from cylinder. See "Clearances" data in Section 1 of the Operator's Manual - "Design Specifications & Data" for tolerances. Clamp piston rod into an appropriate rod holding fixture, using PVC liners to protect rod finish. Verify that holding fixture's PVC liners are clean and oil free. Clamp the piston rods as close to the collar shoulder as possible without hitting piston.

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NOTE: 1. Ariel's D-0961 clamping device (see Figure 1) is available for 1.125" through 2" (29 mm through 51 mm) diameter piston rods. Tighten D-0961's four 7/8" x 14 TPI cap screws to 344 lb-ft (466 Nm). NOTE: 2. For 2.5" (64 mm) diameter piston rod, use a clamping device that produces 60 tons (140 kN) of clamping force (see Figure 2).

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NEWSLETTER
Nominal Piston Rod Diameter Inches 1.125 1.5 2 2.5 6. mm 29 38 51 64 Clamping Force Required Tons 8.67 20.4 35 60 kN 19.3 45.4 78 140

January 31, 1997 No. 41

Apply a thin coating of "Never-Seez" (anti-seize and lubricating compound, Mil Spec A-907) to piston rod shoulder and rod collar locating band, and collar face in contact with the piston, then slide collar onto rod.

NOTE: "Never-Seez" is manufactured by Bostick, Boston Street, Middleton, MA, 01949 USA, Telephone: 508-777-0100 7. Apply a thin coating of "Never-Seez" to piston rod threads at the piston end, then slide piston onto rod and collar.

NOTE: One end of the piston is machined .002" (0.05 mm) undersize across a 3/4" (19 mm) wide band for manufacturing purposes. If piston is symetrical and can be installed in either direction, assemble with the undersize band toward the head end. 8. 9. Apply a thin coating of "Never-Seez" to the piston nut threads and piston mating face. Install nut and hand tighten to make up the piston rod assembly. Tighten the piston nut to the recommended torque shown in table below (Operator's Manual Section 1 - Design Specifications & Data). It may be necessary to use a torque multiplier to achieve the desired torque. Required Piston Nut Tightening Torque Nominal Piston Rod Diameter Inches 1.125 1.5 2 2.5 mm 29 38 51 64 Piston Nut Size Inch x TPI 7/8 x 12 1-1/4 x 12 1-5/8 x 12 2 x 12 (see note 2) Torque Value LB-FT 222 695 1590 3970 Nm 301 942 2156 5383

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NEWSLETTER

January 31, 1997 No. 41

NOTE: 1. When torque multipliers are used on larger fasteners, divide the desired fastener torque by the actual mechanical advantage (which accounts for frictional loss thru the multiplier), rather than design mechanical advantage, to determine torque wrench setting. Example: An X4 torque multiplier, model TD-1000 has a design mechanical advantage of 4.0, but an actual mechanical advantage of 3.6. Therefore a 1590 lb-ft (2156 Nm) required torque needs 442 lb-ft (599 Nm) applied torque to the X4 multiplier. NOTE: 2. Ariel uses a hydraulic torque wrench on 2"x 12 TPI piston nuts, used on 2.5" nominal diameter piston rods. The 3970 lb-ft (5383 Nm) value is based on Ariel rod stretch test results. Torque values for other rod sizes are calculated. 10. After torquing, the piston rod should not protrude more than .010" (0.25 mm) past the piston face. 11. Apply a thin coating of "Never-Seez" to two new Allen set screws. Two new Allen wrenches are also required per nut at each tightening and are discarded after their one time destructive use. Install the set screws and tighten so that the Allen wrench is permanently deformed by tightening past its yield point (twisted through a 15 degree arc). 12. Prick-punch the piston nuts, within 1/16" (1.5 mm) of set screw threads, to lock the set screws in place. Prick-punch marks should deform nut screw threads to lock the set screw in place. 13. Weigh the piston rod assembly with the piston rings and wear band included. Stamp the weight on the piston's head end. Flatten any raised lips to avoid clearance measurement errors. Record this weight for future reference. PISTON NUT TORQUING SPANNER Nominal Rod Diameter Inches 1.125 1.5 2 2.5 mm 29 38 51 64 Nominal Piston Nut Size Inch x TPI 7/8" x 12 1-1/4" x 12 1-5/8" x 12 2'' x 12 A-0279 A-0424 B-1410 B-1503 Ariel Part Number

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NEWSLETTER

January 31, 1997 No. 41

Fixture Part Number D-0961 Collar Piston Rod Piston Nut w/ (2) Set Screws Allen Wrenches (2) Torque Multiplier Torque Wrench Piston Nut Spanner

Figure 1: Piston and Rod Torquing Fixture - 1.125 thru 2" (29 thru 51 mm) Rod Size Piston Nut Torquing Adapter P/N B-1503 (Not Part of Standard Tool Box) Torque Multiplier

60 Tons (140 kN) of Clamping Force Collar Piston Rod

Piston

Torque Wrench

1/8" (3 mm) Thick PVC Liner To Protect Piston Rod Finish

Nut w/ (2) Set Screws 3/4" (19 mm) Wide Undersize Band

Figure 2: Piston and Rod Clamping Requirements - 2.5" (64 mm) Rod Size