Ariel JGM JGN JGP JGQ Manual

JGM-JGN-JGP-JGQ Maintenance & Repair Manual 12/03/2022
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
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Ariel Optional Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Ariel Separately Purchased Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Ariel Separately Purchased Tool Kits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Digital No-Flow Timer (DNFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DNFT Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Programmable DNFTs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
DNFT Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Troubleshooting DNFT’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Proximity Switch A-18255. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Proximity Switch Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Troubleshooting Proximity Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Initial Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Maintenance Intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Daily Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Monthly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Six-Month (4,000-Hour) Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
One-Year (8,000-Hour) Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Two-Year (16,000-Hour) Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Three-Year (24,000-Hour) Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Four-Year (32,000-Hour) Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Six-Year (48,000-Hour) Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Frame Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Oil Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
ARIEL CORPORATION | www.arielcorp.com 1

Oil Sampling Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Oil System Cleanliness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Frame Oil System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Oil Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Oil Pump & Regulating Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Oil Temperature Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Oil Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Oil Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Oil Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Compressor Pre-lube System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Compressor Pre-lube for CNG Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Auxiliary Frame Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Flushing to Change to a PAG Lubricant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Recommended Flushing Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Flushing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Flushing the Force Feed Lubrication System - Common Oil Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Flushing the Force Feed Lubrication System - Independent Oil Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Cylinder and Packing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Force Feed Lubricator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Pressure Relief. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Pump Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Priming the Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Pump Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Pump Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Auto-Relief Valve (ARV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
ARV Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Force Feed Lube Blow-Out Fittings, Rupture Disks, and Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Distribution Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Distribution Block Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Divider Valve Bypass Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Balance Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Selecting Balance Valves and Pressure Gauges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Installing Balance Valves and Pressure Gauges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Adjustment of Balance Valves Fed by a Divider Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Adjustment of Balance Valves Fed by Primary/Secondary Divider Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Subsequent Compressor Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Force Feed System Design, Operating Parameters, and Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Common Oil Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Independent Oil Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Force Feed Lubrication Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Cycle Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Under/Over Lube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Cylinder Lubrication Paper Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Coolant System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Part Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Relieving Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Depressurization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Positioning a Throw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Variable Volume Clearance Pocket (VVCP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
VVCP Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
VVCP Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
VVCP Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
VVCP Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
VVCP Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Compressor Valves - Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Required Tools and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Valve Cap Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Valve Caps on Cast Iron Cylinders or High-Pressure Caps without Spring Energized Seals . . . . . . . . . . . . . . . . 81
Removal of Valve Cap with Spring Energized Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Valve Cap with Spring Energized Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Valve Cap Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Gas Containment Fastener Torque Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Piston and Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Piston Rod Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Five-Piece Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Wear Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Piston Rod Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Piston Rod Packing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Piston Rod Packing Reassembly and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Types of Piston Rod Packing Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
“P” Pressure Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
“PB1” Pressure Breaker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
“UP” Pressure Breaker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
“P1U” Pressure Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
“BTR” Single-Acting Seal Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
“BD” Double-Acting Seal Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Double "WAT" Double-Acting Seal Set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
“AL” Double-Acting Seal Set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
“BT” Single-Acting Seal Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
“BTS” Single-Acting Seal Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
“BTUU” Single-Acting Seal Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

“CU” Single-Acting Seal Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

“CUU” Single-Acting Seal Set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
“RS3” Single-Acting Seal Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
“DS” Double-Acting Seal Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
“STU” Single-Acting Seal Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
“CR” Single-Acting Seal Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
“RTV” Oil Wiper Set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
“3RWS” Oil Wiper Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Crossheads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Crosshead Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Crosshead Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Connecting Rod Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Connecting Rod Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Crank Pin Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Connecting Rod Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Connecting Rod Bushing Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Connecting Rod Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Connecting Rod Bearing Vertical Jack Clearance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Connecting Rod Thrust (Side) Clearance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Crankshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Main Bearing Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Main Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Crankshaft Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Crankshaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Main Bearing Vertical Jack Clearance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Crankshaft Thrust (End) Clearance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Chain Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Chain and Sprocket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Chain Idler Sprocket Replacement (Eccentric Adjustment Caps) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Lube Oil Pump Sprocket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Force Feed Lubricator Chain Sprocket Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Crankshaft Chain Sprocket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Chain Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Warranty Notification - Installation List Data and Start Up Check Lists for Reciprocating
Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Compressor Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Piston Rod Runout Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Ariel Fasteners and Torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Recommendations for Torque Accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
JGM:P:N:Q Fastener Torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Measuring Head End Clearance for Forged Steel Tandem Cylinders with Concentric Valves . . . 161

Frame Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

Opposed Throw - Reciprocating Weight Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Compressor Clearance, Oil, & Temperature Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Balance Valve Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Hold-down Bolting to Resist Shaking Forces and Couples in Reciprocating Compressors. . . . . . . . . 172
Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Soft Foot and Top Plane Flatness Checks for Proper Main Bearing Bore Alignment in Reciprocating
Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Soft Foot Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Top Plane Flatness Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Attachment of Wiring, Tubing, or Pipe Clamps to Ariel Compressor Cylinders . . . . . . . . . . . . . . . . . . . 177
Alternate Attachment Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

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 while the unit is conform to Zone 1 requirements. A Zone 1 environment
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.
Hot gas temperatures (especially the cylinder
• Verify each compressor cylinder is relieved to atmo-
discharge), 190°F (88°C) oil, and high friction areas. Wear
spheric pressure. To relieve residual cylinder bore
proper protection. Shut down unit and allow to cool
pressure after blowdown, open the “Kiene” valves
before maintaining these areas.
on the indicator ports, if so equipped.
WARNING: RELEASED GAS MAY BE POISONOUS
AND/OR FLAMMABLE. CAUTION
Before resuming operation, purge the entire system with
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
personal injury.
on a compressor or control panel, consult the
appropriate Ariel Maintenance and Repair
Manual for specific information before Lifting the Compressor
proceeding. The Maintenance and Repair
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
compressor safety, operation, maintenance, grade cap screws, and properly tightened. Lifting cable
or repair, contact your packager or Ariel. spreaders are required perpendicular to the crankshaft
axis and the lift point. Verify crane capacity is adequate.

JGM-JGN-JGP-JGQ Maintenance & Repair Manual – General Safety for Reciprocating Compressors 12/03/2022
• Determine compressor weight before lifting. more suitable for low temperatures per ASME
See the Ariel Performance Program for frame B18.15 and ASTM F541.
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

Throw and Data Plate Locations

When contacting Ariel with compressor machine. This data helps Ariel representatives
questions, know throw locations and answer quickly and accurately. Contact Ariel for
information on data plates fastened to the replacement if any data plates are missing.
Figure: Integral Guide Compressor Throw and Data Plate Locations - Typical
1 VVCP Dimension Plate 5 Mechanical Inspector Plate and 9 Force Feed Lubricator Data Plate
2 Rotation Direction Plate Frame Serial Number Stamp 10 Cylinder Serial Number, MAWP,
3 Compressor Data Plate 6 Cylinder Data Plate (see #10) and Hydrotest Stamp
4 VVCP Data Plate 7 Force Feed Lubricator Pump Data 11 VVCP Serial Number, MAWP, and
Plate Hydrotest Stamp
8 Oil Filter Change Instruction
Plate

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-
• Customer Technical Bulletins (CTB’s) mation on the use of Ariel compressors in
provide important information on changes, different applications.
corrections, or additions to Ariel products or
services. Read these bulletins before oper- Ariel Technical and Service Schools
ating or servicing equipment.
• Engineering References (ER’s) provide stan- Ariel schedules several in-plant schools each
dard procedures and other useful informa- year, which include classroom and hands-on
tion for operation, maintenance, or repair of training. Ariel also sends representatives to
Ariel compressors or components. Read and provide customized training on location. Contact
follow these procedures for long and trouble- Ariel for details.
free service from your Ariel compressor.
• Maintenance and Repair Manuals provide
detailed maintenance and repair information Ariel Contact Information
on specific Ariel compressor models.
Contact Telephone Fax E-Mail
Ariel Response Center 888-397-7766 (toll-free USA & 740-397-1060 arc@arielcorp.com

Canada) or 740-397-3602
Ariel Parts Sales (International) 740-393-5054 parts@arielcorp.com
Order Entry 740-397-3856 -
Ariel World HQ 740-397-0311 740-397-3856 info@arielcorp.com
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

Tools
A variety of tools are required for safe and specifically designed for use on Ariel units. Clean
effective maintenance of Ariel compressors. all tools before use and verify full tool
Standard hand tools are readily purchased from engagement with the part being removed or
hardware stores or industrial supply companies. installed. If the Tool Kit is missing or if a single
Ariel makes certain special tools available where tool is missing, worn, or broken, call your
needed. distributor. Do not use worn or broken tools, or
substitutes for Ariel furnished tools. See Parts
Ariel Optional Tools List for individual tool part numbers.
Ariel offers an optional tool kit with every

compressor. For JGM:P:N:Q compressors, it
contains the tools shown below, which are
Figure: Optional Furnished Tools for JGM:P:N:Q 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)
10 9/64" Allen Wrench
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)

JGM-JGN-JGP-JGQ Maintenance & Repair Manual – Tools 12/03/2022
Ariel Separately Purchased Tools

Figure: Ariel Separately Purchased Tools for JGM:P:N:Q 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 Tool Kits • 14-piece, 12-point socket set, 7/16” to
1. Ariel SAE Hand Measurement Tool Kit 1-1/4” with clip rail
• Extensions, 1-1/2”, 5”, and 10"
a. 0.0005 in. needle type dial indicator
• Drive adapters: 1/2” to 3/8" and 1/2”
b. 0.001 in. 1-inch travel dial indicator
to 3/4"
c. Magnet base for dial indicator
• 1-1/4” open end crow’s foot adapter
d. 3/8” drive calibrated torque wrench, 40 to
• 10-1/4” ratchet
200 in x lbs
• Speed handle
e. 3/8” drive calibrated torque wrench, 10 to
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”
2. Ariel SAE Hand Tool Kit
• Extensions, 3-1/2”, 8”, and 16”
a. 15-piece combination open/box end • Drive adapters: 3/4” to 1/2", 3/4” to 1",
wrench set, 5/16” to 1-1/4” and 1” to 3/4"
b. 8-piece slot and Phillips screwdriver set • 24” ratchet
c. 3/8" square drive wrench set, including: • 22” breaker bar
• 12-piece, 12-point socket set, 5/16” to f. Adjustable wrenches: 12" and 18"
1”
g. Dead blow semi-soft faced hammers: 3 lb.
• 7” ratchet and 6 lb
• Speed handle h. 3/4” x 36” pry bar
• Extensions, 1-1/2”, 3”, 6”, and 12” i. 12” long feeler gauge set
• Ball type universal joint j. 12” machinist scale with 0.01 in. incre-
• 3/8” to 1/2" drive adapter ments
• 1/4” hex key socket k. 13-piece Allen wrench set, 0.050 in. - 3/8”
• 8-1/2” breaker bar
d. 1/2" square drive wrench set, including:

JGM-JGN-JGP-JGQ Maintenance & Repair Manual – Tools 12/03/2022
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

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

armored cabling as opposed to wiring in conduit to Any arc welding on the skid and/or associated
minimize nuisance shutdowns due to wire chafing equipment and piping can permanently damage solid-
and shorts. Cable in cable trays also facilitates main- state electronic equipment. Welding can cause
tenance access. 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.
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)

JGM-JGN-JGP-JGQ Maintenance & Repair Manual – Instrumentation 12/03/2022
INSTRUMENT SUPPLIER SETTING/REQUIREMENT
Crankcase Level Packager 1/2 to 2/3 sight glass level
- Low Level Shutdown 1/4 sight glass level
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)
- 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 7. Install all safety shutdowns, controls, instru-

1. Install the compressor frame low lube oil mentation, ignition systems, electrical
pressure shutdown set to stop the unit if oil devices, and high temperature piping (gas
pressure downstream of the filter falls below discharge and engine exhaust) in accordance
45 psig (3.1 barg). Compressor operation for with good engineering practice and appli-
only a few seconds without oil pressure cable codes for the area classification at the
causes major damage. Normal oil pressure is end user location. Ensure compatibility of all
about 60 psig (4.1 barg) at full rated speed systems for area classification.
and normal operating temperature. The low 8. If packing vent temperature is monitored,
oil pressure shutdown must activate after oil confirm alarm and shutdown set points
pressure exceeds 45 psig (3.1 barg) at start- through vent flow rates.
up. Ariel provides a 1/4 inch tubing fitting to
connect the low lube oil pressure shutdown
and ties a tag to this connection before each
Digital No-Flow Timer (DNFT)
compressor ships. Do not operate the
compressor for prolonged periods at less
CAUTION
than 50 psig (3.4 barg) oil pressure.
2. Automated pre-lube systems require a start Any arc welding on the skid and/or associated
equipment and piping can permanently damage solid-
permissive to sense minimum required pres- state electronic equipment. Welding can cause
sure/time at oil gallery inlet.See “Compressor immediate failure or reduce electronic equipment life
Pre-lube System”. Unit must shut down if the and void the warranty. To protect electronic equipment
system fails to achieve 45 psig (3.1 barg) oil disconnect all electrical connections including ground,
pressure within 10 seconds after crankshaft and remove batteries, or completely remove the
starts to turn. electronic equipment from the compressor.
3. Mount overhead lube oil supply tanks high close as possible to the area where the welding will
enough to provide oil flow to the level control setting. Welding must not cause a current flow across
at all ambient temperatures. any compressor bearing surface, including but not
4. On multi-nozzle cylinders, Ariel strongly
recommends a temperature device in both A DNFT is a totally enclosed electronic device,
discharge nozzles. combining the latest technology in
5. Install the high lube oil inlet temperature microprocessor and transistor components to
shutdown at the filter inlet connection. detect slow-flow and no-flow of divider block
lubrication systems. The DNFT uses an oscillating
6. At a minimum, install one vibration shut- crystal to accurately monitor the lubrication
down.Mount vibration device near the top of system cycle time to enable precision timed
the frame with the sensitive axis parallel to shutdown capability. The magnet assembly and
the piston rod axis. 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.
DNFTs utilize an LED to indicate each cycle of the

divider valve, which allows easy adjustment and
monitoring of lubrication rates. Programmable
models display total pints, cycle time of divider
valve, total cycles of divider valve, or pints per
day pump flow rate on a liquid crystal display and
operators can adjust alarm time from 20 to 255
seconds.

DNFT Installation remove magnet housing. Do not remove

magnet, spring, or spacer from magnet
Figure: Typical DNFT Magnet Assemblies 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
1 Trabon Style O-ring Seal 7/16-20 of magnet housing to 25 lbs x inch, (2.8 N•m)
2 Trabon Metal Gasket Seal 7/16-20 (1994 or earlier) maximum.
3 Lincoln O-Ring Seal 7/16-20 Extended Nose 5. The LED on the DNFT indicates each divider
valve cycle to allow lubricator pump
Figure: Typical DNFT Installation adjustment for Ariel recommended cycle
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
1 Divider Valve Piston 25 lbs x inch (2.8 N•m) maximum. A blinking
2 Magnet LED indicates correct adjustment. If the LED
3 Magnet Housing fails to blink with divider valve cycling, slide
4 Set Screws (2) DNFT back on the hex of the magnet housing
5 LED
in 1/16" increments until it does.
6 Control Housing 8. Make all conduits and connections
7 Wire Leads appropriate for area classification. Insulate
8 O-Ring unused wires from the ground, other wires,
9 Divider Valve and the case. Support conduit and fittings to
10 Piston Enclosure Plug avoid bending the magnet housing.
1. Loosen the Allen set screws on the DNFT and

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

Figure: A-20514 24 VDC DNFT Wiring Connections for Unit in Operation
Programmable DNFTs
Figure: Typical Programmable DNFT CAUTION
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"
1 Magnet
recessed opening on the face of the DNFT.
2 Magnet Housing The current programming mode (1, 2, 3, or 4)
3 Allen Set Screws immediately displays on the LCD followed by
4 LED "0" 2 seconds later. "0" indicates the current
5 Control Housing mode is ready for programming.
6 LCD
2. If the desired programming mode does not
7 1/8" recessed opening for programming magnet
display, remove and re-insert the
8 Wire Leads programming magnet into the recessed
9 Programming Magnet opening until it does. Leave the programming
Programmable DNFTs come with a small liquid magnet in the recessed opening when the
crystal display (LCD) screen to display total desired programming mode displays.
divider valve cycles (Mode 1), cycle time of 3. Select one of the programming modes below:
divider valve in seconds (Mode 2), total pints of a. Mode 1 - LCD displays total divider
oil used (Mode 3), or pump flow rate in pints per valve cycles; program alarm time.
day (Mode 4). Operators can also adjust alarm • To set alarm time, press and release
time in Mode 1. the spring-loaded magnet assembly
until the desired alarm time in
seconds displays on the LCD. Set
alarm time from a minimum of 20

seconds to a maximum of 255 magnet into the recessed opening, selects

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: 3 O-Ring
24 + 24 + 24 = 72. 4 Control Housing
• Press and release the spring-loaded 5 Polarized Connector
magnet until the divider valve total 6 Field Replaceable Battery
displays on the LCD. Maximum value: 7 1/2" Pipe Plug
120. If not set, device defaults to zero 8 #22 AWG 18" (0.46 m) Leads
and prevents Mode 4 flow rate display. 9 Spring
• Remove programming magnet. The 10 Spacer
DNFT displays total pints on the LCD if 11 Allen Set Screws
left in this mode.
d. Mode 4 - LCD displays pump flow rate in The DNFT operates on a field-replaceable lithium
pints per day. battery that should last six to ten years. If the
• Remove programming magnet with battery voltage drops below 2.5 VDC, the DNFT
Mode 4 displays. LCD displays pump shuts down and the compressor cannot be
flow rate in pints per day based upon restarted until the battery is replaced.
the divider valve total set in Mode 3.
Mode 4 requires a minimum 4 second
cycle time.
The DNFT stores all programmed information
until the operator inserts the programming

10. Programmable DNFTs require

reprogramming of the alarm time (Mode 1)
CAUTION and divider valve total (Mode 3) after a power
Do not open a DNFT in an explosive gas atmosphere. interruption. See the programming section of
this document.
1. Shut down the compressor. 11. To verify DNFT operation, pre-lube the
2. Disconnect DNFT wiring. system and check for LED blink.
3. Use 1/8 inch Allen wrench to loosen Allen set Troubleshooting DNFT’s
screws and remove control housing to a safe
atmosphere.
NOTE: When installing multiple DNFTs, wire each to a
4. Use 3/8 inch ratchet wrench to remove pipe separate alarm circuit of the control panel, annunci-
plug. ator, or PLC to simplify lubrication system and DNFT
5. Remove the battery and disconnect from the troubleshooting. See ER-105.3.1 for DNFT bench test
polarized connector. procedures.
6. Test battery. The voltage should read 3.6
VDC. Problem:
7. Connect the new battery to the polarized • LED does not blink and control panel indi-
connector. cates lube no-flow. (see also Erratic Shut-
down)
8. Insert the new battery and reinstall the pipe
• ARV bypasses or rupture disk bursts and
plug. Apply Teflon tape to plug threads and
divider valve seizes after DNFT installation.
torque to 25 ft x lb (34 N•m).
• Erratic shutdown or LED blink.
9. Place DNFT control housing on the magnet
housing in its original position and tighten set
screws. Reattach wiring and conduit.
Troubleshooting: DNFT Lube No-Flow
Problem
LED does not blink and control panel indicates lube no-flow. (see also Erratic Shutdown)
Possible Cause 2. Either pump clean oil through lubrication

system with a purge pump or run the
Improperly adjusted DNFT.
compressor to cycle the divider valve.
Solution 3. If necessary, slide DNFT back in 1/16“
increments until LED blinks with each
1. Loosen set screws, slide DNFT all the way divider valve cycle.
onto hex of magnet housing and torque to
25 lbs x inch (2.8 N•m) max.
(Do not over tighten).

Possible Cause Possible Cause

Broken spring or magnet in magnet housing. Bent magnet housing.
Solution Solution
1. Loosen set screws, remove DNFT from 1. Loosen set screws, remove DNFT from
magnet housing. magnet housing.
2. Remove magnet housing from divider 2. Check for damaged or bent magnet
valve. housing.
3. Remove magnet, spring, and spacer and 3. Remove magnet assembly from divider
check for damage. valve.
4. Replace damaged components. 4. Replace magnet housing, magnet, spring,
and spacer.
5. Re-install magnet housing on divider valve
and DNFT on magnet housing. 5. Re-install new magnet housing on divider
valve and DNFT on magnet housing.
6. If necessary, adjust DNFT, check for LED
blink. 6. If necessary, adjust DNFT, check for LED
blink.
7. Purge air from system with purge pump.
7. Purge air from system with purge pump.
Possible Cause
Low battery voltage.
Solution
1. Remove battery from DNFT and test it.
2. Replace battery with a factory
recommended replacement lithium battery
if voltage is below 2.5 VDC.
Troubleshooting: DNFT ARV Bypasses
Problem
ARV bypasses or rupture disk bursts and divider valve seizes after DNFT installation.
Possible Cause 2. Check for correct magnet housing for

divider valve manufacturer.
Wrong magnet housing installed on divider
valve. 3. Remove and replace with correct magnet
housing.
Solution 4. Re-install DNFT on new magnet housing.
1. Loosen set screws and remove DNFT from
magnet housing.

5. If necessary adjust DNFT, check for LED 2. If needed, install pressure gauge to monitor
blink. lubrication system operation:
6. Purge air from system with purge pump. a. Loosen outlet plugs in front of valve
blocks.
Possible Cause b. Purge lubrication system with a purge
pump until clean, clear, air-free oil flows
Air or debris in divider valve assembly. from plugs.
c. Loosen, but do not remove, each piston
Solution
enclosure plug individually to purge air
1. Check system pressure to verify oil flows to from behind piston. To ensure proper
divider valves. lube system operation, all tubing and
components MUST be filled with oil and
free of air before start-up.
d. Tighten all divider valve plugs.
e. Adjust proximity switch.
Troubleshooting: DNFT Erratic Shutdown
Problem
Erratic shutdown or LED blink.
Possible Cause Normally Open

Faulty wiring from DNFT to control panel or air 1. Attach ohmmeter to orange wires; insulate
in system (see air in system). violet wires from each other.
2. Should read 10Ω or less in alarm.
Solution
Normally Closed
Part numbers: A-10753, A-10772, and A-
1. Attach ohmmeter to orange wires.
20513
2. Short violet wires together.
Normally Open
3. Should read open loop in alarm.
1. Attach ohmmeter to red wires.
2. Should read 10MΩ in operation and less than
Possible Cause
10Ω in alarm.
Faulty lube pump.
Normally Closed
1. Attach ohmmeter to orange wires. Solution
2. Should read less than 10Ω in operation and 1. Check system pressure to verify oil flows to
open loop in alarm. pump and divider valves. If needed, install
pressure gauge to monitor lubrication
Part number: A-10754, and A-20514 system operation.

2. Check gauge to verify pump builds The time for the proximity switch to repeat a
sufficient pressure to inject oil into cylinder. contact transition (ex. from open to closed) is
Do not remove tubing from check valve and known as the cycle time of the divider valve
pump oil to atmosphere to check oil flow assembly. The proximity switch must work with a
into cylinder.
PLC or some other counter/timer device to
3. Replace pump. produce a shutdown. See "Instrumentation" in
the Ariel Packager Standards for interpretation of
Possible Cause proximity switch pulse output.
Overtightened divider valves
Solution
1. Step-torque divider valves to 75 lb x in (8.5
N•m) to the backplate.
Proximity Switch A-18255
CAUTION
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
disconnect all electrical connections including ground,
and remove batteries, or completely remove the
electronic equipment from the compressor.
close as possible to the area where the welding will
setting. Welding must not cause a current flow across
any compressor bearing surface, including but not
A proximity switch installs into a divider valve in

place of a piston end plug and can be used to
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
the reed switch. With every divider valve cycle,
the piston moves the magnet, which opens and
closes the reed switch contacts.

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
1 Trabon Style O-ring Seal 7/16-20
6 Spring
2 Trabon Metal Gasket Seal 7/16-20 (1994 or earlier)
7 Switch Housing
3 Lincoln O-Ring Seal 7/16-20 Extended Nose
8 Wire Leads (yellow)
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.

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

Troubleshooting: Proximity Switches Lube No-Flow
Problem
Switch does not cycle and control panel indicates lube no-flow. (see also Erratic Operation)
Possible Cause 4. Re-install magnet housing on divider valve

and proximity switch on magnet housing.
Improperly adjusted proximity switch.
5. If necessary, adjust proximity switch and
Solution test switch functionality.
1. Loosen set screws, slide proximity switch 6. Purge air from system with purge pump.
all the way onto hex of magnet housing and
torque to 25 lbs x inch max. (Do not over Possible Cause
tighten).
Bent magnet housing.
2. Either pump clean oil through lubrication
system with a purge pump or run the Solution
compressor to cycle the divider valve.
1. Loosen set screws, remove proximity
3. If necessary, slide proximity switch back in
switch from magnet housing.
1/16“ increments until the switch
opens/closes with each divider valve cycle. 2. Check for damaged or bent magnet
housing.
Possible Cause 3. Remove magnet assembly from divider
valve.
Broken spring or magnet in magnet housing.
4. Replace magnet housing, magnet, spring,
Solution and spacer.
1. Loosen set screws, remove proximity 5. Re-install new magnet housing on divider
switch from magnet housing. valve and proximity switch on magnet
housing.
2. Remove magnet housing from divider
valve. 6. If necessary, adjust proximity switch and
test switch functionality.
3. Remove magnet, spring, and spacer and
check for damage. Replace damaged 7. Purge air from system with purge pump.
components.
Troubleshooting: Proximity Switches ARV Bypasses
Problem
ARV bypasses or rupture disk bursts and divider valve seizes after proximity switch installation.


Wrong magnet housing installed on divider Air or debris in divider valve assembly.
valve.
Solution
Solution
1. Check system pressure to verify oil flows to
1. Loosen set screws and remove proximity divider valves.
switch from magnet housing. 2. If needed, install pressure gauge to monitor
2. Check for correct magnet housing for lubrication system operation:
divider valve manufacturer. a. Loosen outlet plugs in front of valve
3. Remove and replace with correct magnet blocks.
housing. b. Purge lubrication system with a purge
pump until clean, clear, air-free oil flows
4. Re-install proximity switch on new magnet
from plugs.
housing.
c. Loosen, but do not remove, each piston
5. If necessary adjust proximity switch and enclosure plug individually to purge air
test switch functionality. from behind piston. To ensure proper
6. Purge air from system with purge pump. lube system operation, all tubing and
components MUST be filled with oil and
free of air before start-up.
d. Tighten all divider valve plugs.
e. Adjust proximity switch.
Troubleshooting: Proximity Switches Erratic Operation
Problem
Erratic Operation.

Faulty wiring from proximity switch to control Faulty lube pump.
panel or air in system (see air in system).
Solution
Solution
1. Check system pressure to verify oil flows to
1. Check electrical wiring and connections for pump and divider valves. If needed, install
damage or poor contact. See Figure: A- pressure gauge to monitor lubrication
18255 Proximity Switch Wiring Connections system operation.
for Unit in Operation. 2. Check gauge to verify pump builds
sufficient pressure to inject oil into cylinder.
Do not remove tubing from check valve and
pump oil to atmosphere to check oil flow
into cylinder.
3. Replace pump.

Maintenance
Ariel compressors, like all industrial equipment, • Consistent adherence to safety policies,
require maintenance. The severity of compressor procedures, and equipment warning labels.
service directly influences the frequency and • Daily operational checks.
amount of maintenance needed. Below are • Routine trending and review of operational
recommended intervals for inspections and parameters.
replacements to help determine appropriate • Routine oil analysis and trending.
intervals for a given compressor application. • Detailed records of all maintenance.
Careful documentation of inspection results is To avoid contamination, keep all covers in place
critical to establish whether recommended where access is not required. Use paper towels
intervals are adequate or require more or less during internal maintenance.
frequency.
WARNING
Continuous Duty: The compressor operates
To reduce risk of injury or death, only trained personnel
continuously, 24 hours a day, shutting down only who have read and thoroughly understand the
for short durations, usually for maintenance and appropriate Ariel Technical Manual and Packager
information should attempt any maintenance.
unexpected shut-downs. The recommended
maintenance procedures in this manual apply to • Always wear appropriate personal protection equip-
continuous duty compressors. ment and follow your company safety and opera-
tional procedures.
Short-Term Intermittent Duty: The compressor • Never tighten or loosen any fastener while the unit is
operates for short durations, starting and operating or pressurized.
• Verify neither driver nor compressor can turn during
stopping perhaps several times per day, such as maintenance.
in many CNG filling station applications that • Follow packager instructions to completely isolate
require operation based on consumer demand. and vent the system; call the packager for assis-
tance.
Long-Term Intermittent Duty: The compressor • Verify each compressor cylinder is relieved to atmo-
operates continuously for extended durations, spheric pressure. To relieve residual cylinder bore
with extended shut-down periods, such as in on the indicator ports, if so equipped.
some storage/withdrawal applications and fuel WARNING: RELEASED GAS MAY BE POISONOUS
gas booster applications. AND/OR FLAMMABLE.
Many factors affect bearing life including the the gas being compressed to avoid a potentially
explosive gas/air mixture in the system. A gas/air
number of starts, starting conditions, and run mixture under pressure can explode and cause severe
hours. Consider site-specific conditions when injury or death.
adjusting maintenance intervals.
NOTE: For intermittent duty service, see ER-8.2.2. Initial Maintenance

Comply with Ariel Packager Standards and the
As part of your maintenance program, Ariel compressor Start Up Check List. Adhere to all
recommends: items before and after start-up.

JGM-JGN-JGP-JGQ Maintenance & Repair Manual – Maintenance 12/03/2022
For cold alignment, account for the difference in

thermal growth height between the compressor
and driver. Table: Thermal Growth of JGM:P:N:Q
Compressors lists compressor centerline height
change based on 6.5 x 10-6/°F (11.7 x 10-6/°C).
Figure: Thermal Growth

1 HOT Centerline
2 Thermal Growth
3 COLD Centerline
Table: Thermal Growth of JGM:P:N:Q Initial Frame Temp. °F Thermal Growth Inch
Compressors (°C) (mm)
Initial Frame Temp. °F Thermal Growth Inch 80 (27) 0.005 (0.14)

(°C) (mm)
90 (32) 0.005 (0.12)
0 (-18) 0.010 (0.26)
100 (38) 0.004 (0.11)
10 (-12) 0.010 (0.25)
110 (43) 0.004 (0.09)
20 (-7) 0.009 (0.23)
120 (49) 0.003 (0.08)
30 (-1) 0.008 (0.21)
130 (54) 0.002 (0.06)
40 (4) 0.008 (0.20)
50 (10) 0.007 (0.18) NOTE: Thermal growth numbers were calculated

60 (16) 0.007 (0.17) using 170°F (77°C) as the frame operating tempera-
ture. Initial frame temperature is the temperature of
70 (21) 0.006 (0.15)
the frame during cold alignment. Obtain driver
thermal growth predictions from the driver manufac-
turer.

Figure: Angular Coupling-Hub Face Alignment After running a new, relocated, reconfigured, or
Limits overhauled compressor for 24 hours, shut down,
vent the gas system, and perform the following
maintenance:
1. Perform a hot alignment check within 30
minutes of shutdown as described above.
Adjust discharge bottle supports and head
end supports, if applicable.
NOTE: To avoid cylinder distortion, lift discharge
bottles only 0.003 to 0.005 inch (0.08 to 0.13 mm)
using the supports.
2. Check fastener torque on gas nozzle flanges,
valve caps, cylinder heads, piston rod
packing flanges, crosshead guide hold down,
Center the coupling between the driver and frame hold down, crosshead guide to
compressor so it does not thrust or force the cylinder, and crosshead guide to frame
crankshaft against either thrust face. bolting, if applicable. See Appendix A for
To ensure parallel and concentric drive train correct torques.
alignment, position connected equipment so 3. Repeat torque check after 750 hours. Recheck
misalignment is as close to zero as possible. fasteners found loose in any of these intervals
Limits for Total Indicator Reading (TIR): after an additional 750 hours. If loosening
• Maximum rim (outside diameter), (parallel) continues, contact your package supplier
misalignment is 0.005 inch (0.13 mm). immediately.
• Face (angular) misalignment must be within
0.005 inch (0.13 mm) for hub diameters up to
17 inches (430 mm). For hubs greater than 17 Maintenance Intervals
inches (430 mm), use the following formula: Ariel compressors, like all industrial equipment,
Hub O.D. x 0.0003 = max angular misalign-
require maintenance. The severity of compressor
ment. See Figure: Angular Coupling-Hub Face
Alignment Limits. service directly influences the frequency and
amount of maintenance needed. What follows
For laser alignment tools: are the recommended intervals for inspections
• Maximum parallel misalignment is 0.0025 and replacements to help determine appropriate
inch (0.064 mm). intervals for a given compressor application.
• Maximum angular misalignment is 0.0003
inch/1 inch (0.03mm/100mm). NOTE: Careful documentation of inspection results is
critical to establish whether recommended intervals
NOTE: If laser is adjusted to display TIR, use TIR limits. are adequate or require more or less frequency.

Daily Maintenance 4. Log and trend piston rod packing vent/drain

temperature and check distance piece vents
1. Log and trend the following: for leakage. If the piston rod packing
• Operating RPM, gas pressure and vent/drain temperature is trending high, then
temperatures - determine if the unit is verify leak rate before performing
operating within design parameters and maintenance.
expectations.
5. Verify all cylinder high discharge gas
NOTE: Verify high and low pressure shutdowns
temperature shutdowns are set to within 10%
are set as close as practical to normal operating
or as close as practical above the normal
conditions. Set points must protect the machine
operating discharge temperature. Do not
from exceeding compressor limits.
exceed the maximum discharge temperature
• Bearing temperatures - if the unit is shutdown setting for the application.
equipped with main bearing temperature 6. Check lubricator block cycle time. See
sensors. lubricator box data plate for correct cycle
• Compressor frame oil pressure - at oper- time. Changes in gas composition may
ating temperature (190°F (88°C) max. inlet require a review of cycle time. Check lube
oil temperature), it should be 50 to 60 psig sheet for units not running at the speed on
(3.5 to 4.2 barg) at the filter gauges. If the data tag. If applicable, verify auto relief
pressure falls below 50 psig (3.5 barg), valve indicator does not show sign of over-
shut down the compressor then deter- pressurization.
mine and correct the cause.
7. Check for gas, oil, and coolant leaks.
• Compressor frame inlet oil temperature.
• Cylinder valve cap temperatures.
• Compressor frame oil filter differential CAUTION
pressure - differential pressure exceeding Do not attempt to repair leaks while the unit is operating
the filter change value indicates a need or pressurized.
for a filter change. See filter information
plate on top cover or “Oil Filter” in Frame 8. Check for unusual noises or vibrations.
Oil System Components for procedure.
9. See packager documentation for additional
2. Check compressor frame oil level. It should recommended checks, i.e. scrubber liquid
be about mid-level in the sight glass and free levels, dump valve operation, cooler louver
of foam when running. If not, determine and positions, etc.
correct the cause. Do not overfill. Check oil
makeup tank for sufficient oil supply. For dry
sump frames, check the package sump oil
Monthly Maintenance
level. Do not add oil to the crankcase through 1. Perform all Daily maintenance.
the breather hole while the unit runs. This
causes oil foaming and unnecessary no-flow 2. Verify safety shutdown functionality.
shutdowns in the force feed lubrication 3. Sample compressor frame oil and send it to a
system. reputable lubricant lab for analysis. See "Oil
3. Check force feed lubricator box oil level. It Maintenance" for a list of what an oil analysis
should be full to the overflow line. should provide. If analysis results indicate
increasing levels of lead, tin, or copper
particles in the oil, shut down unit. Remove
frame top cover and crosshead guide side

covers. Visually inspect for debris. Do not 7. Change compressor oil. Extremely dirty
disassemble further without good reason. If environments, oil supplier
debris indicates, replace affected parts, then recommendations, or oil analysis results may
change oil, oil filter, and clean the strainer dictate a different oil change interval. Follow
with a suitable solvent. these steps:
NOTE: Operate the unit to bring oil temperature to a a. Drain oil from frame, associated piping,
minimum operating temperature of 150°F (66°C) to and oil cooler.
drive off any entrained water.
b. Clean oil strainer with a suitable solvent.
4. Check and log cylinder clearance devices in In dry sump applications, the strainer is
use and their settings. located at the oil reservoir.
c. Remove frame top cover and crosshead
Six-Month (4,000-Hour) Maintenance guide side covers. Visually inspect for
debris. Do not disassemble further
1. Perform all Daily and Monthly maintenance. without good reason. If debris indicates,
2. Shut down unit and allow sufficient time for replace affected parts, then change the oil
components to cool. filter and clean the strainer with a suitable
solvent.
3. Inspect crankcase breather filter and clean
with suitable solvent. d. Refill compressor frame with fresh, clean
oil.
4. Drain and replace force feed lubricator box
oil. 8. Check for adequate cylinder lubrication. See
“Cylinder Lubrication Paper Test” for
5. Where applicable, clean sintered element in procedure.
the small oil filter on the force feed
lubrication system now or at every main oil 9. Re-tighten hold down fasteners to proper
filter change. Use a suitable solvent.Where torque (compressor frame feet and
applicable, replace force feed lubricator inlet crosshead guide/distance piece support
filter in independent supply system. feet). Inspect for frame twist or bending to
verify main bearing bore alignment. See
6. Change compressor oil filter. See top cover Appendix H for flatness and soft foot
filter information plate or “Oil Filter” in Frame requirements.
Oil System Components for procedure. Do
not exceed 12 month installed period for filter 10. Perform a coupling alignment (see "Initial
element. Maintenance").
NOTE: For replaceable element style filters, drain the 11. Remove and inspect inlet screens on each
canister completely before removing the element. stage; clean if clogged with debris or replace
Inspect elements for cleanliness and damage. Do not if damaged. Clean inlet screens regularly to
install dirty or damaged elements. avoid increased pressure that may collapse
them. More debris in the screen may dictate
more frequent inspections. Inlet screens may
be removed if they catch little or no debris
and the gas stream is clean (optional).

One-Year (8,000-Hour) Maintenance the valves where needed. Provide the

valve repair shop an Ariel torque chart
1. Perform all Daily, Monthly, and Six-Month and valve service guide.
maintenance.
c. Visually inspect cylinder gas passages and
2. Grease VVCP stem threads at grease fitting, clean them of all debris.
with 2 to 3 pumps of cylinder lube compatible
grease using a standard manual grease 7. If applicable, visually inspect suction valve
pump. Turn VVCP adjustment handle all the unloader actuator stems for damage or wear.
way in and all the way out to lubricate the Visually inspect stem seals for damage or
threads. Measure or count turns to return the wear and confirm that the actuator moves
handle to its original position. freely.
3. Open force feed lubricator box and visually 8. If applicable, visually inspect pneumatic
inspect pump followers, cams, and gears for clearance pockets for damage or wear
wear. (seating surface and stems/stem seals).
Confirm that actuator moves freely.
4. Pressure test distribution blocks. See
“Divider Valve Bypass Pressure Test” for 9. Inspect cylinder bores for damage or wear.
procedure. Replace the cylinder body or restore the bore
if any of the following conditions exist:
5. Measure, log, and trend the following: • Bore surface blemishes or gouges.
• Main bearing, connecting rod bearing, • Bore out of round more than 0.001 inch
and crankshaft jack and thrust clear- per inch of bore diameter (0.001 mm/mm)
ances. See "Main Bearing Vertical Jack Clear- or tapered.
ance Measurement", "Connecting Rod
Bearing Vertical Jack Clearance Measure- • Main bore is worn to counterbore diam-
ment", and "Crankshaft Thrust (End) Clear- eter or larger.
ance Measurement" in Section 4. 10. Inspect piston rings and wearband:
NOTE: Clearance trends along with oil analysis a. Measure and log piston ring condition,
and crankcase visual inspection can indicate the end gap, side clearance, and piston
need for bearing replacement. Do not disas- groove width.
semble to check clearances. Disassemble only if
b. Replace rings that are damaged or
clearance checks indicate excessive clearance.
outside limits listed in Appendix B.
Contact Ariel for original assembly clearances.
c. When replacing rings, re-measure and log
• Crosshead to guide clearances. See ring side clearance to check for groove
“Crosshead Installation” in Section 4. wear.
• Piston rod runout. See “Piston Rod
d. Measure and log radial projection of wear
Runout” in Section 4.
band.
If any of the above items are outside limits speci-
fied in Appendix B, find the cause and correct it. It 11. Inspect piston rods for damage and excessive
may require part replacement. wear. Replace rod if any of these conditions
exist (see “Piston and Rod Removal” in
6. Remove valves and valve gaskets: Section 4):
a. Visually inspect valve pockets for • Gouges or scratches on the rod.
damage. Verify all old valve seat gaskets
• Under size more than 0.005 inch (0.13
are removed.
mm).
b. Have a qualified valve repair shop disas-
• In the packing travel length, out of round
semble, visually inspect, and refurbish
more than 0.001 inch (0.03 mm).

• Anywhere in the packing travel area, 3. If applicable, use new piston and stem seals
tapered more than 0.002 inch (0.05 mm) . to rebuild actuators on suction valve
12. Rebuild piston rod pressure packing cases. unloaders and fixed volume pneumatic
See “Piston Rod Packing” in Section 4 for pockets. Replace piston stem assemblies
procedure. where stem is damaged or worn.
13. Re-install valves, retainers, and valve caps 4. Check auxiliary end chain drive for undercut
using new valve seat gaskets and valve cap O- sprocket teeth and chain for excessive
rings/seals. See “Valve Installation” in stretching. Replace as required.
Section 4. Use proper installation techniques
and torque procedures for valve caps. Three-Year (24,000-Hour) Maintenance
14. Check and re-calibrate all required 1. Perform all Daily, Monthly, Six-Month, and
instrumentation. One-Year maintenance.
15. Clean crankcase breather filter with suitable 2. Replace connecting rod bearings. See
solvent. “Connecting Rods in Section 4”.
16. Check and, if needed, adjust drive chains. See NOTE: Main and connecting rod bearing wear and
“Chain Adjustment” in Section 4 for replacement intervals are heavily dependent on
procedure. many factors including speed, load, oil temperature,
oil cleanliness, and oil quality. Depending on the
17. If the compressor is equipped with crankcase severity of service, the bearing maintenance interval
over-pressure relief valves, visually inspect may be longer or shorter.
and exercise valves to manufacturer
recommendations.
Four-Year (32,000-Hour) Maintenance
18. Check fastener torques of gas nozzle flanges,
head end head or unloader, valve caps, 1. Perform all Daily, Monthly, Six-Month, One-
piston rod packings, crosshead pin thru- Year, and Two-Year maintenance.
bolts, crosshead guide to frame, frame hold 2. Remove crosshead pins.
down, crosshead guide to cylinder, cylinder
a. Measure and log crosshead pin to cross-
mounting flange to forged steel cylinder,
head pin bore and connecting rod
distance piece to cylinder, distance piece to
bushing bore clearances.
crosshead guide, and tandem cylinder to
cylinder. b. Check crosshead pin end caps and thru-
bolt for wear.
Two-Year (16,000-Hour) Maintenance c. Replace if needed.
1. Perform all Daily, Monthly, Six-Month, and 3. Check for bushing wear in the auxiliary end
One-Year maintenance. drive chain tightener.
2. Rebuild oil wiper cases. 4. Check for ring groove wear in pistons.
Six-Year (48,000-Hour) Maintenance

1. Perform all Daily, Monthly, Six-Month, One-
Year, Two-Year, and Three-Year
maintenance.
2. Replace lubricator distribution blocks.

3. Replace crosshead bushings and connecting ensure the oil meets the specifications below and
rod bushings. See “Crossheads” and is suitable for the given application, and
“Connecting Rods” in Section 4. diligently complete maintenance procedures.
4. Replace connecting rod bearings. See
“Connecting Rods” in Section 4. Viscosity
5. Replace main bearings. See “Crankshaft” in
The minimum allowable viscosity of the oil
Section 4.
entering the frame is 16 cSt. Typically, this is the
6. Replace auxiliary end torsional damper, if viscosity of ISO 150 grade oil at about 190°F
applicable. See assembly drawing in
(88°C).The maximum viscosity at this
compressor build book for procedure.
temperature is 60 cSt. For JGM:P:N:Q frames, the
maximum viscosity to start the compressor is
Frame Oil 3,300 cSt and the maximum viscosity to load the
There are several oil specifications, maintenance compressor is 1,000 cSt. See Figure: Viscosity vs.
procedures, and operating conditions which Temperature Graph of Different Lubricants.
affect oil performance. For optimal performance,
Figure: Viscosity vs. Temperature Graph of Different Lubricants
Oil Pressure (inspector tag displayed). If factory tested as

mechanically incomplete (no inspector tag), the
The factory sets normal pressure on the
packager sets normal oil pressure at initial start-
discharge side of the oil filter at 60 psig (4.1 barg)
up to 60 psig (4.1 barg) at the lower of the frame
for compressors tested mechanically complete
or cylinder rated speed, or driver speed at normal

operating temperature. Adjust the oil pressure Oil System Cleanliness

after the filter to 60 psig at minimum operating
Clean the compressor frame oil piping system
speed and normal operating temperature.
and components of all foreign matter such as
Ariel uses the pump safety relief valve to regulate sand, rust, mill scale, metal chips, weld spatter,
pressure into the compressor. If oil pressure into grease, and paint. Use proper cleaning
the compressor at minimum operating speed procedures with proper cleaners, acids, and/or
and normal operating temperature does not read mechanical cleaning to meet cleanliness
about 60 psig (4.1 barg), adjust the pump safety requirements. Ariel recommends flushing all oil-
relief valve. With compressor running at piping systems with an electric or pneumatic
minimum operating speed, turn the adjustment driven pump and filtered, clean production oil.
screw clockwise to increase oil pressure, or Ariel thoroughly cleans all compressor frame
counter-clockwise to decrease it. The cavities prior to assembly and test runs
compressor requires a 45 psig (3.1 barg) low oil compressors with a filtered closed loop lube
pressure shutdown for protection. system.
NOTE: If oil pressure drops below 50 PSIG (3.4 barg) Table: Maximum Angle from a Horizontal
when crankshaft speed equals or exceeds minimum Plane Allowed in Transient Motion without
rated operating speed, find the cause and correct it. Dry Sump
1 or 2
Framea Throw
4 Throw 6 Throw
Oil Temperature
JGM:P:N:Q 4° N/A N/A
Maintain frame inlet oil temperature as close to
170°F (77°C) as possible. Minimum lube oil
operating temperature is 150°F (66°C) to drive off NOTE: Ariel recommends not disturbing lube oil
water vapor. Maximum allowable oil piping downstream of the installed oil filter. Contam-
inants that enter this piping or open ports flush into
temperature into the compressor frame is 190°F
the bearings causing catastrophic damage. If contam-
(88°C). Higher temperatures increase the
ination is suspected in the supply piping downstream
oxidation rate of mineral oil. Every 18°F (10°C) of the oil filter or in the oil gallery, remove the supply
within the operating range doubles the oxidation piping and thoroughly clean both the piping and
rate of mineral oil. gallery. Before performing this work, contact Ariel
Technical Service for best practices and procedures.
For proper operation of the thermostatic control To remove or alter piping, cover the inlets to the oil
valve, the maximum differential pressure gallery, the ends of the piping, and the filter outlet so
between the hot oil supply line and the cooled oil no contaminants enter. Before reinstallation, chem-
return line is 10 psid (0.7 bard). ical and mechanical cleaning is required. Flush the
pipe in accordance with Ariel cleanliness require-
ments (see Table: Oil Flush Cleanliness Requirements
Oil Sampling Valve
).
Install an oil sampling valve between the oil
pump and filter at an easily accessible location. Prior to start-up, flush all compressors installed
Minimize the distance between sampling valve with an electric or pneumatic powered pre-lube
and oil circulating through the system. pump and less than 50 feet (15 m) of oil piping as

outlined below. Include cooler oil passages in the • Operational and viewable oil pressure
flushing loop. While oil systems for compressors transducer or gauge, oil filter differential-
without an electric or pneumatic powered pre- pressure transducers or gauges, and oil
temperature RTD or indicator.
lube pump and less than 50 feet (15 m) of oil
2. Start pre-lube pump. Record oil pressure, oil
piping must be clean, oil flushing is desirable, but
filter differential-pressure, and oil tempera-
not required.
ture. Minimum oil pressure is 30 psig (2.1
For all compressors with oil piping systems barg) for effective flushing. Do not exceed 90
greater than 50 feet (15 m), cleaning and flushing psig (6.2 barg).
must result in a cleanliness level to ISO-4406,
3. Flush continuously for one hour. Oil filter
Grade 13/10/9 and/or NAS-1638, Class 5 (see
differential pressure must not increase more
Table: Oil Flush Cleanliness Requirements ), prior
than 10% of measured oil pressure into the
to start-up.
filter. Record the oil pressure, oil filter differ-
Table: Oil Flush Cleanliness Requirements ential pressure, and oil temperature every 15
minutes. Oil temperature increases of more
ISO-4406 GRADE 13/10/9
than 10°F (5.5°C) during an hour of flushing
Particle Size
Grade Particles invalidate the system cleanliness test, due to
µm/ml Oil
Requirement Allowed oil viscosity change.
Sample
/13 Greater than 4 40 to 80 4. After one hour of pre-lube flushing, if differen-

/10 Greater than 6 5 to 10 tial pressure or temperature increases
exceed the limits above, continue flushing. If
/9 Greater than 14 2.5 to 5
the lube oil filter differential pressure exceeds
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
and temperature increase limits.
15 to 25 1,424
25 to 50 253 See ISO-4406 "International Standard - Hydraulic

fluid power - Fluids - Method for coding level of
50 to 100 45
contamination by solid particles" and/or NAS-
Over 100 8
1638 "National Aerospace Standard, Aerospace
Industries Association of America, Inc. -
1. Prior to assembling lube oil piping, remove
Cleanliness Requirements for Parts Used in
scale, weld slag, rust and any other matter
Hydraulic Systems" for complete information.
that could contaminate lube oil. Confirm:
Use a competent oil lab for sample testing. To
• Complete and closed lube oil system. flush the entire oil system see “Flushing
• Crankcase filled to the correct level with Procedure”.
appropriate oil.
• Proper and correctly installed lube oil
filters.

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
Oil Strainer prevents debris from entering the pump and

damaging it. Ariel supplies a 30 mesh (595
An oil strainer installed upstream of the pump
microns) or 40 mesh (400 microns) on all frames,

depending on frame size. It is located on the Oil Pump & Regulating Valve
auxiliary end of the crankcase below oil level.
The oil pump constantly supplies oil to all journal
Remove the strainer basket and wash it in an
bearings, bushings, and crosshead sliding
appropriate solvent whenever lubricating oil is
surfaces. The crankshaft drives it by a chain and
changed.
sprocket to provide adequate oil flow to bearings
when the compressor operates at the minimum
speed rating (typically half of maximum rated
speed).
Figure: Typical JGM:P:N:Q Lube Oil Pump
1 Discharge
2 Safety Relief Valve
3 Dust Cap
4 Suction
Smaller compressor models have
threaded suction/discharge connections.
JGM:P:N:Q compressors maintain oil pressure Oil Cooler

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

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

Oil Maintenance When filter differential pressure reaches 10 psid

(0.7 bard) or once every six months, whichever
Proper oil maintenance is vital to the efficient
comes first, replace oil filter with a genuine Ariel
operation of the compressor. The severity of
filter.
compressor service affects the frequency of oil
and filter changes. 1. Remove old filter, clean filter head surfaces,
and verify old gasket is removed.
Oil Filter Replacement 2. Inspect new filter for damage or debris. Do
Replace oil filters or elements with only genuine not install damaged or dirty filters. Never
Ariel parts. See parts list or name plate for part operate a unit with a damaged or leaking
oil filter.
numbers.
3. Apply clean oil to the filter gasket and thread
the filter with gasket onto the head.
CAUTION 4. Tighten the filter one turn after the filter
gasket contacts the head. Install 1/2 inch NPT
Before oil filter replacement, use the frame-mounted
pressure gauges to confirm system depressurization. Be
drain plug.
careful - hot oil may cause burns! Wear proper personal 5. Use the compressor pre-lube pump to fill the
protection equipment. oil filter with oil and purge air from the oil
system. Manually filling the filter with oil can
Simplex Spin-on Filter Replacement introduce debris on the clean side of the
filter. This debris can damage the compressor
Figure: Mounted Thermostatic Valve Drain Plug
to the point of bearing failure.
6. After starting the unit, check for leaks, and
retighten if necessary.

Compact Duplex Filter Cartridge Replacement 7. Install drain plug in the filter housing.
Figure: Typical Compact Duplex Filter Vessels 8. Inspect and replace the filter gasket if
damaged. Install the gasket and attach the
filter housing. Step torque the bolts to 40 Lb x
Ft (54 N•m).
9. Determine unit state:
• If unit is shut down: Crack open the
filter vent. Use compressor pre-lube
pump to fill the oil filter. Close vent
once air is purged. Manually filling the
filter with oil can introduce debris on
the clean side of the filter. Debris can
damage the compressor to the point
of bearing failure.
• If unit is running: Crack the vent of
the empty vessel. Rotate transfer
valve slightly to slowly fill empty
vessel. Close vent once air is purged.
Allow additional flow to the new
element to push any remaining air
downstream. Position transfer valve
1 Filter Vent
handle to put desired filter in service.
2 Transfer Valve Indicator
3 Filter Head 10. Check for leaks.
4 Filter Housing
5 Filter Element Compressor Pre-lube System
6 Filter Gasket
Ariel compressors must be pre-lubed anytime the
7 Drain Plug
crankshaft is turned and prior to starting. Ariel
strongly recommends an automated pre-lube
1. The triangle indicator on top of the transfer
system to extend driveline component life.
valve handle points toward the active filter.
Turn transfer valve handle until it stops to Ariel requires automated pre-lube systems for
make the inactive filter the active filter. compressors that meet any of the following
2. Loosen the inactive filter vent to relieve any criteria:
pressure.
• Electric motor driven compressors.
3. Drain the inactive filter housing. • Unattended-start compressors, regardless of
4. Remove the filter housing, clean and inspect. driver type.
5. Remove the filter element and properly See Figure: Standard Frame Lube Oil Schematic
dispose of. for pre-lube circuit design.
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 If the compressor fails to achieve 45 psig (3.1
pre-lube pump can circulate oil continuously barg) oil pressure within 10 seconds after
through the bearings while on standby. reaching engine idle speed or electric motor start
initiation, ensure shutdown and correct the
Ariel requirements are based on a pre-lube pump
cause. Repeat pre-lube before each start
sized for 25% of frame oil pump flow to ensure oil
attempt.
flow to bearings, bushings, and oil-filled
clearances prior to turning or start-up (see NOTE: If a compressor fails to start or shuts down at
Appendix C for frame oil pump flow rates). start-up due to low oil pressure, DO NOT re-start until
the cause is corrected.
The following statements depend on oil supply
and sump viscosities, which depend on oil
temperature. Oil supply temperature at the filter Compressor Pre-lube for CNG Applications
head or frame oil gallery is not always a true
representation of total oil sump temperature. The normal minimum pre-lube pressure
See Figure: Viscosity vs. Temperature Graph of requirement is 30 psig (2.1 barg) for 2 minutes for
Different Lubricants to determine oil viscosity continuous duty compressors. In CNG
based on temperature. applications, the compressors can start and stop
as much as 50 to 100 times a day. This special
• During a cold start of the unit when oil supply
service demands exceptions to normal pre-lube
viscosity is greater than 50 cSt, pre-lube pres-
sure should be 30 psig (2.1 barg) at the oil and cold weather starting requirements.
gallery for a minimum of 2 minutes prior to
turning or starting. NOTE: The requirements below apply only to
JGM:P:N:Q/2 and KB100 compressors in CNG applica-
• During a hot re-start of the unit when oil
tions. No other frames or applications are exempt
supply viscosity is less than 50 cSt, pre-lube
from normal pre-lube requirements.
pressure should be 20 psig (1.4 barg) at the oil
gallery for a minimum of 2 minutes prior to
1. The minimum pre-lube pressure is 30 psig
turning or starting.
(2.1 barg) for at least 30 seconds.
NOTE: A 10 to 15 minute pre-lube is required after: 2. The minimum oil temperature to pre-lube
• Any major drive line maintenance and start is 30°F (-1°C) when using a PAG type
• The main lube oil system is drained oil that is acceptable per "Cylinder/Packing
• Oil filter replacement
Oil Requirements in the Packager Standards
Manual", or 50°F (10°C) when using a non-PAG
Instrumentation: Automated pre-lube systems type oil such as a PAO or mineral oil that is
require a start permissive logic and acceptable per "Cylinder/Packing Oil
instrumentation to satisfy the minimum required Requirements in the Packager Standards
pressure and duration at the oil gallery inlet. Manual". The compressor must have an oil
It is highly recommended that the compressor temperature sensor to ensure this low oil
low oil pressure shutdown be Class B. Inhibited temperature permissive is met. Maximum
time shall be no longer than 10 seconds after idle allowable oil temperature into the crankcase
speed is achieved on gas engines or start is 190°F (88°C).
initiation for electric motors.

3. The low oil temperature start limit must be no Flushing to Change to a PAG
less than the oil temperature required for Lubricant
adequate viscosity to load the compressor.
The maximum viscosity to load is 1000 cSt. Cylinder and frame lubrication systems require
flushing when changing to or from a PAG
4. Ambient temperatures below 0°F (-18°C) lubricant or when applying a PAG lubricant to
require a standalone circulating auxiliary newly installed equipment.
lube oil heating system for the compressor. In
extreme cold, an immersion heater is inade- Recommended Flushing Oil
quate. Maintain oil temperature between at
least 70°F to 100°F (21°C to 38°C). The preferred flushing oil is soluble in both the
original oil and PAG lubricant. A linear diester is
5. A small bypass line downstream of the circu- preferred, such as Shell Corena DE 150 or Mobil
lating heating system that sends oil directly Rarus 829. If this is unavailable, use the desired
into the frame sump will help flow sufficient PAG lubricant fill oil as the initial flushing oil.
oil to build and maintain heat in the
compressor. The bypass line must be a small
Flushing Procedure
diameter so the pre-lube pump can build and
maintain adequate pressure. A bypass pres- Below is a general flushing procedure
sure relief valve may instead be used to main- recommended to change from mineral or PAO
tain pre-lube pressure and sufficient oil flow oils to a synthetic PAG lubricant.
through the system independent of oil 1. Drain old oil from frame while the oil is still
viscosity. See Figure: Standard Frame Lube warm.
Oil Schematic.
2. Drain all supply and return lines upstream of
the frame lube oil filter, filter housing (if
Auxiliary Frame Oil Pump applicable), coolers, and other peripheral
equipment in the lubricant supply loop.
Operation below half the frame operating speed
requires an auxiliary frame oil pump to maintain 3. Remove standing oil in the frame and guide
compartment low points. Remove as much
oil pressure. Size the auxiliary oil pump for at
oil as possible with a vacuum hose. If heavy
least 25% of the rated oil flow at 60 psig deposits are visible, remove them as best as
published in the frame datasheets. Pipe the possible by hand using clean, dry, lint-free
auxiliary oil pump in parallel with the main oil rags.
pump and include an adjustable pressure relief 4. Install new frame lube oil filters.
valve. The relief valve must accommodate the
5. Remove and either clean or replace the Y-
entire auxiliary pump flow in case of downstream
strainer element.
blockage. Operate the auxiliary oil pump when
frame oil pressure falls to alarm set point. The 6. Reconnect oil piping and install drain plug in
frame.
auxiliary oil pump may be used for frame oil pre-
lubrication. 7. Connect a diaphragm pump upstream of the
frame mounted oil filter.

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

6. Reconnect the purge pump to the force feed 6. Reconnect the purge pump to the force feed
pump purge/vent outlet connection. If pump purge/vent outlet connection. If
pumps are paired together at their outlets, pumps are paired together at their outlets,
close one of the purge/vent connections. close one of the purge/vent connections.
7. For the zone fed by the force feed pump being 7. For the zone fed by the force feed pump being
primed, disconnect lube lines at the inlet of primed, disconnect lube lines at the inlet of
the double-ball check valves. the double-ball check valves.
8. Place paper towels or suitable collection 8. Place paper towels or suitable collection
containers beneath each disconnected lube containers beneath each disconnected lube
line to catch flushing oil during priming. line to catch flushing oil during priming.
9. Prime flushing oil from the force feed pump 9. Prime flushing oil from the force feed pump
purge/vent connection to downstream purge/vent connection to downstream
tubing, divider blocks, and check valves. tubing, divider blocks, and check valves.
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 Lubrication 14. Repeat steps 6 thru 12 for remaining zones.
System - Independent Oil Supply 15. Install a new oil filter.
1. Drain daytank, oil filter, and lube lines 16. Reconnect lube lines between daytank and
upstream of the force feed pump inlet. Oil pump inlets. Reinstall sintered filter (if
trapped in piping can be vacuumed out or provided).
flushing oil can be pumped through these
lines to displace the old oil. 17. Place a collection container beneath the
disconnected lube line near the force feed
2. If installed, drain the sintered filter and clean pump inlet connection.
the element with solvent.
18. Add enough flushing oil to the daytank to
3. Drain tubing/manifold feeding the force feed prime the system up to the disconnected line
pump(s). in step 17.
4. Remove the purge/vent connection on the 19. Collect oil until no air bubbles appear in the
outlet of each force feed pump. flushing oil.
5. Use a purge pump filled with clean/filtered 20. Reconnect feed line to force feed pump.
flushing oil (See "Recommended Flushing
Oil") to prime each force feed pump by 21. Bleed trapped air by loosening tube
forcing oil through the pump inlet and out the connections nearest each pump inlet.
purge/vent connection.

Cylinder and Packing Lubrication Force Feed Lubricator

The cylinder lubrication system injects The force feed lubrication system oils the
lubrication into cylinder bores and packings. The compressor cylinders and piston rod packings.
system consists of an oil supply, an oil filter, a Oil flows to the suction side of the force feed
force feed lubricator pump, divider blocks, lubricator pump directly from the pressure side
pressure indicators, check valves, and flow of the frame lubrication system, or from an
monitoring shutdown devices. The system is overhead tank. A self-contained oil reservoir oils
progressive; each piston in the divider block the force feed lubricator worm gear and cam. The
must complete a cycle before the system cycles force feed lubricator sight glass shows the
again. This type of system offers better reservoir oil level.
lubrication precision and eases monitoring.
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
This equipment stays pressurized until pressure
is manually relieved. To prevent serious injury
from pressurized fluid, such as skin injection,

splashing fluid, and moving parts, follow this

procedure before cleaning, checking, or servicing
the equipment:
1. Stop lubricator pump.
2. If installed, close oil supply valve located
upstream from pump.
• If the supply valve cannot be closed, de-
energize and relieve pressure of pressur-
ized oil supplies feeding the pump.
3. Slowly crack open fluid line fittings to relieve
pressure.
Pump Installation
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 1 Reservoir Cover Mounting Hole
system. Refer to Figure: Pump Installation during 2 Pump Mounting Hole
installation. 3 Washer
4 Mounting Bolt
Figure: Pump Installation 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").
The pump has an internal discharge check valve

that has a cracking pressure of 55 psi (3.79 bar).
Any oil pressure greater than this cracking
pressure allows unrestricted oil flow through the

pump, even in a pump at rest or adjusted to zero

stroke. Pumps fed 60 psig (4.13 barg) oil from the
compressor frame must pass through a 14 psi
(0.96 bar) check valve installed at the lube oil
gallery connection.
Specifications
Max. Outlet
Piston Dia. In. Max. Flowa In.3
Pressure psi
(mm) (cm3)
(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 1 O-ring
• Strokes/Minute: Max. 50; Min. 3 2 Flow Adjustment Screw Locknut
• Stroke Length: Max. 1/2 inch (12.7 mm) 3 Flow Adjustment Screw
• Weight: 2.7 lbs (1.22 kg) 4 Pump Priming Stem
• Wetted Parts: carbon steel, stainless steel, 5 Pump Inlet
aluminum, PTFE, fluoroelastomer 6 Pump Outlet
• Max. allowable inlet pressure for priming: 150 1. Remove and discard the plastic plugs in the
PSI (10.34 bar) pump inlet and outlet.
• Allowable viscosity range independent of
2. Apply thread sealant (user supplied) to inlet
temperature: 80-5000 SUS (16-1100 cSt)
and outlet line fittings.
Priming the Pump 3. Install the inlet and outlet fittings on the
pump.
Use filtered oil when priming the pump and force
feed system (minimum 5 micron nominal filter). 4. Connect the inlet line to the inlet fitting.
Refer to Figure: Pump Priming and Adjustment 5. Introduce oil into the inlet line using a clean
during priming. priming pump filled with cylinder oil
connected to the purge/vent connection. If
Figure: Pump Priming and Adjustment installed, open oil supply valve from day tank
(located upstream from pump).
6. Wipe the pump priming stem clean and
lubricate with oil.
7. Manually prime pump by using a priming
pump or by pressing the pump priming stem
repeatedly (if connected to a day tank) until
clean, air-free oil flows from the outlet fitting.
8. Connect outlet line to outlet fitting.

9. Manually prime pump by using a priming 4. Check force feed lubricator data plate or Ariel
pump until clean, air-free oil flows from the lube sheets for correct cycle time. Adjust flow
outlet line at the cylinder and packing lube until desired cycle time is achieved with the
points. force feed system operating.
10. Connect the outlet line to the lube point. 5. Repeat Steps 2 and 3 as needed.
11. After start-up, adjust individual pumps to 6. After adjustment to the proper cycle time,
meet required flow rates. See "Pump tighten the adjustment screw locknut.
Adjustment". NOTE: Inconsistent flow can occur if pump stroke is
set below 20% of maximum stroke. A dust seal inside
Pump Adjustment the flow adjustment screw holds the priming stem
stationary during operation.
The flow adjustment screw controls pump flow
rate; turning it changes the length of the piston Pump Troubleshooting
stroke which changes the pump discharge
volume. Refer to "Figure: Pump Priming and Relieve all pressure from the system before
Adjustment" during adjustment. cleaning, checking, or servicing the equipment.
1. Loosen the flow adjustment screw locknut. Pump Problem:

2. Lubricate the o-ring beneath the adjustment • No flow
screw locknut with oil. • Low flow or erratic operation
3. Turn the flow adjustment screw. • Low discharge pressure
Counterclockwise increases flow and • Fluid flows from pump outlet when not
decreases cycle time; clockwise decreases running
flow and increases cycle time.
Pump No flow
Problem
Pump no flow.

Stroke adjusted to zero. Plugged pump outlet.
Solution Solution
1. Adjust pump stroke for desired output. See 1. Clean/flush pump outlet.
"Pump Adjustment".
Possible Cause
Damaged outlet check valve.
Solution
1. Replace pump.


Damaged or worn inlet check ball and/or seat. Insufficient oil supply.
Solution Solution
1. Replace pump. 1. Check for line and filter restrictions
upstream of pump. Verify pump inlet is free
of debris.
Possible Cause
Stuck piston.
Possible Cause
Solution Air bubbles in the oil.
1. Replace pump.
Solution
1. Prime pump. See "Priming the Pump".
Possible Cause
Stuck pump priming stem.
Possible Cause
Solution High oil viscosity.
1. Clean and lubricate the priming stem.
Solution
Replace pump if priming stem is corroded.
1. Decrease flow restrictions upstream of
pump.
2. Heat oil to maintain viscosity ‹1100 cSt.
3. Consult oil supplier for temperature.
Low Flow or Erratic Pump Operation
Problem
Low flow or erratic pump operation.

Stroke adjusted to minimal travel. Damaged or worn inlet check ball and/or seat.
Solution Solution
1. Adjust pump stroke for desired output. See 1. Replace pump.
"Pump Adjustment".
Possible Cause Solution

Damaged or worn outlet check ball and/or seat. 1. Replace pump.


Sticking piston or priming stem. Air bubbles in the oil.
Solution Solution
1. Replace pump. 1. Prime pump. See "Priming the Pump".

Insufficient oil supply. High oil viscosity.
Solution Solution
1. Check for line and filter restrictions 1. Decrease flow restrictions upstream of
upstream of pump. 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. Check/inspect lube box cam gear for wear.
Low Pump Discharge Pressure
Problem
Low discharge pressure.

Worn piston and bore. Damaged or worn inlet check ball and/or seat.
Solution Solution
1. Replace pump. 1. Replace pump.
Fluid Flows From Pump Outlet
Problem
Fluid flows from pump outlet when not running.

Inlet pressure exceeds cracking pressure of Damaged or worn outlet check ball and/or seat.
pump outlet check valve.
Solution
Solution
1. Replace pump.
1. Reduce inlet pressure to below the cracking
pressure. See "Pump Setup".

Auto-Relief Valve (ARV)

An auto-relief valve (ARV) is a mechanical valve
that protects force-feed lubrication systems from
over-pressure conditions. Unlike a rupture disk
assembly, the ARV is reusable and does not expel
oil onto the compressor skid.
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 When a force-feed pump encounters a

downstream restriction, pump discharge
Figure: ARV Operation pressure increases. If discharge pressure exceeds
ARV cracking pressure, the ARV bypasses excess
oil back to the low-pressure inlet side of the
pump (Figure: ARV Operation – High Pressure).
Bypassing oil limits the pressure created by the
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
1 Normal Pressure (pin does not protrude) over-pressure condition. The indicator pin is a
2 High Pressure (pin protrudes)
“tattle tale” and remains protruding after the
3 Pressure Relieved (pin not reset)

ARV bypasses oil (Figure: ARV Operation– After downstream blockage/restriction removal,
Pressure Relieved ). Two bypass conditions are the indicator pin can be manually reset by
possible: depressing the indicator pin until it is flush with
the ARV housing.
Intermittent blockage downstream of the
pump - A brief condition or one-time event that Force Feed Lube Blow-Out Fittings, Rupture
prevents the shutdown device from timing out Disks, and Tubing
and allows the compressor to continue to
Force feed lube pump discharge lines require
operate.
blow-out fittings and the properly rated rupture
Significant blockage downstream of the pump disk installed. The disk color should show at the
- A condition of long enough duration to cause fitting blow-out hole. A system blockage causes
the shutdown device to timeout and shutdown pressure build-up that ruptures the disk. Venting
the compressor. 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 supplied to Ariel after March 2005 are completely
disks are color-coded to identify rupture coated with color. Disks need not be replaced
pressure ratings. Some disks come with half the because of this change and existing disk stock
finished face coated. If the disk color coating is may be used-up.
less than half the face surface, the color may not
show through the small centered blow-out hole
when installed in the blow-out fitting. When this CAUTION
happens, a visual inspection for color coding may Use a mirror to inspect rupture disk color if force feed
not indicate the correct disk is installed, and lube system is pressurized. A rupturing disk or high
fitting disassembly is required to confirm the pressure oil can potentially cause personal injury.
proper disk installation. To correct this issue in
the future, the finished face of rupture disks

When installing a rupture disk, tighten the blow- Distribution Blocks

out hex fitting cap to 40 lb. x in. (4.5 N•m) torque.
Distribution blocks consist of three to seven
Do not over tighten cap or blow-out pressure
divider valves and an optional bypass block
may decrease, which may increase nuisance
fastened to a segmented baseplate. Viton O-rings
shutdowns.
(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
2 Crossport Plate
3 Inlet Port
4 Inlet Block
5 O-Rings
6 Check Valve
7 Intermediate Blocks
8 Outlet Port (correct position is off-center
toward inlet block)
9 End Block
10 Tie Rod Nut
11 Tie Rod
12 Divider Valve
13 Valve Screw
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.
Bypass blocks can replace a divider valve section
NOTE: Pistons are matched to a specific divider valve. to eliminate the lubrication points. Plug both
Do not try to place a different piston into a divider outlets below the bypass block. A bypass block
valve. can mount in any baseplate location, but it

requires at least three working divider valves in adequate pressure to force oil into the injection
the block assembly (i.e. bypass blocks cannot be point. The supplier pressure tests all new Ariel
used on 3-section baseplates). divider valves.
The baseplate contains the divider valve inlet To test distribution blocks for valve by-passing
and outlet connections, interrelated requires a manual purge pump with a pressure
passageways, and built-in check valves. All gauge capable of developing 5000 psig (350
lubricant piping to and from the distribution barg). Ariel offers an optional force feed
block connects to the baseplate. The baseplate lubrication hand purge pump with a pressure
consists of one inlet block, three to seven gauge (see Section 1). Pressure test each divider
intermediate blocks, one end block, and three tie valve one at a time, complete with pin indicators
rods. The number of baseplate intermediate installed.
blocks determines the number of divider valves
allowed. Each distribution block requires a
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.
Divider Valve Bypass Pressure Test

Lubricant can leak (by-pass) from a divider valve
when the divider valve piston becomes worn.
Pressure test or replace all divider valves every
twelve months. Testing verifies the piston fits
tightly enough in the divider valve bore for

Figure: Pressure Testing Divider Valves
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

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
the maximum injection pressure indicated at
7. Repeat Steps 4 thru 6 for the remaining
each divider block gauge, balance valve set
outlets on the divider block assembly.
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
1. Start the compressor and bring the cylinders
cylinder bore lubrication rates and/or
up to normal operating pressure.
aftermarket devices that measure flow.
2. Allow operating pressures to stabilize.

3. See the cylinder lube sheets for balance valve is also true for the inner lube point on
locations and proper spring type for each high-pressure, two lube point packings.
device. c. For the outer lube point on high-pressure,
two lube packings, assume lube line pres-
Selecting Balance Valves and Pressure Gauges sure is zero.
Balance valves are used in high differential d. For intermediate packing lube points on
long two-compartment distance pieces,
pressure distribution block applications to
the lube line pressure is zero.
reduce system problems such as bypassing, no-
e. For inlet gas flushing lines, commonly
flow switch errors, or blown rupture disks. Since
used in sour gas applications, lube line
9/98, Ariel supplies balance valves and pressure pressure equals suction pressure.
gauges on new compressors with high
f. The bore lube line pressure of each
differential force feed lube pressures. Balance cylinder in a tandem pair equals suction
valves add pressure to distribution block pressure of the low-pressure cylinder in
discharge ports when differential pressure the pair.
exceeds 1200 psi (8300 kPa). 2. Determine pressure differentials between
If a compressor experiences excessive each individual lube line and the highest lube
line pressure for the distribution block
distribution block differential pressure, select
system. For example, if pressure at a lube
and install balance valves (and pressure gauges, point is 700 psig (5500 kPa) and the highest
if required) by the following procedure: cylinder mean pressure is 2000 psig (13800
1. Determine lube point line pressures, either by kPa), then a balance valve must be added to
measurement on the compressor with a the 700 psig (5500 kPa) lube line to achieve a
calibrated pressure gauge, or by calculation pressure differential below 1200 psig (8300
of expected pressures for a given distribution kPa). Select a valve spring (see Table: Balance
block system: Valve Springs) by multiplying the highest lube
line pressure by 0.85 to calculate the balance
a. Expect cylinder bore lube line pressure valve set pressure. For example, if the highest
midway between suction and discharge lube line pressure is 2000 psig (13800 kPa),
pressure. Calculate: P = (Pd + Ps) ÷ 2. The the valve set pressure is 2000 x 0.85 = 1700
bore line pressure of double-acting psig, which requires an orange spring.The
forged steel (VS) cylinders equals the Ariel part number for the balance valve
suction pressure of the cylinder. without springs is CA-8005. The highest
b. For single lube packings, expect lube line pressure lube point requires no balance valve
pressure to equal suction pressure of a or pressure gauge.
double-acting or crank end cylinder. This

Table: Balance Valve Springs Table: Rupture Disk Data

Set Pressure Rupture Disc Rated Pressure Blowout Orifice
Ariel Spring
Spring Color Range psig Color psig (kPa) Dia. in. (mm)
(only) Part No.
(kPa)
Purple 3250 (22400) 1/4 (6)
A-9662 Purple 750 to 1500
(5000 to 10000) Yellow 3700 (26000) 1/8 (3)
A-8087 Orange 1501 to 2250 Red 4600 (32000) 1/8 (3)

(10001 to 16000) Orange 5500 (38000) 1/8 (3)
A-8007 Brown 2251 to 3000 Aluminum 6400 (44000) 1/8 (3)
(16001 to 21000)
Blue 7300 (50000) 1/8 (3)
A-9912 White 3001 to 4000
(21001 to 28000)
Table: Pressure Gauges - Back-mounted, 1/4
A-9911 Red 4001 to 5000
(28001 to 34000) inch - NPT
Pressure Range, psig
Ariel Part No.
3. Balance valves and pressure gauges are not (kPa)
required for pump to point systems, zoned A-8727 0 to 3000 (0 to 20000)
systems, or any system that does not exceed
A-8728 0 to 5000 (0 to 32000)
1200 psi (8300 kPa) differential pressure.
Tandem cylinder compressors with only one A-9093 0 to 7500 (0 to 50000)
tandem bore lube point that exceeds 1200 psi
(8300 kPa) differential pressure require no Installing Balance Valves and Pressure Gauges
balance valves or pressure gauges. With more
than two balance valves applied to a single Before balance valve and pressure gauge
divider block assembly, it is advisable to installation, a mechanic should verify correct
install a pressure gauge upstream of each balance valve, spring, appropriate fittings, and
balance valve. Pressure gauges aid in the pressure gauge quantities. The highest pressure
setting and adjustment of balance valves.
lube point of a given pump system requires no
Select a pressure gauge with the maximum
pressure on the gauge face greater than or balance valve or pressure gauge.
equal to rupture disk pressure (see Table: 1. Install balance valves with the flow direction
Rupture Disk Data and Table: Pressure arrow properly positioned in the direction of
Gauges - Back-mounted, 1/4 inch - NPT). The oil flow toward the compressor cylinder.
only exception to this rule is the 3000 psig
(20000 kPa) gauge used with the 3250 psig 2. Install a pressure gauge, if required,
(22400 kPa) rupture disk. upstream of each valve (between the balance
valve and distribution block).
3. Verify the maximum pressure on the gauge
face is greater than or equal to rupture disk
pressure – see Table: Rupture Disk Data. The
only exception to this rule is the 3000 psig
(20000 kPa) gauge used with the 3250 psig
(22400 kPa) rupture disk.

4. Install the proper spring in each balance 4. Calculate the balance valve set pressure by
valve as determined in the selection multiplying the maximum recorded pressure
procedure above for each applicable by 0.85.
pressure lube point line, and install the valve
5. Set balance valve(s) downstream of the
cap.
selected divider block to the pressure
5. Tighten the cap against the spring, but do not calculated in step 4 by rotating the
compress the spring. adjustment cap clockwise to increase
6. Tighten the lock nut against the cap, hand pressure. Set pressure within ±50 psi (3.5 bar)
wrench tight. of the calculated value.
6. Monitor the divider block gauge for one
Adjustment of Balance Valves Fed by a Divider minute and record the minimum and
Block maximum pressures in Appendix E. The
difference between the minimum and
Figure: Balance Valves Fed by Divider Block 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.
9. After setting all balance valves in the force
feed system, operate the system for 4 to 6
1 Balance Valve hours, then repeat step 6 for each divider
2 Balance Valve Pressure Gauge block.
3 Adjustment Cap
4 Lock Nut
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.

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
1 Primary Balance Valve Divider Block" for each primary or secondary
2 Primary Balance Valve Pressure Gauge divider block.
3 Adjustment Cap
4 Lock Nut
5 Primary Divider Block Pressure Gauge
6 Primary Divider Block
7 Secondary Divider Block Pressure Gauge
8 Secondary Divider Block
9 Secondary Balance Valve
10 Secondary Balance Valve Pressure Gauge
NOTE: Set secondary balance valves before setting

primary balance valves. If the system contains no
secondary balance valves downstream of a
secondary divider block, proceed to step 4.
1. Select one secondary divider block that feeds

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".

Subsequent Compressor Start-Up 7. Monitor the selected divider block gauge for
one minute and record the minimum and
Table: Balance Valve Part Numbers maximum pressures in Appendix E.
Description Ariel Part No. 8. See "Selecting Balance Valves and Pressure
Balance Valve without CA-8005 Gauges" if any of the conditions below occur:
Spring a. The difference between the maximum
Balance Valve Springs See "Table: Balance Valve and minimum recorded divider block
Springs" pressures exceeds 1200 psig (82.7 barg).
Balance Valve Seal Repair A-8005-K b. The maximum recorded balance valve
Kit pressure exceeds 85% of the maximum
recorded divider block pressure.
Balance Valve Plug A-10330
c. The divider block gauge exhibits erratic
Pressure Gauges See "Table: Pressure needle movement as the divider block
Gauges - Back-mounted,
cycles.
1/4 inch - NPT"
1. Verify tightness of all fittings and fix any Force Feed System Design,
known leaks. Purge force feed lube system. Operating Parameters, and
2. If the force feed lube system has been Conditions
disassembled or parts replaced since the last
start-up, purge the force feed lube system See specific packager data to confirm designed
with a high-pressure hand purge pump. When gas composition, operating pressures, and
purging the system, use the same oil that is speed. If operating outside design conditions,
recommended for the cylinder application, to system may need to be reviewed. To optimize
remove any trapped air or gas in the system. force-feed lubrication system operation, Ariel
DO NOT USE ANY OTHER FLUIDS FOR uses these general guidelines:
PURGING! Call the Ariel Response Center for
details about purchasing a hand purge pump. 1. Maintain lube rates within prescribed limits
and cycle times as low as possible (normally
3. Start the compressor and bring up to normal
operating pressure. 10 sec minimum) to lubricate each point as
frequently as possible.
4. Operate the unit for 2 to 3 hours to allow the
operating pressures to stabilize. DO NOT 2. Multiple pumps may be manifolded to
adjust the balancing valves immediately after achieve required lubrication rates.
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
period of run time and the system pressures stroke or they become inconsistent. When
will stabilize as components increase in two or more pumps are manifolded to feed
temperature. one distribution block, adjust them equally.
5. See the cylinder lube sheets for balance valve Start with pumps wide open, and adjust them
locations and proper spring type for each together so that when break-in cycle time is
device. set, the pumps stroke about the same. After
6. Select one divider block that feeds one or break-in period, adjust the pumps in the
more balance valves. same manner, provided the final pump
stroke is not too short. Try to keep the stroke

greater than 20% of maximum; a shorter 7. Prime the force feed lubrication system with
stroke produces unreliable pump output. If a proper priming pump just prior to starting
needed, close one pump to stop its flow and the compressor (see "Force Feed Lubricator"
open the other(s) to make the “normal” cycle for pump illustration). Use clean force feed
time, and maintain a stroke greater than 20% lubricating oil of same type and grade as used
in the functioning pump(s). in service. Do not use any other fluid type or
grade to prime.
4. In some applications, one divider valve
delivers lubrication to both a packing and a 8. For recently overhauled units, adjust force
cylinder to optimize lubrication system oper- feed cycle time for maximum delivery.
ation. In some applications, cross-ported Loosen adjusting screw locknut. Turn
divider valves deliver the proper proportion plunger stroke adjustment screw to the full
of lubricant to a given point. up position. Tighten adjusting screw locknut.
After two hours of operation or before leaving
5. During operation, verify oil fills the lubricator
site, reset to “normal” cycle time.
reservoir sight glass to the overflow line.
Reservoir oil lubricates the worm gear and
cam; it does not flow through the system. The
Common Oil Supply
reservoir also catches force feed lube pump Figure: Force Feed Lubrication System Common
leakage. Add oil only if needed to raise reser- Oil Supply shows the force feed lube system
voir oil level. See Table: Force Feed Lubri- installation when compressor frame lube oil is
cator Reservoir Oil Capacity. also used for cylinder and packing lubrication.
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.

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 • Increase pipe and fitting size from tank to
force feed pump.
When cylinders and packing require oil different • Heat the oil.
from frame oil, the force feed lubricator system • Heat trace and insulate the line from the tank.
requires an independent oil supply system (see • Pressurize the supply tank (tank must be
Figure: Force Feed Lubrication System designed for pressure).
Independent Oil Supply). An elevated tank must
supply pressurized force feed lube oil at a
minimum of 1 psig (0.07 barg) to the force feed
pump inlet manifold.
To prevent force feed oil from contaminating

compressor frame oil, disconnect lubricator box
overflow tubing from compressor frame and
direct it to a suitable drain system.
Independent force feed lube systems require oil

with a viscosity below 1100 cSt at the lubricator
pump inlet (e.g. ISO 320 at 73°F (23°C), contact
lube supplier about specific lubricants). Possible
ways to ensure force feed pump is fed oil during
suction stroke:

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 Conditions are calculated based on the gas analysis,
operating conditions, and applied speed
specified in the compressor order. If gas
CAUTION conditions were not supplied with the
compressor order, the data plate/lube sheet
To prevent personal injury, verify driver or compressor
cylinder gas pressure cannot turn compressor rates default to clean, dry, 0.65 specific gravity,
crankshaft during maintenance. Before any sweet gas and cylinder MAWP. If the applied
maintenance or component removal, relieve all pressure
speed is not specified, the cycle time is based on
from compressor cylinders. See Packager’s instructions
to completely vent the system. After maintenance, purge maximum rated speed of the frame or cylinders,
the entire system with gas prior to operation to avoid a whichever is less. The lube sheets in the Ariel
potentially explosive air/gas mixture.
Parts Book state gas conditions and list the base
rate multiplier at each lube point.
Cycle Time
Break-in Rate - Set the break-in lube rate about
Lubricant flow rates are measured in seconds per twice the recommended daily rate (150%
cycle of the distribution block. The calculated minimum); i.e. set the break-in cycle time about
break-in and normal cycle times are stamped on half the normal cycle time (67% max.) to increase
the lubricator box data plate. These cycle times lube rate. Maintain break-in rate for 200 hours of

operation for new equipment. Contact Ariel if Changes in operating conditions (such as gas
existing pump is incapable of minimum flow rate properties or pressures, temperatures, flow
required. requirements, or cylinder re-configuration)
require lubrication rate re-calculation and
Lube Rate and Speed - Recommended lube
possible force-feed lubrication system
rates for break-in or normal operation, in
alteration. Consult the Ariel Packager Standards,
seconds per cycle, are calculated at the frame
the Packager, and/or Ariel.
rated speed (RPM) stamped on the frame data
plate or the cylinder rated RPM stamped on the
cylinder data plate, whichever is lower. Lube rate
Under/Over Lube
decreases with speed, (as compressor actual Inadequate lubrication causes premature wear
running speed decreases, cycle time increases, of piston and packing ring materials. Indications
reducing lube rate): of under lubrication are black, gummy deposits
in the distance piece, packing case, cylinder, and
(RPMmax ÷ RPMactual) x cycle time seconds from
valves. When symptoms indicate under
lube plate = cycle time seconds at actual running
lubrication:
speed.
• Verify proper operation of force feed lubri-
See the Ariel Parts Book Lubrication Sheets for cator pumps.
the Cycle Time (seconds) vs. RPM (compressor • Confirm distribution block cycle time
speed) table at various running speeds at stated matches the lube sheet or force feed lubri-
gas operating conditions and lubricant. cator data plate.
• Verify all tubing and fitting tightness; check
Adjusting the cycle time changes the lubrication for leakage. Check fittings inside cylinder gas
rate for all the compressor cylinders and passages.
packings supplied by a particular pump. To • Pressure test or replace divider valves to
change the lubrication rate for only one cylinder ensure they do not bypass.
or packing requires individual divider valve Over lubrication can result in excessive oil
changes. Contact your packager or Ariel for carryover into the gas stream, and increased
information. valve and gas passage deposits. Valve plate
To set proper force-feed lubricator pump flow breakage and packing failure may also indicate
rate, read or measure the cycle time from the over-lubrication.
installed device. For a magnetic cycle indicator
assembly, time the cycle from initial indicator pin
movement at the fully retracted position to the
time when the pin returns to the fully retracted
position and just begins initial movement out
again. Adjust the lubricator pump to provide the
required cycle time.
NOTE: Pump output can become inconsistent if flow

rate is set too low. See “Force Feed System Design,
Operating Parameters, and Conditions”.

Cylinder Lubrication Paper Test 4. Repeat this procedure for all cylinders. If the
test indicates a lubrication rate reduction or
1. Remove head end head and position piston increase for a cylinder, change in 5%
for the desired cylinder at inner dead center. increments by adjusting cycle time at the
2. Using light pressure, wipe the cylinder bore force feed lube pump (see "Pump
with two layers of regular unwaxed cigarette Adjustment"). Repeat oil film testing, for
paper together. Begin at the top and wipe affected cylinders, after 24 hours of
downward about 20° along the bore operation. For a formal lube rate reduction
circumference. The paper against the bore program, see Ariel ER-125.
surface should be stained (wetted with oil), NOTE: The paper test indicates only oil film quantity.
but the second paper should not be soaked Aftermarket devices exist that measure flow. Neither
through. method indicates viscosity quality. Oils diluted with
water, hydrocarbons, or other constituents may
3. Repeat the test at both sides of the bore at
appear to produce an adequate film or flow, but dilu-
about 90° from the top, using two clean
tion will reduce lubricant effectiveness below require-
papers for each side. Paper against the bore
ments.
surface not stained through may indicate
under-lubrication; both papers stained
through may indicate over-lubrication. In Coolant System Requirements
either case, Ariel normally recommends
changing lubrication rate accordingly and Coolant flow = number of packing cases x 1 US
repeating all paper tests until passed. gallon per minute (gpm), minimum for each inch
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.
See Figure: Typical Packing Cooling System.
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.

Part Replacement
Major frame assembly components include the Relieving Gas Pressure
crankcase, crankshaft and bearings, connecting
rods, chain drive system, and crossheads. An Before conducting maintenance on the
aluminum top cover and crosshead guide side compressor, it is vital to ensure the cylinders
covers provide easy access to internal contain no gas pressure. During maintenance,
components. Below are general guidelines to unrelieved gas pressure could cause equipment
follow during maintenance. damage, personal injury, or even death.
1. Cleanliness during part replacement:

Isolation
• Use lint-free wiping cloths.
• When not working on a frame with access Isolate the compression system from all energy
covers removed, cover it to protect the sources prior to any maintenance. To ensure 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
Fully depressurize the compression system prior
inspect gaskets at non-pressure loca-
tions. If damaged, replace them. to any maintenance. If the application involves a
corrosive or poisonous gas, purging is necessary
• Always replace pressure-retaining
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:
1. Isolate inlet gas from entering the system.
If replacing a connecting rod assembly, piston,
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.

JGM-JGN-JGP-JGQ Maintenance & Repair Manual – Part Replacement 12/03/2022
5. If so equipped, open the indicator valves on possible. In the outer dead center position, the
the individual cylinders to remove any crossheads slide away from the crankcase as far
residual pressure in the cylinder(s). 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
application. lowest position. In the figure below, the throw on
the left is in its highest position and the throw on
the right is in its lowest position.
Positioning a Throw
WARNING

who have read and thoroughly understand the
appropriate Ariel Technical Manual and Packager
ment and follow your company safety and opera-
tional procedures.
• Never tighten or loosen any fastener while the unit is
operating or pressurized.
maintenance.
and vent the system; call the packager for assis-
tance.
AND/OR FLAMMABLE.
the gas being compressed to avoid a potentially
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
crossheads slide toward the crankcase as far as

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.

VVCP Removal
WARNING

tional procedures.
maintenance.
tance.
AND/OR FLAMMABLE.
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: freely. Turn the adjustment handle. For VVCP
After venting the cylinder, loosen the locking with a metal thread protector: After venting
handle so the adjustment handle can turn the cylinder, unscrew the metal thread

protector. Loosen the locking handle or around the piston ring can form a seal that traps
adjustment locknut so the piston stem can gas within the VVCP assembly, sometimes at
turn freely. With a wrench, turn the piston substantial pressure.
stem.
CAUTION CAUTION
A hard to turn adjustment handle or piston stem may Trapped gas pressure can present a personal safety
indicate pressurized gas trapped within the VVCP. See hazard when servicing the VVCP. Work in a well-
VVCP Disassembly caution. ventilated, non-sparking area, particularly with sour gas
applications. Do not breathe gas emission from VVCP
when venting trapped gas.
2. Tighten the locking handle or adjustment
locknut.
3. Disconnect the VVCP vent.
4. Remove plastic plug from eyebolt hole and
thread an eyebolt into the eyebolt hole.
5. Use the Ariel supplied eyebolt to support the
weight of the VVCP.
6. Remove all flange bolts and slide the VVCP
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.
VVCP Disassembly
The VVCP piston ring is not gas-tight to allow a
nearly balanced gas pressure, which eases VVCP
adjustment with the cylinder pressurized. Gas
pressure behind the VVCP piston normally vents
when the cylinder vents. Process debris or rust

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.

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.

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

15. Install locking handle or adjustment locknut 18. For VVCP with an adjustment handle, install
onto the piston stem, but do not lock it. For the locknut onto the piston stem and tighten
VVCP with bellows thread protector, it to prevent the adjustment handle from
assemble the locking handle with the loosening.
protector facing up.
19. Bellows thread protector: Slide thread
16. For VVCP with an adjustment handle, slide protector bellows onto the adjustment
the adjustment handle onto the piston stem handle lip and verify that it grips securely.
and use a soft hammer to ensure full Metal thread protection: Thread protector
engagement of the tapered fit. over the piston stem.
17. Use the adjustment handle or piston stem 20. Apply 3-4 pumps of all-purpose petroleum
hex to turn the piston stem counter- grease with a grease pump at the grease
clockwise to tighten the seal between the fitting.
adapter and head, then lock the locking
handle or adjustment locknut. VVCP Installation
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
4. Reconnect VVCP vent. Verify piston end
seating surface.
clearances. See Appendix B.
2. Slide the VVCP into the cylinder and align the
5. Install valves and torque the valve caps. See
adapter flange bolt holes with the cylinder
"Compressor Valves - Removal and
bolt holes.
Installation".

VVCP Adjustment Compressor Valves - Removal and

Users may change VVCP clearance volume with Installation
the compressor running or stopped. The Before servicing any valve, see the correct valve
expected change in compressor flow and assembly drawing, parts list, and service
absorbed power depends on compression ratio literature in the Ariel Parts Book. The cylinder
and properties of the compressed gas. Consult cover sheet in the Ariel Parts Book lists the valve
packager instructions regarding where to set the originally supplied with each cylinder. Changes
VVCP. Also see the VVCP data sheet in the Ariel in operating pressures, temperatures, RPM, or
Parts Book. To open VVCP to a desired gas composition may require alternate valve
percentage: configuration including springing and lift.
Figure: VVCP Dimension Plate Contact your Packager and/or Ariel for help in
valve selection.
ARIEL CORPORATION A-12927
FULLY CLOSED A =
FULLY OPEN A = Required Tools and Materials
A A VVCP S.N.
• Appropriate Ariel parts list
REMOVE ALUMINUM THREAD PROTECTOR WHERE APPLICABLE
1. For VVCP with a bellows thread protector: • Appropriate Ariel Maintenance and Repair
Loosen the locking handle so the adjustment manual
handle can turn freely. For VVCP with a • Calibrated torque wrench with the appro-
metal thread protector: Unscrew the metal priate range for target values
thread protector.Loosen the locking handle • Lubricant specified in Appendix A
or adjustment locknut so the piston stem can
• Appropriate personal protection equipment
turn freely.
• Bottle brush
2. Find the VVCP dimension plate. • Pressurized liquid solvent
3. Subtract fully closed dimension from fully • Valve Tool
open dimension. The Ariel Performance
program also lists these dimensions if the
VVCP dimension plate is missing.
4. Multiply the step 3 result by the desired
percentage expressed as a decimal.
5. Add the step 4 result to the fully closed
dimension.
6. Turn the adjustment handle or piston stem
until the measurement from the base of the
locking handle or adjustment locknut, when
locked, to the top of the adjustment handle or
piston stem equals the step 5 result.

Valve Cap Removal
Valve Caps on Cast Iron Cylinders or High-

Pressure Caps without Spring Energized Seals
WARNING

tional procedures.
maintenance.
tance.
AND/OR FLAMMABLE.
injury or death.

Figure: Valve Cap Assembly

Cast Iron Cylinder High-Pressure without Spring Energized Seal
1 Cap Screw 1 Valve Cap

2 Valve Cap 2 Valve Retainer
3 O-Ring 3 Valve Assembly
4 Valve Retainer 4 Valve Seat Gasket
5 Valve Assembly 5 Metallic Wire Gasket
6 Valve Seat Gasket
1. Slightly loosen all valve cap fasteners in steps 3. Remove cap screws and valve cap. Take care
and evenly; the cap should stay in its original to prevent damage to fasteners.
position. If it pushes outward, STOP!
WARNING
Completely vent the cylinder. See Warning
above. Even with the above precautions, the cylinder bore
could still be pressurized if the valve assemblies are
2. Continue to turn the cap screws out, for a fouled with deposits from the gas stream. Continue to
total of three complete 360° turns. Pry the use caution until at least one complete valve assembly
valve cap out, observing cap movement to has been removed from each acting end of the cylinder,
which completely assures there is no gas pressure.
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.
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.

Removal of Valve Cap with Spring Energized

Seal
WARNING

1 Hex Nut
tional procedures. 2 Cap Nut
• Never tighten or loosen any fastener while the unit is 3 Valve Cap
operating or pressurized. 4 Seal Keeper
• Verify neither driver nor compressor can turn during 5 Retainer
maintenance.
6 Valve
and vent the system; call the packager for assis- 7 Valve Gasket
tance. 8 Keeper Bolt
• Verify each compressor cylinder is relieved to atmo- 9 2-Piece Wedge Lock Washer
spheric pressure. To relieve residual cylinder bore 10 Spring Energized Seal
on the indicator ports, if so equipped. 1. Remove cap nuts from long studs.
AND/OR FLAMMABLE.
2. Slightly loosen all hex nuts on each valve cap
Before resuming operation, purge the entire system with in steps and evenly. With all the nuts loose,
the gas being compressed to avoid a potentially the cap should stay in its original position. If it
explosive gas/air mixture in the system. A gas/air pushes out of its own accord, STOP!
mixture under pressure can explode and cause severe Completely vent the cylinder. See Warning
injury or death. above.
3. After the above safety checks and with hex
Figure: High-Pressure Valve Cap Assembly with
Spring Energized Seal
nuts still in place but loosened, remove hex
nuts from short studs.
4. Evenly back off hex nuts on long studs while
pulling the valve cap from the cylinder. Use a
pair of pry bars, one on each side of the cap,
to remove the cap. Ensure the spring
energized seal completely disengages from
the cylinder before removing the hex nuts
from long studs.
NOTE: Long studs are assembled with thread locker
to eliminate the possibility of the studs backing out of
the cylinder while the hex nut is removed.
5. Remove long stud hex nuts and valve cap.

6. Inspect seal for damage. If undamaged, the

spring energized seal is re-usable.
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 Cap with Spring Energized Seal

1 Hex Nut
2 Cap Nut
WARNING 3 Valve Cap
To reduce risk of injury or death, only trained personnel 4 Seal Keeper
who have read and thoroughly understand the 5 Retainer
appropriate Ariel Technical Manual and Packager 6 Valve
information should attempt any maintenance. 7 Valve Gasket
8 Keeper Bolt
ment and follow your company safety and opera- 9 2-Piece Wedge Lock Washer
tional procedures. 10 Spring Energized Seal
operating or pressurized. 1. Remove cap nuts from long studs.
• Verify neither driver nor compressor can turn during 2. Slightly loosen all hex nuts on each valve cap
maintenance. in steps and evenly. With all the nuts loose,
the cap should stay in its original position. If it
tance. pushes out of its own accord, STOP!
• Verify each compressor cylinder is relieved to atmo- Completely vent the cylinder. See Warning
spheric pressure. To relieve residual cylinder bore above.
3. After the above safety checks and with hex
nuts still in place but loosened, remove hex
AND/OR FLAMMABLE. nuts from short studs.
Before resuming operation, purge the entire system with 4. Evenly back off hex nuts on long studs while
pulling the valve cap from the cylinder. Use a
mixture under pressure can explode and cause severe pair of pry bars, one on each side of the cap,
injury or death. to remove the cap. Ensure the spring
energized seal completely disengages from
Figure: High-Pressure Valve Cap Assembly with the cylinder before removing the hex nuts
Spring Energized Seal from long studs.
NOTE: Long studs are assembled with thread locker
to eliminate the possibility of the studs backing out of
the cylinder while the hex nut is removed.
5. Remove long stud hex nuts and valve cap.

6. Inspect seal for damage. If undamaged, the

spring energized seal is re-usable.
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
Section 1 for an illustration of the tool.
2. It may be necessary to loosen the plastic
thumb screws in the valve retainers. In some
cylinder classes, the discharge valve retainer
is held in place with an O-ring - simply pull the
retainer out to remove it.
3. For high pressure applications that use a
metallic wire gasket seal under the valve cap,
the cylinder vents upon loosening the cap
screws. Use the valve tool to unseat the
metallic wire gasket.
4. Remove the valve and retainer together.
5. In most cases, the flat metal gasket remains
in the pocket. It is difficult to see. A flashlight
and a small mirror on an adjustable rod are
the best tools to see the gasket clearly. On
cylinders with horizontal valves, the gasket
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 3. Use the valve tool to insert the valve and
insert it into the valve pocket or stick it on the retainer into the pocket together (see tools
valve. In either case, do not allow the gasket for your compressor model in Section 1).
to fall into the gas passage. Replace valve Verify the valve seats properly in the pocket.
seat gaskets anytime a valve is removed from When installed correctly, the valve rotates
a cylinder, if the unit has been in service. freely by hand.
2. Install suction valves only in suction pockets 4. Plastic thumbscrews or o-rings hold valve
and discharge valves only in discharge retainers in position in bottom valve pockets.
pockets. The valve pockets have Tighten thumbscrews just enough to provide
identification plates. Install all valves with friction so retainers and valves in bottom
valve fastener(s) positioned away from the pockets stay in position during valve cap
cylinder bore (see Item 1, Figure: Typical installation. Do not replace plastic
Valve Assemblies). If a valve is not marked for thumbscrews with metal.
suction or discharge, manually depress the
5. Lubricate a new O-ring with oil and install it in
valve plate to verify the type. Preferably, use
the groove on the valve cap nose. Some high
a tool softer than the valve plate material or
pressure cylinders use a soft metallic wire
exercise care to prevent damage to the plate.
gasket or spring-energized seal in lieu of the
A suction valve plate may be depressed only
O-ring. Continue to "Valve Cap Installation".
from the valve fastener (bolting) side of the
NOTE: For 10-3/4P-HE valve installation, see the "10-
valve; a discharge valve plate may be
3/4 Valve Installation" video on the Ariel website.
depressed only from the side of the valve that
faces the cylinder bore.
Valve Cap Installation
Depending on the application, Ariel compressor
cylinders utilize different styles of valve caps.
Cast iron cylinders utilize valve caps in which an

O-ring on the valve cap seals gas within the Installation of Valve Caps on Cast Iron Cylin-
cylinder.Forged steel cylinders utilize a valve cap ders or High-Pressure Caps without Spring
with either a spring-energized seal or a round Energized Seals
metallic gasket to seal gas within the cylinder. 1. Install valve assembly (and high clearance
The valve cap presses the round metallic gasket spacer, if applicable), with the valve seat
into a triangular cross section during the torque gasket and valve retainer in the valve pocket.
See "Valve Installation".
procedure.
2. For high-pressure valve caps only: Place a
Ensure all threads are clean and free of debris or new, round, metallic wire gasket. Always use
burrs. Use a bottle brush and pressurized liquid a new wire gasket when installing a high-
solvent to clean threaded holes thoroughly. pressure valve cap; gaskets are not re-
Avoid sending debris into cylinder gas passage. useable.
Bolts should thread into hole and bottom out on 3. Oil and install a new O-ring on the valve cap.
the valve cap by hand without resistance or use Install the valve cap.
of a wrench. If bolts do not thread into hole 4. For standard fasteners in iron cylinders,
freely, contact ARC for thread repair instructions. lubricate threads and bolt seating surfaces
with mineral oil. For stainless steel fasteners
See Appendix A for critical information on torque
or in steel cylinders, lubricate threads and
accuracy. Valve cap bolt failures can occur if the bolt seating surfaces with Never Seez regular
cap is torqued improperly. Draw bolting to full grade. Do not use Never Seez on standard
torque in even, gradual steps, without bias on fasteners. See Appendix A for correct valve
one bolt or cocking the valve cap in the bore. cap bolt torque.
Such bias or cocking can unevenly crush the 5. For high-pressure applications, the valve cap
gasket, which may cause leakage and/or bolt joint design requires pressing a round
failure. In correct assemblies with new valves, the metallic wire gasket into a triangular cross
distance from the underside of the cap to the section (see Figure: Gasket Crush). This
surface of the cylinder is a uniform 1/8 inch (3 requires multiple passes in a crisscross
pattern with the torque wrench. See
mm). The distance is slightly less with re-worked
Appendix A
valves. Proper tightening of gas containment
fasteners is critical to ensure safe and reliable
operation.
CAUTION
Severe personal injury and property damage may result

from improperly torqued valve cap bolts. See Appendix
A for correct torque and detailed recommendations.

Figure: Gasket Crush

A Before Torque
B After Torque
1 Cylinder
2 Valve Cap
3 Metallic Wire Gasket
4 Valve Retainer
Installation of Valve Cap with Spring Ener-

gized 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 applicable.

and valve retainer in the valve pocket. See
2. Inspect and lightly lubricate spring energized
"Valve Installation". Verify valve retainer
seal with petroleum oil.
openings are aligned with the cylinder gas
passage. Re-tighten thumb screws, if

3. Install valve cap so the roll pins engage the Some cylinder classes require other designs,
clearance slots in the seal keeper. Be careful including one-piece (integral) piston/piston rods,
not to gouge the bore, or distort or damage and there are some multi-piece assemblies that
the gasket. do not use a crank-end collar.
4. Liberally coat the valve cap stud threads and
hex nut seating surface with Never-Seez. Piston Rod Inspection
5. See Appendix A for correct valve cap fastener
torque. At the specified recommended maintenance
interval, inspect piston rods for damage and
6. Continue to torque the valve cap at 100%
excessive wear.
torque value until no bolt movement is
observed. Even minute bolt movement • For condemning limits, see Section 3.
warrants another pass around the valve cap
in a crisscross pattern.
7. Tighten cap nuts on long studs, hand wrench
tight.
Gas Containment Fastener Torque Checks

Per Per Section 5 (start-up checklists) and
Section 3 (Recommended Maintenance
Intervals), Ariel recommends checking all gas
containment fastener torques by the schedule
below. Gas containment components include
cylinders, valve caps, cylinder heads, unloaders,
gas passage caps, flanges, and packings. Include
this schedule in your computerized maintenance
management system (CMMS):
1. Prior to start-up
2. 24 hours after start-up
3. 750 hours after start-up
4. Every 8,000 hours after start-up
Per Section 3, re-check any fasteners found loose

in any of these intervals after an additional 750
hours. If loosening continues, contact your
packager immediately.
Piston and Rod

Most piston and rod assemblies consist of
separable pistons that attach to the piston rod
with a crank-end collar and a head-end nut.

Piston and Rod Removal 3. In tandem cylinders, where the outboard

cylinder bore is smaller than the inboard
bore, remove the outboard cylinder. Support
such cylinders during removal and
WARNING
installation, to avoid excessive weight on the
To reduce risk of injury or death, only trained personnel piston and rod assembly that may bend
who have read and thoroughly understand the them.
information should attempt any maintenance. 4. If the piston uses a wear band, measure
Prior to performing any maintenance activities: piston to cylinder clearance at bottom of
• Always wear appropriate personal protection equip- piston with a feeler gauge. See Appendix B for
ment and follow your company safety and opera- tolerances. If out of tolerance, replace
tional procedures.
wearband.
operating or pressurized. 5. Move crosshead to outer dead center, then
• Verify neither driver nor compressor can turn during use the piston nut spanner to turn the piston
maintenance. and rod assembly out of the crosshead. The
two dowels on the tool fit the piston nut
tance. holes. Remove the crosshead nut from the
• Verify each compressor cylinder is relieved to atmo- piston rod.
spheric pressure. To relieve residual cylinder bore 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
AND/OR FLAMMABLE. damage wiper or packing rings.
Before resuming operation, purge the entire system with 7. For one-piece piston rings, slide the piston
rod assembly from the cylinder, then
mixture under pressure can explode and cause severe carefully remove the piston rings. For two-
injury or death. piece piston rings (in high pressure
applications), slide the piston rod assembly
out of cylinder until a fraction of the first ring
NOTE: See Section 1 for illustrations of tools clears the cylinder. Hold the first ring in the
mentioned below. For non-lube cylinders, see piston groove by hand, or use a band for
Appendix F. larger sizes, until the ring clears the cylinder,
then carefully remove the ring. This prevents
1. Loosen cylinder head bolts. Remove cylinder the ring from popping out of the groove and
head and all crosshead guide side covers. damaging the ring. Remove succeeding two-
piece rings and wear band in the same way.
2. Move crosshead to inner dead center. Back
off, but do not remove, the crosshead
balance nut set screws. Loosen crosshead
balance nut with the special slugging wrench.
Use the open end wrench for hex nuts or the
peg wrench for round nuts.

Handle all piston rings carefully with clean

tools and hands to protect them from nicks, NOTE: Ariel offers a clamping fixture for 1.125 to 2
marring, and bending. Despite their inch (29 to 51 mm) diameter piston rods.
toughness in service, some rings are fragile
when removed. 1. Securely bolt clamping fixture to a base to
prevent it from turning with the piston rod.
8. The weight of the piston and rod assembly is Place it at a height of about three feet (0.9 m).
stamped on the head end. Support the piston
either manually or with a crane as 2. Verify the clamping fixture saddle where the
appropriate as it slides from the cylinder clamping ring seats, the clamping ring, and
bore. The piston rod must remain parallel the piston rod are clean, dry, and free of any
with the bore until it leaves the bore oil. Even a small amount of oil can cause the
completely. Take care not to ding any piston rod to turn in the fixture during
surfaces. torquing, and a small amount of debris
clamped under high force can damage a
Piston and Rod Manual Disassembly piston rod.
3. Clamp the piston and rod assembly in an
Figure: Clamping Fixture with Clamping Rings
appropriate clamping fixture using the
(Ariel P/N D-0961)
appropriate clamping ring for the rod size.
Clamp it as close to the collar as possible
without fixture interference with the piston.
Torque the four fixture cap screws to 345 lb x
ft (465 N•m) to prevent the rod from turning.
The fixture properly holds the piston rod to
prevent damage to the parts and promote
safety during disassembly and reassembly.
Nom. Piston Rod Clamping Force

Diameter Inches (mm) Required Ton (kN)
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.

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. 4. Verify the clamping fixture saddle where the
5. After piston nut removal, slip the piston and clamping ring seats, the clamping ring, and
collar off the end of the piston rod. the piston rod are clean, dry, and free of any
oil. Even a small amount of oil can cause the
piston rod to turn in the fixture during
Piston and Rod Manual Reassembly torquing, and a small amount of debris
1. Clean all piston and rod assembly parts clamped under high force can damage a
thoroughly.Verify piston is internally clean piston rod.
and dry. 5. Clamp the piston and rod assembly in an
NOTE: Any reassembly of used parts requires re- appropriate clamping fixture using the
cleaning and re-lubrication of threads and seating appropriate clamping ring for the rod size.
surfaces. Clamp it as close to the collar as possible
without fixture interference with the piston.
2. Inspect collar (or collar area on rod, when
Torque the four fixture cap screws to 345 lb x
collar is integral and not separable), piston,
ft (465 N•m) to prevent the rod from turning.
and piston nut for nicks, burrs, or scratches.
The fixture properly holds the piston rod to
Replace if surfaces are damaged, worn, or
prevent damage to the parts and promote
galled. Inspect piston ring grooves. If
safety during disassembly and reassembly.
damaged, or ring groove width is out of
tolerance, replace the piston (see Appendix B 6. Apply a thin coat of Never-Seez Regular Grade
for tolerances). Dress surfaces with a fine grit to piston rod shoulder, rod collar locating
stone as required. Fit collar and nut into band, and collar face in contact with piston,
piston to verify the outside diameter fits and then slide collar onto rod.
turns freely by hand in the piston. 7. Apply a thin coat of Never-Seez Regular Grade
3. Inspect piston rod threads and collar to piston rod threads at the piston end, then
shoulder. Clean and de-burr threads. Install slide piston onto rod and collar.
collar and nut onto piston rod to verify inside NOTE: If one end of the piston has an undercut, and
diameter fits and rotates freely. Turn piston the piston has the same number of piston ring
nut until rod threads protrude to verify grooves on each side of the wearband, assemble with
freedom of thread engagement. Remove nut the undercut toward the head end. For pistons with a
and collar. different number of piston ring grooves on each side
of the wearband, assemble with the side of fewer
piston ring grooves toward the head end.

8. Apply a thin coat of Never-Seez Regular Grade 12. Use a punch within 1/16 inch (1.5 mm) of set
to piston nut threads and piston mating face. screw threads to deform the threads and
Install nut and hand tighten to make up the stake set screws in place (see Figure: Staking
piston rod assembly. a Set Screw).
9. Use the piston nut spanner and clamping 13. Use a calibrated scale to weigh piston rod
fixture to torque piston nut to the torque assembly with piston rings and wear band.
listed in Appendix A. A torque multiplier may Stamp weight on piston head end. Flatten
be necessary to achieve required torque. any raised lips to avoid clearance
Loosen the piston nut without disassembling measurement errors. Record weight on a new
and re-tighten to required torque. Repeating balance sheet and send to Ariel. See
the torque properly seats components and “Opposed Throw - Reciprocating Weight
enhances the integrity of the assembly. Balancing” in Appendix C for approximate
NOTE: To calculate torque wrench setting when using component weights.
a torque multiplier, divide desired fastener torque by
the multiplier actual mechanical advantage, not
design mechanical advantage. Example: A multiplier
with a design mechanical advantage of 4.0, but an
actual mechanical advantage of 3.6 requires 442 lb x
ft (599 N•m) of applied torque to achieve a 1590 lb x ft
(2156 N•m) torque.
10. After tightening, the piston rod should not
protrude more than 0.010 inch (0.25 mm)
past the piston face. If it does, contact your
packager and/or Ariel.
11. Apply a thin coat of Never-Seez Regular Grade
to two new Allen set screws. To install a set
screw, tighten it 15° past the Allen wrench
yield point. Discard the deformed Allen
wrench, and use a new Allen wrench to
tighten the other set screw in the same way. If
Allen wrenches are unavailable, use the
torques in Appendix A.
Figure: Staking a Set Screw

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.

mm) and larger cylinders, insert feeler Piston Rod Runout

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

Throw 1 2 3 4
Vertical (0°) Piston @ C. E. 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
Mid-Stroke
Piston @ H. E.

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

Most cylinders use one-piece angle-cut filled seal-joint rings and other ring styles, always position
PTFE piston rings. High-pressure cylinders use the seal-joint rings farthest from the pressure side.
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 Rings
without pistons (see Appendix B for minimum
Straight-cut chamfered piston rings are
end gap dimensions).
directional and require correct installation.
Install them with chamfers or dots toward the
Seal-Joint Piston Rings
pressure and with the end gaps staggered.
Seal-joint piston rings are directional and require
correct installation.

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 Rings Gas pressure in the wear band area escapes past
the piston rings via the face cuts during the
Face-cut piston rings are typically used in
suction stroke to prevent loading the wear band
cylinders with 2500 psi MAWP or higher, and
and increase service life. Also, do not align the
generally with notched and fluted wear bands.
ring end gaps; stagger them to minimize gas
The rings install with the face cuts toward the
leakage.
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
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.
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 the next planned run time may fully degrade the
is chamfered, the chamfer faces the nearest head wear band and allow the piston to contact the
or highest pressure. The first outer ring has no cylinder bore.
face-cut (notch) and double match marks, and
the second outer ring has a face-cut (notch) and Piston Rod Packing
single match marks. Install both outer rings with
match marks facing the nearest head or highest The piston rod packing prevents gas from
pressure. When the match marks are correct, the entering the crosshead guide. Piston rod rings
end gaps of the outer rings do not align. within the packing wear over time and need
replacement.
Non-Face-Cut Rings: When the inner ring is
chamfered, the chamfer faces the nearest head
Piston Rod Packing Removal
or highest pressure. The first outer ring has
double match marks and the second outer ring
has single match marks. Install both outer rings
WARNING
with match marks facing the nearest head or
highest pressure. When the match marks are
correct, the end gaps of the outer rings do not appropriate Ariel Technical Manual and Packager
align. information should attempt any maintenance.
Wear Bands ment and follow your company safety and opera-
tional procedures.
Most cylinders use one-piece angle-cut filled • Never tighten or loosen any fastener while the unit is
PTFE wear bands. High-pressure cylinders use operating or pressurized.
two-piece thermoplastic bands (see Figure: High- • Verify neither driver nor compressor can turn during
maintenance.
Pressure Face-Cut Piston Ring Orientation). • Follow packager instructions to completely isolate
During installation, check and record wear band tance.
end gap and projection. To measure end gap, • Verify each compressor cylinder is relieved to atmo-
insert one or two-piece wear band into cylinder spheric pressure. To relieve residual cylinder bore
without the piston then measure the total gap
while the band maintains full contact with the WARNING: RELEASED GAS MAY BE POISONOUS
cylinder bore. See Appendix B for end gap AND/OR FLAMMABLE.
dimensions. Before resuming operation, purge the entire system with
To measure wear band projection, install the explosive gas/air mixture in the system. A gas/air
entire piston assembly or remove the head to injury or death.
check during maintenance. Measure the gap
between the piston and cylinder bore at the 1. Remove piston and piston rod. See "Piston
bottom of the cylinder. Compare the wear band and Rod Removal".
projection to the as-new condition (recorded at
2. Remove packing diaphragm (if applicable)
new wear band installation or found in Appendix and oil wiper packing.
B). Replace the bands if there is any indication

3. Disconnect all tubing and instrumentation (if 8. Pry loose the metal or spiral-wound gasket
applicable) from packing flange. Ensure there on the end cup with a sharp awl. Do not
is no debris in the tubing between the check scratch the sides of the gasket groove.
valve and packing flange. Remove the twelve- Discard the used gasket.
point cap screws that hold the pressure
9. Before reassembly, clean all parts
packing gland to the crank end of the
thoroughly.
cylinder/head.
4. Typically, the small nuts are not removed
from the studs as they hold the packing case
together for removal as an assembly.
However, some packings are too big to fit
through the distance piece or crosshead
guide doors, so removal of the small nuts and
the packing flange is necessary. For certain
longer, higher pressure rating packing cases,
knurled nuts hold the remaining packing
assembly together to assist with installation
and removal.
5. Remove the pressure packing and take it to a
clean place for disassembly.
6. Set pressure packing on a clean surface on its
nose cup or cylinder end. Usually, packing
cups are marked to represent the assembly
order starting with the cup closest to the
cylinder as number 1. If the cups are not
matchmarked, then match mark the outside
diameter of the cups and flange for proper
reassembly. Long tie studs hold the pressure
packing together. The stud holes are
unequally spaced to prevent misalignment of
the stack of parts. Remove the nuts and
unstack the pressure packing. Replace these
nuts each time the pressure packing is
serviced.
7. To check ring wear, place assembled rings
(note match-marks) on the piston rod. Check
end gap clearance. If the ends butt, or nearly
butt, replace the rings. See "Types of Piston
Rod Packing Rings" for correct ring
orientation.

Piston Rod Packing Reassembly and Instal-

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

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

“P” Pressure Breaker “UP” Pressure Breaker

This single ring is cut radially into three equal This single solid ring breaks down or slows gas
segments. It breaks down or slows gas flow flow without sealing it completely.
without sealing it completely.
Figure: “UP” Pressure Breaker
Figure: “P” Pressure Breaker
1 Pressure
1 Pressure
“P1U” Pressure Breaker
“PB1” Pressure Breaker
This two-ring set allows controlled leakage in one
This single ring is cut radially into three equal direction only and installs in the first or second
segments. It breaks down or slows gas flow packing cup (closest to the piston). The first ring
without sealing it completely. This ring uses a (pressure side) is one-piece with a single radial
solid wire spring. cut; the second ring is solid and has a bore larger
Figure: “PB1” Pressure Breaker
than the rod diameter.
Figure: “P1U” Pressure Breaker
1 Pressure
1 Pressure

“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 1 Pressure
dowel.
Double "WAT" Double-Acting Seal Set
Figure: “BTR” Single-Acting Seal Set
In this three-ring PTFE set, the first two rings
(pressure side) are radially cut; the third is
tangentially step cut. The last two rings are
doweled to stagger the cuts from one ring to the
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
1 Pressure rings must be centered when installed in the
packing case.
“BD” Double-Acting Seal Set
Figure: Double "WAT" 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.
Figure: “BD” Double-Acting Seal Set
1 Pressure
“AL” Double-Acting Seal Set

This five-ring PTFE set functions like a double-
ended “WAT” ring set. AL rings must be centered
when installed in the packing case.
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 “BTUU” Single-Acting Seal Set
first ring (pressure side) is radially cut; the second
This four-ring set seals in one direction only. The
is tangentially step cut. The rings are doweled to
stagger the cuts from one ring to the other and
is tangentially step cut. These rings are doweled
form a tight gas seal.
to stagger the cuts from one ring to the other. The
Figure: “BT” Single-Acting Seal Set 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
pressure and seal against the piston rod.
Figure: “BTUU” Single-Acting Seal Set
1 Pressure
“BTS” Single-Acting Seal Set

1 Pressure
first ring (pressure side) is radially cut. The “CU” 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 radially cut. The
one ring to the other. The third ring is called a second ring is tangentially cut. The first two rings
back-up ring. It is an uncut one-piece ring with are doweled to stagger the cuts from one ring to
clearance over the rod. It allows the joints of the the other. The third ring is a solid back-up ring
first two rings to form a gas-tight seal and and has a bore larger than the rod diameter,
prevents extrusion of the tangent ring. allowing radial joints of the first two rings to form
Figure: “BTS” Single-Acting Seal Set a tight gas seal.
Figure: “CU” Single-Acting Seal Set

1 Pressure
1 Pressure
“DS” Double-Acting Seal Set
“CUU” Single-Acting Seal Set
This two-ring set consists of tangentially step cut
This four-ring set seals in one direction only. The
rings doweled to stagger the tangential cuts from
one ring to the other. This double acting set seals
is tangentially cut. These rings are doweled to
in either direction. In cylinders operating near
stagger the cuts from one ring to the other. The
atmospheric pressure, it prevents air from
third and fourth rings are solid and have bores
entering the cylinder. Install with the match mark
larger than the rod diameter, allowing the radial
letters facing towards the cylinder.
joints of the first two rings to form a tight gas seal.
Figure: “DS” Double-Acting Seal Set
Figure: “CUU” Single-Acting Seal Set
1 Pressure
“RS3” Single-Acting Seal Set

1 Pressure
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
Figure: “STU” Single-Acting Seal Set
perpendicular to the rod, allows their joints to
form a seal, and prevents extrusion of the
tangent ring.
Figure: “RS3” Single-Acting Seal Set

1 Pressure 1 Oil Side
“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 seals in one direction only. The crosshead and crosshead pin bushings, where
first ring (pressure side) is radially cut. The required. Most crossheads use a layer of soft
second ring is tangentially cut. The first two rings babbitt material on the shoes, which are the
are doweled to stagger the cuts from one ring to surfaces that slide in the crosshead guide bore.
the other. The third ring is called a back-up ring.
It is radially cut and has a bore larger than the rod NOTE: Some small-line and JGH crossheads do not
use a bushing or babbitt.
diameter to allow the radial joints to form a tight
gas seal.
Take care during maintenance to avoid
Figure: “RTV” Oil Wiper Set damaging the babbitt or the bushings.

Crosshead Removal
WARNING

tional procedures.
maintenance.
tance.
AND/OR FLAMMABLE.
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)

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

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

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

head end head or unloader properly installed
(closed position) and fasteners tightened,
rotate crankshaft 180° to outer dead center
WARNING
position of throw. Remove a top head end
valve.Determine required piston head end To reduce risk of injury or death, only trained personnel
clearance limits from cylinder data plate or who have read and thoroughly understand the
Appendix B.Measure head end clearance at
the top of the head end, using feeler gauges Prior to performing any maintenance activities:
through the open valve pocket. Determine if • Always wear appropriate personal protection equip-
measured clearance is within tolerance. ment and follow your company safety and opera-
Tighten the crosshead-balance nut set tional procedures.
screws. Re-install valve assemblies and • Never tighten or loosen any fastener while the unit is
properly tighten fasteners.See "Valve operating or pressurized.
Installation".For tandem cylinders: Set • Verify neither driver nor compressor can turn during
maintenance.
piston head end clearance. See "Measuring
Head End Clearance for Forged Steel Tandem and vent the system; call the packager for assis-
Cylinders with Concentric Valves" in tance.
Appendix B. • Verify each compressor cylinder is relieved to atmo-
10. Check piston rod runout and crosshead pressure after blowdown, open the “Kiene” valves
clearances upon re-assembly, any time a on the indicator ports, if so equipped.
piston rod is removed. Check crosshead WARNING: RELEASED GAS MAY BE POISONOUS
guide to crosshead clearance at the top by AND/OR FLAMMABLE.
inserting a standard 0.5 inch (13 mm) wide Before resuming operation, purge the entire system with
feeler stock from one side edge of the the gas being compressed to avoid a potentially
crosshead across to the opposite side - do explosive gas/air mixture in the system. A gas/air
this at both ends. Check bottom clearance injury or death.
with 0.0015 inch (0.038 mm) feeler stock at
the four corners. If the feeler at the bottom
inserts more than 0.5 inch (13 mm), the 1. Remove top cover from crankcase and side
assembly is not acceptable.See Appendix B covers from crosshead guides.
for crosshead clearances. 2. Move throw to outer dead center position.
11. Examine top cover and side cover seals. If 3. Remove crosshead as described in
there is doubt about their condition, replace "Crosshead Removal".
them. Oil the O-ring and apply a light coating
4. Turn the crankshaft until the throw is at its
of corrosion inhibitor or marine grease to
highest point.
mating surface. Replace top cover and
crosshead guide side covers. Tighten all cap 5. Loosen all connecting rod fasteners
screws hand wrench tight. approximately 1/8 in. (3.2 mm).
6. Pry or manually pull the small end of the
Connecting Rods connecting rod towards the cylinder until cap
and rod separate.
A connecting rod assembly consists of a rod with
bushing, a rod cap, rod cap bolts (4), and two half
bearing shells. The bearing shells join together to
form the connecting rod bearing.

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..
7. 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.
8. 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.
9. 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.
10. Carefully remove the connecting rod through
the crosshead compartment window.

Connecting Rod Bearing Removal Figure: Rod/Rod Cap Separation
WARNING

tional procedures.
maintenance.
• Follow packager instructions to completely isolate 1 Top Face
and vent the system; call the packager for assis- 2 Connecting Rod Bolts
tance. 3 Rod Cap
• Verify each compressor cylinder is relieved to atmo- 4 Rod
on the indicator ports, if so equipped. 1. Remove frame top cover and all crosshead
WARNING: RELEASED GAS MAY BE POISONOUS guide covers.
AND/OR FLAMMABLE.
2. Remove all head end heads.
the gas being compressed to avoid a potentially 3. Rotate crankshaft to approximately 45º (see
explosive gas/air mixture in the system. A gas/air Figure: Crank Rotation)
injury or death. Figure: Crank Rotation
4. Loosen all connecting rod bolts about 1/8 in.

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

NOTE: Do not pry on any machined running 7. 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
8. 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)
6. 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.

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

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

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
1. To install a new connecting rod, stamp match dirt, then lubricate them per Appendix A and
mark numbers matching the throw location insert all bolts into rod cap. Rotate the cap
on the tops of the connecting rod and bearing and fit the connecting rod to the rod pin and
cap (with bearing notches up). See Figure: snug the bolts, pulling the cap and rod
Typical Connecting Rod. together evenly.
2. Check new bearing shells for handling 4. Reconnect rod and crosshead with pin. Install
damage, scratches, burrs, and loose material end plates, thru-bolt, and new lock nut.
at the tabs. DO NOT RUB BEARING SURFACE Tighten lock nut to the torque listed in the
WITH FINGERNAIL. New bearing shells and Appendix A.
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.

5. Follow the "Recommendations for Torque measurements on a copy of the form in

Accuracy" in Appendix A to tighten Appendix D. If measurements are out of
connecting rod cap screws to the tolerance after installing new bearings,
recommended torque. contact your packager or Ariel before
6. Measure each connecting rod bearing to proceeding.
crankshaft jack clearance and connecting rod 7. 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.Oil the O-ring and apply a light coating
Measurement" and "Connecting Rod Thrust of corrosion inhibitor or marine grease to
(Side) Clearance Measurement"). Record mating surface. Replace top cover and
crosshead guide side covers. Tighten all cap
screws hand wrench tight.
Connecting Rod Bearing Vertical Jack

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

Connecting Rod Thrust (Side) Clearance

Measurement
Figure: Typical Connecting Rod Thrust (Side) Clearance Measurement
Dial indicator magnetic stand Dial indicator placement. Thrust rod tight toward and away
placement. from dial indicator.
1. Turn the crankshaft pin of the desired throw Crankshafts

to its highest position.
The crankshaft is the heart of the compressor.
2. Attach the magnetic base of a dial indicator to
With proper maintenance, it should provide
the crankshaft web adjacent to the
connecting rod. Place the button of the dial years of trouble-free service. If replacing a
indicator against the thrust surface of the crankshaft fitted with torsional detuners, contact
connecting rod (see Figure: Typical the Ariel Response Center with the frame and
Connecting Rod Thrust (Side) Clearance crankshaft serial numbers and the part numbers
Measurement). and quantity of detuners to ensure compatibility.
3. Use a pry bar to pry gently against the
crankshaft web and thrust the connecting rod
tight toward the dial indicator (do not pry on
rod cap). Release pressure and zero the dial
indicator.
4. Thrust the connecting rod tight in the
opposite direction until the dial indicator
needle stops moving. Release pressure and
note reading. Gently pry connecting rod in
opposite direction to ensure the dial returns
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.

Main Bearing Removal
WARNING

tional procedures.
maintenance.
tance.
AND/OR FLAMMABLE.
injury or death.
1. Remove top cover.

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

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.
Main Bearing Installation
4. To limit debris entering the system, work on
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 RUB BEARING SURFACE WITH FINGERNAIL.

Keep the backs of shells dry and clean; 6. Reverse lockout procedures.
installation requires perfectly clean bearing
7. After replacing bearings, it is recommended
shells. Install bearing shells in caps, and
to pre-lube compressor for 10-15 minutes at
frame journals, properly located in the tab
30 psi (2.1 barg) to ensure bearing lubrication
notch, (rotate in the un-tabbed end
and to help remove foreign materials from
first).JGM:P:N:Q units use a thrust bearing,
the lube system.
where the thrust plate is integral to one
bearing shell, and the other shell has no 8. Run the compressor according to the time
thrust plate. Install the bearing shell with the intervals listed on the form in Appendix D.
integral thrust plate into the #1 main bearing After each run, shut down and remove the
cap. frame top cover. After each shutdown,
visually inspect the crankcase for signs of
2. Apply clean, new lube oil liberally to the crank
excessive heat in bearing areas, and babbitt
journal. Verify oil is compatible with oil used
or other debris. If any are found, find and
in the frame.
correct the problem before continuing.
3. Main bearing caps have position match- Measure main and connecting rod bearing
marks corresponding with frame. Install main cap temperatures with a hand held
bearing caps with new bearing shells in their thermocouple probe or infrared
correct locations. Verify proper alignment of thermometer and record them on a copy of
main bearing cap dowels with the holes in the the form in Appendix D. Complete the form
crankcase base.A set screw on top of each and file it in the unit records for future
dowel prevents it from backing out. Seat the reference.
cap by tapping it with the handle of a hammer
or screwdriver. It is a machined fit, not a press
fit, and the cap should not rock in the jaw fit
when it seats. Do not use bolting to force the
cap to seat. Tighten the cap screws. Tighten
the main bearing cap bolts in the pattern and
torque listed in Appendix A.
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.
5. Account for all tools, equipment, supplies,
and parts to ensure none are left inside the
crankcase. Examine top cover and side cover
seals. If there is doubt about their condition,
replace them. For O-ring seals, oil the O-ring
and apply a light coating of corrosion
inhibitor or marine grease to mating surface.
Replace top cover and crosshead guide side
covers. Tighten all cap screws hand wrench
tight. Bar compressor over 360° to ensure free
rotation.

Crankshaft Removal
WARNING

tional procedures.
maintenance.
tance.
AND/OR FLAMMABLE.
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.Remove coupling 2. Remove top cover. Remove connecting rods.
hub. Remove all drive end cover mounting
bolts. Remove the two tapered dowel pins
from the drive end cover.

3. Do not damage the sharp corners on each Crankshaft Installation

end of the crankcase top. They form a
junction between the end covers, top cover, 1. Thoroughly clean the oil gallery that runs
and base; keep them sharp and unmarred to from the drive end to the auxiliary end of the
prevent oil leaks. crankcase and the vertical and horizontal
intersecting oil passages that lube the main
4. See "Connecting Rod Bearing Removal". bearings and crosshead guides. Any debris
5. Remove chain eccentric adjustment left in the oil gallery or intersecting
capscrews. Turn the eccentric to loosen the passageways could cause bearing or
chain and slip it off the crankshaft sprocket. crosshead failure. Deburr and clean main
For more clearance while lifting the bearing caps to prepare for installation.
crankshaft, remove the force feed lubricator 2. Thoroughly clean new main bearing half
drive sprocket. shells and install them in the frame saddles.
6. Remove main bearing caps. See "Main Cover bearings with clean paper towels to
Bearing Removal". prevent debris contamination.
7. Before removing the crankshaft, prepare 3. Remove towels just before seating the crank
wooden saddles or blocks of wood with sides in the saddles. Lubricate bearing surfaces
high enough to prevent the webs or oil slinger with clean crankcase oil.
from touching the floor to store the 4. Lift the crankshaft from the throw #2 journal.
crankshaft during maintenance - even if for The crankshaft lifts at an angle and should
only a short time. Also, protect the crankshaft enter the crankcase with the drive stub
from above so dropped tools or equipment angled downward.
cannot mar pin and journal surfaces.
5. Before connecting rod installation, measure
8. Turn throw #2 to its highest position, then lift each crankshaft journal bearing jack
from the throw #2 journal. The crankshaft lifts clearance with a dial indicator (see procedure
from the crankcase at an angle. on "Main Bearing Vertical Jack Clearance
NOTE: Lower half bearing shells sometimes stick to Measurement" and allowable clearances in
the shaft journals. After lifting the shaft about ¼ inch Appendix B).
(6mm) clear of the saddles, verify the lower half
bearing shells remain on the saddles. If not, tap them 6. Reattach connecting rods (See "Connecting
back onto the saddles before lifting the shaft further. Rod Installation"), packing diaphragms, and
unloaders/head end heads.
9. While one person raises the crane very slowly,
the second person must grasp the crankshaft 7. Reinstall chain drive. (See “Chain Drive
at the drive end with one hand on the System”).
counterweight or one of the throws and the 8. Examine top cover and side cover seals. If
other on the shaft end to keep the crankshaft there is doubt about their condition, replace
level. It may be necessary to lower the crank them.Oil the o-ring and apply a light coating
and reposition the straps to achieve a of corrosion inhibitor or marine grease to
balanced lift. Wear clean gloves for a good mating surface. Replace top cover and
grip, to avoid cuts from the slinger, and to crosshead guide side covers. Tighten all cap
avoid marring the running surface. As the screws hand wrench tight.
shaft slowly raises, lift the drive and auxiliary
ends at the same rate. Carefully guide the
crankshaft to avoid marring its surfaces.

Main Bearing Vertical Jack Clearance

Measurement
Figure: Typical Crankshaft Journal Bearing Vertical Jack Clearance Measurement
Dial Indicator magnetic stand Dial indicator placement. Place lifting strap around
placement. crankshaft web - attach strap to
crane.
1. Turn crankshaft until the web adjacent to the 6. Repeat measurement process for each main
desired main bearing is vertical (see Figure: bearing. If a reading is outside tolerances in
Typical Crankshaft Journal Bearing Vertical Appendix B, contact your packager or Ariel.
Jack Clearance Measurement). NOTE: Remove magnetic bases, dial indicators, and
2. Loop a clean, appropriately sized and rated lifting strap after measurement.
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 crankshaft. The dial indicator
needle moves steadily until the crane/hoist
overcomes crankshaft oil stiction, at which
point the needle jumps a little. Stop lifting
immediately at this point, and note the
reading.
5. Release crane/hoist pressure and verify
indicator returns to zero. Repeat step 4 to
verify measurement.

Crankshaft Thrust (End) Clearance

Measurement
Figure: Typical Crankshaft Thrust Clearance Measurement
Dial indicator magnetic stand Dial indicator placement against Pry against compressor frame to
placement on main bearing cap. the side of crankshaft web. thrust crankshaft back and forth.
1. Attach the magnetic base of a dial indicator to sprocket attached to the eccentric adjustment
any stable frame surface. Place the button of cap controls chain tightness. The chain dips into
the dial indicator against the side of the the crankcase oil for constant lubrication. In dry
adjacent crankshaft web (see Figure: Typical sump applications, an oil sprayer lubricates the
Crankshaft Thrust Clearance Measurement).
chain.
NOTE: Do NOT place magnetic base on end cover- it
can flex if pried against, resulting in inaccurate read-
ings.
2. Use a pry bar to pry against the compressor
frame and thrust the crankshaft tight toward
the dial indicator. Release pressure and zero
the dial indicator.
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
the auxiliary end of the frame. For JGM:P:N:Q
compressors, a single chain runs the lube oil
pump and force feed lubricator. An idler

Figure: JGM:P:N:Q Chain Drive System - Standard And Reverse Rotation

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
Chain and Sprocket Replacement Figure: Measuring to Check Chain Elongation
WARNING

1 X- Measure outside rollers at 10 pitches
• Always wear appropriate personal protection equip- 2 Y - Measure inside rollers at 10 pitches
tional procedures. Replace chain(s) if elongation exceeds 0.084
inches (2.13 mm) over a 10 pitch length. Measure
• Verify neither driver nor compressor can turn during the section of chain with vernier calipers while it
maintenance. is stretched tight in position in the compressor.
• Follow packager instructions to completely isolate Add a measurement outside the rollers at 10
tance. pitches (X) to a measurement between the inside
• Verify each compressor cylinder is relieved to atmo- of the same rollers (Y), and then divide by two.
spheric pressure. To relieve residual cylinder bore Replace the chain if the result exceeds 3.834
on the indicator ports, if so equipped. inches (97.4 mm).
Replace sprockets showing any undercutting or
AND/OR FLAMMABLE.
Before resuming operation, purge the entire system with other damage.
injury or death.

Chain Idler Sprocket Replacement (Eccen-

tric Adjustment Caps)
WARNING

tional procedures.
maintenance.
tance.
AND/OR FLAMMABLE.
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. loosen chain for removal. Drop the chain off
2. Remove all dust plugs from the eccentric cap the idler sprocket and remove entire
and all cap screws holding the eccentric cap assembly from the end cover.
to the end cover. Rotate eccentric cap to NOTE: Chain idler sprocket location varies for stan-
dard versus reverse rotation.

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".

Lube Oil Pump Sprocket Replacement
WARNING

tional procedures.
maintenance.
tance.
AND/OR FLAMMABLE.
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

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.

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

tional procedures.
maintenance.
• Follow packager instructions to completely isolate 1 Mounting Bracket Cap Screws (4)
and vent the system; call the packager for assis- 2 Auxiliary End Cover
tance.
3 O-Ring
spheric pressure. To relieve residual cylinder bore 4 Shaft Oil Seal
pressure after blowdown, open the “Kiene” valves 5 Key
on the indicator ports, if so equipped. 6 Set Screw
WARNING: RELEASED GAS MAY BE POISONOUS 7 Sprocket
AND/OR FLAMMABLE.
the gas being compressed to avoid a potentially 1. With a good machinist rule, measure exact
explosive gas/air mixture in the system. A gas/air distance from inside face of auxiliary end
mixture under pressure can explode and cause severe cover to near face of lubricator sprocket.
injury or death.
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.

6. Install a new key. Verify it fits into the new

sprocket (see build book for key type and
dimensions). If too thick, polish it with emery
cloth on a flat surface until it easily slides into
the notch. The top edge may also require a
little polishing.
7. After new key installation, verify the new
sprocket fits, oil the new O-ring, and remount
lubricator to the end cover.
8. Slide new sprocket onto the shaft and set to
dimension measured in step 1. Tighten set
screw.
9. Using a straight edge, to within 1/32 inch (1
mm), check alignment to crankshaft drive
sprocket with crankshaft centered in end
play. When aligning this sprocket with the
idler sprocket, take into account that the idler
sprocket is thinner than the other sprockets.
If misaligned, adjust sprocket position as
needed.
10. Install chain and adjust according to "Chain
Adjustment".
11. Re-attach all tubing to lubricator.

Crankshaft Chain Sprocket Replacement Figure: Crankshaft Sprocket Removal
WARNING

tional procedures.
maintenance.
tance. 1 Strike here with chisel.
spheric pressure. To relieve residual cylinder bore Examine sprocket carefully for wear; sprockets
operating for five years or more may require
WARNING: RELEASED GAS MAY BE POISONOUS replacement. To replace a sprocket on a
AND/OR FLAMMABLE. JGM:P:N:Q:
the gas being compressed to avoid a potentially 1. Drill a hole in the sprocket hub parallel to the
explosive gas/air mixture in the system. A gas/air shaft centerline and big enough to remove
mixture under pressure can explode and cause severe most of the hub cross section (see figure to
injury or death. the right). Multiple smaller holes may be
required. DO NOT touch shaft with drill. Mark
CAUTION the drill with tape to avoid drilling through
the sprocket and into the crankshaft face. The
Do not touch hot surfaces without proper protection.
hole relieves most of the shrink, and a few
radial strikes with a hammer and chisel opens
the sprocket enough for easy removal.
2. Suspend the new sprocket with a wire and
heat it with a small torch to about 400°F
(204°C), then slip it over the auxiliary end of
the crankshaft. Hold the sprocket in place
and rotate it slightly to ensure squareness
until it cools enough to shrink onto the
crankshaft

Chain Adjustment mm) increments, apply finger pressure to

measure the distance from the straight edge
Figure: Typical Chain Deflection Measurement to a chain roller at the center of the span.
Record the measurement and check to see if
it is in tolerance.
4. If adjustment is required, remove the cap
screws and plastic plugs from the eccentric
cap. Rotate the cap clockwise to line up the
first two new cap screw holes. If this tightens
the chain too much, turn the cap
counterclockwise for a different hole
alignment.
5. Replace and tighten the two cap screws hand
wrench tight.
CAUTION
Over tightening may result in bent shafts.

1 Finger Pressure
2 Machinist's Scale 6. Roll the crankshaft to check tightness in
3 Straight Edge several positions. At its tightest position, the
4 Span Length chain should deflect within the shaded limits
in Figure: Allowable Chain Deflection.
1. Roll the crankshaft to the tightest position of Replace plastic caps to keep the holes clean.
the chain. This prevents snugging the chain at
a slack position and breaking rollers, or
ruining the pump and lubricator bearings
when the chain goes through its tightest
position.
2. Use a tape measure to measure the longest
most easily accessible span from sprocket
center to sprocket center, where the
deflection will be gauged. Determine
allowable deflection limits for the measured
span as defined by the shaded area in Figure:
Allowable Chain Deflection.
3. Measure chain deflection from a straight edge
held on the chain rollers where it wraps over
the two sprockets of the span (see Figure:
Typical Chain Deflection Measurement).
Using a machinist’s rule with 0.01 inch or (1.0

Figure: Allowable Chain Deflection, Inches (mm)
A Deflection B Length of 1 Maximum 2 Minimum Deflec- 3 Allowable

Measured Span Deflection tion Deflection

Start Up
Warranty Notification - Installation Administrative Assistant - Sales, Ariel

List Data and Start Up Check Lists for Corporation
Reciprocating Compressors 35 Blackjack Road
Mount Vernon, Ohio 43050 USA
Download the Installation List Data and Start Up Phone: 740-397-0311 FAX: 740-397-3856
Check Lists forms, which is designed to ensure a Email: warrantyregistration@arielcorp.com
successful start-up of Ariel reciprocating
compressors. Ariel warranty coverage requires
these completed forms be sent to:

Compressor Troubleshooting
Expect minor problems during routine operation Recording inter-stage pressures and
of an Ariel compressor. These troubles most temperatures on multistage units is valuable.
often trace to liquid, dirt, improper adjustment, Any variation when operating at a given load
or operators unfamiliar with Ariel compressors. point indicates trouble in one of the stages.
These difficulties can usually be corrected by Normally, a decrease in inter-stage pressure
cleaning, proper adjustment, elimination of an indicates trouble in the lower pressure cylinder.
adverse condition, part replacement, or proper An increase usually indicates trouble in the
training. higher pressure cylinder. Below is a list of
common problems and possible causes.
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.
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.

JGM-JGN-JGP-JGQ Maintenance & Repair Manual – Compressor Troubleshooting 12/03/2022
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
temperature.
• 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.
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.
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 connec-
tion 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 due to the clearance in the bore. As the piston
negative. A positive reading indicates the piston drops, the rod rises, yielding a positive reading
drops as it moves to the head end of the cylinder on the indicator. If the cylinder is not supported

properly, it could droop causing the piston to rod runout tolerance requires correction for safe,
drop as it moves to the head end of the cylinder. efficient compressor operation (see Appendix B).
A negative reading indicates the piston climbs as Piston rod runout correction first requires
it moves to the head end of the cylinder. When verification (and correction, if needed) of the
the piston climbs, the rod drops, yielding a crosshead clearance. See flowcharts below.
negative reading. Any reading outside the Ariel
Figure: Crosshead Clearance Verification/Correction Flowchart
NOTE: Review all steps before troubleshooting. If

issues persist, contact the Ariel Response Center.

Figure: Piston Rod Runout Verification/Correction Flowchart
NOTE: Verify crosshead clearance is within Ariel specs

per the manual before checking piston rod runout.

Ariel Fasteners and Torques

This document lists fastener lubrication and standard cap screws, contact your packager
torque requirements for proper assembly of or Ariel.
JGM:P:N:Q 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, packing, crank end Never-Seez Regular Grade
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
All stainless steel fasteners except valve fasteners
listed in Table: Hoerbiger Valve Assembly Fastener
Torques
Connecting rod cap Lubriplate 630-AA
Crosshead balance nut 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)

JGM-JGN-JGP-JGQ Maintenance & Repair Manual – Ariel Fasteners and Torques 12/03/2022
Figure: Bolt Head Grade and Material Identification
5. Always apply a steady, slow force to a torque

wrench, and stop immediately when the
CAUTION
wrench clicks. Do not bounce, jerk, or double
To replace a fastener, see parts list for fastener grade tap the wrench – it significantly increases the
and part number. Do not use a lesser or greater material
grade. Use Ariel parts to replace special fasteners and applied torque. Perform final tightening with
fasteners with reduced body diameter for fatigue a torque wrench.
resistance. Do not torque fasteners with compressor
running or pressurized. Read technical manual safety 6. Do not break fasteners loose with a torque
warnings. wrench - it may overload the wrench and
affect its accuracy.
Recommendations for Torque 7. Determine torque wrench accuracy range
Accuracy 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
8. Clean and de-burr all threads before
operation. On Ariel compressors, these joints
assembly. Ensure no oil or debris is in the
have specified torque or other engineered
bottom of the bolt hole when installing bolts.
tightening methods. Only mechanics prop-
Apply oil only to fasteners, not in the bolt
erly trained in bolted flange joint assembly
hole.
should maintain these joints.
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
fastener contact area on the bolted part.
3. Use the correct lubricant on the fastener (see Address any findings before proceeding.
Table: Fastener Thread & Seating Surface
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.

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.

Figure: Pressure Containing Joint Recommended Torque Sequences
A 3 Fasteners F 8 Fasteners J 12 Fasteners N 20 Fasteners

B 4 Fasteners G 9 Fasteners K 14 Fasteners O 22 Fasteners
C 5 Fasteners H 10 Fasteners L 16 Fasteners P 24 Fasteners
D 6 Fasteners I 11 Fasteners M 18 Fasteners Q Obround Flange
E 7 Fasteners
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.
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
14. If using an offset adapter with a torque line).
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)

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)d -

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 - 24 120 Lb x In (14) 66 Lb x In (7.5)
3/8 - 24 16 (22) 96 Lb x In (11)
1/2 - 20 36 (49)c 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 29 (39) for 1/2 - 20 bottom half Drake lock nut with non-metallic valve plates in liftwasher valves.
d Use this torque only with a 17-4PH 900H material center stud.

JGM:P:N:Q Fastener Torques

Torque Lb x Ft
Nominal Size Inch -
Fastener Type (N·m), unless
TPI
specified
Main Bearing Cap - Cap Screw 1/2 - 13 12 Point - Grade 8 58 (79)
Connecting Rod Cap - Cap Screw 1/2 - 13 12 Point - Grade 8 58 (79)
1/2 - 20 67 (91)
Crosshead Pin Thru Bolt - Lock Nut 3/8 - 24 Hex - Nylon Insert 25 (34)
Cylinder to Frame; Unloader Actuator to 1/2 - 13 12 Point or Hex 48 (65)

Valve Cap - Cap Screw Grade 8
Eccentric Vernier Cap - Cap Screw 5/16 - 18 12 Point or Hex Hand Wrench Tight
Grade 8
Idler Sprocket Thru Bolt - Lock Nut 1/2 - 20 Hex - Prevailing 41 (55)
Rod Packing - Cap Screw a 1/2 - 13 12 Point - Grade 8 35 (48)
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 Nut b 7/8 - 12 Ariel Design 220 (300)
Piston Nut Set Screw #10 - 32 Socket Head 36 Lb x In. (4.1) c

Crosshead Balance Nut 1” - 12 Ariel Design Slugging Method
Rupture Disk - Blow-Out Fitting Cap 1/4 Nom. Tube Hex - Tube Fitting 40 Lb x In. (4.5)
Frame Foot Hold Down - Nut 5/8 - 11 Hex Nut 100 (140) d
Crosshead Guide to Support - Cap Screw 5/8 - 11 Hex - Grade 8 or 9 90 (120)

Torque Lb x Ft
Nominal Size Inch -
TPI
specified
Cap Screw e 5/16 - 18 Hex Grade 8 or 9, 12 108 Lb x In. (12)

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

17-4PH
5/8 - 11 79 (105)
Ariel Supplied Companion Flange Except 1/2 - 13 Hex Nut on Grade 8 40 (54)
"Peanut" Dual Nozzle or 17-4PH Stud
1/2 - 20 46 (62)
ANSI Flange to Cylinder Nozzle See Cylinder Outline Provided by See ER-127.
Packager
Tandem Cylinder to Cylinder - Cap Screw e 1/2 - 13 Hex - Grade 8 or 9 or 44 (60)

12 Point - Grade 8
5/8 - 11 88 (120)
3/4 - 10 160 (215)
3/4 - 16 180 (245)
Fanshaft to Crankshaft - Central Stud g 3/4 - 16 Ariel Design 250 (340)

Torque Lb x Ft
Nominal Size Inch -
TPI
specified
Stud Seating 3/8 - 16 Dog Point Grade 8 or 107 Lb x In. (12)

17-4PH
NOTE: In valve cap assemblies with a 7/16 - 14 172 Lb x In. (19)
spring energized seal, install longer studs 1/2 - 13 22 (30)
with Loctite 242.
1/2 - 20 26 (35)
9/16 - 12 32 (43)
5/8 - 11 44 (60)
5/8 - 18 51 (69)
3/4 - 10 79 (105)
3/4 - 16 90 (120)
7/8 - 9 130 (175)
7/8 - 14 145 (195)
1” - 8 200 (270)
1" - 14 200 (270)
Distribution Block Tie Rod - Nut 1/4 - 28 Hex 68 Lb x In. (7.7)
Distribution Block Divider Valve - Screw 1/4 - 28 Socket Head 75 Lb x In. (8.5) h
Force Feed Lube Box - Bearing Housing 1-3/8 - 20 LH Bearing Housing 70 (95)
Force Feed Lube Box - Jam Nut 1” - 14 Hex 75 (100)
Force Feed Lube Pump Mounting 1/4 - 20 Hex - Grade 5 50 Lb x In. (5.6)
Auto Relief Valve 1/2 i Ariel Design 75 Lb x In. (8.5)

Torque Lb x Ft
Nominal Size Inch -
TPI
specified
Auto Relief Valve Manifold Plug #10 - 24 Ariel Design 50 Lb x In. (5.6)
1/4 NPT Hex Hand Wrench Tight
Grade 5 - Hex Cap Screw All Hex - Grade 5 Hand Wrench Tight
Valve Cap Assembly 3/4 - 16 Cap Nut Hand Wrench Tight
Valve Cap Seal Keeper - Cap Screw 5/16 - 18 12 Point - 17-4PH 120 Lb x In. (14)
a Repeat final torque for rod packing bolts until they no longer turn before the torque wrench clicks.
b Tighten, loosen, and re-tighten to ensure proper torque.
c 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.
d Minimum torque to stress recommended 5/8 - 11 TPI hold-down stud to 55,000 psi (380 MPa). Use studs with an ulti-
mate strength of 100,000 psi (690 MPa) or greater. If greater, increase torque stress to about 55% of ultimate
strength, as specified by packager.
e For studs specified for cylinder applications, tighten nuts to the same torque as cap screws in similar applications.
f Excludes socket head cap screws, which are installed hand wrench tight.
g Tighten three times; loosen to hand tight between each tightening.
h Step-torque first to 40 Lb x In. (4.5 N•m), and then to 75 Lb x In. (8.5 N•m).
i "1/2" indicates the wrench size. Auto relief valve can swivel in the manifold once torqued. See assembly drawing.
j See ER-136 for Taper-Lok installation instructions.
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)

Clearances
Table: JGM:P:N:Q 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, JGN:Q (Babbitted Ductile Iron with 0.004 to 0.008 (0.10 to 0.20) (Feeler Gauge)
bushings)
Crosshead to Guide, JGM:P (Gray Iron, no bushings) 0.006 to 0.010 (0.15 to 0.25) (Feeler Gauge)
Crosshead to Guide, (Babbitted Bronze , no bushings)
Crosshead Pin to Connecting Rod Bushing 0.0014 to 0.0031 (0.036 to 0.079)
Crosshead Pin to Crosshead Bushings, JGN:Q 0.0014 to 0.0036 (0.036 to 0.091)
Crosshead Pin to Crosshead, JGM:P (Iron, no bushings) 0.0015 to 0.0025 (0.038 to 0.064)
Crosshead Pin to Crosshead (Bronze, no bushings)
Fan Shaft Maximum Total Indicator Reading (TIR) 0.010 (0.25)
Shaft Seal Housing, Centered on Crankshaft 0.008 (0.20) (Feeler Gauge All Around)
Table: JGM:P:N:Q 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 - Tandem 0.090 to 0.180 (2.29 to 4.57)
Piston End Clearance - Crank End (Tandem) 0.035 (0.89)
Piston End Clearance - Head End (Tandem) 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.
Table: JGM:P:N:Q Max. Acceptable Piston Rod Runout, in. (mm)

Description Runout
Vertical Runout 0.0010 (0.0254)
Horizontal Runout 0.0005 (0.0127)

JGM-JGN-JGP-JGQ Maintenance & Repair Manual – Clearances 12/03/2022
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)

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)

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

Diametera Clearance New Maximum
1.25 (32)b 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)b 0.020 to 0.027 (0.51 to 0.69) 0.108 (2.74)
2.25 (57)b 0.007 to 0.016 (0.18 to 0.41) 0.064 (1.63)
2.5 (64)b 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) 0.027 to 0.033 (0.69 to 0.84) 0.132 (3.35)
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)

Piston to Bore Diametral Piston Ring End Gap - Non-Metallic

Diametera Clearance New Maximum
3.875 (98) 0.011 to 0.016 (0.28 to 0.41) 0.039 to 0.047 (0.99 to 1.19) 0.188 (4.78)
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)
7.5 (191) 0.089 to 0.109 (2.26 to 2.77) 0.430 (10.92)
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)
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); and 3-5/8JG-CE, 3.375 (86), and 3.625 (92), which use
piston/rider rings. Piston/rider rings are optional for other JG Cylinders, except for 1-3/4JG-FS-HE which uses
conventional rings and wear band.
b This size uses conventional piston rings and wear band, see TABLE 1-21 for wear band values.

Table: Piston-to-Bore Clearance & Piston/Rider Ring End Gap, in. (mm) - JG & SG Class Cylinders
Piston to Bore Diametral Piston/Rider Ring End Gap

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) 0.047 to 0.063 (1.19 to 1.60) 0.252 (6.40)
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)
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) & 3 (76); and 3-5/8JG-CE, 3.375 (86) & 3.625 (92), which all use
piston/rider rings. Piston/rider rings are optional for other JG Cylinders, except for 1-3/4JG-FS-HE, which uses
conventional rings and wear band.
Table: New Wear Band End Gap and Radial Projection, in. (mm) - 1-3/4JG-FS-HE, 1-3/4SG-FS-HE,
and 2-1/2SG-FS-HE Class Cylinders
Bore Diameter Min. End Gap Radial Projection Side Clearance
1.25 (32) 0.049 (1.24) 0.005 to 0.012 (0.13 to 0.30) 0.010 to 0.014 (0.25 to 0.36)
1.5 (38) 0.049 (1.24) 0.0075 to 0.0145 (0.19 to

0.37)
1.625 (41) 0.052 (1.32)
1.75 (44) 0.058 (1.47)
2 (51) 0.065 (1.65) 0.006 to 0.015 (0.15 to 0.38) 0.010 to 0.015 (0.25 to 0.38)
2.25 (57) 0.072 (1.83)
2.5 (64) 0.080 (2.03)

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

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 (1.17 to 1.42) 0.224 (5.69)
3.875 (98) 0.047 to 0.057 (1.19 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)
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)
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) 0.021 to 0.027 (0.53 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)
13 (330) 0.026 to 0.032 (0.66 to 0.81) 0.155 to 0.175 (3.94 to 4.45) 0.700 (17.78)
13.5 (343) 0.027 to 0.033 (0.69 to 0.84) 0.162 to 0.182 (4.12 to 4.62) 0.728 (18.49)
a Conventional piston rings are standard for all M, P, and SP cylinders, except for 1-3/4M-FS with bore diameters of
1.625” (41) & 1.75” (44), which use piston/rider rings. Piston/rider rings are optional for all other M, P, & SP cylinders.

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

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) 0.090 to 0.096 (2.29 to 2.44) 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 Footnote b
8 (203)
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 all M, P, and SP class cylinders, except for 1-3/4M-FS 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 M, P,
and SP class cylinders, except for 1-3/4SG-FS-HE which uses conventional rings and wear band.
b 8M x 3.5 (88.9 mm) stroke & 8SP-HE, 7.5 (191) bore: New - 0.099 to 0.129 (2.51 to 3.28), Max. - 0.516 (13.11).
8M x 3 (76.2) stroke, 7.5 (191) bore: New - 0.088 to 0.118 (2.24 to 3.00), Max. - 0.472 (11.99).
8M x 3.5 (88.9) stroke & 8SP-HE, 8 (203) bore: New - 0.106 to 0.136 (2.69 to 3.45), Max. - 0.544 (13.82).
8M x 3 (76.2) stroke, 8 (203) bore: New- 0.095 to 0.125 (2.41 to 3.18), Max. - 0.500 (12.70).
Measuring Head End Clearance for

Forged Steel Tandem Cylinders with
Concentric Valves

Figure: Position Piston At Outer Dead Center dead center. Manually turn crankshaft to find
the 0.010 inch (0.25 mm) position, before and
after outer dead center. Then turn crankshaft
to position piston at outer dead center (see
Figure: Position Piston At Outer Dead Center).
3. Dimension A: Measure from cylinder head
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
outer face, with the cylinder near to outer

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

• 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.

Frame Specifications
For more information, see the Ariel Performance
Program.Rated speeds for non-lube and
lubricated process applications may vary.
Table: JGM:P Frame Specifications

Specification JGM/1 JGM/2 JGP/1 JGP/2
Stroke, in. (mm) 3.5 (89) 3 (76)
Maximum Allowable 1500 1800

Speed a, RPM
Minimum Speed b, 750 900

RPM
Piston Speed c, FPM To 875 (4.5) To 900 (4.6)

(m/s)
Horsepower, hp (kW) 84 (63) 168 (125) 85 (63) 170 (127)
Maximum Length, in. 37 (0.94)

(m)
Maximum Overall 17 (0.43) to top of aluminum cover

Height, in. (m)
Maximum Width with See appropriate frame, guide, and cylinder outline drawings.
Cylinders
Height - Bottom to 9.250 (235)

Crankshaft
Centerline, in. (mm)
Approximate Weight See Ariel Performance Program.

with Cylinders
Connecting Rod 8.250 (210)

Centerline to
Sump Capacity, US 2.5 (9)

gal. (L)
Oil Pump Flow Rate 4 (0.25) 5 (0.32)

d
, GPM (L/s)
Oil Heat Rejection 8400 (2.5) 16,800 (4.9)

BTU/hr (kW)
Piston Rod Diameter, 1.125 (28.6)

in. (mm)
Internal Rod Load - Double Acting

JGM-JGN-JGP-JGQ Maintenance & Repair Manual – Frame Specifications 12/03/2022
Specification JGM/1 JGM/2 JGP/1 JGP/2
Compression+Tensio 12,000 (53)

n, lbf (kN)
Tension, lbf (kN) 6000 (27)
Compression, lbf 7000 (31)

(kN)
Internal Rod Load - Single Acting
Tension, lbf (kN) 6000 (27)
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.
Table: JGN:Q Frame Specifications

Specification JGN/1 JGN/2 JGQ/1 JGQ/2
Stroke, in. (mm) 3.5 (89) 3 (76)
Maximum Allowable 1500 1800

Speed a, RPM
Minimum Speed b, 750 900

RPM
Piston Speed c, FPM To 875 (4.5) To 900 (4.6)

(m/s)
Horsepower, hp (kW) 126 (94) 252 (188) 140 (104) 280 (209)
Maximum Length, in. 37 (0.94)

(m)
Maximum Overall 17 (0.43) to top of aluminum cover

Height, in. (m)
Maximum Width with See appropriate frame and cylinder outline drawings.
Cylinders
Height - Bottom to 9.250 (235)

Crankshaft
Approx. Weight with See Ariel Performance Program.

Cylinders
Connecting Rod 8.250 (210)

Centerline to

Specification JGN/1 JGN/2 JGQ/1 JGQ/2
Sump Capacity, US 2.5 (9)

gallons (L)
Oil Pump Flow Rate 4 (0.25) 5 (0.32)

d, GPM (L/s)
Oil Heat Rejection, 8400 (2.5) 16,800 (4.9)

BTU/hr (kW)
Piston Rod Diameter, 1.125 (28.6)

in. (mm)
Internal Rod Load - Double Acting
Compression + 18,000 (80) 20,000 (89)

Tension, lbf (kN)
Tension, lbf (kN) 9000 (40) 10,000 (44)
Compression, lbf 10,000 (44) 11,000 (49)

(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 - Reciprocating differential. If not within recommended limits,

Weight Balancing the compressor may require new balance nuts
and/or crossheads.
Ariel recommends a reciprocating weight
differential between opposing throws of 1.0 To exchange opposing throw cylinder locations,
pound (0.45 kg) or less for JGM:P:N:Q exchange all reciprocating components to the
compressors. opposite throw, except the connecting rod
assemblies. Check the Balancing Record and
To replace a connecting rod assembly, piston, recalculate reciprocating weight differential,
piston and rod assembly, balance nuts, or including the weight of the connecting rods. If
crosshead, weigh component parts on a scale not within recommended limits, the compressor
calibrated to 0.1 pound (0.05 kg) and compare to may require new crosshead balance nuts to
the Balancing Record in the compressor Parts reduce differential.
Book. If the weight changes, recalculate
opposing throw reciprocating weight

If unable to balance opposing throws within force feed oil distribution system may also need
recommended limits, contact the packager or resized. Contact the packager or the Ariel
Ariel.When applying or re-applying a different Response Center for detailed information about
cylinder to a throw, recalculate opposing throw recommended reciprocating weight differential
reciprocating weight differential; new balance between opposing throws.
nuts and/or crossheads may be required. The
Table: JGM:N:P:Q Approximate Component Weights, Lbs (Kg)

Component Weight Component Weight
Main/Connecting Rod .5 (.2) Crosshead See Note a

Bearing
Top Cover 18 (8) Crosshead Pin 4 (2)
Shaft Seal Housing 8 (2) Lube Oil Pump 7 (3)
Crankshaft b 98 (44) • Frame Assembly See Ariel Performance

w/o Cylinders Program.
Main Journal Caps 6 (3)
• VVCP
Connecting Rod 12.5 (6) • Cylinder Assembly
• Piston & Rod
Assembly
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.

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)

JGM-JGN-JGP-JGQ Maintenance & Repair Manual – Compressor Clearance, Oil, & Temperature Record 12/03/2022
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).

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)

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)
JGM:P:N:Qb 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 material for metric sizes to meet the
Support Foot & Frame Foot Hold-down minimum clamp load necessary for opera-
Fasteners, the ultimate strength (Su) of the tion. Higher strength materials require higher
stud material must equal or exceed 100,000 torques than shown in the tables for added
psi (690 MPa); higher strength stud material is fastener stretch and preload. Material
preferred. In all cases, torque the nuts to strength and torque are directly propor-
stress the stud to about 55% of the ultimate tional. Example: for 120,000 psi (830 MPa)
strength of the stud material. Torques shown ultimate strength Imperial bolting: 120,000 ÷
in Table: Crosshead Guide Support Foot & 100,000 = 1.2 x min. torque for Imperial size
Frame Foot Hold-down Fasteners are based from table = required torque for given nut
on 100,000 psi ultimate strength material for size. To use a different stud diameter, consult
imperial sizes and 830 MPa ultimate strength Ariel for feasibility and torque.

JGM-JGN-JGP-JGQ Maintenance & Repair Manual – Hold-down Bolting to Resist Shaking Forces and Couples in 12/03/2022
Reciprocating Compressors
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)
JGM:P:N:Q Framef 3/4 (19) 5/8 - 11 100 (140) M16x2 125 (170)
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 = ( fastener torque) x (target fastener root area ÷ fastener root area).
f Crosshead guide supports do not apply to JGM:P:N:Q frames.
4. Compressor frame foot hold-down studs and

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

sion after installation.
7. Follow lubrication guidelines and recom-

mended procedures for torque accuracy in
Appendix A

Soft Foot and Top Plane Flatness Checks for Proper Main Bearing
Bore Alignment in Reciprocating Compressors
Main bearing bore alignment is critical to main
NOTE: If at any time frame hold down fasteners are
bearing and crankshaft life. Ariel manufactures
loose, perform soft foot check and top plane flatness
the top cover mounting surface of a compressor measurement. If a crankcase is damaged, top plane
frame in close tolerance to a flat plane, to the flatness must be within tolerance prior to any
main bearing bores, and to the bottom of the machining in the shop or on site.
compressor feet. The main bearing bores align
when frame feet are supported so the top cover
mounting surface is flat within a plane created by Soft Foot Check
two measurement points on one top rail and one 1. Properly install and torque compressor frame
measurement point on the opposite top rail. hold down bolting. See Appendix G for proper
After establishing the plane, adjust frame feet to frame foot and crosshead guide bolt size and
within acceptable limits. Frame flatness ensures torques.
the main bore is straight and not distorted. Level 2. Loosen each hold down bolt individually
the compressor before flatness adjustment. For while checking the frame foot to skid deflec-
leveling limits, see Appendix H in the Packagers tion with a calibrated dial indicator. If there
Standards Manual. are two bolts on a foot, loosen both for this
A best practice is to install and use reference check.
pads to measure level and flatness during skid 3. Correct any hold down position that deflects
fabrication. Verify skid level and flatness is more than 0.002 inches (0.05 mm) when
satisfactory on site using the pads. When released. Re-torque the hold down bolt or
documented properly and duplicated, this bolts and repeat on each frame foot.
practice reduces labor to re-establish major
component alignment.
Top Plane Flatness Check
For JGM:P:N:Q frames, the soft foot check is 1. Remove or reposition the top cover(s) and
required; the top plane flatness measurement is gasket(s) to expose the frame top cover
optional. mounting surface. Verify it is clean.
Soft foot checks and top plane flatness NOTE: On frames with O-ring seal top covers, the
frame top rail is lightly coated with Cortec VPCI
measurements are required:
368 corrosion inhibitor or equivalent to protect
• On new installations or if a unit is relocated. the aluminum to cast iron joint. If the top cover is
Perform measurements both prior to skid removed, clean both the top rail and the top cover
grouting and at final shaft alignment prior to and re-coat the frame top rail with a light coat of
initial startup. the same compound. If VPCI 368 or equivalent is
• At 6 months or 4000 hours to ensure skid not available, use marine grade grease. Apply
stability. If no changes are found, the interval only a light coat of the corrosion inhibitor; do not
can then be extended to 12 months or 8000 allow excess material to flow into the frame when
hours. the top cover is installed.

JGM-JGN-JGP-JGQ Maintenance & Repair Manual – Soft Foot and Top Plane Flatness Checks for Proper Main 12/03/2022
Bearing Bore Alignment in Reciprocating Compressors
2. Use measurement equipment with a 4. Frame temperature can greatly affect flat-
published accuracy of ±0.001 inches (0.025 ness readings. Factors such as direct sunlight
mm) over the distance required to measure on a portion of the frame or cooling after unit
the entire length of both frame rails. Measure shut down can cause measurement inaccu-
the top surface of both sides of the frame rails racy. Ensure frame temperature is consistent
based on the frame type as shown in figures throughout the measurement process. Ariel
below. For proper alignment, readings recommends flatness measurement while
between any two adjacent points must be the frame is at ambient temperatures to mini-
within 0.002 in. (0.05 mm). mize the effects of thermal expansion.
3. The ER-82 software tool determines if read-

NOTE: If the unit will not be restarted immediately,
ings meet ER-82 specifications, and if not,
re-preserve the unit in a manner appropriate to the
provides recommendations for shim correc- time duration until restart.
tions as well. Contact Ariel Technical Service
for the latest version of this tool.
Figure: Flatness Measurement Locations for Frames with Single Anchor Bolts

JGM-JGN-JGP-JGQ Maintenance & Repair Manual – Soft Foot and Top Plane Flatness Checks for Proper Main 12/03/2022
Bearing Bore Alignment in Reciprocating Compressors
Figure: Flatness Measurement Locations for Frames with Pairs of Anchor Bolts
Figure: Flatness Measurement Locations for KBE:K:T:C:D:F Frames
1 Loosen both when taking soft foot.

Attachment of Wiring, Tubing, or Pipe Clamps to Ariel

Compressor Cylinders
DO NOT drill holes to mount wiring, tubing, Plugs and Tapped Holes). Installing this plug in
instrumentation, or pipe clamps to any pressure cylinder indicator ports provides locations to
containing component. Pressure containing secure unloader tubing or instrumentation lines.
components include cylinders, valve caps, The plug is designed for high pressure and will
cylinder heads, unloaders, gas passage caps, and not affect existing Ariel cylinder MAWP in any
flanges. DO NOT use pressure containment application. Also, standard cylinder plugs may be
fasteners to mount brackets or other structural replaced with this plug without a hydrotest.
attachments. These practices can compromise Packagers may purchase this plug (A-28373)
the integrity of pressure containing components. through Ariel Parts Sales.
Newer Ariel cylinder designs include 1/4-20 UNC

tapped holes to the milled pad that contains the
CAUTION
cylinder indicator port holes (see Figure: Typical
Do not drill holes in any pressure containing Cylinder Plugs and Tapped Holes). These extra
components for any reason.
tapped holes will provide additional
accommodation to clamp unloader tubing or
Figure: Typical Cylinder Plugs and Tapped Holes
instrumentation lines.
Alternate Attachment Method

An alternate method to attach clamps to
compressor cylinders is to use an epoxy resin.
Ariel recommends Loctite 331 or Loctite 332
applied to clean, unpainted metal. Follow all
manufacturer instructions and
1 Standard Plug recommendations to prepare the area for the
2 Plug A-28373
adhesive. The clamp and unpainted surface can
3 New 1/4-20 UNC Tapped Holes
be painted after the adhesive cures. This clamp
Ariel offers a 1/2-inch NPT pipe plug with a 1/4-20 attachment method does not compromise
UNC tapped hole to accommodate a tubing cylinder integrity.
clamp or bracket (see Figure: Typical Cylinder

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JGM-JGN-JGP-JGQ Maintenance & Repair Manual 12/03/2022

ARIEL CORPORATION | www.arielcorp.com 1

Oil Sampling Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

ARIEL CORPORATION | www.arielcorp.com 2

ARIEL CORPORATION | www.arielcorp.com 3

“CU” Single-Acting Seal Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

ARIEL CORPORATION | www.arielcorp.com 4

Frame Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

ARIEL CORPORATION | www.arielcorp.com 5

General Safety for Reciprocating Compressors

If applicable, do not remove the pin from the crosshead

ARIEL CORPORATION | www.arielcorp.com 6

ARIEL CORPORATION | www.arielcorp.com 7

Throw and Data Plate Locations

ARIEL CORPORATION | www.arielcorp.com 8

Other Ariel Resources

Ariel Website • Packager Standards provide detailed

Contact Telephone Fax E-Mail

Ariel Response Center 888-397-7766 (toll-free USA & 740-397-1060 arc@arielcorp.com

Order Entry 740-397-3856 -

Ariel World HQ 740-397-0311 740-397-3856 info@arielcorp.com

Technical Services fieldservice@arielcorp.

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

ARIEL CORPORATION | www.arielcorp.com 9

Ariel offers an optional tool kit with every

Figure: Optional Furnished Tools for JGM:P:N:Q Compressors

ARIEL CORPORATION | www.arielcorp.com 10

Ariel Separately Purchased Tools

ARIEL CORPORATION | www.arielcorp.com 11

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

ARIEL CORPORATION | www.arielcorp.com 12

NOTE: Ariel recommends the use of shipboard or CAUTION

Table: Required Instrumentation Summary

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

Oil Pressure Packager

- 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 Temperature Packager

- Minimum, operating 150°F (66°C)

- Maximum, shutdown 190°F (88°C)

ARIEL CORPORATION | www.arielcorp.com 13

INSTRUMENT SUPPLIER SETTING/REQUIREMENT

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

- Low Level Shutdown 1/4 sight glass level

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

- Lubricated Cylinders 350°F (177°C)

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