HG17G

Rotary Screw
Gas Compressor
Operation and
Maintenance
Handbook
2
 Introduction
Thank you for choosing our Cummins powered LeROI rotary
screw compressor system for your production needs. We
specialize in well head gas compression with packages ranging
from 15 to 500 horsepower. As an ASME code welding shop, we
have the capability and flexibility to fabricate a custom package to
suite all of your well head and booster production needs. We have
engineered our units to have optimum production, maximum run
times (including cold weather environments), and years of great
performance when properly maintained.

Please read through this handbook prior to installation and use it

as a reference manual for operations and maintenance. These
instructions will explain how the unit functions and any necessary
precautions prior to installation, for operation, and for
maintenance.

Thank you for investing in our product. Feel free to contact us

anytime with questions or suggestions.

3
 Table of Contents
Warnings………………………………………..…………………………5

Installing the Unit………………………………………..………………..6

Pre-start Checklist……………………………………………….……..…7

Starting Procedure…………………………………………..…………….8

Shutdown Procedure and Extended Downtime Requirements…………..11

Commissioning…………………………………………………………..12

Maintenance………………………………………………….……….….14

• PM Schedule……...………………………..…….…………..14

• Maintenance Parts and Specifications…………….……...…..15

• Daily Routine Inspection………...….………...……………...16

• 750 Hours M1……………………………………………......17

• 1500 Hours M2……………………..………………………..19

• 21000 Hours M3……………………………………..............21

• 39000 Hours M4……………………………………..............22

LeROI O&M Manual…………………..…………….…….….................24

TTD Control Panel Wiring Diagrams…………...…………………….....39

General Terms of Sale and Warranty…...………………………………..42

4
 CAUTION!
Read before proceeding!
WARNING: If the information in these instructions is not followed exactly, a
fire or explosion may result, causing property damage, personal injury, or loss
of life.

WARNING----DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE

VAPORS OR LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE.

WARNING----INSTALLATION AND SERVICE MUST BE PERFORMED BY A

QUALIFIED INSTALLER, SERVICE AGENCY, OR THE GAS SUPPLIER.

WARNING----BE EXTREMELY CAREFUL WHEN USING THE “AUTOSTART”

FEATURE (IF EQUIPPED). UNIT MAY START WITHOUT WARNING.

WARNING--- COMPRESSION SYSTEM GENERATES HIGH TEMPERATURES.

BEWARE OF HOT COMPRESSOR HOUSING, DISCHARGE PIPING, DISCHARGE
VESSEL, FLUIDS, AND ENGINE EXHAUST AND COOLING SYSTEMS. AFTER
SHUTTING UNIT DOWN, ALWAYS ALLOW AMPLE TIME FOR THE SYSTEM TO
COOL DOWN BEFORE DOING ANY MAINTENANCE WORK.

WARNING--- THIS MACHINE INCORPORATES ROTATING EQUIPMENT.

PERSONNEL, TOOLS, AND CLOTHING MUST REMAIN CLEAR OF ALL ROTATING
PARTS. IF GAURDS ARE DAMAGED OR MISSING, DO NOT START MACHINE,
TAKE APPROPRIATE ACTION TO CORRECT THE SITUATION.

WARNING--- COMPRESSOR SYSTEMS CAN GENERATE HIGH NOISE LEVELS.

HEARING PROTECTION IS REQUIRED.

WARNING--- POISONOUS GASES MAY EXIST. H2S MONITOR MUST BE WORN IN

THE VICINITY OF THIS EQUIPMENT AT ALL TIMES. LETHAL GASES MAY EXIST
AT ANY TIME AND IN ANY GAS COMPRESSION SYSTEM OR PIPELINE.

WARNING----THIS COMPRESSOR SYSTEM DOES NOT MEET THE REQUIREMENTS

OF A CLASS I DIVISION 2 GROUP D AREA AND MUST NEVER BE ENCLOSED IN
ANY TYPE OF BUILDING. THERE MUST BE ADEQUATE AIRFLOW AT ALL TIMES
FOR SAFETY AND PERFORMANCE.

WARNING--- IF EVER A PROBLEM EXISTS OR IF THE OPERATOR IS

UNCOMFORTABLE OR UNFAMILIAR WITH THE OPERATION OF THIS
EQUIPMENT, DO NOT ATTEMPT TO OPERATE THE MACHINE. CONTACT FLUID
COMPRESSOR PARTNERS FOR ASSISTANCE.

ALWAYS WEAR PERSONAL PROTECTIVE EQUIPMENT NEAR UNIT.

Never alter the manufactured system in any way. Any changes will void the warranty and
product liability if not authorized in writing by Fluid Compressor Partners.

5
 Installing the Unit
1. Set the unit on a flat, level, and packed surface. The suction inlet and discharge
outlet are oriented on opposite ends of the skid and sight preparation should be
handled with this in mind. Fluid Compressor’s equipment is built for rugged
reliability. However, care should be taken when moving the unit to prevent
damage.
2. When planning the installation, consider the cooling air flow. This machine’s
heat exchanger uses an induced draft cooling air flow (air flows through the cooler
towards the engine). Do not set unit where the prevailing winds will be opposite
of cooling air flow.
3. Install a by-pass in the flow line and full port valves at the suction and discharge
to isolate the compressor. Therefore, if the compressor has to be maintained your
gas flow will not be shut off. It is also recommended to install a check valve in
the by-pass that will allow gas to flow past the machine during a plunger cycle or
downtime.
4. Depending on the site conditions, a suction pressure controller may be required.
Be sure it is of sufficient design to positively hold against the highest possible
well-head build up pressures and that it is adequately sized for the expected flow
rates.
5. Depending on the site conditions and machine configuration, a discharge back-
pressure regulator may be required. Be sure it is of sufficient pressure rating to
handle the highest possible discharge pressures and is adequately sized for the
expected flow rates.
6. Open sight glass valves on the engine coolant surge tank and open the compressor
lube oil block valve at the discharge separator oil outlet. Open all ball valves on
engine oil supply system, except for the drain hose valve. Ensure all engine jacket
water valves are open, including the vessel heat trace lines and the coolant filter
block valves that are located on the engine.
** Unit shipped with valves closed.

6
 Pre-start Checklist
1. Before starting, read and adhere to the warnings on page 5.
2. Check engine oil level on the dipstick on the right side of the engine. Oil can be
added through the filler next to the dipstick. Do not run the engine if the oil
level is too high or too low.
3. Check compressor lube oil level. Oil should be visible in the discharge vessel
sight glass above the minimum level line.
4. Ensure all valves in the engine and compressor oiling systems are fully open.
5. Ensure engine coolant is visible in sight glass on surge tank and is at least at half
level.
6. Check suction scrubber sight glass and drain if fluids are present. Ensure there
is no pressure or vacuum on the system before opening drain valve!
7. Drain fuel gas bottle daily. If fluids are continually present, slightly open the
needle valve that will allow the liquid to drain into the suction scrubber’s
blowcase.
8. Ensure all drain valves are fully closed. Drain valves are included on the suction
scrubber, discharge, filtration, engine oil, cooler, and fuel vessels.
9. Check V-belts for proper tension, alignment, and for cracks or wear.
10. If equipped with TTD annunciator panel, set shutdown pins in panel box. The
sizing and conditions determine the settings for suction and discharge pressure
shutdowns. If there is no oil pump, the low discharge shutdown must be set at
60 psig higher than the actual suction pressure. Never operate outside of design
conditions unless sizing calculations have been made by Fluid Compressor
Partners. Engine oil pressure gauge should be set at 20 psig. Use a hex head
wrench to adjust. Engine temperature gauge should be set at 245 º F.
11. If well pressure exceeds design suction pressure due to head pressure build up, a
pressure regulating device must be installed on the inlet side of the compressor.
12. Ensure Versatrol control valves are in the open position.
13. If equipped with a mechanical governor, turn the throttle cable clockwise until it
stops to be in the idle position.
14. Visually inspect and listen for leaks. Correct any problems before starting.
15. Ensure all guards are in place, secure, and undamaged before starting.

7
 Starting Procedure
1. Before starting, read and adhere to the warnings on page 5.
2. Open discharge valve to sales line.
3. Open suction valve. Refer to previous page if high well pressures exist.
4. Set system power to on.
5. If equipped with an electronic governor, set switch to idle and turn
potentiometer knob fully counterclockwise.
6. Press reset on the Murphy TTD annunciator.
7. Push and hold start button, engine should start quickly. Release start button
when engine is running.
8. If engine does not start quickly, do not hold start button for more than 10
seconds.
9. Let engine idle until oil pressure is above 20 psig and all operating conditions
are checked. Ensure pressure gauges are functioning.
10. Ensure all four Versatrol valve position indicators are extended (unloaded). If
not, change position of the control valves under the panel.
11. Ensure engine manifold vacuum is 3” hg vacuum or deeper vacuum. If it is at
less vacuum than 3” hg, reduce suction pressure.
12. Allow engine to reach 125 deg F before increasing speed.
13. For electronic governors, switch from idle to rated. Engine will ramp up to
potentiometer set point. Increase speed slowly, while watching gauges, by
turning the potentiometer clockwise. Operate Engine between 1500 rpm and
1800 rpm.
14. For mechanical governors, turn throttle cable slowly counter-clockwise while
watching gauges to increase speed. Operate Engine between 1500 rpm and 1800
rpm.
15. Once at full speed, allow compressor to warm up until discharge temperature is
at least 125 deg F.
16. Load Versatrol ports one at a time while watching gauges, particularly manifold
vacuum and discharge pressure. Do not over-load the machine. Often times, the
well must be pulled down before there is enough power to fully load the
compressor.
17. The loading order for the Versatrol valves is 4,3,2,1, and the unloading order is
opposite. (See the LeROI compressor section of this document for more detail
on Versatrol valves).
18. The indicator on each Versatrol valve will be fully retracted when loaded.
19. Ensure all conditions stabilize and are within operating specs and design
capabilities of the machine.

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 PLC Panel Starting Procedure
1. Before starting, read and adhere to the warnings on page 5.

Initial Set-Up and Configuration

1. Pull ESD button and turn power switch on.
2. From the Main Screen, touch the CONFIG PAGE button.
3. All shutdown and set-up information can be entered through the screens
accessed from the CONFIG PAGE. Most if this data is machine specific and
will be factory pre-set for your unit. Some of the data is location specific and
may need adjusting.
4. The setpoints for shutdown will be pre-set to protect the machine, but as an
operator, you may have a need for change. An example may be that you
cannot draw the suction into a vacuum, in which case, you will need to change
your low suction setpoint.
Starting Procedure (Manual Mode)
1. Pull ESD button
2. Set the operating mode to manual and ensure Versatrol poppet valve status is
unloaded
3. Set the engine speed to IDLE
4. Turn the power/run switch on
5. The status should ready READY. If in fault mode, touch the ALARMS button
at the bottom to review the fault or touch the RESET button to clear the fault.
The fault can also be cleared by cycling the power switch.
6. When in the ready state, you have a time limit to start it before it faults on low
engine oil pressure, low discharge pressure, etc.
7. Press and hold the start button until the engine starts. The PLC will not allow
the user to hold the start button for too long to protect the system.
8. Check all operating parameters and ensure it is within specification and
operating normally.
9. Increase engine speed with one of the two options below:
• Touch the MAX button on the speed control section of the Main screen
to ramp the engine to full speed
• Touch the SETPOINT button on the speed control section of the Main
screen. A keypad will appear that you can enter a specific speed into.
The PLC will not allow an entry that is too fast or too slow.
10. Check all operating parameters and ensure it is within specification and
operating normally.
11. Load machine by touching the LOAD cells in the bottom right hand corner of
the Main screen. They can be commanded to load in any order and the PLC
will ensure they are loaded in the proper order.
12. Visually inspect the Versatrol valves on the screw and ensure the position
indicators are fully retraced when the screen shows that they are loaded.
13. You may leave any number of the valves unloaded if conditions require it.

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 PLC Panel Starting Procedure Continued
1. Before starting, read and adhere to the warnings on page 5.

Starting Procedure (Auto Mode)

1. Pull ESD button
2. Set the operating mode to AUTO
3. If a target suction pressure or discharge pressure is desired, or if automatic re-
start is desired, these setpoints can be adjusted in the CONFIG PAGE,
accessed from the Main screen.
4. Turn the power/run switch on
5. The status on the Main screen should ready READY. If in fault mode, touch
the ALARMS button at the bottom to review the fault or touch the RESET
button to clear the fault. The fault can also be cleared by cycling the power
switch.
6. When in the ready state, you have a time limit to start it before it faults on low
engine oil pressure, low discharge pressure, etc.
7. Press and hold the start button until the engine starts. The PLC will not allow
the user to hold the start button for too long to protect the system.
8. Check all operating parameters and ensure it is within specification and
operating normally.
9. No further settings are required in AUTO mode. When the temperatures are at
the minimum limits and the conditions allow it, the panel will automatically
speed the engine up and load the Versatrol valves as needed.

During normal operation, when left untouched, the screen will go into a screen
saver mode that scrolls through screens displaying various gauge functions in a very
large easy to read format.
Touching the screen at any point will return you to the Main screen.

10
 Shutdown Procedure
Before shutting down machine, read and adhere to the warnings on page 5.
Check all gauges for normal function and operating conditions and listen for
unusual sounds or signs of problems or maintenance requirements. Look for leaks.
Ensure that performance is as expected. If all checks out OK, proceed with shut-
down:
1. Unload compressor (ignore if Versatrol indicators are extended (unloaded)).
• With manual Versatrol control, unload valves in the order 1,2,3,4 slowly
while watching gauges between each step.
• With PLC automation, select MANUAL operating mode from the
touchscreen, then touch the UNLOAD cells. All valves can be
commanded to unload and the computer will ensure they unload in the
proper order.
2. Slow the engine down to idle speed (900 rpm to 1400 rpm is acceptable).
• For mechanical governors, turn the throttle cable clock-wise slowly
while watching gauges.
• For electronic governors and TTD panels, turn the potentiometer
counter-clockwise slowly while watching gauges.
• For PLC automated panels, select IDLE from the Main page on the
touchscreen.
3. Allow the system to cool down for 2 minutes idling in an unloaded state.
4. Stop the engine.
• For TTD panels, press stop on the annunciator.
• For PLC panels, turn the switch to the off position.
• Do not use the ESD button to stop the engine unless it is an emergency.

Extended Downtime Requirements

If unit is to be left for more than 5 days without running, follow these steps to
ensure there is no damage done to the machine.

1. Shutdown machine in accordance to above procedure.

2. Close suction and discharge valves to isolate the machine.
3. Open bypass at well head to allow flow.
4. Close manual fuel valve, turn power to off, and press in ESD button.
5. Relieve all gas pressure on the machine.
6. Drain fuel gas scrubber and suction scrubber.
7. Perform Maintenance One (M1) as outlined in the maintenance section of this
manual.
8. Disconnect batteries.

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 Commissioning
Always follow previously outlined start-up and shutdown procedures, including
safety precautions outlined on page 5, but when a machine is started for the first time
on a location or when operating conditions change considerably, some very specific
settings and adjustments must be made.
*First, start compressor and fully load in accordance to previously outlined steps.

Ignition Timing
1. Per the Cummins manual, check timing and adjust if necessary.
• The factory setpoint is 26 deg BTDC. This is ideal for most applications
running on natural gas.
• High elevations or unusual fuel or temperature conditions may require
timing changes.
• If timing is to be adjusted, follow procedures outline in the Cummins
manual.
• Beware that this is a 24VDC system and will ruin a 12 volt timing light.

Fuel Pressure
Adjust the fuel pressure as follows:
• Ensure engine is at full speed and load.
• First cut regulator should be set to allow 25 psi on the fuel gas scrubber.
• Second cut regulator should be set to allow 14” water column pressure.
This is to be checked at the 1/8” valve on the upstream side of the final
cut regulator (on the bottom of the regulator).
• Final cut regulator is to be set to allow 5” water column pressure to the
carburetor. This pressure is to be checked at the downstream 1/8” ball
valve on the bottom of this regulator.

Fuel Mixture
1. Ensure engine is at full speed and load.
2. If equipped with an air/fuel ratio controller, manually set the controller to the
off position.
• Scroll down on the controller to the password section and enter the
password.
• The password is the serial number of the controller, plus 10 (ex: s/n of
1234 would have a password of 1244).
• Scroll to the operating mode and set it to OFF.
• The enclosed manual gives full detail on the operation of the controller.
• If the area requires the use of the AFRC, it must be turned on again after
carburetor adjustments are made.
3. With properly calibrated test equipment, analyze the exhaust gas content.

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 4. If equipped with a catalytic converter, the exhaust gas must be sampled from
upstream of the element. There is a 3/8” stainless steel line connected to the
upstream sampling port of the housing running down the face of the cooler.
5. The specified excess O2 content is 0.54%.
6. Less O2 indicates a rich condition which will cause severe engine damage.
7. More O2 indicates a lean condition which limits the engine’s power and can
cause damage if extremely lean.
8. Adjust the power valve on the carburetor until the mixture reads the specified
O2.
9. The adjustment is made by inserting a 1/8” Allen wrench into the hole directly
opposite of the fuel inlet.
10. To richen the mixture, turn the screw counter-clockwise.
11. To lean out the mixture, turn the screw clockwise.
12. Make small changes and allow the analyzer time to stabilize before changing
again. ¼ turn increments would be a good starting point with smaller changes
when you are getting close to the specified setpoint.
13. Check exhaust gas temperatures after all adjustments are made and ensure they
are within operating limits.
• Note that the rated 100% load is not acceptable for continuous operation.
Never allow the engine to run with less than 3” hg vacuum on the intake
manifold.

Compressor Set-Up
1. Ensure bearing lube oil pressure is at least 60 psig above suction pressure. It is
recommended to keep 75 psig or more on it.
• If the pressure is too low, consult the attached LeROI operation manual
for instruction on changing orifice size.
• When changing the orifice, always follow the shutdown and re-start
procedures and be sure the unit is isolated and all pressure is relieved.
2. Adjust vi ratio for optimum performance per the LeROI manual.

13
 Maintenance
This compression package will offer years of trouble free service if properly operated
and maintained.

BEFORE BEGINNING ANY MAINTENANCE, ALWAYS

PERFORM THE FOLLOWING:

1. Read and adhere to all warnings outlined on page 5.

2. Shut down compressor.
3. Close manual fuel valve and turn off control panel power.
4. Close suction and discharge valves to isolate unit.
5. Open well head by-pass to allow gas flow.
7. Bleed all pressure off of unit through blow down valve.
8. Check gauges to ensure all pressure is relieved.

PREVENTATIVE MAINTENANCE SCHEDULE

1. DAILY: Routine Inspection – General overview of operating status

and performance.

2. 750 HOURS: M1 – Engine oil and filter change, plus Routine

Inspection procedure.

3. 1500 HOURS: M2 – Ignition and valve train tune-up/inspection,

plus M1 maintenance procedure.

4. 21000 HOURS: M3 – Top end overhaul, including replacement of

cylinder heads and M2 maintenance procedure.

5. 39000 HOURS: M4 – Engine overhaul or replacement, including

M2 maintenance procedure.

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 MAINTENANCE/REPAIR PARTS LIST
Part Number Brand/Vendor Description
HDAX LA
Chevron/Texaco Engine oil
15W-40

LF9009 Fleetgaurd Engine oil filter

Spark plug (can be substituted w/ Champion

RC78PYP Champion
RN79G)

3075639 Cummins Spark plug gasket (included w/ new spark plugs)

4090456 Cummins Spark plug wire

3394581 Cummins Seal, O-Ring (spark plug extension tube)

WF2071 Cummins Water Filter (includes 4 units of DCA4 additive)

3054841 Cummins Valve cover gasket

AF373 Cummins Air filter element

217638 Cummins Fan belt

3076489 Cummins Thermostat

186760 Cummins Thermostat housing gasket

3804826RX Cummins Water pump

CAPACITIES AND SPECIFICATIONS

• Crankcase oil capacity……………………….15 US Gallons

• Engine coolant capacity………………...........60 US Gallons
• Fuel Pressure at Carburetor…………………..5” water column
• Fuel consumption at max hp………………....1616 SCFH
• Max continuous hp (500 ft, 70 deg F)………..166 BHP
• Maximum engine speed………………………1800 RPM
• Ignition timing………………………………...26 deg BTDC
• Excess O2 in exhaust (at maximum load)…….0.54%

15
 DAILY: ROUTINE INSPECTION
Operating conditions
Check all gauges and record the following. Ensure the conditions are within
design parameters.
• Suction Pressure
• Discharge Pressure
• Discharge Temperature
• Engine Manifold Vacuum
• Engine Oil Pressure
• Engine Jacket Water Temperature
• Gas Production Volume (if available to read)

Fluid Levels
Visually inspect the following fluid levels and replenish if necessary. (Where
applicable, ensure sight glass valves are opened).
• Engine Oil Level (when running, check sight glass on level maintainer,
with engine down, check at dip stick)
• Engine Oil Day Tank Level
• Engine Jacket Water Level
• Compressor Lube Oil Level
• Suction Scrubber (dump if liquids are present)
• Fuel Gas Scrubber (auto drain valve may be cracked open if fluids exist)
• Governor Sump Oil Level (check only with engine down. Uses same oil
as engine. Only applies to mechanical governors)

Machine Status
Check the following items to ensure they are within allowable parameters.
Take appropriate action as needed.
• Compressor Lube Oil Filter Differential Indicator
• Compressor Lube Oil Injection Pressure (must be 60 psig or more above
suction pressure unless oil pump is present)
• Inlet Filter Differential Pressure (install test gauge in ports before and
after filter)
• Discharge Coalescent Filter Differential Pressure (install test gauge in
ports before and after filter)
• Engine Air Filter Restriction Indicator
• Test Spark Plug Firing Voltage (all firing within 25% of each other and
all firing with no more than 25 KV)
• Check Ignition Timing (26 degrees BTDC unless conditions require
otherwise)
• Check for leaks and unusual noises or vibrations

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 750 HOURS: MAINTENANCE ONE (M1)
Routine Inspection
Before performing M1, the daily routine inspection procedure (previous page)
must be performed.
After the inspection is completed, unload and shutdown the compressor in
accordance with the shutdown procedure on page 11.

Oil and Filter Change

• Close valves between day tank and level maintainer
• Connect drain hose to evacuation system and drain oil
• Replace oil filter (lubricate O-ring and partially fill with clean oil)
• Close drain valves
• Fill crankcase through opening next to dip stick. Do not over-fill
• Top off day tank. It can be filled through the ball valve on the bottom
• Open valves on level maintainer system

Governor Oil Change

*Only applies to Woodward PSG hydraulic governor
• Check oil level while engine is down to ensure the seals are not leaking
• Drain oil from Allen head plug
• Re-fill through dipstick hole. Do not over-fill

Coolant Testing and Filter Change

To protect the engine, a coolant filter is used. The coolant has DCA4 additive
for engine longevity and the coolant filter supplements this additive. It is only to be
changed as needed as too much additive can damage the engine.
• Test coolant per the instructions on the DCA4 test kit
• Room temperature is ideal for testing the fluid
• If readings are “in the green”, do not replace coolant filter
• If coolant filter is to be replaced, isolate flow to it by closing the two
globe valves and turning the valve on the filter manifold to the off
position
• Remove filter, lightly oil O-ring on new filter (do not let oil get into
cooling system), replace filter
• Turn valve on filter manifold to on and open globe valves

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General PM Inspection and Maintenance
• Remove and inspect air filter, replace if necessary
• Grease cooling fan bearings per the label on the cooler shroud
• Remove mesh pad from crankcase vent and thoroughly clean
• Inspect engine accessory belt and cooling system belts
• Inspect unit for leaks, loose fittings and bolts, cracked welds, etc
• Inspect cooling system for cracked hoses
• Inspect throttle linkages for damage or wear
• Inspect exhaust system for cracks, leaks, loose catalyst door latches, etc
• Wash unit as needed. A clean unit is safer, easier to maintain, and acts
as an example of our company’s commitment to the environment

Re-start compressor per the start-up procedure outlined on pages 8-10.

Carefully watch all gauges until machine is at full speed, temperature, and
operating conditions.
Listen for unusual sounds.
Carefully inspect for leaks.
Check flow meter to ensure performance is as expected for the local
conditions.
Check O2 level in exhaust and adjust per procedure on pages 12-13.

*Note: Upon the very first preventative maintenance, M2 must be performed.

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 1500 HOURS: MAINTENANCE TWO (M2)
Routine Inspection
Before performing M1, the daily routine inspection procedure (page 14) must
be performed.
After the inspection is completed, unload and shutdown the compressor in
accordance with the shutdown procedure on page 11.

750 Hour M1
Before performing M2, M1 (previous pages) must be performed.

Spark Plugs
If spark voltage was near or exceeding 25 KV during routine inspection,
replace spark plugs. If voltage was normal and had less than 25% variance between
cylinders, remove and inspect spark plugs. Use a clean, magnetic spark plug socket.
Replace with new spark plugs if:
• Electrode appears worn or is fouled with deposits
• Electrode insulator has cracks
• Porcelain has cracks, corona marks, or flashover (dark markings that
will not wipe clean)
If sparks plugs appear good upon inspection, re-install them:
• Check gap. Set at 0.020”. Do not pry between electrode and ground;
this will damage the precious metal electrode. Only bend ground
• Clean porcelain with rubbing alcohol and do not touch it
• Replace spark plug gasket (PN 3075639)
• Install with clean magnetic spark plug socket (rubber inserts will
contaminate the spark plug that you just cleaned)
• Hand tighten all spark plugs gently, then torque each to 28 ft-lbs
* New spark plugs must also have the gap set, be kept clean, and be properly
torqued. They will come with new gaskets.
* Always use dielectric grease on wires. Clean wires and apply dielectric
grease at coil connection and spark plug connection.
* Never use any type of power or air tool on spark plugs. The harsh vibrations
will crack the ceramic.

*NOTE: If inductive voltage measuring tool is not available, replace spark plugs at
each M2 interval

Over-Head Set (Valve Lash Adjustment)

This procedure must be done in accordance with the steps outlined in the
Cummins manual, pages 6-13 to 6-17.
• Remove spark plug wires, crankcase breather cover, and valve covers

19
 • Rotate engine by turning the nut on the accessory drive (in front of the
magneto) with a 1 5/16” end wrench. It can be accessed from the
bottom without removing the guard. Turn it until the timing indicator
lines up with the 1-6 VS mark.
• If at the #1 TDC compression stroke, both rocker arms on cylinder one
can be moved side to side. If not, turn the engine one full revolution and
stop again at the 1-6 VS mark
• Adjust the cross heads to zero lash per the manual. This can be done by
feel by loosing the jam nut, holding the cross head down, and adjusting
the screw until it just touches, then turn it about 1/24th of a turn, which is
the distance of ¼ of a wrench flat on the jam nut. Re-set jam nut while
holding screw in place with large screwdriver
• Loosen jam nuts on valves and adjust with a screwdriver until a feeler
gauge between the valve stem and rocker arm can be moved between
them with drag. Set the jam nut while holding the screw in place
• The clearance for the intake valves is 0.014”. The intake valves are the
inner two on each rocker box.
• The clearance for the exhaust valves is 0.038”. The exhaust valves are
the outer two on each rocker box
• Do the above steps for valves:
o Cyl 1 intake and exhaust
o Cyl 2 intake
o Cyl 3 exhaust
o Cyl 4 intake
o Cyl 5 exhaust
• Rotate engine 360 degrees by turning the nut on the accessory until the
timing indicator lines up with the 1-6 VS mark again. You should be
able to move the rockers side to side for both valves on cylinder 6
• Make the same adjustments as above, but for valves:
o Cyl 2 exhaust
o Cyl 3 intake
o Cyl 4 exhaust
o Cyl 5 intake
o Cyl 6 intake and exhaust
• Re-install valve covers with new gaskets. The torque spec for the valve
cover bolts is 59 ft-lbs
Re-start compressor per the start-up procedure outlined on pages 8-10.
Carefully watch all gauges until machine is at full speed, temperature, and
operating conditions.
Listen for unusual sounds and carefully inspect for leaks.
Check flow meter to ensure performance is as expected for the local
conditions.
Check O2 level in exhaust and adjust per procedure on pages 12-13.

20
 21000 HRS: MAINTENANCE THREE (M3)
Routine Inspection
Before performing M3, the daily routine inspection procedure (page 14) must
be performed.
After the inspection is completed, unload and shutdown the compressor in
accordance with the shutdown procedure on page 11.

Top End Over-Haul

• Drain engine jacket water, including heat trace system
• Replace cylinder heads per the master over-haul manual
• Replace water pump and thermostat
• Set valve clearances per the procedure outlined in the previous pages
• Install new spark plugs per the procedure outlined in the previous pages

Replenish Fluids
• Re-fill cooling system with new coolant and DCA4 additive. The
mixture is 1.2 units of DCA4 per gallon, which in this system equates to
approximately 7.5 quarts of additive and 60 US gallons of 50/50
antifreeze and water mixture
• Change engine oil and filter, water filter, and top off day tank
• Change governor oil (Woodward PSG hydraulic governor only)

General PM Inspection and Maintenance

• Remove and inspect air filter, replace if necessary
• Grease cooling fan bearings per the label on the cooler shroud
• Remove mesh pad from crankcase vent and thoroughly clean
• Inspect engine accessory belt and cooling system belts
• Inspect unit for leaks, loose fittings and bolts, cracked welds, etc
• Inspect cooling system for cracked hoses
• Inspect throttle linkages for damage or wear
• Inspect exhaust system for cracks, leaks, loose catalyst door latches, etc
• Wash unit as needed. A clean unit is safer, easier to maintain, and acts
as an example of our commitment to the environment

Re-start compressor per the start-up procedure outlined on pages 8-10.

Carefully watch all gauges until machine is at full speed, temperature, and
operating conditions.
Listen for unusual sounds and carefully inspect for leaks.
Check flow meter to ensure performance is as expected for the local
conditions.
Check O2 level in exhaust and adjust per procedure on pages 12-13.

21
 39000 HRS: MAINTENANCE FOUR (M4)
Routine Inspection
Before performing M4, the daily routine inspection procedure (page 14) must
be performed.
After the inspection is completed, unload and shutdown the compressor in
accordance with the shutdown procedure on page 11.

Engine Over-Haul
• Drain engine jacket water, including heat trace system
• Drain engine oil
• Over-haul engine per the master over-haul manual
• Set valve clearances per the procedure outlined in the previous pages
• Install new spark plugs per the procedure outlined in the previous pages

Engine Replacement
An alternative to an in-frame overhaul would be to replace the engine with a
new or remanufactured engine
• Properly support the front of the screw compressor or remove the
compressor
• Remove cooling fan belts and guard
• Remove fuel plumbing, oil plumbing, etc
• Replace engine
• Re-install compressor, guards, plumbing, etc
• Set valve clearances per the procedure outlined in the previous pages
• Install new spark plugs per the procedure outlined in the previous pages

Replenish Fluids
• Re-fill cooling system with new coolant and DCA4 additive. The
mixture is 1.2 units of DCA4 per gallon, which in this system equates to
approximately 7.5 quarts of additive and 60 US gallons of 50/50
antifreeze and water mixture
• Change engine oil and filter, water filter, and top off day tank
• Change governor oil (Woodward PSG hydraulic governor only)

22
General PM Inspection and Maintenance
• Remove and inspect air filter, replace if necessary
• Grease cooling fan bearings per the label on the cooler shroud
• Inspect engine accessory belt and cooling system belts
• Inspect unit for leaks, loose fittings and bolts, cracked welds, etc
• Inspect cooling system for cracked hoses
• Inspect throttle linkages for damage or wear
• Inspect exhaust system for cracks, leaks, loose catalyst door latches, etc
• Wash unit as needed. A clean unit is safer, easier to maintain, and acts
as an example of our commitment to the environment

Re-start compressor per the start-up procedure outlined on pages 8-10.

Carefully watch all gauges until machine is at full speed, temperature, and
operating conditions.
Listen for unusual sounds and carefully inspect for leaks.
Check flow meter to ensure performance is as expected for the local
conditions.
Check O2 level in exhaust and adjust per procedure on pages 12-13.

23
 THE FOLLOWING SECTION OUTLINES THE
MAINTENANCE AND OPERATING REQUIREMENTS OF
THE LEROI ROTARY SCREW COMPRESSOR

24
Identifying Your Compressor
LeROI gas compressors have a nameplate that provides valuable information

on your compressor. This information is needed for ordering parts and

conversion kits, as well as for accessing warranty information and

understanding the design of the compressor. Below is a Model Designation

chart to help you identify your

compressor.

25
 Oil Flow and Orifice Sizing
As mentioned previously in this manual, rotary screw compressors require oil lubrication of

the bearings, cylinder and rotors. Bearing lubrication is necessary for long life. Cylinder and

rotor lubrication does three things:

1. Reduces friction between the rotors

2. Provides a seal between the cylinder and rotors to reduce gas slippage.

3. Cools the gas.

In certain applications the pressure differential (discharge-suction) is such that an oil pump is not required.

However, if the application has a lower pressure differential than an oil pump will be required. It is

important for the application to be reviewed especially if the the unit will be moved from one site to

another resulting in different conditions.

Figure 5 – Typical Oil Flow Figure 6 – Orifice Installation

LeROI gas compressors have an oil injection manifold that distributes oil supplied by the pump or pressure

differential. The orifice creates a restriction. A smaller orifice results in a greater restriction, which forces

more oil to the bearing and less oil to the rotors. The goal is to create a proper balance in the compressor

for reliable operation.

26
 Oil Flow and Orifice Sizing
Pumps are installed at the factory based on packager instructions or specified operating

conditions. Every LeROI compressor is tested at the factory to ensure reliable

operation. After testing, the standard orifce or an orifice specified by the customer is

installed in the unit.

IT IS ALWAYS GOOD PRACTICE TO VERIFY THAT THE PUMP AND ORIFICE

SELCTION ARE CORRECT FOR THE FIELD OPERATING CONDITIONS DURING

COMMISSIONING OF THE COMPRESSOR PACKAGE.

There are several size options for each compressor. In the event that an orifice is needed and one is not

readily available one can easily be created. Simply drilling a hole in a solid plug will provide the orifice. It is

also important to note that you may need to create an orifice in the event your desired size is in between

manufacturer available sizes.

Temperature/Viscosity/Pressure
Refer to Figure 7 for temperature and pressure methods and locations.

Gas discharge temperature range: 175-210 oF

(Temperature must be high enough to reduce condensation in separator tank.)

High temperature shut down: 230 oF

(Switch must be located between compressor discharge flange and separator tank inlet.)

WARNING! NEVER EXCEED 230oF DISCHARGE

27
 Temperature/Viscosity/Pressure (Continued)

For Most Situations:

Temperature rise - From oil injection to gas discharge: 30 – 40 o F

For heavy gas streams, a 30-40 °F temperature difference may not be possible

Temperature rise – From oil injection to discharge bearing oil drain: 15 oF

WARNING! NEVER EXCEED 20oF BEARING RISE

Oil pressure difference – gas inlet versus oil injection: 60-100 psi

(When gas discharge pressures are 50 psig or less, it may not be possible

to achieve 60 psig oil pressure. That is acceptable if all other specifications are met.)

Oil viscosity at injection temperature: 13-40 cSt

(Refer to oil supplier data for viscosity at actual injection temperature.)

28
 Field Evaluation of Pump & Oil
Injection Orifice Size
Temperature measurements at points A, B, and C should
Equipment & Measurement Location be made on sections of pipe or tube (not fittings) as
close to the compressor as possible.
Although other permanent instrumentation is
necessary for monitoring overall package Pressures at points D and E should be as close to the
performance, the following are specifically for the compressor as possible. There is typically an unused
purpose of evaluating the pump and orifice size. port on the oil injection manifold for E. Point D is
Table 2 Instruments & Measurement Locations located in the package inlet piping. If pressures are not
Instrument Data Location
taken at these specific locations, they should at least be
Infrared (IR) a. oil injection (A) pipe located on the compressor side of any major restrictions
temperature
gun
temperature
b. gas discharge (B) pipe
such as a filter.
temperature
c. discharge bearing
oil drain temperature
(C) tube (goes
down on some
WHEN TO CHANGE A PUMP OR ORIFICE
models) Yes
Pressure gage or d. gas inlet pressure (D) inlet pipe Is difference between gas Larger pump or orifice is
transducer 1 disch & oil injection temp required. Use
o
Pressure gage or e. oil injection (E) injection more than 40 F? performance program to
transducer 2 pressure manifold resize
No

D Is difference between gas Yes Is gas molecular weight Yes

disch & oil injection temp high? OK
o
less than 30 F?
E
A No No

C
B Smaller pump or orifice is
required. Use performance
program to resize

Is gas disch temp more Yes Reduce oil injection temp

o
than 210 F? by changing cooler or
thermostat
No
Figure 7 -Temperature / Pressure Measurement Locations

Although probes inserted directly in the gas or oil Is diff between bearing
oil drain & oil injection Install smaller injection
stream will give more accurate results, an infrared temp more than 20 F?
o
orifice.
(IR) temperature gun is recommended for this OR Is oil injection
pressure less than 60 PSI
procedure. Since a probe cannot be readily used on above gas inlet? (see Note: When gas disch
pressure is below 60 PSI it
the discharge bearing drain, the IR gun will allow a Note)
may not be possible to
better comparison. No
achieve 60 PSI oil pressure,
even with the smallest orifice.
This is acceptable if the
For best results when using an IR gun, slowly bearing oil drain temp is
moving the IR gun over the item to obtain the Is diff between bearing
no oil within spec.
drain & oil injection temp
highest temperature. Be careful not to pick up less than 3°F? OR is oil Yes
Install larger injection
temperatures from background objects. injection pressure more
orifice.
than 100 PSI above inlet
pressure?

29
 Variable VI Adjustment
Variable Vi is used to minimize the power required by the compressor. It does not change flow
directly, but can allow an increase in flow through more efficient use of power. Vi is the volume
compression ratio of a compressor: V1 / V2. The internal Vi of the compressor is determined by the size
of the discharge port. A small port causes gas to be released later in the compression cycle resulting in a
higher internal Vi, while a larger port allows the gas to be released earlier in the cycle resulting in a lower
internal Vi. The ideal Vi for an application can be calculated if the inlet and discharge pressures and k
(Cp/Cv) of the gas are known.

The compressor makes the most efficient use of power when the internal Vi equals the ideal Vi. For
example, if the internal Vi is high but the ideal Vi is low, the gas is compressed to a pressure greater than
the external pressure prior to being released. On the other hand, if the internal Vi is low but the ideal Vi
is high, gas momentarily flows backward into the compressor and is re-compressed. Both of these
scenarios result in wasted energy.

The standard discharge housings of the HG17, HG24, LG30, and LGL30 compressors have a 4.4 Vi
port, but are fitted with four valves that can be opened to increase the total size of the discharge port, so
that the following internal Vi’s can be achieved.

Vi = 4.4 (HIGH) All valves closed

Vi = 3.0 (MEDIUM) Two inner valves opened (two outer valves closed)
Vi = 1.9 (LOW) All valves opened

Instructions
THE COMPRESSOR CAN BE VERY HOT!
PROTECT YOUR SKIN WHEN ADJUSTING A RUNNING OR HOT
COMPRESSOR.

DO NOT TIGHTEN VALVES.

Valves are not intended to be closed or opened by tightening. Doing so may
damage the valve and/or compressor rotors. The valve should only be turned until
it “touches” the end of its stroke and then backed off about 1/16 of a turn.

The first item to be performed is to determine the ideal Vi of the application.

There are three ways to do this:

(1) Trial and error – adjust the valves while monitoring horsepower draw.
(2) Use the LeROI Screw Compressor Performance Program by alternatively selecting High,
Medium, and Low Vi on the Compressor tab, and see which results in the lowest horsepower.
(3) Calculate the ideal Vi mathematically (or from a spreadsheet calculator available from
www.leroigas.com):
Vi = (P2/P1)1/k

30
 P1 and P2 must be in PSIA, and be at the compressor inlet and discharge flanges. Be sure to
account for package pressure drops, which decrease the inlet pressure and increase the
discharge pressure at the compressor flanges. As a quick reference, for a typical natural gas
with k = 1.26, the pressure ratios that correspond to available internal Vi’s are:

Vi P2 / P1
4.4 6.5
3.0 4.0
1.9 2.2

Since there are three available internal Vi settings, each must cover a range of ideal application
Vi’s:

Ideal Vi Select Internal Vi

Greater than 3.5 HIGH (All valves closed)
Greater than 2.5, but not greater MEDIUM (Inner valves open, Outer
than 3.5 valves closed)
Less than or equal to 2.5 LOW (All valves opened)

After Determining the appropriate Vi ratio perform the following steps to adjust the internal
Vi ratio:

Figure 8:
Compressor discharge end showing four
closed Vi valves fitted with special locknut-
thread protectors.

Compressor models may also have an oil

pump mounted above the two valves on the
left.

Figure 9:
Remove locknuts with wrench before
making adjustments.

It is not necessary to remove the outer

locknuts if only the inner valves are being
adjusted.

The model represented in the figure has a

pump and is part of a package.

31
 Figure 10: For MEDIUM Vi, turn the inner
valves counterclockwise until they are fully
out.

DO NOT FORCE THE VALVES.

Once they “touch” the end of their stroke
reverse them by 1/16 of a turn. This also
applies when closing valves.

Figure 11: For LOW Vi, in addition to

turning the valves for MEDIUM, turn the
outer valves counterclockwise until they are
fully out.

DO NOT FORCE THE VALVES.

Once they “touch” the end of their stroke
reverse them by 1/16 of a turn. This also
applies when closing valves.

Figure 12: Reinstall and tighten locknuts just

snugly while holding valves so they do not
turn. The valve positions in this figure are
low Vi. Note that all of the valves are out.
PERIODICALLY LUBRICATE THE
VALVE STEM THREADS WITH
GREASE TO PREVENT RUST AND
ALLOW FOR FUTURE
ADJUSTMENT.

Figure 13: The valves in this figure are in a

MEDIUM Vi position (inner valves out,
outer valves in). It is not possible to hold the
outer valve while tightening the locknut –
just tighten the locknut lightly to prevent
jamming the valve.

32
 Versatrol Capacity Control
Versatrol capacity control is used to regulate compressor flow and reduce power requirements.
Versatrol consists of a set of pressure actuated valve assemblies mounted on the side of the compressor.
When opened, these valves allow gas to leave the compression cycle and return to the compressor inlet
prior to compression and delivery, thus reducing flow and horsepower. A valve is closed by applying
actuating pressure and opened by releasing actuating pressure. This can be used to ramp up the
compressor during start up. Start the compressor with all the ports open then close them.

The by-pass valve assemblies are sometimes referred to as unloaders or pockets.

Versatrol is available on the HG12 and larger models. Due to the small cylinder size, the HG12 has two
valves and an external by-pass (Figure 14). All larger models have four valves with an internal by-pass
(Figures 15 and 16).

Figure 14 - Depending on actual operating

HG12 showing conditions, Versatrol can reduce
one of two flow by approximately 50% and
Versatrol pockets. power by 25%. Versatrol can be
Second identical operated in steps or stepless.
pocket is on the
opposite side
Step Control - each valve is fully
opened of closed. For each valve
opened in sequence, capacity and
power will be reduced by
approximately 13% and 6%
Figure 15 – respectively.
HG17 showing
four Versatrol
pockets. HG24
arrangement is Stepless Control - each valve is
the same positioned anywhere between fully
(Pockets 2 and 4 opened and fully closed, thus
are under the throttling the by-pass and allowing
compressor) infinitely variable flow control.
Stepless control is achieved
through the use of electronic
Figure 16 – controls, which monitors flow and
LG30 showing power, and adjusts valve position.
four Versatrol LeROI-RCT does not supply
pockets. (Pockets control systems, but they are
on HG17 and commercially available.
HG 24 are on the
other side)

33
 Versatrol Capacity Control Continued
Actuation:
The Versatrol valves can be operated with pressurized air, gas or lubricating fluid depending on
whether it is step or stepless control. The actuation pressure should be the same or nearly the same
as the compressor discharge pressure. The valves should be opened in the 1-2-3-4 sequence and
closed in the 4-3-2-1 sequence, except the HG12. The HG12 can be opened or closed in any
sequence.

Oil may be used for either step or stepless control. Oil taken from the gas/ oil separator or after the
oil pump should have adequate pressure to allow Versatrol actuation. Oil should always be filtered
prior to entering the control system.

Air or gas can be used for step control systems only. Air and gas are compressible and will not allow
accurate or quick control responses. Air can be used for stepless control systems without a problem.

As mentioned previously, the valve is unloaded or opened by reducing the control pressure. When
the control pressure is reduced the higher pressure inside of the compressor opens the valve.
Therefore, it is important for the actuation pressure during the unloading stage to be lower than the
cylinder pressure. To ensure this occurs, the Versatrol valve assembly should be vented to the
cylinder inlet if actuated by gas or oil. If the air is used in the control system then it will have to be
vented to the atmosphere.

NEVER UNDER ANY NEVER UNDER ANY

CIRCUMSTANCES VENT GAS OR CICUMSTANCES VENT AIR
OIL TO THE ATMOSPHERE INTO A GAS COMPRESSOR

An oversight that occasionally occurs is the testing of a compressor on air with a

vacuum inlet. If the Versatrol valve is vented to atmospheric pressure, the valve
frequently does not open because the pressure in the cylinder is less than
atmospheric pressure.

Plumbing:
Steel or stainless steel tubing and fittings should be used. Copper tubing is not recommended.
Copper and gas can react and reduce the reliability of your system.

Tubing runs should not be any longer than necessary in order to avoid reduced response times
between controls and the Versatrol valves. Tubing should be 3/8”. Tubing size increases in
importance in cold environments or when tubing runs exceed 4 feet.

Control Valve Selection:

Since actuating pressure is applied and released through the same port in the Versatrol assembly, it is
necessary to use a valve that can be turned between the pressure source and a vent (cylinder for oil
and gas, atmosphere for air). Generally, a three or a four-way valve is required. Three-way valves are
a good choice for manually operated Versatrol. Four-way valves are best for automatic, stepless
control systems.

34
 Oil and Related Items
The lubrication system is vital for reliable operation of LeROI gas compressors. Following these guidelines
about oil and related items will ensure years of reliable service.

Start-Up: Prior to start-up the compressor should be pre-lubed.

Oil Filter: Check after first 100 hours. Change once a month if continuously operated or every 1000
hours otherwise. Filter must be changed with every oil change.
At the minimum a differential pressure is recommended for the oil filter. A differential gauge
with an alarm is advised.

Viscosity: The packager/user is responsible for selecting oil that is compatible with the gas, and can
maintain minimum viscosity at the operating conditions. The recommended viscosity is 15
centistokes regardless of the operating conditions. The minimum viscosity is 13 centistokes
regardless of the operating conditions.

Oil viscosity greater than 15 centistokes can affect performance, especially horsepower.

Analysis: Oil should be analyzed on a regular basis. Oil should be checked once a week for the first
month, with at least two of those samples being analyzed. If the first month of samples is
okay then the analysis can be reduced to once a month. Increases in water content and metals
should be watched closely. All reputable oil suppliers and manufacturers will analyze oil
samples at no charge.

Recirculation: It is important that the oil recirculates at least two times per minute, especially with heavier
hydrocarbon and water saturated gases. This keeps the oil temperature higher, thereby
reducing the possibility of hydrocarbons condensing and affecting the viscosity of the oil, or
having water condense and cause lubrication problems.

Strainer: When there is an oil pump, it is recommended that a Y-strainer be installed between the
separator and the suction to the pump

It is recommended that a Y-strainer be installed downstream of where the oil leaves the
discharge bearing retainer, and where it is injected in the casing. This will reduce the
possibility of a catastrophic failure if a bearing fails on the discharge end.

Coalescing: The coalescing element in the gas oil separator should be monitored with a differential
pressure gauge. This element should be changed as required. It should be checked at least
once a year. It is important that the filter element have enough surface area to remove oil
from the gas stream.

Gas Filtration: Gas filtration is recommended. Particulate in the gas stream can contaminate the oil and
cause premature failure.

Temperature: Oil temperature in and out of the rear-bearing retainer should be checked regularly. If
differential is greater than 30°F, there may not be sufficient lubrication for that are. This
could also be an indication of worn bearings.

35
 Service Procedures - Components
BEFORE REMOVING ANY COMPONENTS SHUT THE UNIT DOWN,
CLOSE ALL INLET AND DISCHARGE SHUTOFF VALVES, RELIEVE ALL
PRESSURE BY “PUMPING OUT”. MAKE CERTAIN THE PRESSURE
SYSTEM REMAINS VENTED TO ATMOSPHERE. DISABLE, LOCKOUT
AND TAG THE PRIME MOVER.

Compressor Service:
The compressor for these units is serviced only as a complete assembly using a new or factory rebuilt
compressor. Parts available for field service include the input shaft rotary oil seal and the seal retainer
gasket or o-ring seal.

Input Shaft Seal Replacement:

The compressor input shaft rotary seal may be replaced as follows, Refer to Figure 21:
1. Make certain the unit cannot be started and system has all pressure removed.
2. Remove any coupling guards and/ or shields.
3. Clean the front of the compressor thoroughly to prevent dirt from entering the
compressor.
4. Disconnect the drive coupling.

If the compressor or prime mover must be unfastened from the

frame, save and mark all mounting shims if any, for reuse.

5. Remove the compressor input shaft drive hub.

6. Remove the rotary seal retainer attaching cap screws and remove the retainer with
the gasket or o-ring seal.
7. Remove the oil seal assembly, including the spring and spring guide, from the input
shaft.
8. Remove the oil seal face insert, with o-ring, from the seal retainer.
9. Thoroughly clean all remaining parts.
10. Lubricate the new seal face insert and o-ring with clean compressor oil and install
the insert in the seal retainer.
11. Lubricate the rotary seal assembly with clean compressor oil, including the carbon
ring, and install the spring guide, spring and seal assembly on the input shaft

BE CAREFUL NOT TO SCRATCH THE SEAL FACE INSERT OR

BREAK OR SCRATCH THE CARBON RING. WIPE THE LAPPED
(MATING) SURFACES WITH A CLEAN, LINT-FREE CLOTH
BEFORE INSTALLING THE SEAL RETAINER.

12. Carefully reinstall the seal retainer, retainer capscrews and tighten all capscrews
securely.
13. Reinstall the compressor input shaft drive hub. Reconnect the drive coupling and
align, if necessary, following the coupling manufacturer’s instructions
14. Reinstall all coupling guards and/ or shields.

36
 Service Procedure Components

Figure 21-Compressor Input Shaft Seal Figure 22- Minimum Pressure Check Valve (Small)

Minimum Pressure/ Check Valve Service

The minimum pressure valve may be purchased as an assembly if required. Service parts are available,
however, to repair/overhaul this valve. This valve may be serviced as follows:
1. Make certain the unit cannot be started and that all the pressure has been removed from the
system.
2. Remove the service piping from the minimum pressure valve.
3. Remove the valve from the receiver-oil reservoir cap.
4. Securely clamp the valve in a vertical position (cap end up) in a suitable fixture (bench vise).
5. With a suitable wrench remove the valve cap from the valve body.

The spring beneath the cap is

under pressure; exercise extreme
care when removing the cap

37
 Service Diagnosis

MALFUNCTION PROBABLE CAUSE REMEDY

High Discharge 1. Insufficient or incorrect oil. 1. Fill, or drain and re-fill oil reservoir to correct
Temperature level with correct oil.
2. Operating above rated pressure or at 2. Operate at correct pressures.
excessive ratio.
3. Excessive inlet temperature. 3. Lower inlet temperature.
4. Restricted oil cooler (inside or 4. Clean (inside and outside) or replace with
outside). new cooler.
5. Damaged or inoperative thermal by- 5. Service thermal by-pass valve.
pass valve.
6. Restricted cooling oil flow. 6. a. Service oil filter.
b. Check oil lines and hoses for restrictions.
Service as required.

Low Inlet Pressure 1. Improperly set inlet valve or other 1. Set or adjust control correctly.
control.
2. Restricted inlet (dirty or clogged filters, 2. Service inlet filters or screens.
screens, etc).
3. Damaged or faulty inlet pressure 3. Service inlet pressure regulator.
regulator.

High Inlet Pressure 1. Improperly set inlet valve or other 1. Set or adjust control correctly.
control.

High Discharge Pressure 1. Operating at higher than rated 1. Adjust to operate at rated pressure.
pressure. 2. Service discharge check valve.
2. Damaged or worn discharge check
valve. 3. Install correct minimum pressure valve.
3. Incorrect minimum pressure valve 4. Service minimum pressure valve.
installed.
4. Damaged or worn minimum pressure 5. Correct cause of excessive restriction.
valve.
5. Excessive restriction in separator or
outlet piping.

Excessive Oil Consumption 1. Incorrect oil installed in reservoir. 1. Drain unit and install correct oil.
2. Reservoir over-filled.
3. External oil leaks. 2. Drain to correct level.
4. Operating with discharge pressure too 3. Check for and correct all leaks.
low. 4. Operate at rated pressure.
5. Drain tube missing, broken or not
touching bottom of separator element. 5. Replace drain tube with correct length tube.
6. Worn, damaged, or restricted
separator element. 6. Service separator element.
7. Clogged or restricted separator drain
line drain tube or filter. 7. a. Service drain line filter.
b. Check condition and installation of drain
line check valve. Clean or install correctly.
Replace if worn. Service drain line as
required.

38
 Fluid Compressor Partners, Limited
General Terms of Sale and Warranty Information

GENERAL TERMS OF SALE

1. GENERAL This order together with any additional writings signed by Seller shall represent the final, complete and
exclusive statement of the Agreement between the parties and may not be modified, supplemented, explained or
waived by parol evidence, Buyer's purchase order, a course of dealing, Seller's performance of delivery, or in any
other way except in writing signed by an authorized employee of the Seller. These terms are intended to cover all
activity of Seller and Buyer hereunder, including sales and use of products, parts and work and all related matters
(references to products include parts and references to work include construction, installation, and start-up). Any
reference by Seller to Buyer's specification and similar requirements are only to describe the products and work
covered hereby, and no warranties or other terms therein shall have any force or effect. Catalogs, circulars and
similar pamphlets of the Seller are issued for general information purposes only and shall not be deemed to modify
the provisions hereof.

2. CONTRACT PERFORMANCE, INSPECTION AND ACCEPTANCE

A. All products shall be finally inspected and test run, by an FCP representative, upon delivery at a single point to
ensure functionality. After test running, customer must immediately sign a Proof of Workability sheet. Future
transportation of the product is the sole responsibility of the Buyer and any damage that occurs during future
transportation will not be considered a warranty item. However, if there is an issue with workmanship and design
function, refer to the PRODUCT WARRANTY section.

B. All claims whatsoever by Buyer, excepting only those provided for under the WARRANTY statement and
PATENTS Clause hereof, must be asserted in writing by Buyer within ten (10) days period or they are waived. If this
contract involves partial performance, all such claims must be asserted within said ten (10) day period for each partial
performance. There shall be no revocation of acceptance. Rejection may be only for defects substantially impairing
the value of products or work and Buyer's remedy for lesser defects shall be those provided for under the
WARRANTY statement.

C. Seller shall not be responsible for nonperformance or delays in performance occasioned by any causes beyond
Seller's reasonable control, including, but not limited to labor difficulties, delays of vendors or carriers, fires,
governmental actions and material shortages. Any so occasioned shall effect a corresponding extension of Seller's
performance dates, which are in any event, understood to be approximate. In no event shall Buyer be entitled to
incidental or consequential damages for late performance or failure to perform.

3. TITLE AND RISK OF LOSS Full risk of loss (including transportation delays and losses) shall pass to the Buyer
upon delivery of products to the Ex-works point or if Seller consents to a delay in shipment beyond the contract date
at the request of the Buyer upon notification by the Seller that the products are manufactured.

4. PATENTS Seller agrees to assume the defense of any suit for infringement of any United States patents brought
against Buyer to the extent such suit charged infringement of an apparatus or product claim by Seller's product in and
of itself, provided (i) said products is built entirely to Seller's design, (ii) Buyer notifies Seller in writing of the filing of
such suit within ten (10) working days after the service of the process thereof, and (iii) Seller's given complete control
to the defense of such suit, including the right to defend, settle and make changes in the product for the purpose of
avoiding infringement. Seller assumes no responsibility for charges of its infringement of any process or method
claims, unless infringement of such claims is the result of following specific instructions furnished by Seller.

5. TERMS OF PAYMENT
A. Unless other terms are specified, all payment shall be in US dollars and shall become due in 30 days after
shipment. All shipments, unless otherwise specified, shall be Ex-works manufacturer's plant. If delivery is delayed by
purchaser, date of readiness for delivery shall be billed separately for payment purposes. If manufacture is delayed
by purchaser, a payment shall be due based on purchase price and percentage of completion. Balance payable in
accordance with terms stated herein.
B. If Seller has not received full payment within thirty (30) days after such payment is due then Buyer's outstanding
balance will be subject to an interest charge equal to two (2) percentage points above prime rate.

6. TAXES Any sales, use or other similar type taxes imposed on this sale or on this transaction are not included in the
price. Such taxes shall be billed separately to the Buyer. Seller will accept a valid exemption certificate from the Buyer

42
is applicable, however, if an exemption certificate previously accepted is not recognized by the governmental taxing
authority involved and the Seller is required to pay the tax covered by such exemption certificate. Buyer agrees to
promptly reimburse Seller for taxes paid.

7. CANCELLATION Following approval by Seller, Buyer may not cancel except upon payment of fifty percent (50%)
to one hundred percent (100%) of the total price of the product and work depending on the status of completion, plus
Seller's non-recoverable costs (including incidental and consequential damages) attributed to this order.

8. SECURITY INTEREST Buyer represents that the product is to be used for business, and shall remain personality.
Buyer grants Seller a security interest in the product to secure the payment of the purchase price. Buyer will not
lease, transfer or encumber the product and will keep it free from any and all liens and security interest. Upon default,
Seller shall have all the remedies available to it under the Uniform Commercial Code and other applicable laws of the
state in which the product is located and shall be entitled to all legal costs, reasonable attorney's fees, and all other
reasonable expenses and costs permitted by law which are incurred by Seller in enforcing its remedies. The security
interest herein granted shall be in Buyer's interest in the product and shall be fully discharged upon receipt by Seller
of the unpaid balance of the purchase price. Buyer agrees (a) to sign all financing statements and other instruments
or documents that Seller may reasonably believe are necessary to protect this security interest (b) i movement of the
product to another location is allowed under any other documents relating to this proposal to give Seller at least thirty
(30) days advance written notice of any such change in location, (c) to inform Seller of any change in the law of
jurisdiction in which the product is located whether such change is statutory or otherwise, which change could affect
the continued status of the product as personality and (d) to procure and maintain insurance on the product for its full
purchase price, the policy to name the Seller as loss payee.

9. CONFIDENTIALITY Technical data and layouts supplied by Seller in connection herewith are confidential pending
Buyer's acceptance of this proposal.

10. OSHA LAWS Seller has taken the Occupational Safety and Health Act of 1970 (OSHA) and like state and local
laws into account in the design of its products with the objectives that when such equipment is placed in appropriate
environment it will enable the operator or user to comply with the applicable OSHA and similar requirements,
however, because compliance is significantly affected by many factors over which Seller has little control (such as
installation, plant layout, building acoustics, materials processed, processing procedures and supervision and training
of employees), Seller does not represent or warrant that equipment sold by it complies with OSHA or any like state or
local law or regulation and the cost for modifications and responsibility for compliance are the Buyer's responsibility.

PRODUCT WARRANTY

43
Subject to the terms and conditions hereinafter set forth and set forth in General Terms of Sale, FCP (the seller)
warrants products and parts of its manufacture, when shipped, and its work (including start-up) when performed, will
be of good quality and will be free from defects in material and workmanship. This warranty applies only to Seller's
equipment, under use and service in accordance with seller's written instructions, recommendations and ratings for
installation, operating, maintenance and service of products, for a period as stated in the table below.

Equipment in question must be returned to FCP, via prepaid freight, at which time either FCP or original equipment
manufacturer will determine reason for failure due to abuse, neglect or workmanship. No warranty assessment will
be made without the product being examined at an FCP facility or at original manufacturer’s facility, either of which
must be authorized by FCP.

All replacement products not purchased from FCP will void warranty and the performance, maintainability or longevity
of the system will not be guaranteed.

Product Type Warranty Duration

New, Repaired or Remanufactured Compression Systems 90 days from date of service
Items not manufactured by FCP 90 days from date of service
Natural Gas Drivers, components and fuel gas accessories 2500 hours
Filters (Oil, coalescent, canister, SURE) 24 hours from date of service

THIS WARRANTY EXTENDS ONLY TO BUYER AND/OR ORIGINAL END USER, AND IN NO EVENT SHALL THE
SELLER BE LIABLE FOR PROPERTY DAMAGE SUSTAINED BY A PERSON DESIGNATED BY THE LAW OF
ANY JURISDICTION AS A THIRD PARTY BENEFICIARY OF THIS WARRANTY OR ANY OTHER WARRANTY
HELD TO SURVIVE SELLER'S DISCLAIMER.

All accessories furnished by Seller but manufactured by others bear only a 90 day, or 2500 hour, warranty.

All claims for defective products, parts, or work under this warranty must be made in writing immediately upon
discovery and, in any event within 5 days from date of shipment of the applicable item and all claims for defective
work must be made in writing immediately upon discovery and in any event within 10 days from date of delivery
thereof by Seller. Unless done with prior written consent of Seller, any repairs, alterations or disassembly of Seller's
equipment shall void warranty. Installation and transportation costs are not included and defective items must be held
for Seller's inspection and returned to Seller upon request.

THERE ARE NO WARRANTIES, EXPRESSED, IMPLIED OR STATUTORY WHICH EXTEND BEYOND THE
DESCRIPTION ON THE FACE HEREOF, INCLUDING WITHOUT LIMITATION, THE IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS OF PURPOSE.

After Buyer's submission of a claim as provided above and its approval, Seller shall at its option either repair or
replace its product, part, or work at the original point of shipment, or refund an equitable portion of the purchase price.

The products and parts sold hereunder are warranted only for specific conditions in which the compression system
was quoted, excluding quality of natural gas. The system is not intended for operation with erosive or corrosive
material or those which may lead to build up of material within the product supplied, nor those which are incompatible
with the materials of construction. The Buyer shall have no claim whatsoever and no product or part shall be deemed
to be defective by reason of failure to resist erosive or corrosive action nor for problems resulting from build-up of
material within the unit nor for problems due to incompatibility with the materials of construction.

Any improper use, operation beyond capacity, substitution of parts not approved by Seller, or any alteration or repair
by others in such manner as in Seller's judgment affects the product materially and adversely shall void this warranty.

No employee or representative of Seller other than a Partner of the Company is authorized to change this warranty in
any way or grant any other warranty. Any such change by an Officer of the Company must be in writing.

44
The foregoing is Seller's only obligation and Buyer's only remedy for breach of warranty, and except for gross
negligence, willful misconduct and remedies permitted under the General Terms of Sale in the sections on
CONTRACT PERFORMANCE, INSPECTION AND ACCEPTANCE and the PATENTS Clause hereof, the foregoing
is BUYER'S ONLY REMEDY HEREUNDER BY WAY OF BREACH OF CONTRACT, TORT OR OTHERWISE,
WITHOUT REGARD TO WHETHER ANY DEFECT WAS DISCOVERED OR LATENT AT THE TIME OF DELIVERY
OF THE PRODUCT OR WORK. In no event shall Buyer be entitled to incidental or consequential damages. Any
action for breach of this agreement must commence within one 90 days after the cause of action has occurred.

45
 PROOF OF WORKABILITY SHEET
(START-UP AND COMMISIONING RECORD REQUIRED FOR WARRANTY)

START
SKID NUMBER: MODEL:
DATE:

END USER CUSTOMER NAME: COMPRESSOR SITE LEASE NAME:

ADDRESS: STATE:
CITY: COUNTY:
STATE: ZIP CODE: NOTES:
OPERATING CONDITIONS: MACHINE SPECIFICS:
ELEVATION: ENGINE MODEL:
AMBIENT TEMP: ENGINE SERIAL NUMBER:
FUEL GAS TYPE: COMPRESSOR MODEL:
SUCTION PRESSURE: COMPRESSOR GEAR RATIO:
DISCHARGE PRESSURE: COMPRESSOR SERIAL NO:
SALES VOLUME: CONTROL PANEL MODEL:
ENGINE SPEED: CONTROL PANEL SERIAL NO:
ENGINE MANIFOLD VACUUM: COOLING PACKAGE MODEL:
ENGINE OIL PRESSURE: COOLING PACKAGE SERIAL NO:
COMPRESSOR OIL INJECTION PRESS: HOUR METER AT START-UP:
DISCHARGE TEMPERATURE: SAFETY SHUT-DOWN SETPOINTS:
ENGINE TEMPERATURE: HI DISCHARGE PRESS:
EXHAUST
TEMPERATURE: LO DISCHARGE PRESS:
IGNITION TIMING: HI SUCTION PRESS:
EXHAUST GAS OXYGEN CONTENT: LO SUCTION PRESS:
FUEL GAS SCRUBBER PRESSURE: LO ENGINE OIL PRESS:
FIRST CUT FUEL PRESSURE: ENGINE OVERSPEED:
FUEL PRESSURE AT CARBURETOR: ENGINE UNDERSPEED:
START-UP AND INSPECTION BY: HI DISCHARGE TEMP:
NAME: LO DISCHARGE TEMP:
TITLE: HI ENGINE TEMP:
COMPANY: HI EXHAUST GAS TEMP:
SIGNATURE: HI ENGINE MANIFOLD PRESS:

REMOVE THIS PAGE AND REMIT TO:

FLUID COMPRESSOR PARTNERS
ATTN: WARRANTY CLAIMS DEPARTMENT
2538 WEST KENTUCKY AVE
PAMPA, TEXAS 79065
PHONE: 806-669-7499
FAX: 806-669-7399

NOTICE: A GAS ANALYSIS MUST ACOMPANY THIS FORM. IF A SEPARATE FUEL

SOURCE IS USED, THEN AN ANALYSIS FOR THE COMPRESSED GAS AS WELL AS
THE FUEL GAS MUST BE SUBMITTED FOR WARRANTY CONSIDERATION.
For any questions that are not addressed, please contact us at 806-669-7499. We
will be happy to answer any questions.