Ariel JG JGA Manual

JG-JGA Maintenance & Repair Manual 01/27/2023
Table of Contents
General Safety for Reciprocating Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Lifting the Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Throw and Data Plate Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Other Ariel Resources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Ariel Website . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Ariel Technical and Service Schools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Ariel Contact Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Ariel Optional Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Ariel Separately Purchased Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Ariel Separately Purchased Tool Kits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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
Main Bearing Temperature Alarms and Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Thermocouples - J (Iron-Constantan) or K (Chromel-Alumel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Resistance Temperature Devices (RTD). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Testing RTD’s and Thermocouples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
RTD Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Thermocouple Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Initial Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Daily Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Recommended Maintenance Intervals for Continuous Duty Operation . . . . . . . . . . . . . . . . . . . . . . . 35
Monthly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Six-Month (4,000-Hour) Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
One-Year (8,000-Hour) Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Two-Year (16,000-Hour) Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Three-Year (24,000-Hour) Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
ARIEL CORPORATION | www.arielcorp.com 1

Four-Year (32,000-Hour) Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Six-Year (48,000-Hour) Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Frame Oil System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Oil Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Oil Pump & Regulating Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Oil Temperature Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Oil Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Oil Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Oil Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Compressor Pre-lube System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Flushing to Change to a PAG Lubricant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Recommended Flushing Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Flushing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Flushing the Force Feed Lubrication System - Common Oil Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Flushing the Force Feed Lubrication System - Independent Oil Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Cylinder and Packing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Force Feed Lubricator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Pressure Relief. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Pump Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Priming the Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Pump Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Pump Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Auto-Relief Valve (ARV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
ARV Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Force Feed Lube Blow-Out Fittings, Rupture Disks, and Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Distribution Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Distribution Block Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Divider Valve Bypass Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Balance Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Selecting Balance Valves and Pressure Gauges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Installing Balance Valves and Pressure Gauges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Adjustment of Balance Valves Fed by a Divider Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Adjustment of Balance Valves Fed by Primary/Secondary Divider Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Subsequent Compressor Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Force Feed System Design, Operating Parameters, and Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Common Oil Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Independent Oil Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Force Feed Lubrication Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Cycle Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Under/Over Lube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Cylinder Lubrication Paper Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Coolant System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Part Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Relieving Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Depressurization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Positioning a Throw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Variable Volume Clearance Pocket (VVCP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
VVCP Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
VVCP Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
VVCP Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
VVCP Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
VVCP Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Compressor Valves - Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Required Tools and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Valve Cap Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Valve Caps on Cast Iron Cylinders or High-Pressure Caps without Spring Energized Seals . . . . . . . . . . . . . . . . 83
Removal of Valve Cap with Spring Energized Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Valve Cap Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Installation of Valve Caps on Cast Iron Cylinders or High-Pressure Caps without Spring Energized Seals . . . 87
Installation of Valve Cap with Spring Energized Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Gas Containment Fastener Torque Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Piston and Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Piston Rod Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Piston and Rod Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Piston and Rod Manual Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Piston and Rod Manual Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Piston and Rod Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Piston Rod Runout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Piston Rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Seal-Joint Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Straight-Cut Chamfered Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
High-Pressure Face-Cut Piston Rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Three-Piece Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Five-Piece Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Wear Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Piston Rod Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Piston Rod Packing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Piston Rod Packing Reassembly and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Reassembling and Testing Cooled Packing Cases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Long Two-Compartment Intermediate Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Types of Piston Rod Packing Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
“P” Pressure Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
“PB1” Pressure Breaker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
“UP” Pressure Breaker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
“P1U” Pressure Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
“BTR” Single-Acting Seal Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
“BD” Double-Acting Seal Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Double "WAT" Double-Acting Seal Set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
“AL” Double-Acting Seal Set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
“BT” Single-Acting Seal Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
“BTS” Single-Acting Seal Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

“BTU” Single-Acting Seal Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

“BTUU” Single-Acting Seal Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
“CU” Single-Acting Seal Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
“CUU” Single-Acting Seal Set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
“RS3” Single-Acting Seal Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
“DS” Double-Acting Seal Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
“STU” Single-Acting Seal Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
“CR” Single-Acting Seal Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
“RTV” Oil Wiper Set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
“3RWS” Oil Wiper Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Crossheads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Crosshead Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Crosshead Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Connecting Rod Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Connecting Rod Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Crank Pin Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Connecting Rod Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Connecting Rod Bushing Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Connecting Rod Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Connecting Rod Bearing Vertical Jack Clearance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Connecting Rod Thrust (Side) Clearance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Crankshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Oil Slinger Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Main Bearing Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Main Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Crankshaft Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Crankshaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Main Bearing Vertical Jack Clearance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Crankshaft Thrust (End) Clearance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Chain Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Chain and Sprocket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Chain Idler Sprocket Replacement (Eccentric Adjustment Caps) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Lube Oil Pump Sprocket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Force Feed Lubricator Chain Sprocket Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Crankshaft Chain Sprocket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Chain Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Component Cleaning & Thread Lube for Non-Lube Compressor Cylinders . . . . . . . . . . . . . . . . . . . 141
Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Warranty Notification - Installation List Data and Start Up Check Lists for Reciprocating
Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Compressor Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Piston Rod Runout Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Ariel Fasteners and Torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Recommendations for Torque Accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
JG:A Fastener Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Measuring Head End Clearance for Forged Steel Tandem Cylinders with Concentric Valves . . . 169
Frame Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Opposed Throw - Reciprocating Weight Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Compressor Clearance, Oil, & Temperature Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Balance Valve Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Cleaning, Handling, and Assembly Lubricants for Non-Lubricated Compressor Cylinders. . . . . . . . . 178
Hold-down Bolting to Resist Shaking Forces and Couples in Reciprocating Compressors. . . . . . . . . 180
Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Soft Foot and Top Plane Flatness Checks for Proper Main Bearing Bore Alignment in Reciprocating
Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Soft Foot Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Top Plane Flatness Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Attachment of Wiring, Tubing, or Pipe Clamps to Ariel Compressor Cylinders . . . . . . . . . . . . . . . . . . . 186
Alternate Attachment Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Recommended Maintenance Intervals for Intermittent Duty Operation. . . . . . . . . . . . . . . . . . . . . . . . . 187
400-Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
2,000-Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
4,000-Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
8,000-Hour or 22,000 Starts Maintenance (whichever occurs first) . . . . . . . . . . . . . . . . . . . . . . . . . . 189
16,000-Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
32,000-Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Latest Manual Revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
01/27/2023. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

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
proceeding. The Maintenance and Repair
Lifting the Compressor
Manual applies to current design and build; it
may not apply to equipment built prior to the
CAUTION
date on the front cover and is subject to
change without notice. For questions of When lifting a compressor with lifting lugs, use only
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.

JG-JGA Maintenance & Repair Manual – General Safety for Reciprocating Compressors 01/27/2023
• Determine compressor weight before lifting. • Standard lifting lug and eyebolt materials can
See the Ariel Performance Program for frame fail when subject to shock loads at low
and cylinder weights. Also account for any ambient temperatures. Follow ASME B18.15
extra weight such as external and internal guidelines. If necessary, eyebolts may be
flywheels, etc. replaced with forged eyebolts of materials
• Each compressor ships with an attached more suitable for low temperatures per ASME
Compressor Lifting Information packet. Refer B18.15 and ASTM F541.
to the Compressor Lifting Information docu- • Use spreader bars or lifting beams for a
ment for each specific compressor frame vertical pull on eyebolts or lifting lugs. Chains
serial number. Ariel can provide the weight, or straps attached to eyebolts or lifting lugs
center of gravity, and lifting hook locations should be within 5 degrees of vertical. For
for the compressor via the Ariel Performance eyebolt load capacity rating or if pulling on an
software, or by contacting the Ariel Response eyebolt in a direction other than along the
Center. threaded axis, consult ASME B18.15.
• If you are not experienced in lifting large • Verify lifting tackle, spreader bars, and crane
compressors, Ariel recommends using quali- capacity are adequate, properly attached
fied professional riggers/movers. and properly rigged for the load. Keep
• Ariel-supplied eyebolts (attached to cross- compressor level when lifting and setting.
head guides), brackets (attached to cylinder Heavier cylinders and/or blank throws can
nozzles) and lifting lugs (attached to frame significantly affect center of gravity.
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.

Throw and Data Plate Locations

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

Other Ariel Resources
Ariel Website • Packager Standards provide detailed

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

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

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

JG-JGA Maintenance & Repair Manual – Tools 01/27/2023
Figure: Optional Furnished Tools for JG:JGA Compressors

1 Tool Box
2 Main Bearing Removal Tool
3 Crank End Clearance Setting Tool
(included only for 2-3/4M, 3M, 2-3/4P-CE,
and 3-1/4P-CE class cylinders)
4 Piston Rod Entering Sleeve
5 3/8" Allen Wrench (2 provided)
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)
Ariel Separately Purchased

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

JG-JGA Maintenance & Repair Manual – Tools 01/27/2023
Ariel Separately Purchased • 1/2” and 5/8” hex key sockets

e. 3/4" square drive wrench set, including:
Tool Kits • 18-piece, 12-point socket set, 3/4” to
1. Ariel SAE Hand Measurement Tool Kit 2”
a. 0.0005 in. needle type dial indicator • Extensions, 3-1/2”, 8”, and 16”
b. 0.001 in. 1-inch travel dial indicator • Drive adapters: 3/4” to 1/2", 3/4” to 1",
c. Magnet base for dial indicator and 1” to 3/4"
d. 3/8” drive calibrated torque wrench, 40 to • 24” ratchet
200 in x lbs • 22” breaker bar
e. 3/8” drive calibrated torque wrench, 10 to f. Adjustable wrenches: 12" and 18"
100 ft x lbs g. Dead blow semi-soft faced hammers: 3 lb.
f. 1/2” drive calibrated torque wrench, 50 to and 6 lb
250 ft x lbs h. 3/4” x 36” pry bar
g. 3/4” drive calibrated torque wrench, 120 i. 12” long feeler gauge set
to 600 ft x lbs
j. 12” machinist scale with 0.01 in. incre-
2. Ariel SAE Hand Tool Kit ments
k. 13-piece Allen wrench set, 0.050 in. - 3/8”
a. 15-piece combination open/box end
wrench set, 5/16” to 1-1/4”
b. 8-piece slot and Phillips screwdriver set Recommended Tools
c. 3/8" square drive wrench set, including:
Ariel compressor maintenance and repair
• 12-piece, 12-point socket set, 5/16” to
normally requires only Ariel furnished tools and
1”
separately purchased tools and tool kits.
• 7” ratchet
However, Ariel also recommends purchasing the
• Speed handle
additional tools below. Contact Ariel for
• Extensions, 1-1/2”, 3”, 6”, and 12”
questions about tools for Ariel units.
• Ball type universal joint
1. 12-point box end torque adapter extension
• 3/8” to 1/2" drive adapter
wrench set
• 1/4” hex key socket
2. Tape measure
• 8-1/2” breaker bar
d. 1/2" square drive wrench set, including: 3. Flashlight
• 14-piece, 12-point socket set, 7/16” to
4. Small mirror on a flexible extension rod
1-1/4” with clip rail
• Extensions, 1-1/2”, 5”, and 10" 5. Small magnet on a flexible extension rod
• Drive adapters: 1/2” to 3/8" and 1/2”
6. Electric and/or pneumatic drill
to 3/4"
• 1-1/4” open end crow’s foot adapter 7. Twist drill set
• 10-1/4” ratchet
8. Torque multiplier
• Speed handle
• Ball type universal joint
• 18” breaker bar

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)

JG-JGA Maintenance & Repair Manual – Instrumentation 01/27/2023
INSTRUMENT SUPPLIER SETTING/REQUIREMENT
Crankcase Level Packager 1/2 to 2/3 sight glass level
- Low Level Shutdown 1/4 sight glass level
Main Bearing Temp. Ariel Recommended, but optional.
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-

mentation, ignition systems, electrical
1. Install the compressor frame low lube oil
devices, and high temperature piping (gas
pressure shutdown set to stop the unit if oil
discharge and engine exhaust) in accordance
pressure downstream of the filter falls below
with good engineering practice and appli-
45 psig (3.1 barg). Compressor operation for
cable codes for the area classification at the
only a few seconds without oil pressure
end user location. Ensure compatibility of all
causes major damage. Normal oil pressure is
systems for area classification.
about 60 psig (4.1 barg) at full rated speed
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
than 50 psig (3.4 barg) oil pressure. CAUTION
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
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
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 shutdown
crystal to accurately monitor the lubrication
for two and four throw frames and two for six
system cycle time to enable precision timed
throw frames. Mount vibration devices near
shutdown capability. The magnet assembly and
the top of the frame with the sensitive axis
control housing mount directly to a divider valve.
parallel to the piston rod axis.
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
fails to blink with divider valve cycling, slide
3 Magnet Housing
DNFT back on the hex of the magnet housing
4 Set Screws (2)
in 1/16" increments until it does.
5 LED
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,
and the case. Support conduit and fittings to
9 Divider Valve
avoid bending the magnet housing.
10 Piston Enclosure Plug
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
magnet in the recessed opening when the
Programmable DNFTs come with a small liquid
desired programming mode displays.
crystal display (LCD) screen to display total
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
the spring-loaded magnet assembly
time in Mode 1.
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
flow rate in pints per day based upon shuts down and the compressor cannot be
the divider valve total set in Mode 3. restarted until the battery is replaced.
Mode 4 requires a minimum 4 second
cycle time.
The DNFT stores all programmed information
until the operator inserts the programming

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

screws and remove control housing to a safe Troubleshooting DNFT’s
atmosphere.
4. Use 3/8 inch ratchet wrench to remove pipe NOTE: When installing multiple DNFTs, wire each to a
plug. separate alarm circuit of the control panel, annunci-
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-
8. Insert the new battery and reinstall the pipe down)
plug. Apply Teflon tape to plug threads and • ARV bypasses or rupture disk bursts and
torque to 25 ft x lb (34 N•m). divider valve seizes after DNFT installation.
9. Place DNFT control housing on the magnet • Erratic shutdown or LED blink.
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
and remove batteries, or completely remove the
electronic equipment from the compressor.
close as possible to the area where the welding will
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 • Switch does not cycle and control panel indi-
cates lube no-flow. (also see Erratic Opera-
Switches tion)
• ARV bypasses or rupture disk bursts and
NOTE: When installing multiple proximity switches, divider valve seizes after proximity switch
wire each to a separate circuit in the control panel, installation.
annunciator, or PLC to simplify lubrication system • Erratic Operation.
and proximity switch troubleshooting.
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.

Main Bearing Temperature Resistance Temperature Devices

Alarms and Shutdown (RTD)
Main bearing thermocouples or RTD temperature Figure: Typical Dual Element RTD Wiring
sensors are optional for JG:JGA frames. Diagram
Thermocouples - J (Iron-
Constantan) or K (Chromel-
Alumel)
A thermocouple is two dissimilar conductors
joined together at one end to form a sensor that
produces a thermoelectric voltage as an accurate
function of temperature. Appropriate controls
interpret the thermocouple voltage as
temperature.
1 Element 1
2 White Wire
3 Red Wire
4 Element 2
5 Black Wire
6 Green Wire
An RTD is a sensor that produces electrical

resistance as an accurate function of
temperature. Appropriate controls interpret the
electrical resistance as temperature. A typical
measurement technique sends a small constant
current through the sensor and measures voltage
across the sensor with a digital voltmeter to
indicate resistance by a computer and wave-
fitting equations.
For main or thrust bearing temperature sensing,

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

To simplify wiring, RTD's come with two green After RTD installation:
wires and one black for one element, and two red 1. Set multimeter to the 100 Ohms resistance
wires and one white for the other. See Figure: scale.
Typical Dual Element RTD Wiring Diagram.
2. Touch one multimeter lead to the white
A Zone 1 environment may require the element wire, and the other lead to one of the
installation of proper, intrinsically safe or red element wires.
equivalent protection to fulfill electrical • The multimeter should read between 100
requirements. Ohms (RTD at 32°F) to 112 Ohms (RTD at
90°F).
• Test the other red wire with the white
Testing RTD’s and Thermocouples wire. Resistance should be similar for
both red wires. Resistance outside the
Ariel uses resistive temperature devices (RTD) or specified range indicates a damaged or
thermocouples (TC) to monitor main bearing and broken element.
packing temperatures. An RTD has either three or
3. For dual element RTD’s, perform step 2 with
six wires; a TC has two. Both types of devices are the black and two green wires.
tested on the assembly floor after installation,
4. Set the multimeter to check for continuity
but before the run-test.
( ).
5. Isolate all element wires from the tube bend
RTD Testing
and transition piece. Check for continuity
Figure: Typical RTD/Thermocouple between each wire and these components.
• The multimeter displays “1.” to indicate
the circuit is not continuous.
• It displays a value between .001 and .010
and beeps to indicate a continuous
circuit.
• Only the white wire tested with either red
wire and (for dual element RTD’s) the
black wire tested with either green wire
should yield a continuous circuit.
1 Temperature Probe • A continuous circuit between any
2 Tube Bend element wire and any component indi-
3 Transition Piece cates a damaged RTD that needs
4 PTFE Insulated Foil Shield, FEP Jacket replaced.
5 Element Wires (3 or 6 for RTD; 2 for TC)
Ariel uses two types of RTD: single and dual

element. Single element consists of one white
wire and two red wires. Dual element consists of
one element of one white wire and two red wires,
and another of one black wire and two green
wires.

Thermocouple Testing • The multimeter displays “1.” to indicate

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

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

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

JG-JGA Maintenance & Repair Manual – Maintenance 01/27/2023
Figure: Thermal Growth

1 HOT Centerline
2 Thermal Growth
3 COLD Centerline
Table: Thermal Growth of JG:JGA

NOTE: Thermal growth numbers were calculated
Compressors
using 170°F (77°C) as the frame operating tempera-
Initial Frame Temp. °F Thermal Growth Inch ture. Initial frame temperature is the temperature of
(°C) (mm) the frame during cold alignment. Obtain driver
0 (-18) 0.011 (0.29) thermal growth predictions from the driver manufac-
turer.
10 (-12) 0.011 (0.27)
20 (-7) 0.010 (0.26)

Figure: Angular Coupling-Hub Face Alignment
30 (-1) 0.010 (0.26) Limits
40 (4) 0.009 (0.22)
50 (10) 0.008 (0.20)
60 (16) 0.007 (0.19)
70 (21) 0.007 (0.17)
80 (27) 0.006 (0.15)
90 (32) 0.005 (0.14)
100 (38) 0.005 (0.12)
110 (43) 0.004 (0.10)
120 (49) 0.003 (0.09)
130 (54) 0.003 (0.07)

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

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

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

Six-Month (4,000-Hour) 7. Change compressor oil. Extremely dirty

environments, oil supplier
Maintenance recommendations, or oil analysis results may
1. Perform all Daily and Monthly maintenance. dictate a different oil change interval. Follow
these steps:
2. Shut down unit and allow sufficient time for
a. Drain oil from frame, associated piping,
components to cool.
and oil cooler.
3. Inspect crankcase breather filter and clean b. Clean oil strainer with a suitable solvent.
with suitable solvent. In dry sump applications, the strainer is
4. Drain and replace force feed lubricator box located at the oil reservoir.
oil. c. Remove frame top cover and crosshead
5. Where applicable, clean sintered element in guide side covers. Visually inspect for
the small oil filter on the force feed debris. Do not disassemble further
lubrication system now or at every main oil without good reason. If debris indicates,
filter change. Use a suitable solvent.Where replace affected parts, then change the oil
applicable, replace force feed lubricator inlet filter and clean the strainer with a suitable
filter in independent supply system. solvent.
6. Change compressor oil filter. See top cover d. Refill compressor frame with fresh, clean
filter information plate or “Oil Filter” in Frame oil.
Oil System Components for procedure. Do 8. Check for adequate cylinder lubrication. See
not exceed 12 month installed period for filter “Cylinder Lubrication Paper Test” for
element. procedure.
NOTE: For replaceable element style filters, drain the
9. Re-tighten hold down fasteners to proper
canister completely before removing the element.
torque (compressor frame feet and
Inspect elements for cleanliness and damage. Do not
crosshead guide/distance piece support
install dirty or damaged elements.
feet). Inspect for frame twist or bending to
verify main bearing bore alignment. See
Appendix H for flatness and soft foot
requirements.
10. Perform a coupling alignment (see "Initial
Maintenance").
11. Remove and inspect inlet screens on each
stage; clean if clogged with debris or replace
if damaged. Clean inlet screens regularly to
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) 6. Remove valves and valve gaskets:

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

11. Inspect piston rods for damage and excessive Two-Year (16,000-Hour)
wear. Replace rod if any of these conditions
exist (see “Piston and Rod Removal” in
Maintenance
Section 4): 1. Perform all Daily, Monthly, Six-Month, and
• Gouges or scratches on the rod. One-Year maintenance.
• Under size more than 0.005 inch (0.13 2. Rebuild oil wiper cases.
mm).
3. If applicable, use new piston and stem seals
• In the packing travel length, out of round
to rebuild actuators on suction valve
more than 0.001 inch (0.03 mm).
unloaders and fixed volume pneumatic
• Anywhere in the packing travel area, pockets. Replace piston stem assemblies
tapered more than 0.002 inch (0.05 mm) . where stem is damaged or worn.
12. Rebuild piston rod pressure packing cases. 4. Check auxiliary end chain drive for undercut
See “Piston Rod Packing” in Section 4 for sprocket teeth and chain for excessive
procedure. stretching. Replace as required.
13. Re-install valves, retainers, and valve caps
using new valve seat gaskets and valve cap O-
rings/seals. See “Valve Installation” in
Three-Year (24,000-Hour)
Section 4. Use proper installation techniques Maintenance
and torque procedures for valve caps.
1. Perform all Daily, Monthly, Six-Month, and
14. Check and re-calibrate all required One-Year maintenance.
instrumentation.
2. Replace connecting rod bearings. See
15. Clean crankcase breather filter with suitable “Connecting Rods in Section 4”.
solvent. NOTE: Main and connecting rod bearing wear and
16. Check and, if needed, adjust drive chains. See replacement intervals are heavily dependent on
“Chain Adjustment” in Section 4 for many factors including speed, load, oil temperature,
procedure. oil cleanliness, and oil quality. Depending on the
severity of service, the bearing maintenance interval
17. If the compressor is equipped with crankcase
may be longer or shorter.
over-pressure relief valves, visually inspect
and exercise valves to manufacturer
recommendations. Four-Year (32,000-Hour)
18. Check fastener torques of gas nozzle flanges, Maintenance
head end head or unloader, valve caps,
piston rod packings, crosshead pin thru- 1. Perform all Daily, Monthly, Six-Month, One-
bolts, crosshead guide to frame, frame hold Year, and Two-Year maintenance.
down, crosshead guide to cylinder, cylinder 2. Remove crosshead pins.
mounting flange to forged steel cylinder,
distance piece to cylinder, distance piece to a. Measure and log crosshead pin to cross-
crosshead guide, and tandem cylinder to head pin bore and connecting rod
cylinder. bushing bore clearances.
b. Check crosshead pin end caps and thru-
bolt for wear.
c. Replace if needed.

3. Check for bushing wear in the auxiliary end

drive chain tightener.
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
rod bushings. See “Crossheads” and
“Connecting Rods” in Section 4.
4. Replace connecting rod bearings. See
5. Replace main bearings. See “Crankshaft” in
Section 4.
6. Replace auxiliary end torsional damper, if
applicable. See assembly drawing in
compressor build book for procedure.

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

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

sump lubrication systems.

Oil Strainer Oil Pump & Regulating Valve

An oil strainer installed upstream of the pump The oil pump constantly supplies oil to all journal
prevents debris from entering the pump and bearings, bushings, and crosshead sliding
damaging it. Ariel supplies a 30 mesh (595 surfaces. The crankshaft drives it by a chain and
microns) or 40 mesh (400 microns) on all frames, sprocket to provide adequate oil flow to bearings
depending on frame size. It is located on the when the compressor operates at the minimum
auxiliary end of the crankcase below oil level. speed rating (typically half of maximum rated
Remove the strainer basket and wash it in an speed).
appropriate solvent whenever lubricating oil is
changed. Figure: Typical JG:JGA Lube Oil Pump
1 Discharge
2 Safety Relief Valve
3 Dust Cap
4 Suction
Smaller compressor models have
threaded suction/discharge connections.
JG:JGA compressors maintain oil pressure with a Oil Cooler

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

Oil Temperature Control Valve

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

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

filter replacement limit until the oil reaches When filter differential pressure reaches 10 psid
operating temperature.On the same schedule, or (0.7 bard) or once every six months, whichever
with every main oil filter change, clean the comes first, replace oil filter with a genuine Ariel
sintered element in the small oil filter of the force filter.
feed lubricator. 1. Remove old filter, clean filter head surfaces,
and verify old gasket is removed.
Oil Maintenance
2. Inspect new filter for damage or debris. Do
Proper oil maintenance is vital to the efficient not install damaged or dirty filters. Never
operation of the compressor. The severity of operate a unit with a damaged or leaking
compressor service affects the frequency of oil oil filter.
and filter changes. 3. Apply clean oil to the filter gasket and thread
the filter with gasket onto the head.
Oil Filter Replacement 4. Tighten the filter one turn after the filter
gasket contacts the head. Install 1/2 inch NPT
Replace oil filters or elements with only genuine drain plug.
Ariel parts. See parts list or name plate for part
5. Use the compressor pre-lube pump to fill the
numbers.
oil filter with oil and purge air from the oil
system. Manually filling the filter with oil can
introduce debris on the clean side of the
CAUTION filter. This debris can damage the compressor
to the point of bearing failure.
Before oil filter replacement, use the frame-mounted
pressure gauges to confirm system depressurization. Be 6. After starting the unit, check for leaks, and
careful - hot oil may cause burns! Wear proper personal retighten if necessary.
protection equipment.
Simplex Spin-on Filter Replacement

Figure: Mounted Thermostatic Valve Drain Plug

Compact Duplex Filter Cartridge 7. Install drain plug in the filter housing.
Replacement 8. Inspect and replace the filter gasket if
damaged. Install the gasket and attach the
Figure: Typical Compact Duplex Filter Vessels 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
handle to put desired filter in service.
1 Filter Vent
10. Check for leaks.
2 Transfer Valve Indicator
3 Filter Head
4 Filter Housing Compressor Pre-lube System
5 Filter Element
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.
Ariel requires automated pre-lube systems for
Turn transfer valve handle until it stops to
make the inactive filter the active filter. compressors that meet any of the following
criteria:
2. Loosen the inactive filter vent to relieve any
pressure. • Electric motor driven compressors.
• Unattended-start compressors, regardless of
3. Drain the inactive filter housing.
driver type.
4. Remove the filter housing, clean and inspect.
See Figure: Standard Frame Lube Oil Schematic
5. Remove the filter element and properly for pre-lube circuit design.
dispose of.
6. Inspect new filter element and place it over NOTE: The pre-lube return into the frame must be
the seat in the top of filter head. It requires a upstream of the oil filter.
small amount of force to seat the element
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
head or frame oil gallery is not always a true Flushing to Change to a PAG
representation of total oil sump temperature. Lubricant
See Figure: Viscosity vs. Temperature Graph of
Different Lubricants to determine oil viscosity Cylinder and frame lubrication systems require
based on temperature. flushing when changing to or from a PAG
lubricant or when applying a PAG lubricant to
• During a cold start of the unit when oil supply
viscosity is greater than 50 cSt, pre-lube pres- newly installed equipment.
sure should be 30 psig (2.1 barg) at the oil
gallery for a minimum of 2 minutes prior to Recommended Flushing Oil
turning or starting.
• During a hot re-start of the unit when oil The preferred flushing oil is soluble in both the
supply viscosity is less than 50 cSt, pre-lube original oil and PAG lubricant. A linear diester is
pressure should be 20 psig (1.4 barg) at the oil preferred, such as Shell Corena DE 150 or Mobil
gallery for a minimum of 2 minutes prior to
Rarus 829. If this is unavailable, use the desired
turning or starting.
PAG lubricant fill oil as the initial flushing oil.
NOTE: A 10 to 15 minute pre-lube is required after:
• Any major drive line maintenance Flushing Procedure
• The main lube oil system is drained
• Oil filter replacement Below is a general flushing procedure
recommended to change from mineral or PAO
Instrumentation: Automated pre-lube systems oils to a synthetic PAG lubricant.
require a start permissive logic and
1. Drain old oil from frame while the oil is still
instrumentation to satisfy the minimum required
warm.
pressure and duration at the oil gallery inlet.
2. Drain all supply and return lines upstream of
It is highly recommended that the compressor the frame lube oil filter, filter housing (if
low oil pressure shutdown be Class B. Inhibited applicable), coolers, and other peripheral
time shall be no longer than 10 seconds after idle equipment in the lubricant supply loop.
speed is achieved on gas engines or start
initiation for electric motors.

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

mineral oil or synthetic PAO lubricant to a PAG 11. Reconnect lube lines to double ball check
synthetic lubricant: valves in the primed zone.
a. Drain old oil from lubricator box. 12. Continue to prime 2 fluid ounces of oil per
b. Rinse lubricator box with flushing oil (see throw through the primed zone.
"Recommended Flushing Oil").
13. Repeat steps 6 thru 12 for remaining zones.
c. Fill lubricator box with PAG lubricant to
be used for the cylinders.
Flushing the Force Feed
Flushing the Force Feed Lubrication System - Independent
Lubrication System - Common Oil Oil Supply
Supply 1. Drain daytank, oil filter, and lube lines
upstream of the force feed pump inlet. Oil
1. If installed, drain the sintered filter and clean trapped in piping can be vacuumed out or
the element with solvent. flushing oil can be pumped through these
2. Drain the lube line upstream of the force feed lines to displace the old oil.
pump inlet. 2. If installed, drain the sintered filter and clean
3. Drain tubing/manifold feeding the force feed the element with solvent.
pump(s). 3. Drain tubing/manifold feeding the force feed
4. Remove the purge/vent connection on the pump(s).
outlet of each force feed pump. 4. Remove the purge/vent connection on the
5. Use a purge pump filled with clean/filtered outlet of each force feed pump.
flushing oil (see "Recommended Flushing 5. Use a purge pump filled with clean/filtered
Oil") to prime each force feed pump by flushing oil (See "Recommended Flushing
forcing oil through the pump inlet and out the Oil") to prime each force feed pump by
purge/vent connection. forcing oil through the pump inlet and out the
6. Reconnect the purge pump to the force feed purge/vent connection.
pump purge/vent outlet connection. If 6. Reconnect the purge pump to the force feed
pumps are paired together at their outlets, pump purge/vent outlet connection. If
close one of the purge/vent connections. pumps are paired together at their outlets,
7. For the zone fed by the force feed pump being close one of the purge/vent connections.
primed, disconnect lube lines at the inlet of 7. For the zone fed by the force feed pump being
the double-ball check valves. primed, disconnect lube lines at the inlet of
8. Place paper towels or suitable collection the double-ball check valves.
containers beneath each disconnected lube 8. Place paper towels or suitable collection
line to catch flushing oil during priming. containers beneath each disconnected lube
9. Prime flushing oil from the force feed pump line to catch flushing oil during priming.
purge/vent connection to downstream 9. Prime flushing oil from the force feed pump
tubing, divider blocks, and check valves. purge/vent connection to downstream
10. Prime until no air bubbles appear in the tubing, divider blocks, and check valves.
flushing oil at all disconnected lube lines in 10. Prime until no air bubbles appear in the
the zone. flushing oil at all disconnected lube lines in
the zone.

11. Reconnect lube lines to double ball check Force Feed Lubricator
valves in the primed zone.
The force feed lubrication system oils the
12. Continue to prime 2 fluid ounces of flushing
oil per throw through the primed zone. compressor cylinders and piston rod packings.
Oil flows to the suction side of the force feed
13. Disconnect the purge pump and install cap
lubricator pump directly from the pressure side
for purge/vent connection.
of the frame lubrication system, or from an
14. Repeat steps 6 thru 12 for remaining zones. overhead tank. A self-contained oil reservoir oils
15. Install a new oil filter. the force feed lubricator worm gear and cam. The
16. Reconnect lube lines between daytank and force feed lubricator sight glass shows the
pump inlets. Reinstall sintered filter (if reservoir oil level.
provided).
17. Place a collection container beneath the
disconnected lube line near the force feed
pump inlet connection.
18. Add enough flushing oil to the daytank to
prime the system up to the disconnected line
in step 17.
19. Collect oil until no air bubbles appear in the
flushing oil.
20. Reconnect feed line to force feed pump.
21. Bleed trapped air by loosening tube
connections nearest each pump inlet.
Cylinder and Packing

Lubrication
The cylinder lubrication system injects
lubrication into cylinder bores and packings. The
system consists of an oil supply, an oil filter, a
force feed lubricator pump, divider blocks,
pressure indicators, check valves, and flow
monitoring shutdown devices. The system is
progressive; each piston in the divider block
must complete a cycle before the system cycles
again. This type of system offers better
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 4. Align the pump mounting holes with the

reservoir cover mounting holes.
Before installation, verify the lubricator box and
5. Install washers and bolts. Tighten the bolts
lube system are sized appropriately for the
securely, then torque each bolt to 50 Lb x In
selected pressure. Verify a pressure relief device (5.65 N•m).
suitable for the application is installed in the
system. Refer to Figure: Pump Installation during Pump Setup
installation.
Before setup, relieve all pressure from the force
Figure: Pump Installation 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 Reservoir Cover Mounting Hole
1/4 (6.35) 6000 (414) 0.021 (0.344)
2 Pump Mounting Hole
3 Washer 3/8 (9.53) 3500 (241) 0.048 (0.786)
4 Mounting Bolt
5 Pump Gasket • Inlet Size: 1/4” - 18 NPTF
6 Pump Body • Outlet Size: 1/8”- 27 NPTF
• Strokes/Minute: Max. 50; Min. 3
1. Clean pump body.
• Stroke Length: Max. 1/2 inch (12.7 mm)
2. Remove protective film from gasket and • Weight: 2.7 lbs (1.22 kg)
adhere gasket to pump body.
• Wetted Parts: carbon steel, stainless steel,
3. Orient pump so the roller bearing on the aluminum, PTFE, fluoroelastomer
bottom of the pump aligns with the cam • Max. allowable inlet pressure for priming: 150
inside the reservoir. PSI (10.34 bar)
• Allowable viscosity range independent of
temperature: 80-5000 SUS (16-1100 cSt)

Priming the Pump 6. Wipe the pump priming stem clean and
lubricate with oil.
Use filtered oil when priming the pump and force
7. Manually prime pump by using a priming
feed system (minimum 5 micron nominal filter).
pump or by pressing the pump priming stem
Refer to Figure: Pump Priming and Adjustment repeatedly (if connected to a day tank) until
during priming. clean, air-free oil flows from the outlet fitting.
Figure: Pump Priming and Adjustment 8. Connect outlet line to outlet fitting.
9. Manually prime pump by using a priming
pump until clean, air-free oil flows from the
outlet line at the cylinder and packing lube
points.
10. Connect the outlet line to the lube point.
11. After start-up, adjust individual pumps to
meet required flow rates. See "Pump
Adjustment".
Pump Adjustment
The flow adjustment screw controls pump flow
rate; turning it changes the length of the piston
stroke which changes the pump discharge
volume. Refer to "Figure: Pump Priming and
Adjustment" during adjustment.
1 O-ring 1. Loosen the flow adjustment screw locknut.
2 Flow Adjustment Screw Locknut
2. Lubricate the o-ring beneath the adjustment
3 Flow Adjustment Screw
screw locknut with oil.
4 Pump Priming Stem
5 Pump Inlet 3. Turn the flow adjustment screw.
6 Pump Outlet Counterclockwise increases flow and
decreases cycle time; clockwise decreases
1. Remove and discard the plastic plugs in the flow and increases cycle time.
pump inlet and outlet.
4. Check force feed lubricator data plate or Ariel
2. Apply thread sealant (user supplied) to inlet lube sheets for correct cycle time. Adjust flow
and outlet line fittings. until desired cycle time is achieved with the
3. Install the inlet and outlet fittings on the force feed system operating.
pump. 5. Repeat Steps 2 and 3 as needed.
4. Connect the inlet line to the inlet fitting. 6. After adjustment to the proper cycle time,
5. Introduce oil into the inlet line using a clean tighten the adjustment screw locknut.
priming pump filled with cylinder oil NOTE: Inconsistent flow can occur if pump stroke is
connected to the purge/vent connection. If set below 20% of maximum stroke. A dust seal inside
installed, open oil supply valve from day tank the flow adjustment screw holds the priming stem
(located upstream from pump). stationary during operation.

Pump Troubleshooting • No flow

• Low flow or erratic operation
Relieve all pressure from the system before
• Low discharge pressure
cleaning, checking, or servicing the equipment.
• Fluid flows from pump outlet when not
Pump Problem: running
Pump No flow
Problem
Pump no flow.

Stroke adjusted to zero. Stuck piston.
Solution Solution
1. Adjust pump stroke for desired output. See 1. Replace pump.
"Pump Adjustment".
Possible Cause
Possible Cause
Stuck pump priming stem.
Plugged pump outlet.
Solution
Solution
1. Clean and lubricate the priming stem.
1. Clean/flush pump outlet. Replace pump if priming stem is corroded.

Damaged outlet check valve. 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
Damaged or worn inlet check ball and/or seat.
Possible Cause
Solution Air bubbles in the oil.
1. Replace pump.
Solution
1. Prime pump. See "Priming the Pump".

Possible Cause 2. Heat oil to maintain viscosity ‹1100 cSt.

High oil viscosity. 3. Consult oil supplier for temperature.
Solution
1. Decrease flow restrictions upstream of
pump.
Low Flow or Erratic Pump Operation
Problem
Low flow or erratic pump operation.

Stroke adjusted to minimal travel. Insufficient oil supply.
Solution Solution
1. Adjust pump stroke for desired output. See 1. Check for line and filter restrictions
"Pump Adjustment". upstream of pump.
2. Verify pump inlet is free of debris.
Possible Cause 3. Check/inspect lube box cam gear for wear.
Damaged or worn inlet check ball and/or seat.
Possible Cause
Solution
Air bubbles in the oil.
1. Replace pump.
Solution
Possible Cause 1. Prime pump. See "Priming the Pump".
Damaged or worn outlet check ball and/or seat.
Possible Cause
Solution
High oil viscosity.
1. Replace pump.
Solution
Possible Cause 1. Decrease flow restrictions upstream of
Sticking piston or priming stem. pump.
2. Heat oil to maintain viscosity ‹1100 cSt.
Solution
3. Check/inspect lube box cam gear for wear.
1. Replace pump.

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

pump. The pump will operate in bypass
Figure: ARV Operation condition until either the divider valve no-flow
device times out due to lack of flow or pressure
downstream of the pump decreases allowing the
ARV to close (Figure: ARV Operation– Pressure
Relieved).
When the ARV begins bypassing, an indicator pin

protrudes from the top of the ARV indicating an
over-pressure condition. The indicator pin is a
“tattle tale” and remains protruding after the
ARV bypasses oil (Figure: ARV Operation–
Pressure Relieved ). Two bypass conditions are
possible:
Intermittent blockage downstream of the

1 Normal Pressure (pin does not protrude)
2 High Pressure (pin protrudes)
pump - A brief condition or one-time event that
3 Pressure Relieved (pin not reset) prevents the shutdown device from timing out
and allows the compressor to continue to
When a force-feed pump encounters a operate.
downstream restriction, pump discharge Significant blockage downstream of the pump
pressure increases. If discharge pressure exceeds - A condition of long enough duration to cause
ARV cracking pressure, the ARV bypasses excess the shutdown device to timeout and shutdown
oil back to the low-pressure inlet side of the the compressor.
pump (Figure: ARV Operation – High Pressure).

After downstream blockage/restriction removal, Force Feed Lube Blow-Out Fittings,

the indicator pin can be manually reset by Rupture Disks, and Tubing
depressing the indicator pin until it is flush with
the ARV housing. Force feed lube pump discharge lines require
blow-out fittings and the properly rated rupture
disk installed. The disk color should show at the
fitting blow-out hole. A system blockage causes
pressure build-up that ruptures the disk. Venting
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

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

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

1 Piston
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.
NOTE: Pistons are matched to a specific divider valve.

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

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

divider valve assembly drawings, parts lists, and
repair kits.
1. Thread three tie rods into inlet block until the

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

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
7. Repeat Steps 4 thru 6 for the remaining the maximum injection pressure indicated at
outlets on the divider block assembly. each divider block gauge, balance valve set
pressures, and divider block cycle time at least
NOTE: Test distribution blocks at higher pressures if once a day for each zone in the system. See
the application dictates higher system operating
Appendix E.
pressure.
Do not adjust balance valves prior to operating
If a divider valve fails, replace it. Discard worn the unit. Verify the tightness of all fittings and fix
divider valves. If the tested valve passes the test, any known leaks. To remove any trapped air or
relieve the pressure, move the plug to the next gas in the force feed lube system, use a high-
outlet, and repeat the test for all divider valves. pressure hand purge pump and the same oil
When all divider valves either pass this pressure recommended for the cylinder application to
test or are replaced, reassemble the distribution purge it. DO NOT USE ANY OTHER FLUIDS FOR
block, purge it with the proper force feed PURGING! Call the Ariel Response Center for
lubricant, and put it into service. details about purchasing a hand purge pump. To
prepare for balance valve adjustment:
Ariel recommends periodic tests for proper
cylinder bore lubrication rates and/or 1. Start the compressor and bring the cylinders
aftermarket devices that measure flow. up to normal operating pressure.
2. Allow operating pressures to stabilize.

3. See the cylinder lube sheets for balance valve gauges on new compressors with high
locations and proper spring type for each differential force feed lube pressures. Balance
device. valves add pressure to distribution block
discharge ports when differential pressure
Selecting Balance Valves and Pressure exceeds 1200 psi (8300 kPa).
Gauges If a compressor experiences excessive
Balance valves are used in high differential distribution block differential pressure, select
pressure distribution block applications to and install balance valves (and pressure gauges,
reduce system problems such as bypassing, no- if required) by the following procedure:
flow switch errors, or blown rupture disks. Since 1. Determine lube point line pressures, either by
9/98, Ariel supplies balance valves and pressure measurement on the compressor with a
calibrated pressure gauge, or by calculation
of expected pressures for a given distribution
block system:
a. Expect cylinder bore lube line pressure
midway between suction and discharge
pressure. Calculate: P = (Pd + Ps) ÷ 2. The
bore line pressure of double-acting
forged steel (VS) cylinders equals the
suction pressure of the cylinder.
b. For single lube packings, expect lube line
pressure to equal suction pressure of a
double-acting or crank end cylinder. This
is also true for the inner lube point on
high-pressure, two lube point packings.
c. For the outer lube point on high-pressure,
two lube packings, assume lube line pres-
sure is zero.
d. For intermediate packing lube points on
long two-compartment distance pieces,
the lube line pressure is zero.
e. For inlet gas flushing lines, commonly
used in sour gas applications, lube line
pressure equals suction pressure.
f. The bore lube line pressure of each
cylinder in a tandem pair equals suction
pressure of the low-pressure cylinder in
the pair.
2. Determine pressure differentials between
each individual lube line and the highest lube
line pressure for the distribution block
system. For example, if pressure at a lube
point is 700 psig (5500 kPa) and the highest

cylinder mean pressure is 2000 psig (13800 equal to rupture disk pressure (see Table:
kPa), then a balance valve must be added to Rupture Disk Data and Table: Pressure
the 700 psig (5500 kPa) lube line to achieve a Gauges - Back-mounted, 1/4 inch - NPT). The
pressure differential below 1200 psig (8300 only exception to this rule is the 3000 psig
kPa). Select a valve spring (see Table: Balance (20000 kPa) gauge used with the 3250 psig
Valve Springs) by multiplying the highest lube (22400 kPa) rupture disk.
line pressure by 0.85 to calculate the balance
valve set pressure. For example, if the highest Table: Rupture Disk Data
lube line pressure is 2000 psig (13800 kPa), Rupture Disc Rated Pressure Blowout Orifice
the valve set pressure is 2000 x 0.85 = 1700 Color psig (kPa) Dia. in. (mm)
psig, which requires an orange spring.The
Purple 3250 (22400) 1/4 (6)
Ariel part number for the balance valve
without springs is CA-8005. The highest Yellow 3700 (26000) 1/8 (3)
pressure lube point requires no balance valve
Red 4600 (32000) 1/8 (3)
or pressure gauge.
Orange 5500 (38000) 1/8 (3)
Table: Balance Valve Springs
Aluminum 6400 (44000) 1/8 (3)
Set Pressure
Ariel Spring Blue 7300 (50000) 1/8 (3)
Spring Color Range psig
(only) Part No.
(kPa)
Table: Pressure Gauges - Back-mounted, 1/4
A-9662 Purple 750 to 1500
(5000 to 10000) inch - NPT
A-8087 Orange 1501 to 2250 Pressure Range, psig
Ariel Part No.
(10001 to 16000) (kPa)
A-8007 Brown 2251 to 3000 A-8727 0 to 3000 (0 to 20000)

(16001 to 21000)
A-8728 0 to 5000 (0 to 32000)
A-9912 White 3001 to 4000
A-9093 0 to 7500 (0 to 50000)
(21001 to 28000)
A-9911 Red 4001 to 5000

(28001 to 34000) Installing Balance Valves and Pressure
Gauges
3. Balance valves and pressure gauges are not
Before balance valve and pressure gauge
required for pump to point systems, zoned
systems, or any system that does not exceed installation, a mechanic should verify correct
1200 psi (8300 kPa) differential pressure. balance valve, spring, appropriate fittings, and
Tandem cylinder compressors with only one pressure gauge quantities. The highest pressure
tandem bore lube point that exceeds 1200 psi lube point of a given pump system requires no
(8300 kPa) differential pressure require no balance valve or pressure gauge.
balance valves or pressure gauges. With more
than two balance valves applied to a single 1. Install balance valves with the flow direction
divider block assembly, it is advisable to arrow properly positioned in the direction of
install a pressure gauge upstream of each oil flow toward the compressor cylinder.
balance valve. Pressure gauges aid in the 2. Install a pressure gauge, if required,
setting and adjustment of balance valves. upstream of each valve (between the balance
Select a pressure gauge with the maximum valve and distribution block).
pressure on the gauge face greater than or

3. Verify the maximum pressure on the gauge Adjustment of Balance Valves Fed by a
face is greater than or equal to rupture disk Divider Block
pressure – see Table: Rupture Disk Data. The
only exception to this rule is the 3000 psig Figure: Balance Valves Fed by Divider Block
(20000 kPa) gauge used with the 3250 psig
(22400 kPa) rupture disk.
4. Install the proper spring in each balance
valve as determined in the selection
procedure above for each applicable
pressure lube point line, and install the valve
cap.
5. Tighten the cap against the spring, but do not
compress the spring.
6. Tighten the lock nut against the cap, hand
1 Balance Valve
wrench tight.
2 Balance Valve Pressure Gauge
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.
4. Calculate the balance valve set pressure by
multiplying the maximum recorded pressure
by 0.85.
5. Set balance valve(s) downstream of the
selected divider block to the pressure
calculated in step 4 by rotating the
adjustment cap clockwise to increase
pressure. Set pressure within ±50 psi (3.5 bar)
of the calculated value.

6. Monitor the divider block gauge for one Adjustment of Balance Valves Fed by
minute and record the minimum and Primary/Secondary Divider Blocks
maximum pressures in Appendix E. The
difference between the minimum and Figure: Primary/Secondary Divider Block
maximum should not exceed 1200 psig (82.7 System
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
hours, then repeat step 6 for each divider
block.
1 Primary Balance Valve

2 Primary Balance Valve Pressure Gauge
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".

3. Repeat steps 1 and 2 for any remaining Subsequent Compressor Start-Up

secondary divider blocks that feed one or
more secondary balance valves nearest the Table: Balance Valve Part Numbers
compressor cylinder/packing.
Description Ariel Part No.
4. Select one primary divider block that feeds
Balance Valve without CA-8005
one or more primary balance valves located Spring
prior to a secondary divider block or lube
point. Balance Valve Springs See "Table: Balance Valve
Springs"
5. For the selected primary divider block and
balance valves, perform steps 2 through 7 in Balance Valve Seal Repair A-8005-K
Kit
"Adjustment of Balance Valves Fed by a
Divider Block". Balance Valve Plug A-10330
6. Repeat steps 4 and 5 for any remaining Pressure Gauges See "Table: Pressure
primary divider block that feeds one or more Gauges - Back-mounted,
balance valves located prior to a secondary 1/4 inch - NPT"
divider block or lube point.
1. Verify tightness of all fittings and fix any
7. After setting all balance valves in the force
known leaks. Purge force feed lube system.
feed system, operate the system for 4 to 6
hours, then repeat steps 3 through 7 in 2. If the force feed lube system has been
"Adjustment of Balance Valves Fed by a disassembled or parts replaced since the last
Divider Block" for each primary or secondary start-up, purge the force feed lube system
divider block. with a high-pressure hand purge pump. When
purging the system, use the same oil that is
recommended for the cylinder application, to
remove any trapped air or gas in the system.
DO NOT USE ANY OTHER FLUIDS FOR
PURGING! Call the Ariel Response Center for
details about purchasing a hand purge pump.
3. Start the compressor and bring up to normal
operating pressure.
4. Operate the unit for 2 to 3 hours to allow the
operating pressures to stabilize. DO NOT
adjust the balancing valves immediately after
start-up. It is possible that some lube point
injection pressures will fluctuate after a short
period of run time and the system pressures
will stabilize as components increase in
temperature.
5. See the cylinder lube sheets for balance valve
locations and proper spring type for each
device.
6. Select one divider block that feeds one or
more balance valves.

7. Monitor the selected divider block gauge for same manner, provided the final pump
one minute and record the minimum and stroke is not too short. Try to keep the stroke
maximum pressures in Appendix E. greater than 20% of maximum; a shorter
8. See "Selecting Balance Valves and Pressure stroke produces unreliable pump output. If
Gauges" if any of the conditions below occur: needed, close one pump to stop its flow and
a. The difference between the maximum open the other(s) to make the “normal” cycle
and minimum recorded divider block time, and maintain a stroke greater than 20%
pressures exceeds 1200 psig (82.7 barg). in the functioning pump(s).
b. The maximum recorded balance valve
pressure exceeds 85% of the maximum 4. In some applications, one divider valve
recorded divider block pressure. delivers lubrication to both a packing and a
c. The divider block gauge exhibits erratic cylinder to optimize lubrication system oper-
needle movement as the divider block ation. In some applications, cross-ported
cycles. divider valves deliver the proper proportion
of lubricant to a given point.
Force Feed System Design, 5. During operation, verify oil fills the lubricator
Operating Parameters, and reservoir sight glass to the overflow line.
Reservoir oil lubricates the worm gear and
Conditions cam; it does not flow through the system. The
reservoir also catches force feed lube pump
See specific packager data to confirm designed
leakage. Add oil only if needed to raise reser-
gas composition, operating pressures, and
voir oil level. See Table: Force Feed Lubri-
speed. If operating outside design conditions,
cator Reservoir Oil Capacity.
system may need to be reviewed. To optimize
force-feed lubrication system operation, Ariel Table: Force Feed Lubricator Reservoir Oil
uses these general guidelines: Capacity
1. Maintain lube rates within prescribed limits
Lubricator Type Ariel
and cycle times as low as possible (normally US Gallons (Liters)
Designs
10 sec minimum) to lubricate each point as
Single Pump 0.25 (1)
frequently as possible.
Dual Pump 0.5 (1.75)
2. Multiple pumps may be manifolded to
achieve required lubrication rates. Four Pump 0.8 (3)
3. Do not operate pumps below 20% of full 6. Ariel primes the force feed system with
stroke or they become inconsistent. When mineral oil. If tubing is missing, or if the
two or more pumps are manifolded to feed system is drained, fill and prime the system
one distribution block, adjust them equally. through a 1/8 inch plug on the discharge end
Start with pumps wide open, and adjust them of the force feed lubricator pump.
together so that when break-in cycle time is
set, the pumps stroke about the same. After
break-in period, adjust the pumps in the

7. Prime the force feed lubrication system with 8. For recently overhauled units, adjust force
a proper priming pump just prior to starting feed cycle time for maximum delivery.
the compressor (see "Force Feed Lubricator" Loosen adjusting screw locknut. Turn
for pump illustration). Use clean force feed plunger stroke adjustment screw to the full
lubricating oil of same type and grade as used up position. Tighten adjusting screw locknut.
in service. Do not use any other fluid type or After two hours of operation or before leaving
grade to prime. site, reset to “normal” cycle time.
Common Oil Supply

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

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

supply pressurized force feed lube oil at a
When cylinders and packing require oil different minimum of 1 psig (0.07 barg) to the force feed
from frame oil, the force feed lubricator system pump inlet manifold.
requires an independent oil supply system (see
Figure: Force Feed Lubrication System

To prevent force feed oil from contaminating • Increase pipe and fitting size from tank to
compressor frame oil, disconnect lubricator box force feed pump.
overflow tubing from compressor frame and • Heat the oil.
direct it to a suitable drain system. • Heat trace and insulate the line from the tank.
• Pressurize the supply tank (tank must be
Independent force feed lube systems require oil designed for pressure).
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 Lube Rate and Speed - Recommended lube

rates for break-in or normal operation, in
Conditions seconds per cycle, are calculated at the frame
rated speed (RPM) stamped on the frame data
plate or the cylinder rated RPM stamped on the
CAUTION cylinder data plate, whichever is lower. Lube rate
To prevent personal injury, verify driver or compressor decreases with speed, (as compressor actual
cylinder gas pressure cannot turn compressor running speed decreases, cycle time increases,
crankshaft during maintenance. Before any
maintenance or component removal, relieve all pressure reducing lube rate):
from compressor cylinders. See Packager’s instructions
to completely vent the system. After maintenance, purge (RPMmax ÷ RPMactual) x cycle time seconds from
the entire system with gas prior to operation to avoid a lube plate = cycle time seconds at actual running
potentially explosive air/gas mixture.
speed.
See the Ariel Parts Book Lubrication Sheets for
Cycle Time the Cycle Time (seconds) vs. RPM (compressor
Lubricant flow rates are measured in seconds per speed) table at various running speeds at stated
cycle of the distribution block. The calculated gas operating conditions and lubricant.
break-in and normal cycle times are stamped on Adjusting the cycle time changes the lubrication
the lubricator box data plate. These cycle times rate for all the compressor cylinders and
are calculated based on the gas analysis, packings supplied by a particular pump. To
operating conditions, and applied speed change the lubrication rate for only one cylinder
specified in the compressor order. If gas or packing requires individual divider valve
conditions were not supplied with the changes. Contact your packager or Ariel for
compressor order, the data plate/lube sheet information.
rates default to clean, dry, 0.65 specific gravity,
sweet gas and cylinder MAWP. If the applied To set proper force-feed lubricator pump flow
speed is not specified, the cycle time is based on rate, read or measure the cycle time from the
maximum rated speed of the frame or cylinders, installed device. For a magnetic cycle indicator
whichever is less. The lube sheets in the Ariel assembly, time the cycle from initial indicator pin
Parts Book state gas conditions and list the base movement at the fully retracted position to the
rate multiplier at each lube point. time when the pin returns to the fully retracted
position and just begins initial movement out
Break-in Rate - Set the break-in lube rate about again. Adjust the lubricator pump to provide the
twice the recommended daily rate (150% required cycle time.
minimum); i.e. set the break-in cycle time about
half the normal cycle time (67% max.) to increase NOTE: Pump output can become inconsistent if flow
lube rate. Maintain break-in rate for 200 hours of rate is set too low. See “Force Feed System Design,
operation for new equipment. Contact Ariel if Operating Parameters, and Conditions”.
existing pump is incapable of minimum flow rate
required.

Changes in operating conditions (such as gas Cylinder Lubrication Paper Test

properties or pressures, temperatures, flow
requirements, or cylinder re-configuration) 1. Remove head end head and position piston
require lubrication rate re-calculation and for the desired cylinder at inner dead center.
possible force-feed lubrication system 2. Using light pressure, wipe the cylinder bore
alteration. Consult the Ariel Packager Standards, with two layers of regular unwaxed cigarette
the Packager, and/or Ariel. paper together. Begin at the top and wipe
downward about 20° along the bore
circumference. The paper against the bore
Under/Over Lube surface should be stained (wetted with oil),
but the second paper should not be soaked
Inadequate lubrication causes premature wear through.
of piston and packing ring materials. Indications 3. Repeat the test at both sides of the bore at
of under lubrication are black, gummy deposits about 90° from the top, using two clean
in the distance piece, packing case, cylinder, and papers for each side. Paper against the bore
valves. When symptoms indicate under surface not stained through may indicate
lubrication: under-lubrication; both papers stained
through may indicate over-lubrication. In
• Verify proper operation of force feed lubri- either case, Ariel normally recommends
cator pumps. changing lubrication rate accordingly and
• Confirm distribution block cycle time repeating all paper tests until passed.
matches the lube sheet or force feed lubri-
cator data plate. 4. Repeat this procedure for all cylinders. If the
test indicates a lubrication rate reduction or
• Verify all tubing and fitting tightness; check
increase for a cylinder, change in 5%
for leakage. Check fittings inside cylinder gas
increments by adjusting cycle time at the
passages.
force feed lube pump (see "Pump
• Pressure test or replace divider valves to Adjustment"). Repeat oil film testing, for
ensure they do not bypass. affected cylinders, after 24 hours of
Over lubrication can result in excessive oil operation. For a formal lube rate reduction
carryover into the gas stream, and increased program, see Ariel ER-125.
NOTE: The paper test indicates only oil film quantity.
valve and gas passage deposits. Valve plate
Aftermarket devices exist that measure flow. Neither
breakage and packing failure may also indicate method indicates viscosity quality. Oils diluted with
over-lubrication. water, hydrocarbons, or other constituents may
appear to produce an adequate film or flow, but dilu-
tion will reduce lubricant effectiveness below require-
ments.

Coolant System Requirements

Coolant flow = number of packing cases x 1 US
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 (0.7-2.1 bar). Coolant into the packing must not
piston rod. exceed 130°F maximum (54°C max.). Lower
• 2 packing cases x 1 gpm per inch of rod diam- coolant temperature increases heat transfer
eter x 2.0 inch rod diameter = 4 gpm from the packing and may be required in high-
• (2 packing cases x 0.149 l/min per mm of rod pressure applications.
diameter x 50.8 mm rod diameter = 15.1
Coolant inlet pressure should be 40-80 psig (2.8-
l/min)
5.5 barg). 300 psig (20.7 barg) is the maximum to
Cooler size = number of cases x 70 preserve the o-ring seal between the cups.
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

Part Replacement
Major frame assembly components include the Relieving Gas Pressure
crankcase, crankshaft and bearings, connecting
rods, chain drive system, crossheads, and Before conducting maintenance on the
guides/distance pieces. Removable end covers, compressor, it is vital to ensure the cylinders
an aluminum top cover, and crosshead guide contain no gas pressure. During maintenance,
side covers provide easy access to internal unrelieved gas pressure could cause equipment
components. Below are general guidelines to damage, personal injury, or even death.
follow during maintenance.
1. Cleanliness during part replacement: Isolation
• Use lint-free wiping cloths.
Isolate the compression system from all energy
• When not working on a frame with access
sources prior to any maintenance. To ensure the
covers removed, cover it to protect the
interior from rain, dust, and other system remains isolated during maintenance, a
airborne debris. lock out procedure is required. This is a
• Place removed components in a safe requirement of most corporate policies and
place away from work area to prevent occupational safety regulatory agencies. The
damage. Take precautions to keep parts extent of the isolation depends on the system.
from rusting.
2. Gasket maintenance:
Depressurization
• When dismantling the machine, carefully
inspect gaskets at non-pressure loca- Fully depressurize the compression system prior
tions. If damaged, replace them. to any maintenance. If the application involves a
• Always replace pressure-retaining corrosive or poisonous gas, purging is necessary
gaskets. to remove the hazard. There are many different
• Always apply an anti-seize lubricant to configurations of compression systems, so refer
both sides of metallic gaskets. to the information provided by the system
3. For major overhauls, drain and flush the provider for depressurization. In general, the
crankcase. following steps are required:
If replacing a connecting rod assembly, piston, 1. Isolate inlet gas from entering the system.
piston and rod assembly, crosshead-balance 2. Isolate discharge gas from entering the
nuts, or crosshead, weigh component parts and system.
compare to the Compressor Balancing Record 3. Vent and isolate scrubber dump lines, vent
included in the parts manual with each and drain lines, flare vent lines, and any
compressor. If there are weight changes, common blow-down lines to prevent back-
recalculate opposing throw reciprocating weight flow into the system.
differential. See "Opposed Throw - Reciprocating
Weight Balancing” in Appendix C. 4. Open the system blow-down line and reduce
the system pressure to atmospheric.

JG-JGA Maintenance & Repair Manual – Part Replacement 01/27/2023
5. If so equipped, open the indicator valves on crossheads slide toward the crankcase as far as
the individual cylinders to remove any possible. In the outer dead center position, the
residual pressure in the cylinder(s). crossheads slide away from the crankcase as far
as possible (see figure below). Some procedures
WARNING
require a dial indicator with magnetic base to
Process gas from these valves can be under high locate the precise inner or outer dead center. At
pressure if the system is not depressurized properly and
other times, a procedure may require turning the
can be flammable and/or poisonous depending on the
application. crankshaft so a throw occupies its highest or
lowest position. In the figure below, the throw on
the left is in its highest position and the throw on
Positioning a Throw the right is in its lowest position.
WARNING
To reduce risk of injury or death, only trained personnel

who have read and thoroughly understand the
tional procedures.
• Never tighten or loosen any fastener while the unit is
• Verify neither driver nor compressor can turn during
maintenance.
and vent the system; call the packager for assis-
tance.
AND/OR FLAMMABLE.
explosive gas/air mixture in the system. A gas/air
mixture under pressure can explode and cause severe
injury or death.
Component replacement often requires

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

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 VVCP Disassembly

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

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 • Retaining Plate

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

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

Users may change VVCP clearance volume with and 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 =
A A
FULLY OPEN A =
REMOVE ALUMINUM THREAD PROTECTOR WHERE APPLICABLE VVCP S.N.
Required Tools and Materials
1. For VVCP with a bellows thread protector: • Appropriate Ariel parts list
Loosen the locking handle so the adjustment • Appropriate Ariel Maintenance and Repair
handle can turn freely. For VVCP with a manual
metal thread protector: Unscrew the metal • Calibrated torque wrench with the appro-
thread protector.Loosen the locking handle priate range for target values
or adjustment locknut so the piston stem can • Lubricant specified in Appendix A
turn freely. • Appropriate personal protection equipment
2. Find the VVCP dimension plate. • Bottle brush
3. Subtract fully closed dimension from fully • Pressurized liquid solvent
open dimension. The Ariel Performance • Valve Tool
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 6 Valve

Energized Seal 7 Valve Gasket
8 Keeper Bolt
9 2-Piece Wedge Lock Washer
10 Spring Energized Seal
WARNING
1. Remove cap nuts from long studs.
who have read and thoroughly understand the 2. Slightly loosen all hex nuts on each valve cap
appropriate Ariel Technical Manual and Packager in steps and evenly. With all the nuts loose,
information should attempt any maintenance. the cap should stay in its original position. If it
pushes out of its own accord, STOP!
Completely vent the cylinder. See Warning
tional procedures. above.
• Never tighten or loosen any fastener while the unit is 3. After the above safety checks and with hex
nuts still in place but loosened, remove hex
maintenance.
nuts from short studs.
• Follow packager instructions to completely isolate 4. Evenly back off hex nuts on long studs while
and vent the system; call the packager for assis- pulling the valve cap from the cylinder. Use a
tance.
pair of pry bars, one on each side of the cap,
to remove the cap. Ensure the spring
pressure after blowdown, open the “Kiene” valves energized seal completely disengages from
on the indicator ports, if so equipped. the cylinder before removing the hex nuts
WARNING: RELEASED GAS MAY BE POISONOUS from long studs.
AND/OR FLAMMABLE. NOTE: Long studs are assembled with thread locker
Before resuming operation, purge the entire system with to eliminate the possibility of the studs backing out of
the cylinder while the hex nut is removed.
mixture under pressure can explode and cause severe 5. Remove long stud hex nuts and valve cap.
injury or death.
6. Inspect seal for damage. If undamaged, the
spring energized seal is re-usable.
Figure: High-Pressure Valve Cap Assembly with
Spring Energized Seal
CAUTION
Valve cap, retainer, and/or valve may fall out of bottom

pockets if not supported. Support them carefully after
removing hex nuts to prevent personal injury.
1 Hex Nut
2 Cap Nut
3 Valve Cap
4 Seal Keeper
5 Retainer

Valve Removal 4. Remove the valve and retainer together.

5. In most cases, the flat metal gasket remains
1. With the valve cap removed and the valve
in the pocket. It is difficult to see. A flashlight
retainer still in place, install a valve tool onto
and a small mirror on an adjustable rod are
the valve center bolt or threaded washer. See
the best tools to see the gasket clearly. On
Section 1 for an illustration of the tool.
cylinders with horizontal valves, the gasket
2. It may be necessary to loosen the plastic may fall into the gas passage. Use a small
thumb screws in the valve retainers. In some magnet on a flexible extension rod to remove
cylinder classes, the discharge valve retainer gasket from cylinder.
is held in place with an O-ring - simply pull the
6. Head end tandem cylinders may require
retainer out to remove it.
removal of suction and discharge piping and
3. For high pressure applications that use a the cylinder head to access the concentric
metallic wire gasket seal under the valve cap, valve. A concentric valve combines suction
the cylinder vents upon loosening the cap and discharge valves in one assembly.
screws. Use the valve tool to unseat the
metallic wire gasket.
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 valve fastener(s) positioned away from the
insert it into the valve pocket or stick it on the cylinder bore (see Item 1, Figure: Typical
valve. In either case, do not allow the gasket Valve Assemblies). If a valve is not marked for
to fall into the gas passage. Replace valve suction or discharge, manually depress the
seat gaskets anytime a valve is removed from valve plate to verify the type. Preferably, use
a cylinder, if the unit has been in service. a tool softer than the valve plate material or
2. Install suction valves only in suction pockets exercise care to prevent damage to the plate.
and discharge valves only in discharge
pockets. The valve pockets have
identification plates. Install all valves with

A suction valve plate may be depressed only Ensure all threads are clean and free of debris or
from the valve fastener (bolting) side of the burrs. Use a bottle brush and pressurized liquid
valve; a discharge valve plate may be solvent to clean threaded holes thoroughly.
depressed only from the side of the valve that Avoid sending debris into cylinder gas passage.
faces the cylinder bore.
Bolts should thread into hole and bottom out on
3. Use the valve tool to insert the valve and the valve cap by hand without resistance or use
retainer into the pocket together (see tools of a wrench. If bolts do not thread into hole
for your compressor model in Section 1).
freely, contact ARC for thread repair instructions.
Verify the valve seats properly in the pocket.
When installed correctly, the valve rotates See Appendix A for critical information on torque
freely by hand. accuracy. Valve cap bolt failures can occur if the
4. Plastic thumbscrews or o-rings hold valve cap is torqued improperly. Draw bolting to full
retainers in position in bottom valve pockets. torque in even, gradual steps, without bias on
Tighten thumbscrews just enough to provide one bolt or cocking the valve cap in the bore.
friction so retainers and valves in bottom
Such bias or cocking can unevenly crush the
pockets stay in position during valve cap
installation. Do not replace plastic gasket, which may cause leakage and/or bolt
thumbscrews with metal. failure. In correct assemblies with new valves, the
distance from the underside of the cap to the
5. Lubricate a new O-ring with oil and install it in
the groove on the valve cap nose. Some high surface of the cylinder is a uniform 1/8 inch (3
pressure cylinders use a soft metallic wire mm). The distance is slightly less with re-worked
gasket or spring-energized seal in lieu of the valves. Proper tightening of gas containment
O-ring. Continue to "Valve Cap Installation". fasteners is critical to ensure safe and reliable
operation.
Valve Cap Installation
Depending on the application, Ariel compressor CAUTION
cylinders utilize different styles of valve caps.
Severe personal injury and property damage may result
Cast iron cylinders utilize valve caps in which an from improperly torqued valve cap bolts. See Appendix
O-ring on the valve cap seals gas within the A for correct torque and detailed recommendations.
cylinder.Forged steel cylinders utilize a valve cap
with either a spring-energized seal or a round Installation of Valve Caps on Cast Iron
metallic gasket to seal gas within the cylinder. Cylinders or High-Pressure Caps
The valve cap presses the round metallic gasket
without Spring Energized Seals
into a triangular cross section during the torque
procedure. 1. Install valve assembly (and high clearance
spacer, if applicable), with the valve seat
gasket and valve retainer in the valve pocket.
See "Valve Installation".
2. For high-pressure valve caps only: Place a
new, round, metallic wire gasket. Always use
a new wire gasket when installing a high-
pressure valve cap; gaskets are not re-
useable.

3. Oil and install a new O-ring on the valve cap. 5. For high-pressure applications, the valve cap
Install the valve cap. joint design requires pressing a round
4. For standard fasteners in iron cylinders, metallic wire gasket into a triangular cross
lubricate threads and bolt seating surfaces section (see Figure: Gasket Crush). This
with mineral oil. For stainless steel fasteners requires multiple passes in a crisscross
or in steel cylinders, lubricate threads and pattern with the torque wrench. See
bolt seating surfaces with Never Seez regular Appendix A
grade. Do not use Never Seez on standard
fasteners. See Appendix A for correct valve
cap bolt torque.
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

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

Gas Containment Fastener Torque Piston and Rod Removal

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

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

3. Clamp the piston and rod assembly in an

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

1 Allen Wrench (for piston nut setscrews)
2 Torque Multiplier
3 Clamping Fixture
4 Spanner (bolts to piston nut)
5 Torque Wrench
4. Remove piston nut using piston nut spanner. 2. Inspect collar (or collar area on rod, when
collar is integral and not separable), piston,
5. After piston nut removal, slip the piston and
and piston nut for nicks, burrs, or scratches.
collar off the end of the piston rod.
Replace if surfaces are damaged, worn, or
galled. Inspect piston ring grooves. If
Piston and Rod Manual damaged, or ring groove width is out of
Reassembly tolerance, replace the piston (see Appendix B
for tolerances). Dress surfaces with a fine grit
1. Clean all piston and rod assembly parts stone as required. Fit collar and nut into
thoroughly.Verify piston is internally clean piston to verify the outside diameter fits and
and dry. turns freely by hand in the piston.
NOTE: Any reassembly of used parts requires re- 3. Inspect piston rod threads and collar
cleaning and re-lubrication of threads and seating shoulder. Clean and de-burr threads. Install
surfaces. collar and nut onto piston rod to verify inside
diameter fits and rotates freely. Turn piston
nut until rod threads protrude to verify
freedom of thread engagement. Remove nut
and collar.

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

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
use dots as match marks - verify the dots
face the pressure side of cylinder. Two-
piece piston rings and wear bands are
manufactured as matched sets; mixing
ring halves may result in incorrect end
gaps.
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.

7. Set piston end clearance (see Appendix B): Piston Rod Runout
a. Using the piston nut spanner, turn the
piston rod into the crosshead. Table: JG:JGA Max. Piston Rod Runout, Inch
b. Place a long feeler gauge equal to the (mm)a
crank end clearance required in the crank
Vertical 0.0010 (0.025)
end top valve pocket between the piston
and the crank end head.For 13 in. (330 Horizontal 0.0005 (0.013)
mm) and larger cylinders, insert feeler a Machines with readings falling outside the limits
gauge through a bottom valve pocket. require disposition by Ariel.
c. Tighten piston against the feeler gauge so
the feeler gauge cannot be pulled out. Check piston rod runout after new unit
d. Tighten the crosshead nut against the installation, unit relocation, or maintenance that
crosshead. may affect rod runout.
e. Tighten the crosshead nut by the slugging
method. See "Crosshead Installation" for Position the stem of a 0.0001 inch (0.001 mm)
hydraulic torquing device. increment calibrated dial indicator against the
f. Tighten the balance nut set screws and be piston rod, close to the packing case. Set the
sure to remove the piston nut spanner. indicator to zero with the piston toward the
crank end. Bar over crankshaft and record
8. See "Crosshead Installation" for details to re-
attach piston rod to crosshead, check piston indicator readings with the piston at mid-stroke
end clearance, piston rod runout and and H. E. positions, in both vertical and
crosshead clearances, and re-assemble to horizontal directions. Record upward vertical rod
close cylinder and crosshead guide. See movement as positive and downward as
Appendix B and "Piston Rod Runout". negative. Record horizontal rod movement
toward the auxiliary end of the frame as positive
and toward the drive end as negative. Copy the
CAUTION
table below to record readings and compare to
Ariel recommends leaving distance piece covers off after Table: JG:JGA Max. Piston Rod Runout, Inch
any piston rod or rod packing ring maintenance. Verify
no ignition sources exist in the area, pressurize the unit, (mm) values.
and check for gas leaks before distance piece cover
installation. This protects against crosshead guide over-
pressure and possible ignition due to incorrect
installation of packing case or components. When
checking for leaks, take proper precautions in process
gas applications, such as H2S.

Table: Piston Rod Runout, Inches

Throw 1 2 3 4 5 6
Vertical (0°) Piston @ C. E. 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000
Mid-Stroke
Piston @ H. E.
Horizontal (0°) Piston @ C. E. 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000
Mid-Stroke
Piston @ H. E.
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 without pistons (see Appendix B for minimum

end gap dimensions).
Most cylinders use one-piece angle-cut filled
PTFE piston rings. High-pressure cylinders use
two-piece thermoplastic rings. Ariel
Seal-Joint Piston Rings
recommends replacing rings when the end gap Seal-joint piston rings are directional and require
increases to three times the new dimension. To correct installation.
measure end gaps, insert rings in the cylinders

NOTE: On tandem cylinders with a combination of

Straight-Cut Chamfered Piston
seal-joint rings and other ring styles, always position Rings
the seal-joint rings farthest from the pressure side.
See Figure: Seal-Joint, Straight-Cut, and Angle-Cut Straight-cut chamfered piston rings are
Piston Ring Installation Orientation. directional and require correct installation.
Install them with chamfers or dots toward the
pressure and with the end gaps staggered.
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
Face-cut piston rings are typically used in
cylinders with 2500 psi MAWP or higher, and
generally with notched and fluted wear bands.
The rings install with the face cuts toward the
highest pressure, or toward the nearest head.
Gas pressure in the wear band area escapes past
the piston rings via the face cuts during the
suction stroke to prevent loading the wear band
and increase service life. Also, do not align the
ring end gaps; stagger them to minimize gas
leakage.

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

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

Piston Rod Packing 3. Disconnect all tubing and instrumentation (if

applicable) from packing flange. Ensure there
The piston rod packing prevents gas from is no debris in the tubing between the check
entering the crosshead guide. Piston rod rings valve and packing flange. Remove the twelve-
within the packing wear over time and need point cap screws that hold the pressure
packing gland to the crank end of the
replacement.
cylinder/head.
4. Typically, the small nuts are not removed
Piston Rod Packing Removal 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
WARNING
guide doors, so removal of the small nuts and
To reduce risk of injury or death, only trained personnel the packing flange is necessary. For certain
who have read and thoroughly understand the longer, higher pressure rating packing cases,
knurled nuts hold the remaining packing
Prior to performing any maintenance activities: assembly together to assist with installation
• Always wear appropriate personal protection equip- and removal.
ment and follow your company safety and opera- 5. Remove the pressure packing and take it to a
tional procedures.
clean place for disassembly.
operating or pressurized. 6. Set pressure packing on a clean surface on its
• Verify neither driver nor compressor can turn during nose cup or cylinder end. Usually, packing
maintenance. cups are marked to represent the assembly
order starting with the cup closest to the
tance. cylinder as number 1. If the cups are not
• Verify each compressor cylinder is relieved to atmo- matchmarked, then match mark the outside
spheric pressure. To relieve residual cylinder bore diameter of the cups and flange for proper
pressure after blowdown, open the “Kiene” valves reassembly. Long tie studs hold the pressure
on the indicator ports, if so equipped. packing together. The stud holes are
WARNING: RELEASED GAS MAY BE POISONOUS unequally spaced to prevent misalignment of
AND/OR FLAMMABLE. the stack of parts. Remove the nuts and
unstack the pressure packing. Replace these
explosive gas/air mixture in the system. A gas/air nuts each time the pressure packing is
mixture under pressure can explode and cause severe serviced.
injury or death.
7. To check ring wear, place assembled rings
(note match-marks) on the piston rod. Check
1. Remove piston and piston rod. See "Piston end gap clearance. If the ends butt, or nearly
and Rod Removal". butt, replace the rings. See "Types of Piston
2. Remove packing diaphragm (if applicable) Rod Packing Rings" for correct ring
and oil wiper packing. orientation.

8. Pry loose the metal or spiral-wound gasket Piston Rod Packing Reassembly
on the end cup with a sharp awl. Do not
scratch the sides of the gasket groove.
and Installation
Discard the used gasket.
9. Before reassembly, clean all parts
thoroughly.
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 4. Before a packing case installation,

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

6. Lay out parts on a work bench for progressive 8. Verify the gasket surface in the packing
installation, with each part in its correct counter bore on the crank end of the
position and the rod rings with their proper cylinder/head is clean and not scratched.
faces toward the pressure. Long tie studs Install a new end cup gasket. Round wire
hold the pressure packing together. The stud gaskets will fit tightly in the gasket
holes are unequally spaced to prevent groove.Spiral-wound or other gasket styles
misalignment of the stack of parts. Note that require application of grease (or adhesive for
all rod ring segments are carefully lettered; non-lube applications) to hold them in place.
assemble them accordingly. This is most
9. Reinstall complete packing case assembly
important for proper sealing. Center side-
with oil supply point on top. Use rod packing
loaded WAT and AL rings prior to tightening
bolts to pull packing into place.
tie stud nuts. Install tie stud nuts and tighten
to the torques in Appendix A. Manually verify 10. Reinstall packing diaphragm (if applicable)
all rings move freely, radially, in their and wiper packing.
grooves. Side-loaded rings are tight, but 11. Reinstall piston and rod. See "Piston and Rod
should still move manually. Center these Installation".
rings.
12. After tightening the crosshead nut, visually
Packing reassembly:
align the packing, to maintain a uniform
a. With no gasket installed, install the studs clearance between the packing case bore and
into the end cup (cup # 1). the piston rod.Tighten rod packing bolts
b. Using cylinder oil, lubricate the cup and evenly in a criss-cross pattern to the
the pressure breaker ring or ring set, then recommended torque in Appendix A. This
install them into cup (see pressure procedure squares the pressure packing on
packing assembly drawing for correct its nose gasket. Rod packing bolt tightening
orientation). on high pressure cylinders requires a torque
c. Install cup # 2 and repeat Step b for the multiplier.
seal ring sets. NOTE: Repeat final torque for rod packing bolts until
the bolts no longer turn. Re-check torque on these
d. Repeat steps above for cups #3, #4, etc,
fasteners at the next service interval.
until packing case is reassembled per the
pressure packing assembly drawing. 13. Retighten tie stud nuts. Reinstall tubing
e. Using a clean oil pump filled with cylinder connections and instruments (if applicable).
oil, squirt oil into the lube fitting(s). If the Take care not to cross-thread tubing nuts.
packing is assembled correctly, the oil will Tubing nuts must be tight.
come out the lube cup. If not, disassemble
the packing and correct the error.
f. Using pressurized air, repeat the above
process for vent and purge lines.
g. For cooled packings the cooling circuit
must be pressure tested (see "Testing").
7. For new installations, carefully clean all
accumulated dirt in the lines and
compressor. Any foreign material lodges in
the packing and becomes destructively
abrasive.

NOTE: After pressure packing installation, see “Force Reassembly

Feed Lubricator” in Section 3 to prime the force feed
lube system and obtain recommended lubrication Figure: Cooled Packing Turnaround Cups
rates for new machine break-in. Priming may be
necessary after extended down time. Break-in lube
rates are approximately twice the normal rates, or
half the normal cycle time.
CAUTION
Ariel recommends leaving distance piece covers off after

any piston rod or rod packing ring maintenance. Verify
no ignition sources exist in the area, pressurize the unit,
and check for gas leaks before distance piece cover
installation. This protects against crosshead guide over-
pressure and possible ignition due to incorrect
installation of packing case or components. When
checking for leaks, take proper precautions in process
gas applications, such as H2S.
1 Coolant turnaround cup circumferential identifica-

Reassembling and Testing Cooled tion groove (all - beginning 2006)
Packing Cases 2 O-Ring Grove
In the event of disassembly, the procedures See pressure packing assembly in the parts book
below detail the reassembly of cooled rod supplied with the unit. Contact the distributor to
packing cases and testing for proper assembly. obtain a parts book. A pressure packing assembly
See also "Piston Rod Packing Reassembly and drawing comes with each pressure packing re-
Installation" and "Types of Piston Rod Packing build kit.
Rings".
Cooled cases are lapped. Take special care not to
scratch cup mating surfaces; it can cause
significant problems. Cup surfaces must be clean
and dry for reassembly.
1. The cups are numbered on the outside
diameter. Assemble them in consecutive
order, starting with the end cup. The offset
studs allow the cups to fit only one way.
2. Ensure the tie studs thread completely into
the end cup. Install the proper ring facing the
proper direction in the groove. Do not scratch
lapped faces when sliding parts onto tie
studs.
3. Install next cup. Install the rings and verify
installation of the two (2) small O-rings
around the coolant holes.

4. Repeat step 3 to assemble remaining parts in Long Two-Compartment

consecutive order per the packing case
drawing.
Intermediate Packing
5. Install tie stud nuts. Tighten 10-24 nuts to 20 Compressors supplied with long two-
Lb x In (2.3 N•m), 1/4-20 to 72 Lb x In (8.1 N•m), compartment distance pieces include an
and 5/16-18 to 144 Lb x In (16 N•m). Verify all intermediate packing assembly that seals
rings move freely, radially, in the grooves. around the rod between the outboard and
Side loaded WAT and AL rings are snug, but
inboard distance pieces. This packing assembly
should move manually.
includes a single AL ring set.
Testing For lubricated service, the force feed lube oils the
1. Verify 100% function for all internal passages. top of the ring set at a very low rate because this
Blow dry, oil-free compressed air through the ring set is not subject to cylinder pressures and
connection taps on the flange and verify that temperatures. The end-to-end seal in the cup
air exits at the proper holes. Air applied to the and the low lube rate of AL ring sets, ensures
connection tap stamped “Coolant In” should newly installed rings run virtually dry for the first
exit the connection tap stamped “Coolant
few hours of operation. To avoid damage to the
Out”. Air applied to the tap stamped “Lube”
should exit the appropriate cup on the inside rings and rod, copiously oil the ring set during
diameter of the case. installation, before rod installation. Use only the
same lubricant in the force feed lube system. If
2. Pressure leak test packing cases as follows:
non-lube, see Appendix F.
a. Plug the “Coolant Out” connection.
b. Apply 60 to 100 psig dry, oil-free
compressed air to the “Coolant In” Types of Piston Rod Packing Rings
connection through a ball valve with a
calibrated pressure gauge located There are several types of piston rod packing
between the ball valve and packing case. rings depending on the application. Below are
c. Close the ball valve and disconnect the air those used in Ariel JG:JGA compressors.
supply. There should be no pressure drop
for 5 minutes, minimum. “P” Pressure Breaker
3. Disassemble, inspect, correct, re-assemble, This single ring is cut radially into three equal
and re-test any case that fails testing. To aid segments. It breaks down or slows gas flow
sealing, bolt a packing case into place in a
without sealing it completely.
cylinder head with properly torqued original
packing retention bolts.

Figure: “P” Pressure Breaker Figure: “UP” Pressure Breaker
1 Pressure 1 Pressure
“PB1” Pressure Breaker “P1U” Pressure Breaker

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

“BTR” Single-Acting Seal Set Figure: “BD” Double-Acting Seal Set
This three-ring set seals in one direction only. The

first ring (pressure side) is radially cut. The
second ring is tangentially step cut and made of
the same material as the first ring. These two
rings are doweled to stagger the cuts from one
ring to the other. The third ring is called a back-
up ring. It is radially cut and has a bore larger
than the rod diameter. This allows the radial
joints to form a tight gas seal. This ring needs no
dowel. 1 Pressure
Figure: “BTR” Single-Acting Seal Set Double "WAT" Double-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
1 Pressure set primarily for low pressure applications. WAT
rings must be centered when installed in the
“BD” Double-Acting Seal Set packing case.
This two-ring set consists of tangentially step cut Figure: Double "WAT" Double-Acting Seal Set
rings doweled to stagger the tangential cuts from
one ring to the other. This double acting set seals
in either direction. In cylinders operating near
atmospheric pressure, it prevents air from
entering the cylinder. Install with the match mark
letters facing towards the cylinder.
1 Pressure
“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 Figure: “BTS” Single-Acting Seal Set
1 Pressure
1 Pressure
“BT” Single-Acting Seal Set
This two-ring set seals in one direction only. The “BTU” Single-Acting Seal Set
first ring (pressure side) is radially cut; the second
is tangentially step cut. The rings are doweled to
stagger the cuts from one ring to the other and
second is tangentially step cut. These first two
form a tight gas seal.
rings are doweled to stagger the cuts from one
Figure: “BT” Single-Acting Seal Set ring to the other. The third ring is called a back-
up ring. It is an uncut one-piece ring with
clearance over the rod, allowing the joints of the
first two rings to form a gas-tight seal. In many
applications, the uncut ring will deflect under
pressure and seal against the piston rod.
Figure: “BTU” Single-Acting Seal Set
1 Pressure
“BTS” Single-Acting Seal Set

1 Pressure
second ring is tangentially step cut. These first
two rings are doweled to stagger the cuts from
one ring to the other. The third ring is called a
back-up ring. It is an uncut one-piece ring with
clearance over the rod. It allows the joints of the
first two rings to form a gas-tight seal and
prevents extrusion of the tangent ring.

“BTUU” Single-Acting Seal Set “CUU” Single-Acting Seal Set

This four-ring set seals in one direction only. The This four-ring set seals in one direction only. The
first ring (pressure side) is radially cut; the second first ring (pressure side) is radially cut; the second
is tangentially step cut. These rings are doweled is tangentially cut. These rings are doweled to
to stagger the cuts from one ring to the other. The stagger the cuts from one ring to the other. The
third and fourth are uncut one-piece rings with third and fourth rings are solid and have bores
clearance over the rod, allowing the joints of the larger than the rod diameter, allowing the radial
first two rings to form a gas-tight seal. In many joints of the first two rings to form a tight gas seal.
applications, the uncut rings will deflect under
Figure: “CUU” Single-Acting Seal Set
pressure and seal against the piston rod.
Figure: “BTUU” Single-Acting Seal Set
1 Pressure
1 Pressure “RS3” Single-Acting Seal Set

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

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

This two-ring set consists of tangentially step cut This three-ring set seals in one direction only. The
rings doweled to stagger the tangential cuts from first ring (pressure side) is radially cut. The
one ring to the other. This double acting set seals second ring is tangentially cut. The first two rings
in either direction. In cylinders operating near are doweled to stagger the cuts from one ring to
atmospheric pressure, it prevents air from the other. The third ring is called a back-up ring.
entering the cylinder. Install with the match mark It is radially cut and has a bore larger than the rod
letters facing towards the cylinder. diameter to allow the radial joints to form a tight
gas seal.
Figure: “DS” Double-Acting Seal Set
Figure: “CR” Single-Acting Seal Set
1 Pressure
1 Pressure
“RTV” Oil Wiper Set
“STU” Single-Acting Seal Set
This three-ring set seals in one direction only. The first ring (pressure side) is radially cut. The
first ring (pressure side) is solid, with radial second ring is tangentially cut. The first two rings
grooves on the pressure side. The second ring is are doweled to stagger the cuts from one ring to
tangentially cut. The third ring is solid. the other. The third ring is called a back-up ring.
Figure: “STU” Single-Acting Seal Set It is radially cut and has a bore larger than the rod
diameter to allow the radial joints to form a tight
gas seal.
Figure: “RTV” Oil Wiper Set
1 Pressure
1 Oil Side

“3RWS” Oil Wiper Set

The three rings in this set are radially cut and
doweled to stagger the cuts from one ring to the
other. They keep crankcase oil out of the packing
and cylinder. Assemble with the blank face
towards the oil (crankcase) and the slotted side
towards the pressure packing.
Figure: “3RWS” Oil Wiper Set
1 Oil Side
Crossheads
The crosshead assembly consists of the
crosshead and crosshead pin bushings, where
required. Most crossheads use a layer of soft
babbitt material on the shoes, which are the
surfaces that slide in the crosshead guide bore.
NOTE: Some small-line and JGH crossheads do not

use a bushing or babbitt.
Take care during maintenance to avoid

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
cylinders, insert feeler gauge through a
NOTE: Return crossheads to their original throw loca- bottom valve pocket.Tighten the piston rod
tion. Use frame oil for lubrication where needed. 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
position of throw. Remove a top head end WARNING
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 appropriate Ariel Technical Manual and Packager
the top of the head end, using feeler gauges information should attempt any maintenance.
through the open valve pocket. Determine if
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
piston head end clearance. See "Measuring maintenance.
Head End Clearance for Forged Steel Tandem • Follow packager instructions to completely isolate
Cylinders with Concentric Valves" in
tance.
Appendix B. • Verify each compressor cylinder is relieved to atmo-
10. Check piston rod runout and crosshead spheric pressure. To relieve residual cylinder bore
clearances upon re-assembly, any time a pressure after blowdown, open the “Kiene” valves
piston rod is removed. Check crosshead
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 mixture under pressure can explode and cause severe
with 0.0015 inch (0.038 mm) feeler stock at injury or death.
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. Remove the middle frame spacer bar of the
11. Examine top cover and side cover seals. If three over the desired pair of throws. Spacer
there is doubt about their condition, replace bars are compressor and throw dependent.
them. Apply Never-seez Regular Grade to They are match-marked with the throw
both sides of the gasket to ease future position and machined with a tight fit. After
removal. Replace top cover and crosshead bolt removal, spacer bars should remove
guide side covers. Tighten all cap screws easily by hand with maybe a slight resistance.
hand wrench tight. A very loose or tight fit indicates an unlevel
frame, softfoot, incorrect crosshead guide
shimming, improperly adjusted discharge
Connecting Rods bottle wedges, or pipe stress affecting the
cylinder flange fit. Correct any of these
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.

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

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

tional procedures.
maintenance. 1 Top Face
2 Connecting Rod Bolts
tance. 3 Rod Cap
• Verify each compressor cylinder is relieved to atmo- 4 Rod
1. Remove frame top cover and all crosshead
guide covers.
AND/OR FLAMMABLE. 2. Remove all head end heads.
the gas being compressed to avoid a potentially 3. Remove spacer bars as needed to access
explosive gas/air mixture in the system. A gas/air connecting rods. If a spacer bar will not easily
mixture under pressure can explode and cause severe come out, it may help to loosen one bolt on
injury or death. each adjacent spacer bar. Spacer bars are
compressor and throw dependent. They are
match-marked with the throw position and
machined with a close-tolerance fit. After bolt
removal, spacer bars should remove easily by
hand with maybe a slight resistance. A very
loose or tight fit indicates an unlevel frame,
softfoot, incorrect crosshead guide
bottle wedges, or pipe stress affecting the
conditions before returning the compressor
to service.
4. Rotate crankshaft to approximately 45º (see
Figure: Crank Rotation)

Figure: Crank Rotation Figure: Prying Behind Crosshead
5. Loosen all connecting rod bolts about 1/8 in.

(3.2 mm).
6. Pry crosshead toward the cylinder until it
bottoms out.
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 conrod do not
separate easily by hand, loosen all bolts an additional NOTE: Do not pry or chisel at joint of connecting
1/8 in. (3.2 mm) and pry the crosshead again. rod cap/rod to separate cap from rod; it damages
the connecting rod and can break the alignment
dowel pins. Do not pry on machined running
surfaces when separating the cap from the rod.
Separate caps by backing out all 4 bolts no more
than 1/4 inch and prying behind the crosshead
(see Figure: Prying Behind Crosshead)
7. Support rod and cap by hand while another
person pries the crosshead toward the
cylinder as much as possible. When the rod is
clear of the crankshaft, carefully rest it in the
guide.

8. Rotate the cap up and remove all bolts, then Connecting Rod Bearing
remove the rod cap and bearing. Hold the
bearing in the cap while lifting it off the pin.
Installation
Do not remove cap with bolts in place.
Figure: Connecting Rod Bearing Installation
9. After removing bearings, clean any coking or
debris from both the rod and rod cap surfaces
with a non-metallic Scotch-Brite or similar
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
A Apply lube oil liberally to this surface.
of the crank pin surface to remove any high spots; 1 Rod
do not slide it back and forth over the length of 2 Rod Bushing
the pin. If the pin is scored around the 3 Dowel Holes
circumference, use 600 grit emery cloth to 4 Rod Notch
remove high spots. After dressing, ensure crank 5 Bearing Shell
pin is clean and dry. Use only lint-free, clean 6 Bearing Shell Tab
paper towels to clean crankshaft pin of any 7 Dowels
debris after dressing. 8 Rod Cap Notch
9 Rod Cap
1. Check new bearing shells for handling

damage, scratches, burrs, and loose material
at the tabs. DO NOT RUB BEARING SURFACE
WITH FINGERNAIL. New bearing shells and
crankshaft crank pin bearing surfaces must
be absolutely clean. Clean new bearings with
appropriate solvent and clean paper towel.
Paper towels do not leave lint behind
compared to rags. Fit the tab of a new, dry
half bearing shell into the rod notch.
NOTE: Where bearings are identified with an ink
pictograph, connecting rod bearings and main bear-
ings are not interchangeable. DO NOT put main bear-
ings in a connecting rod. Do not mix part numbers on
an individual main or connecting rod. Both bearing
half shells must have the same part number.

2. Apply clean, new lube oil liberally to the crank NOTE: If replacing main bearings, continue to "Main
pin. Verify oil is compatible with the oil used Bearing Removal". If not replacing main bearings,
in the frame. continue to Step Install spacer bars so the match
mark is up and next to the spacer bar boss with the
3. Fit the tab of the other bearing shell into the
same mark. Tighten all spacer-bar cap screws to the
rod cap notch.
torque listed in Appendix A..
4. Use the following steps to attach the rod cap
7. Install spacer bars so the match mark is up
to the rod:
and next to the spacer bar boss with the same
a. Support the connecting rod by hand while mark. Tighten all spacer-bar cap screws to
another person rotates the crank towards the torque listed in Appendix A.
the rod. Stop rotating the crank at about a
45º angle (see Figure below). 8. Account for all tools, equipment, supplies,
and parts to ensure none are left inside the
Figure: Attaching Rod to Crankshaft crankcase.
9. 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.
b. Carefully lower the connecting rod cap 10. Reverse lockout procedures.
(WITHOUT BOLTS!) onto the crank pin.
11. After replacing bearings, it is recommended
Verify rod bolts are undamaged and free
to pre-lube compressor for at least 10-15
of dirt. Lubricate them per Appendix A,
minutes at 30 psi (2.1 barg) to ensure bearing
then place all four bolts into the rod cap.
lubrication and to help remove foreign
NOTE: Ensure notches on both the connecting rod materials from the lube system.
and connecting rod cap match. Install with both
notches on top, in the upward position. 12. Run the compressor according to the time
intervals listed on the form in Appendix D.
c. Keep supporting the connecting rod by After each run, shut down and remove the
hand while the second person pries the frame top cover. Measure main and
crosshead towards the crank until the rod connecting rod bearing cap temperatures
bottoms out on the crankshaft. with a hand held thermocouple probe or
d. After ensuring the rod cap seats properly infrared thermometer and record them on a
on the rod, tighten all connecting rod copy of the form in Appendix D. Complete the
bolts to the torque listed in Appendix A. form and file it in the unit records for future
5. Repeat steps 1-4 for all remaining connecting reference.
rods. 13. After each shutdown, visually inspect the
6. Measure each connecting rod bearing jack crankcase for signs of excessive heat in
and thrust clearance as detailed in this bearing areas, and babbitt or other debris. If
document. If clearance readings are not any are found, find and correct the problem
within tolerances of Appendix B, contact your before continuing.
packager or Ariel before proceeding.

Connecting Rod Bushing Removal NOTE: Thoroughly clean bushing and connecting
rod to prevent dirt accumulation between them.
and Installation Immediately assemble them so the bushing does
not warm and stick before it is in place. If the
1. Check crosshead pin to bushing clearance
bushing sticks, remove it by notching as in step 2
(see Appendix B). Determine pin wear by
above.
inspection. Replace pin, if necessary.
2. To replace a bushing, file or hacksaw the 5. Position connecting rod on the press table so
existing bushing to reduce the tightness of the chamfered edge of the rod bushing bore
the shrink fit. From the inside diameter, file or is on top. Press bushing into rod bore.Align
saw across the length of the bushing to within bushing oil hole with connecting rod oil
1/32 inches (1 mm) of its radial thickness. It passage (if applicable) before pressing
can then be easily drifted out. DO NOT file or bushing in. The bushing has an annular
saw into the connecting rod; any bore groove around its outside diameter aligned
damage renders the rod useless and with the oil hole; if the bushing shifts in the
requires rod replacement. connecting rod during operation, oil still
travels to the bushing inside diameter and to
3. Use a hydraulic press in a qualified machine the crosshead pin. However, a new bushing
shop to install the new bushing. Do not installation should cover no more than 1/3 of
hammer bushing into place; it will distort the the rod oil passage hole.
bushing bore.
4. Before installation, cool new bushing in a Connecting Rod Installation
95% alcohol and dry ice solution. Leave
bushing in solution long enough to reach the 1. To install a new connecting rod, stamp match
solution temperature, about -110°F (-80°C). mark numbers matching the throw location
An alternate method of cooling is to on the tops of the connecting rod and bearing
submerge the bushing in liquid nitrogen. cap (with bearing notches up). See Figure:
When the nitrogen stops bubbling, the Typical Connecting Rod.
temperature has reached equilibrium, and
the bushing is ready to install. 2. Check new bearing shells for handling
damage, scratches, burrs, and loose material
at the tabs. DO NOT RUB BEARING SURFACE
CAUTION WITH FINGERNAIL. New bearing shells and
crankshaft crank pin bearing surfaces must
Do not touch cold surfaces without proper protection. be absolutely clean. Snap a new, dry half
Alcohol is flammable; use it only in open air or well-
bearing shell into the rod and rod cap with
ventilated buildings. Avoid sparks and open flame. Avoid
alcohol vapors which may cause injury to nose and eye the bearing tabs properly located in the rod
tissue. Do not return solution to a closed container until and cap notches. Turn the connecting rod pin
it reaches room temperature or container may explode. to the vertical position and oil crankshaft
connecting rod pin bearing surfaces with new
clean lubricating oil, the same type used in
the frame. Carefully lower the connecting rod
cap (without bolts) onto the pin.
NOTE: Connecting rod bearings and main bearings
are not interchangeable. Connecting rod bearings
have a narrower groove or no groove at all. DO NOT
put main bearings in connecting rod bearing loca-
tions.

NOTE: Caps and rods are numbered by throw 3. Verify rod bolts are undamaged and free of
beginning with number one at the drive end. For dirt, then lubricate them per Appendix A and
throw numbering sequence, see Plate Locations. insert all bolts into rod cap. Rotate the cap
Always install rods with numbers up. Protect and fit the connecting rod to the rod pin and
crank pin at all times. Be sure both bearing tabs snug the bolts, pulling the cap and rod
are on top. together evenly.
4. Reconnect rod and crosshead with pin. Install
end plates, thru-bolt, and new lock nut.
Tighten lock nut to the torque listed in the
Appendix A.
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 7. Reinstall spacer bars. All spacer bars are
Accuracy" in Appendix A to tighten match-marked for proper location; reinstall
connecting rod cap screws to the them in their original location. Tighten all
recommended torque. spacer bar bolts to the torque listed in
6. Measure each connecting rod bearing to Appendix A.
crankshaft jack clearance and connecting rod 8. Examine top cover and side cover seals. If
thrust (side) clearance (see "Connecting Rod there is doubt about their condition, replace
Bearing Vertical Jack Clearance them.Apply Never-seez Regular Grade to
Measurement" and "Connecting Rod Thrust both sides of the gasket to ease future
(Side) Clearance Measurement"). Record removal. Replace top cover and crosshead
measurements on a copy of the form in guide side covers. Tighten all cap screws
Appendix D. If measurements are out of hand wrench tight.
tolerance after installing new bearings,
contact your packager or Ariel before
proceeding.

Connecting Rod Bearing Vertical

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

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.
2. Attach the magnetic base of a dial indicator to The crankshaft is the heart of the compressor.
the crankshaft web adjacent to the With proper maintenance, it should provide
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.

Oil Slinger Replacement Main Bearing Removal
CAUTION WARNING
Do not touch hot surfaces without proper protection. To reduce risk of injury or death, only trained personnel
Although the slinger should last indefinitely with information should attempt any maintenance.
proper care, it may become nicked. Prior to performing any maintenance activities:
1. Suspend the crankshaft as detailed in ment and follow your company safety and opera-
"Crankshaft Removal" and heat the slinger to tional procedures.
about 400°F (204°C). When it expands, it is • Never tighten or loosen any fastener while the unit is
easily removed. operating or pressurized.
2. Slide a minimum ½-inch (13mm) diameter maintenance.
rod through the new slinger. Do not mar • Follow packager instructions to completely isolate
slinger surfaces, and be careful of its sharp and vent the system; call the packager for assis-
outer edge. Suspend the slinger and heat it tance.
with a small torch. When it reaches about • Verify each compressor cylinder is relieved to atmo-
400°F (204°C), slip it over the drive end of the spheric pressure. To relieve residual cylinder bore
crankshaft. Hold the slinger in place with high on the indicator ports, if so equipped.
temperature gloves or two pieces of clean WARNING: RELEASED GAS MAY BE POISONOUS
wood. Rotate it slightly to ensure squareness, AND/OR FLAMMABLE.
until it cools enough to shrink onto the Before resuming operation, purge the entire system with
crankshaft. the gas being compressed to avoid a potentially
injury or death.
1. Remove top cover and spacer bars. Spacer

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

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 4. To limit debris entering the system, work on
scratches or dings on pin, inspect crankshaft only one main bearing at a time. Remove
journal, and if needed, carefully stone the main journal bearing shells from under the
journal using an Arkansas stone (Ariel part crankshaft one at a time. If needed, attach
number A-19676). Lightly slide the stone clean nylon straps around the crankshaft and
around the circumference of the journal lift it 0.003 - 0.005 inch (0.076 - 0.127 mm) to
surface to remove any high spots; do not slide lessen weight on the bearings and allow
it back and forth over the length of the easier removal. To remove, rotate shell under
journal. If the crank is scored around the the crankshaft tab side out first, by pushing or
circumference, use 600 grit emery cloth to tapping with a non-metallic tool on the
remove high spots. After dressing, ensure
crank pin is clean and dry. Use only lint-free,
clean paper towels to clean crankshaft
journal of any debris after dressing. Rotate
the crankshaft 180° to expose the other half of
the journal and repeat.

opposite side. Ariel provides an optional tool bearing cap dowels with the holes in the
(B-3340) to push the shell out. Do not damage crankcase base.A set screw on top of each
crankshaft bearing surfaces. Replace with dowel prevents it from backing out. Seat the
new bearing shell, before rotating out the cap by tapping it with the handle of a hammer
next main bearing shell. or screwdriver. It is a machined fit, not a press
5. If any coked oil is observed on bearing cap or fit, and the cap should not rock in the jaw fit
frame saddle surfaces, contact Ariel for when it seats. Do not use bolting to force the
instructions. Check for raised edges on cap to seat. Tighten the cap screws. Tighten
machined surfaces. Verify all surfaces are the main bearing cap bolts in the pattern and
clean and dry as possible and no bolting is torque listed in Appendix A.
damaged. 4. Check crankshaft journal bearing jack
clearances and crankshaft thrust clearance to
values in Appendix B (see procedure below).
Main Bearing Installation Record readings on a copy of the form
1. Clean new bearings with appropriate solvent Appendix D. If readings are out of tolerance
and clean paper towel. Paper towels do not after new bearing installation, contact your
leave lint behind compared to rags. Check packager or Ariel before proceeding.
new bearing shells for damage, scratches, 5. Install spacer bars so the match mark is up
burrs, and loose material at the tab. DO NOT and next to the same match mark on the
RUB BEARING SURFACE WITH FINGERNAIL. frame rail. Tighten all spacer-bar cap screws
Keep the backs of shells dry and clean; to the torque listed in Appendix A.
installation requires perfectly clean bearing
6. Account for all tools, equipment, supplies,
shells. Install bearing shells in caps, and
and parts to ensure none are left inside the
frame journals, properly located in the tab
crankcase. Examine top cover and side cover
notch, (rotate in the un-tabbed end
seals. If there is doubt about their condition,
first).JG:JGA units use a thrust bearing, where
replace them. For O-ring seals, oil the O-ring
the thrust plate is integral to one bearing
and apply a light coating of corrosion
shell, and the other shell has no thrust plate.
inhibitor or marine grease to mating surface.
Install the bearing shell with the integral
Replace top cover and crosshead guide side
thrust plate into the #1 main bearing cap.
covers. Tighten all cap screws hand wrench
NOTE: Where bearings are identified with an ink tight. Bar compressor over 360° to ensure free
pictograph, main and connecting rod bearings are rotation.
not interchangeable. Do not put connecting rod bear-
ings in main bearing locations. Do not mix part 7. Reverse lockout procedures.
numbers on an individual main or connecting rod. 8. After replacing bearings, it is recommended
Both bearing half shells must have the same part to pre-lube compressor for 10-15 minutes at
number except for frames with integrated thrust 30 psi (2.1 barg) to ensure bearing lubrication
bearings (JG:A:M:P:N:Q and KB100). and to help remove foreign materials from
2. Apply clean, new lube oil liberally to the crank the lube system.
journal. Verify oil is compatible with oil used 9. Run the compressor according to the time
in the frame. intervals listed on the form in Appendix D.
3. Main bearing caps have position match- After each run, shut down and remove the
marks corresponding with frame spacer bars frame top cover. After each shutdown,
and spacer bar bosses. Install main bearing visually inspect the crankcase for signs of
caps with new bearing shells in their correct excessive heat in bearing areas, and babbitt
locations. Verify proper alignment of main or other debris. If any are found, find and

correct the problem before continuing.

Measure main and connecting rod bearing
cap temperatures with a hand held
thermocouple probe or 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
reference.

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

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

7. Reattach connecting rods (See "Connecting 11. Use a knife to trim excess from end cover
Rod Installation"), packing diaphragms, and gaskets flush to the compressor frame top
unloaders/head end heads. cover rail.
8. Reinstall chain drive. (See “Chain Drive 12. Examine top cover and side cover seals. If
System”). there is doubt about their condition, replace
9. Replace spacer bars. Locate spacer bar match them.Apply Never-seez Regular Grade to
mark. Install spacer bar so the match mark is both sides of the gasket to ease future
up and next to the spacer bar boss with the removal. Replace top cover and crosshead
same marking. guide side covers. Tighten all cap screws
hand wrench tight.
10. Install drive end cover with new gasket using
the tapered dowel pins to properly align the
cover. Verify at least 0.008 inch (0.2 mm) Main Bearing Vertical Jack
clearance exists between the dust seal Clearance Measurement
housing and crankshaft. Then install a new
dust seal.
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 3. Attach the magnetic base of a dial indicator to
desired main bearing is vertical (see Figure: any stable frame surface. Place the point of
Typical Crankshaft Journal Bearing Vertical the dial indicator against the top of the web
Jack Clearance Measurement). adjacent to the measured bearing and zero
2. Loop a clean, appropriately sized and rated the indicator
lifting strap around the crankshaft web 4. GENTLY lift crankshaft. The dial indicator
adjacent to the main bearing and attach the needle moves steadily until the crane/hoist
strap to a crane. overcomes crankshaft oil stiction, at which
NOTE: If the crane has no fine adjustment, attach a point the needle jumps a little. Stop lifting
chain hoist to the crane lifting hook to prevent exces- immediately at this point, and note the
sive force on the crankshaft and crane. reading.
5. Release crane/hoist pressure and verify
indicator returns to zero. Repeat step 4 to
verify measurement.

6. Repeat measurement process for each main Crankshaft Thrust (End) Clearance
bearing. If a reading is outside tolerances in
Appendix B, contact your packager or Ariel.
Measurement
lifting strap after 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 Chain Drive System

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

Figure: JG:JGA Chain Drive Systems

A Standard Rotation
B Reverse Rotation
1 Force Feed Lubricator
Sprocket
2 Crankshaft Sprocket
3 Eccentric Adjustment
4 Cap Screw
5 Dust Plug
6 Chain
7 Oil Pump Sprocket
Chain and Sprocket Replacement Figure: Measuring to Check Chain Elongation
WARNING

information should attempt any maintenance. 1 X- Measure outside rollers at 10 pitches
2 Y - Measure inside rollers at 10 pitches
tional procedures. Replace chain(s) if elongation exceeds 0.084
• Never tighten or loosen any fastener while the unit is inches (2.13 mm) over a 10 pitch length. Measure
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
and vent the system; call the packager for assis- pitches (X) to a measurement between the inside
tance.
• 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
pressure after blowdown, open the “Kiene” valves inches (97.4 mm).This number applies to either
one-row or two-row chains.
AND/OR FLAMMABLE.
Replace sprockets showing any undercutting or
the gas being compressed to avoid a potentially other damage.
injury or death.

Chain Idler Sprocket Replacement

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

tional procedures.
maintenance.
1 Mounting Bracket Cap Screws (4)
and vent the system; call the packager for assis- 2 Auxiliary End Cover
tance. 3 O-Ring
• Verify each compressor cylinder is relieved to atmo- 4 Shaft Oil Seal
5 Key
on the indicator ports, if so equipped. 6 Set Screw
WARNING: RELEASED GAS MAY BE POISONOUS 7 Sprocket
AND/OR FLAMMABLE.
Before resuming operation, purge the entire system with 1. With a good machinist rule, measure exact
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 Figure: Crankshaft Sprocket Removal

Replacement
WARNING

tional procedures.
maintenance.
• Follow packager instructions to completely isolate 1 Strike here with chisel.
tance. Examine sprocket carefully for wear; sprockets
spheric pressure. To relieve residual cylinder bore operating for five years or more may require
pressure after blowdown, open the “Kiene” valves replacement. To replace a sprocket on a
on the indicator ports, if so equipped. JG:JGA:
AND/OR FLAMMABLE. 1. Drill a hole in the sprocket hub parallel to the
Before resuming operation, purge the entire system with shaft centerline and big enough to remove
the gas being compressed to avoid a potentially most of the hub cross section (see figure to
the right). Multiple smaller holes may be
injury or death. required. DO NOT touch shaft with drill. Mark
the drill with tape to avoid drilling through
the sprocket and into the crankshaft face. The
CAUTION hole relieves most of the shrink, and a few
Do not touch hot surfaces without proper protection. 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.
Replace plastic caps to keep the holes clean.
1. Roll the crankshaft to the tightest position of
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
Component Cleaning & Thread

Lube for Non-Lube CAUTION
Compressor Cylinders Denatured alcohol presents health and safety hazards. It

contains methyl alcohol and is poisonous if ingested.
Avoid eye and skin contact. Keep alcohol away from
Ariel cleans and protects complete non-lube
heat, sparks, flame, and all other ignition sources. Use
cylinders to non-lube service requirements. adequate ventilation, neoprene or butyl gloves, mono-
Clean all internal parts shipped loose, goggles or face-mask, and impermeable apron. Properly
handle and dispose of materials resulting from clean-up.
contaminated internal surfaces, and repair parts
See manufacturer's material safety data sheets for more
prior to installation, to extend the life of rings and details.
non-lube compressors.
Do not use any lubricants or anti-seize
Clean cylinder bore thoroughly with denatured
compounds on parts that may contact the gas
alcohol until a clean, alcohol-soaked, white
stream.
paper towel removes no more debris. This
includes all surfaces of the bore, counter bore, Use very small amounts of Never-Seez regular
valve pockets, etc. Do not use Never-Seez on grade on nut and collar when assembling piston
steel gaskets. Apply a light film of oil to cylinder assembly. Thoroughly clean piston (especially
seating surfaces to seal o-rings. the ring grooves) with denatured alcohol until a
clean, alcohol-soaked towel removes no more
debris.

Disassemble packing case. Wipe all surfaces

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

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

components with denatured alcohol. Use
minimal amounts of oil for the bolt-holes to
ensure oil does not run into the cylinder. Also
install the head end steel gasket without Never-
Seez.
Disassemble and clean the valves with denatured

alcohol, then re-assemble, wipe them again, and
install. Clean retainers and high clearance
assemblies with denatured alcohol. Use only a
thin film of oil for the valve cap O-rings and bolt-
holes.
Assemble cleaned parts immediately to avoid

contamination and corrosion. If cylinder will not
commence immediate service, contact Ariel for
preservation instructions to ER-34.

Start Up
Warranty Notification - Administrative Assistant - Sales, Ariel

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

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.

JG-JGA Maintenance & Repair Manual – Compressor Troubleshooting 01/27/2023
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 it moves to the head end of the cylinder. When
negative. A positive reading indicates the piston the piston climbs, the rod drops, yielding a
drops as it moves to the head end of the cylinder negative reading. Any reading outside the Ariel
due to the clearance in the bore. As the piston rod runout tolerance requires correction for safe,
drops, the rod rises, yielding a positive reading efficient compressor operation (see Appendix B).
on the indicator. If the cylinder is not supported Piston rod runout correction first requires
properly, it could droop causing the piston to verification (and correction, if needed) of the
drop as it moves to the head end of the cylinder. crosshead clearance. See flowcharts below.
A negative reading indicates the piston climbs as
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 • Clean and de-burr all threads.
torque requirements for proper assembly of • Do not use molybdenum disulfide lubricants.
JG:JGA reciprocating compressors. For older • Do not use Never-Seez for fastener lubrica-
units with lower specified torque values, do not tion unless specified or excessive stresses
assume higher values without consulting the may result with specified torques. See Table:
packager and/or Ariel. Fastener Thread & Seating Surface Lubrica-
tion.
• Use only Ariel specified fasteners tightened to • Use anti-seize lubricants sparingly; excessive
the correct torque. amounts cause oil analysis to indicate
• Connecting rod, valve cap, and contamination and may unnecessarily
suction/discharge nozzle (Ariel supplied increase maintenance costs.
flange) fasteners are modified to prevent • Re-preserve any fasteners subject to corro-
fatigue; do not replace them with standard sion after installation.
cap screws. To replace other fasteners with
standard cap screws, contact your packager
or Ariel.
Table: Fastener Thread & Seating Surface Lubrication

NOTE:Lubricate all fasteners both under the head and on the threads.
Application Lubricant
Forged Steel Cylinders: valve cap, cylinder mounting Never-Seez Regular Grade
flange to cylinder body, packing, crank end and head end
head, gas passage
Cast Cylinders: valve cap, tandem cylinder mounting, Mineral oil (ISO 100-150)
packing, crank end and head end head
Frame: jack screws Never-Seez Regular Grade

Pistons: piston nuts, set screws, piston collar, crosshead
threads, tandem piston to piston rod
All stainless steel fasteners except valve fasteners
listed in Table: Hoerbiger Valve Assembly Fastener
Torques
Connecting rod cap Lubriplate 630-AA
Crosshead balance nut, frame to spacer bar Under the head or mating surface: Mineral oil (ISO 100-
150).
On the threads: Never-Seez Regular Grade.
All pipe threads Loctite 567
Fasteners specified with Loctite on threads Loctite only with no additional lube
All other fasteners, all O-rings and stat-o-seals Mineral oil (ISO 100-150)

JG-JGA Maintenance & Repair Manual – Ariel Fasteners and Torques 01/27/2023
Figure: Bolt Head Grade and Material Identification
4. Always turn fasteners in by hand until they

are finger tight and drawn down evenly.
CAUTION
Using a wrench, turn fasteners to draw o-
To replace a fastener, see parts list for fastener grade rings into their bores. Using pneumatic, elec-
and part number. Do not use a lesser or greater material
grade. Use Ariel parts to replace special fasteners and tric, or hydraulic drivers and runners can
fasteners with reduced body diameter for fatigue result in uneven tightening and over-stressed
resistance. Do not torque fasteners with compressor fasteners. If there is significant resistance,
running or pressurized. Read technical manual safety
warnings. remove the fastener to determine and correct
the cause.
5. Always apply a steady, slow force to a torque

Recommendations for Torque wrench, and stop immediately when the
Accuracy wrench clicks. Do not bounce, jerk, or double
1. Critical bolted joints require accurate tap the wrench – it significantly increases the
fastener pre-stress to ensure safe and reliable applied torque. Perform final tightening with
operation. On Ariel compressors, these joints a torque wrench.
have specified torque or other engineered 6. Do not break fasteners loose with a torque
tightening methods. Only mechanics prop- wrench - it may overload the wrench and
erly trained in bolted flange joint assembly affect its accuracy.
should maintain these joints.
7. Determine torque wrench accuracy range
2. When torque is specified for a fastener, use a
before using - most are not accurate at the
properly calibrated torque wrench to torque
extreme lower and higher ends of their range.
the fasteners correctly.
8. Clean and de-burr all threads before
3. Use the correct lubricant on the fastener (see
assembly. Ensure no oil or debris is in the
Table: Fastener Thread & Seating Surface
bottom of the bolt hole when installing bolts.
Lubrication).
Apply oil only to fasteners, not in the bolt
hole.
9. Inspect all joint mating surfaces for

scratches, nicks, gouges, burrs, corrosion and
flatness. This includes the fastener and the
fastener contact area on the bolted part.
Address any findings before proceeding.

Figure: Main Bearing Cap or Connecting Rod Cap • For 3-bolt valve caps, tighten in this
Torque Sequence 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
10. For main bearing cap and connecting rod the appropriate sequence for 25%, 50%,
cap fasteners: If the bearing cap is stamped 75% and 100% of the specified torque.
with torque sequence numbers, tighten After 100% torque is reached, continue
passes until all fasteners stop moving.
fasteners in that sequence. If not stamped,
follow the Figure: Main Bearing Cap or • Inspect the gap under the bolted flange (if
visible) after each pass to ensure a consis-
Connecting Rod Cap Torque Sequence.
tent gap all around. If the gap is not
• Where torque and turn IS NOT SPECI- consistent, the assembly is cocked –
FIED: Apply 50% of specified torque in the disassemble and inspect to determine the
sequence shown to close joint. Once cause, and re-assemble after the cause is
closed, apply 100% of specified torque in corrected.
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.

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
line).
14. If using an offset adapter with a torque
wrench, the torque setting is not the actual
torque applied, unless the adapter is 90° to
the torque wrench. To determine the correct
torque setting:
Table: Hoerbiger Valve Assembly Fastener Torques

Type Torque
Nominal Size
Fastener Lb x Ft (N·m), unless Lb x Ft (N·m), unless
Inch - TPI
specified specified
Center Cap Screwa 5/16 - 24 12 Point - Steel Grade 5 14 (19)

Material Parts: SPL3 & 4
3/8 - 24 24 (33)
7/16 - 20 35 (48)
5/16 - 24 12 Point - Steel Grade 5 22 (30)

Material Parts: SPL or SPL5
3/8 - 24 40 (54)
7/16 - 20 65 (88)
5/16 - 24 12 Point - Stainless Steel 14 (19)

Grade B
3/8 - 24 8M Material Parts: SPL6 24 (33)
7/16 - 20 35 (48)
Peripheral Cap Screw #10 - 32 Hex Socket Head 25 Lb x In (2.8)
#12 - 28 43 Lb x In (4.9)
1/4 - 20 110 Lb x In (12)
5/16 - 18 176 Lb x In (20)
3/8 - 16 21 (28)

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.

JG:A Fastener Torques

Torque
Fastener Nom. Size, Inch - tpi Type Lb x Ft (N·m), unless
specified
Main Bearing Cap - Cap 1/2 - 13 12 Point - Grade 8 58 (79)

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

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

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

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

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

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

Crosshead Guide - Cap
Screw
Distance Piece to Cylinder 3/8 - 16 Socket Head 18 (24)

(11JG) - Cap Screw
Eccentric Vernier Cap - Cap 5/16 - 18 12 Point or Hex Grade 8 Hand Wrench Tight
Screw
Idler Sprocket Thru Bolt - 1/2 - 20 Hex - Prevailing 41 (55)

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

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

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

Mounting
Auto Relief Valve 1/2a Ariel Design 75 Lb x In. (8.5)
Auto Relief Valve Manifold #10 - 24 Ariel Design 50 Lb x In. (5.6)

Plug
1/4 NPT Hex Hand Wrench Tight
Rod Packing - Cap Screwb 1/2 - 13 12 Point - Grade 8 35 (48)
9/16 - 12 12 Point - Grade 8 51 (69)

Torque
specified
Packing Tie Stud Nut #10 - 24 Hex 20 Lb x In. (2.3)
1/4 - 20 72 Lb x In. (8.1)
5/16 - 18 12 Point Flange 144 Lb x In. (16)
Piston Nutc 7/8 - 12 Ariel Design 220 (300)
Piston Nut Set Screw #10 - 32 Socket Head 36 Lb x In. (4.1)d

Crosshead Balance Nut 1” - 12 Ariel Design Slugging Method
Piston Rod Oil Slinger Bolt - 1/4 - 28 Hex Jam-Prevailing 95 Lb x In. (11)
Lock Nut
Rupture Disk - Blow-Out 1/4 Nom. Tube Hex - Tube Fitting 40 Lb x In. (4.5)
Fitting Cap
Frame Foot Hold Down 3/4 - 10 Hex Nut 175 (235) e
Crosshead Guide Support 5/8 - 11 Hex Nut 100 (140) e

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

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

Flange Except "Peanut" 4PH
Dual Nozzlee
1/2 - 20 Hex Nut 12 Point - Grade 8 46 (62)
or 17-4PH
ANSI Flange to Cylinder See Cylinder Outline Provided by Packager See ER-127.
Nozzle
Taper-Lok Flangej 1/2 - 13 Hex Nut on Grade 8 Stud or 40 (54)

17-4 stud
1/2 - 20 46 (62)
5/8 -11 79 (105)
5/8 -18 92 (125)
3/4 - 16 160 (215)
Tandem Piston to Piston 5/16 - 24 Dog Pt. Stud 17-4PH 18 (24)g

Rod

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

- Grade B7M or 8 or 17-4PH,
• Valve Cap 3/8 - 16 193 Lb x In. (22)
or Socket Head
• Cylinder Head
7/16 - 14 26 (35)
• Gas Passage
1/2 - 13 40 (54)
• VVCP or eVCP
Adapter to Headh 9/16 - 12 57 (77)
• VVCP Seal Carrier 5/8 -11 79 (105)
5/8 - 18 92 (125)
3/4 - 10 140 (190)
3/4 - 16 160 (215)
7/8 - 9 230 (310)
7/8 -14 260 (350)
1” - 8 345 (465)
1” - 14 395 (535)
VVCP, FVCP, or eVCP to 1/2 - 13 12 Point - Grade 8 or 17- 40 (54)

Cylinder 4PH
5/8 - 11 79 (105)
Tandem Cylinder to 1/2 - 13 Hex - Grade 8 or 9 or 12 44 (60)

Cylinder - Cap Screwf Point - Grade 8
5/8 - 11 88 (120)
3/4 - 10 160 (215)
1” - 14 440 (595)
Stud Seating 3/8 - 16 Dog Point Grade 8 or 17- 107 Lb x In. (12)
In valve cap assemblies 4PH
with a spring energized 7/16 - 14 172 Lb x In. (19)
seal, install longer studs 1/2 - 13 22 (30)
with Loctite 242.
9/16 - 12 32 (43)
5/8 - 11 44 (60)
3/4 - 10 79 (105)
3/4 - 16 90 (120)
7/8 - 9 130 (175)
7/8 - 14 145 (195)

1” - 8 200 (270)
Distribution Block Tie Rod - 1/4 - 28 Dog Point Grade 8 or 17- 68 Lb x In. (7.7)
Nut 4PH

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

Valve - Screw
Grade 5 - Hex Cap Screw All Socket Head Hand Wrench Tight
Valve Cap Assembly - Cap 3/4 - 16 Hex - Grade 5 Hand Wrench Tight
Nut
Valve Cap Seal Keeper - 5/16 - 18 Cap Nut 120 Lb x In. (14)
Cap Screw
3/8 - 24 12 Point - 17-4PH 21 (28)
a "1/2" indicates the wrench size. Auto relief valve can swivel in the manifold once torqued. See assembly drawing.
b Repeat final torque for rod packing bolts until they no longer turn before the torque wrench clicks.
c Tighten, loosen, then re-tighten to ensure proper torque.
d 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.
e Minimum torque to stress recommended hold-down stud to 55,000 psi (380 MPa). Use studs with an ultimate
strength of 100,000 psi (690 MPa) or greater. If greater, increase torque stress to about 55% of ultimate strength, as
specified by packager.
f For studs specified for cylinder applications, tighten nuts to the same torque as cap screws in similar applications.
g Tighten, loosen, then re-tighten to ensure proper torque.
h Excludes socket head cap screws, which are installed hand wrench tight.
i Step-torque first to 40 Lb x In. (4.5 N•m), and then to 75 Lb x In. (8.5 N•m).
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: JG:JGA Frame and Running Gear Clearances, in. (mm)
Description Clearance
Crankshaft Journal Bearing (Jack) 0.0005 to 0.0035 (0.013 to 0.089)
Crankshaft Thrust (End) 0.0035 to 0.011 (0.089 to 0.279)
Connecting Rod Bearing (Jack) 0.0015 to 0.0040 (0.038 to 0.102)
Connecting Rod Thrust (Side) 0.007 to 0.016 (0.178 to 0.406)
Crosshead to Guide (Babbitted Ductile Iron with 0.004 to 0.008 (0.10 to 0.20) (Feeler Gauge)
bushings)
Crosshead to Guide (Babbitted Bronze, no bushings) 0.006 to 0.010 (0.15 to 0.25) (Feeler Gauge)
Crosshead Pin to Connecting Rod Bushing 0.0014 to 0.0031 (0.036 to 0.079)
Crosshead Pin to Crosshead Bushings 0.0014 to 0.0036 (0.036 to 0.091)
Crosshead Pin to Crosshead (Bronze, no bushings) 0.0015 to 0.0025 (0.038 to 0.064)
Shaft Seal Housing, Centered on Crankshaft 0.008 (0.20) (Feeler Gauge All Around)
Table: JG:JGA Piston End Clearances, in. (mm)a, b

Description Clearance
Total Piston End Clearance - Double Acting 0.090 to 0.145 (2.29 to 3.68)
Piston End Clearance - Crank End - Double Acting 0.035 (0.89)
Piston End Clearance - Head End - Double Acting 0.055 to 0.110 (1.40 to 2.79)
Total Piston End Clearance - Tandemc 0.090 to 0.180 (2.29 to 4.57)
Piston End Clearance - Crank End Tandemc 0.035 (0.89)
Piston End Clearance - Head End Tandemc 0.055 to 0.145 (1.40 to 3.68)
a Measured clearances may not agree due to oil films, wear, etc. Do not use plastigages, solder, etc.
b If total piston end clearance (crank end + head end) is not within table tolerance, contact Packager or Ariel.
c For 2-1/4P-CE cylinders, it is not practical to use the CE clearance tool to set piston clearance.
Table: JG:JGA Max. Acceptable Piston Rod Runout, in. (mm)

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

JG-JGA Maintenance & Repair Manual – Clearances 01/27/2023
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: Wear Band (new) Clearance Specifications - Lubricated 1-3/4JG-FS-HE and 7-1/2JG (with
Heavy Piston) Class, in. (mm)
Bore Diameter Minimum End Gap Radial Projectiona
1.25 (32) 0.039 (0.99) 0.005 to 0.012 (0.13 to 0.30)
1.5 (38) 0.049 (1.24) 0.0075 to 0.0145 (0.19 to 0.37)
1.625 (41) 0.052 (1.32) 0.0075 to 0.0135 (0.19 to 0.34)
1.75 (44) 0.058 (1.47) 0.0075 to 0.0145 (0.19 to 0.37)
7.5 (191) 0.170 (4.32) 0.028 to 0.039 (0.71 to 0.99)
a Replace wear band before piston contacts the cylinder bore.
Table: Wear Band (new) Clearance Specifications - Non-Lube, in. (mm)
Bore Diameter Minimum End Gap Radial Projectiona
2.75 (70) 0.088 (2.24) 0.036 to 0.050 (0.91 to 1.27)
3.375 (86) 0.085 (2.16) 0.027 to 0.034 (0.69 to 0.86)
6.125 (156) 0.201 (5.11) 0.028 to 0.039 (0.71 to 0.99)
7.5 (191) 0.164 (4.17) 0.028 to 0.039 (0.71 to 0.99)
a Replace wear band before piston contacts the cylinder bore.

Table: Piston to Bore Clearance and Conventional Piston Ring End Gap - Non-Lube JG Class
Cylinders, in. (mm)
Piston to Bore Diametral PISTON RING END GAP - NON-METALLIC

Bore Diametera Clearance New Maximum
3.375 (86) 0.075 to 0.083 (1.91 to 2.11) 0.044 to 0.056 (1.12 to 1.42) 0.224 (5.68)
6.125 (156) 0.084 to 0.097 (2.13 to 2.46) 0.073 to 0.093 (1.85 to 2.36) 0.373 (9.47)
7.5 (191) 0.085 to 0.098 (2.16 to 2.49) 0.098 to 0.118 (2.49 to 3.00) 0.472 (11.99)
Table: Piston to Bore Clearance and Piston/Rider Ring End Gap (Seal-Joint a), in. (mm) -
Lubricated JG Class Cylinders

2.75 (70) 0.090 to 0.096 (2.29 to 2.44) 0.047 to 0.059 (1.19 to 1.50) 0.177 (4.50)
3 (76) 0.090 to 0.096 (2.29 to 2.44) 0.051 to 0.063 (1.30 to 1.60) 0.189 (4.80)
a Seal-Joint piston rings are standard for JG Class high-pressure tandem cylinders.
Table: Piston to Bore Clearance and Conventional Piston Ring End Gap - Lubricated M, P and SP
Class Cylinders, in. (mm)

2.0625 (52) 0.007 to 0.011 (0.18 to 0.28) 0.025 to 0.030 (0.64 to 0.76) 0.120 (3.05)
2.25 (57) 0.027 to 0.032 (0.69 to 0.81) 0.128 (3.25)
2.5 (64) 0.030 to 0.036 (0.76 to 0.91) 0.144 (3.66)
2.75 (70) 0.033 to 0.040 (0.84 to 1.02) 0.160 (4.06)
3 (76) 0.036 to 0.044 (0.91 to 1.12) 0.176 (4.47)
3.25 (83) 0.009 to 0.013 (0.23 to 0.33) 0.039 to 0.047 (0.99 to 1.19) 0.188 (4.78)
3.5 (89) 0.042 to 0.052 (1.07 to 1.32) 0.208 (5.28)
3.75 (95) 0.010 to 0.014 (0.25 to 0.36) 0.046 to 0.056 (0.17 to 1.42) 0.224 (5.69)
3.875 (98) 0.047 to 0.057 (0.19 to 1.45) 0.228 (5.79)
4.125 (105) 0.049 to 0.060 (1.24 to 1.52) 0.240 (6.10)
4.375 (111) 0.011 to 0.015 (0.28 to 0.38) 0.052 to 0.064 (1.32 to 1.63) 0.255 (6.48)
4.75 (121) 0.012 to 0.017 (0.30 to 0.43) 0.057 to 0.077 (1.45 to 1.96) 0.308 (7.82)
5.125 (130) 0.061 to 0.081 (1.55 to 2.06) 0.324 (8.23)


5.5 (140) 0.013 to 0.018 (0.33 to 0.46) 0.065 to 0.085 (1.65 to 2.16) 0.340 (8.64)
5.75 (146) 0.068 to 0.088 (1.73 to 2.24) 0.352 (8.94)
6.125 (156) 0.014 to 0.020 (0.36 to 0.51) 0.073 to 0.093 (1.85 to 2.36) 0.372 (9.45)
6.5 (165) 0.077 to 0.097 (1.96 to 2.46) 0.388 (9.86)
7.5 (191) 0.016 to 0.022 (0.41 to 0.56) 0.089 to 0.109 (2.26 to 2.77) 0.430 (10.92)
8 (203) 0.095 to 0.115 (2.41 to 2.92) 0.460 (11.68)
a Conventional piston rings are standard for all M, P and SP Class Cylinders, except for 1-3/4M-FS Class Cylinder with
bore diameters of 1.625” (41) and 1.75” (44) where piston/rider rings are standard. Piston/rider rings are optional
for all other lubricated M, P and SP class cylinders. See Table: Piston to Bore Clearance and Piston/Rider Ring End
Gap, in. (mm) - Lubricated M, P and SP Class Cylinders.

Table: Piston to Bore Clearance and Piston/Rider Ring End Gap, in. (mm) - Lubricated M, P and
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) 0.045 to 0.061 (1.14 to 1.55) 0.244 (6.20)
4.125 (105) 0.049 to 0.065 (1.24 to 1.65) 0.260 (6.60)
4.375 (111) 0.052 to 0.068 (1.32 to 1.73) 0.272 (6.91)
4.75 (121) 0.057 to 0.073 (1.45 to 1.85) 0.292 (7.42)
5.125 (130) 0.062 to 0.078 (1.57 to 1.98) 0.312 (7.92)
5.5 (140) 0.068 to 0.084 (1.73 to 2.13) 0.336 (8.53)
5.75 (146) 0.071 to 0.087 (1.80 to 2.21) 0.348 (8.84)
6.125 (156) 0.069 to 0.099 (1.75 to 2.51) 0.396 (10.06)
6.5 (165) 0.074 to 0.104 (1.88 to 2.64) 0.416 (10.57)
7.5 (191) See Noteb See Noteb
8 (203) See Noteb See Noteb
a Conventional piston rings are standard for all M, P and SP Class Cylinders, except for 1-3/4M-FS Class Cylinder with
bore diameters of 1.625” (41) and 1.75” (44) where piston/rider rings are standard. Piston/rider rings are optional
for all other lubricated M, P and SP class cylinders.
b 8M x 3-1/2 (89) stroke & 8SP-HE with 7.5 (191) bore: new - 0.099 to 0.129 (2.51 to 3.28), max. - 0.516 (13.11).
8M x 3” (76) stroke with 7.5” (191) bore: new - 0.088 to 0.118 (2.24 to 3.00), max. - 0.472 (11.99).
8M x 3-1/2 (89) stroke & 8SP-HE with 8” (203) bore: new - 0.106 to 0.136 (2.69 to 3.45), max. - 0.544 (13.82).
8M x 3” (76) stroke with 8” (203) bore: new - 0.095 to 0.125 (2.41 to 3.18), max. - 0.500 (12.70).

Table: Piston to Bore Clearance and Conventional Piston Ring End Gap (Angular-Cut & Seal-
Joint), in. (mm) - Lubricated JG Class Cylinders
Piston to Bore Diametral PISTON RING END GAP - NON-METALLICb

Diametera Clearance
New Maximum
1.25 (32)c 0.025 to 0.033 (0.64 to 0.84) 0.018 to 0.028 (0.46 to 0.71) 0.112 (2.84)
1.5 (38)b 0.030 to 0.038 (0.76 to 0.97) 0.021 to 0.031 (0.53 to 0.79) 0.124 (3.15)
1.625 (41)b 0.023 to 0.033 (0.58 to 0.84) 0.132 (3.35)
1.75 (44)b 0.025 to 0.035 (0.64 to 0.89) 0.140 (3.56)
2 (51) 0.020 to 0.027 (0.51 to 0.69) 0.108 (2.74)
2.25 (57) 0.007 to 0.016 (0.18 to 0.41) 0.064 (1.63)
2.5 (64) 0.011 to 0.019 (0.28 to 0.48) 0.076 (1.93)

2.75 (70) 0.009 to 0.014 (0.23 to 0.36) 0.028 to 0.040 (0.71 to 1.02) 0.160 (4.06)
3 (76) 0.030 to 0.036 (0.76 to 0.91) 0.144 (3.66)
3.375 (86) 0.010 to 0.015 (0.25 to 0.38) 0.034 to 0.041 (0.86 to 1.04) 0.164 (4.17)
3.625 (92) 0.036 to 0.044 (0.91 to 1.12) 0.176 (4.47)
3.875 (98) 0.011 to 0.016 (0.28 to 0.41) 0.039 to 0.057 (0.99 to 1.45) 0.228 (5.79)
4.125 (105) 0.041 to 0.050 (1.04 to 1.27) 0.200 (5.08)
4.75 (121) 0.012 to 0.018 (0.30 to 0.46) 0.057 to 0.077 (1.45 to 1.96) 0.308 (7.82)
5.125 (130) 0.061 to 0.081 (1.55 to 2.06) 0.324 (8.23)
6.125 (156) 0.013 to 0.019 (0.33 to 0.48) 0.073 to 0.093 (1.85 to 2.36) 0.372 (9.45)
6.5 (165) 0.014 to 0.020 (0.36 to 0.51) 0.077 to 0.097 (1.96 to 2.46) 0.388 (9.86)
7.125 (181) 0.015 to 0.021 (0.38 to 0.53) 0.085 to 0.105 (2.16 to 2.67) 0.409 (10.39)

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

Diametera Clearance
New Maximum
7.5 (191) 0.015 to 0.021 (0.38 to 0.089 to 0.109 (2.26 to 2.77) 0.430 (10.92)
0.53)d
8.5 (216) 0.017 to 0.023 (0.43 to 0.58) 0.102 to 0.122 (2.59 to 3.10) 0.488 (12.40)
8.875 (225) 0.018 to 0.024 (0.46 to 0.61) 0.106 to 0.126 (2.69 to 3.20) 0.504 (12.80)
10.5 (267) 0.022 to 0.027 (0.56 to 0.69) 0.125 to 0.145 (3.18 to 3.68) 0.580 (14.73)
11 (279) 0.022 to 0.028 (0.56 to 0.71) 0.131 to 0.151 (3.33 to 3.84) 0.604 (15.34)
a Conventional piston rings are standard for JG class cylinders, except 2-1/2JG-FS-HE class cylinders with bore diam-
eters of 2.25 (57) and 2.5 (64); 3JG-CE, 2.75 (70) and 3 (76); 3-5/8JG-CE, 3.375 (86) and 3.625 (92); and 13-12JG, 13
(330) and 13.5 (343), which use piston/rider rings. Piston/rider rings are optional for other lubricated JG Cylinders,
except for the 1-3/4JG-FS-HE class, which uses conventional rings, but with seal-joint and wear band.
b Seal-Joint piston rings are standard for JG class high-pressure tandem cylinders.
c The 1-3/4JG-FS-HE class bore diameters use conventional seal-ring piston rings and wear band (see Table: Wear
Band (new) Clearance Specifications - Lubricated 1-3/4JG-FS-HE and 7-1/2JG (with Heavy Piston) Class, in. (mm)).
d For 7.5” (191) bore with a heavy piston, piston to bore clearance is 0.085 to 0.098 (2.16 to 2.49).

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

2.25 (57) 0.090 to 0.096 (2.29 to 2.44) 0.023 to 0.039 (0.58 to 0.99) 0.156 (3.96)
2.5 (64) 0.030 to 0.046 (0.76 to 1.17) 0.184 (4.67)
2.75 (70) 0.044 to 0.060 (1.12 to 1.52) 0.240 (6.10)
3 (76)
3.375 (86)
3.625 (92)
3.875 (98) 0.051 to 0.067 (1.30 to 1.70) 0.268 (6.81)
4.125 (105) 0.055 to 0.071 (1.40 to 1.80) 0.284 (7.21)
4.75 (121) 0.057 to 0.073 (1.45 to 1.85) 0.292 (7.42)
5.125 (130) 0.062 to 0.078 (1.57 to 1.98) 0.312 (7.92)
6.125 (156) 0.069 to 0.099 (1.75 to 2.51) 0.396 (10.06)
6.5 (165) 0.074 to 0.104 (1.88 to 2.64) 0.416 (10.57)
7.125 (181) 0.083 to 0.113 (2.11 to 2.87) 0.452 (11.48)
7.5 (191) 0.088 to 0.118 (2.24 to 3.00) 0.472 (11.99)
8.5 (216) 0.114 to 0.144 (2.90 to 3.66) 0.576 (14.63)
8.875 (225) 0.120 to 0.150 (3.05 to 3.81) 0.600 (15.24)
10.5 (267) 0.144 to 0.174 (3.66 to 4.42) 0.696 (17.68)
11 (279) 0.152 to 0.182 (3.86 to 4.62) 0.728 (18.49)
13 (330) 0.182 to 0.212 (4.62 to 5.38) 0.848 (21.54)
13.5 (343) 0.190 to 0.220 (4.83 to 5.59) 0.880 (22.35)
a Conventional piston rings are standard for JG cylinders, except 2-1/2JG-FS-HE with bore diameters of 2.25 (57) and
2.5 (64); 3JG-CE, 2.75 (70) and 3” (76); 3-5/8JG-CE, 3.375 (86) and 3.625 (92); and 13-12JG, 13” (330) and 13.5 (343),
which use piston/rider rings. Piston/rider rings are optional for other lubricated JG cylinders, except for the 1-3/4JG-
FS-HE class, which uses conventional type seal-joint rings and wear band.
Table: Piston to Bore Clearance and Conventional Piston Ring End Gap, in. (mm) - Non-Lube
(with wear bands) M and P Class Cylinders

Bore Diameter
Clearance New Maximum
2.75 (70) 0.057 to 0.064 (1.45 to 1.63) 0.033 to 0.045 (0.84 to 1.14) 0.180 (4.57)

Measuring Head End Clearance outer dead center. Position a dial indicator to
index off of the crosshead or crosshead nut
for Forged Steel Tandem outer face, with the cylinder near to outer
Cylinders with Concentric dead center. Manually turn crankshaft to find
the 0.010 inch (0.25 mm) position, before and
Valves after outer dead center. Then turn crankshaft
to position piston at outer dead center (see
Figure: Position Piston At Outer Dead Center 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

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.
Table: JG:JGA Frame Specifications

Specification JG/2 JG/4 JGA/2 JGA/4 JGA/6
Stroke, in. (mm) 3.5 (89) 3 (76)
Maximum 1500 1800

Allowable Speed
a, RPM
Minimum Speed 750 900

b
, RPM
Maximum N/A 1200

Lubricated PRC
Speed, RPM
Minimum N/A 750

Lubricated PRC
Speed, RPM
Maximum Non- N/A 1200

Lubricated
Speed, RPM
Minimum Non- N/A 750

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

FPM (m/s)
Horsepower (kW) 252 (188) 504 (376) 280 (209) 560 (418) 840 (626)
Maximum 33 (0.84) 58 (1.47) 33 (0.84) 58 (1.47) 85 (2.16)

Length, in. (m)
Maximum 18 (0.46) to top of aluminum cover

Overall Height,
in. (m)
Maximum Width See appropriate frame, guide, and cylinder outline drawings.
Height - Bottom 10.25 (260)

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

Weight with
Cylinders

JG-JGA Maintenance & Repair Manual – Frame Specifications 01/27/2023
Specification JG/2 JG/4 JGA/2 JGA/4 JGA/6
Connecting Rod 8.25 (210)

Centerline to
Centerline, in.
(mm)
Sump Capacity 4 (15) 10 (38) 4 (15) 10 (38) 16 (61)

US gallons (L)
Oil Pump Flow 4.0 (0.25) 8.0 (0.50) 5.0 (0.32) 9.0 (0.57) 14 (0.88)
Rate d, GPM (L/s)
Oil Heat 8400 (2.5) 16800 (4.9) 16800 (4.9) 34000 (9.9) 51000 (14.9)
Rejection
BTU/hr. (kW)
Piston Rod 1.125 (29)

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

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

lbf. (kN)
Internal Rod Load - Single Acting
Tension, lbf. (kN) 9000 (40) 10,000 (44)
a Maximum Allowable Speed is the highest (potential) speed at which the frame design permits continuous opera-
tion. Compressor frame data plate "Frame Rated Speed (RPM)" is application specific, and may be lower than
Maximum Allowable Speed. Do not exceed the lower of frame rated speed, lowest cylinder rated (RPM), or driver
rated speed.
b Minimum Speed is the lowest frame speed needed to provide adequate oil flow to the compressor bearings.
c Average Piston Speed is based on Maximum Allowable Speed (RPM). The cylinder data-plate rated speed (RPM) or
frame rated speed may be less, resulting in a lower piston speed rating.
d Flow rate at maximum rated speed and 180°F (82°C) oil.
Opposed Throw - To replace a connecting rod assembly, piston,

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

JG-JGA Maintenance & Repair Manual – Frame Specifications 01/27/2023
To exchange opposing throw cylinder locations, If unable to balance opposing throws within
exchange all reciprocating components to the recommended limits, contact the packager or
opposite throw, except the connecting rod Ariel.When applying or re-applying a different
assemblies. Check the Balancing Record and cylinder to a throw, recalculate opposing throw
recalculate reciprocating weight differential, reciprocating weight differential; new balance
including the weight of the connecting rods. If nuts and/or crossheads may be required. The
not within recommended limits, the compressor force feed oil distribution system may also need
may require new crosshead balance nuts to resized. Contact the packager or the Ariel
reduce differential. Response Center for detailed information about
recommended reciprocating weight differential
between opposing throws.
Table: JG:JGA Approximate Component Weights, Lbs (Kg)

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

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

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

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

two)
Spacer Bar 3 (1) Crosshead See Note a
End Cover Drive End 30 (14) Crosshead Pin 4 (2)
End Cover Auxiliary End 42 (19) Lube Oil Pump 2-Throw 7 (3)
Crankshaft 2-Throw b 100 (45) Lube Oil Pump 4-Throw 16 (7)
Crankshaft 4-Throw b 200 (91) Lube Oil Pump 6-Throw 36 (16)
Crankshaft 6-Throw b 280 (127) Frame Assembly w/o See Ariel Performance
Cylinders Program.
Main Journal Caps 6 (3) VVCP
Cylinder Assembly
Connecting Rod 13 (6)
Piston & Rod Assembly a
a For exact weights, see Balancing Record sheet provided by Ariel in the Parts Book for each compressor.
b Crankshaft weight is without flywheel, or vibration detuners.

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)

JG-JGA Maintenance & Repair Manual – Compressor Clearance, Oil, & Temperature Record 01/27/2023
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)

Cleaning, Handling, and Assembly Lubricants for Non-

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

JG-JGA Maintenance & Repair Manual – Cleaning, Handling, and Assembly Lubricants for Non-Lubricated 01/27/2023
Compressor Cylinders
small amounts of Never-Seez, Regular Grade clean them with denatured alcohol, then
on piston nut set screws. After assembly, reassemble. If they appear clean, they require
thoroughly wipe off all Never-Seez from the no additional cleaning provided they are
piston rod assembly exterior in the collar and sealed in their original packaging and have
nut areas with denatured alcohol until a not been contaminated.
clean, alcohol soaked, white paper towel or
13. Clean valve caps, retainers, high clearance
lint-free rag removes no more debris.
assemblies, and steel valve gaskets with
8. The manufacturer should provide packing denatured alcohol. Use only a very thin film of
cases cleaned, preserved, and suitable for oil for valve cap O-rings. Do not use anti-seize
non-lube service. Inspect packing cases for compounds or oil on steel valve gaskets.
cleanliness. If they appear coated with an oil- 14. Assemble cleaned parts immediately. If
based preservative, disassemble and clean cylinder will not see immediate service, see
them with denatured alcohol, then Ariel Engineering Reference ER-34 for
reassemble. If disassembly is required for preservation instructions. Contact Ariel for
water-cooled packing cases, re-assemble and latest version of ER-34.
test to Ariel Engineering Reference ER-51.
Contact Ariel for latest version of ER-51.
9. Wipe down piston rod with denatured CAUTION
alcohol after rod installation. Do not use Ariel non-lube compressor cylinders for
10. Clean VVCP or FVCP components with oxygen service.
denatured alcohol. Separate the unloader
head from the adapter/actuator. Clean all
internal surfaces with denatured alcohol
including behind the unloader piston. Do not
remove VVCP unloader stem seal. Clean
piston ring with denatured alcohol. Do not
use anti-seize compounds or oil on the steel
head gaskets. Use a very thin film of oil when
installing O-rings.
11. Clean crank-end head, head-end head, and
steel head gaskets with denatured alcohol.
Do not use anti-seize compounds or oil on the
steel head gaskets. If the crank-end head uses
an O-ring seal, apply a very thin film of oil to
the lead-in chamfer of the cylinder seating
surface to help prevent shearing of the O-
ring.
12. The manufacturer should provide
compressor valves cleaned, preserved, and
suitable for non-lube service. Inspect valves
for cleanliness. If they appear coated with an
oil-based preservative, disassemble and

Hold-down Bolting to Resist Shaking Forces and Couples

in Reciprocating Compressors
Requirements
Figure: Hold-down Fasteners
1 Crosshead Guide-to-Support
Fastener(see Table: Crosshead Guide-to-
Support Fastener Torques)
2 Crosshead Guide Support Foot and
Frame Foot Hold Down Fastener (see
Table: Crosshead Guide Support Foot &
Frame Foot Hold-down Fasteners)
1. The torque values provided will achieve the 2. The torque values in Table: Crosshead Guide-
minimum clamp load necessary for opera- to-Support Fastener Torques achieve 50,000
tion. psi (345 MPa) prestress in the fasteners. Use
grade 8 or 9 bolting to hold crosshead guides
to supports.
Table: Crosshead Guide-to-Support Fastener Torquesa

Compressor Model Size inch - TPI Torque lb-ft (N•m)
JG:A b 5/8 - 11 90 (120)
a Guide supports purchased from Ariel ship with guide-to-support fasteners.

b Crosshead guide supports do not apply to JGM:P:N:Q and KB100 frames. Use this torque for guide-hold-down
fasteners.
3. To use the torques in Table: Crosshead Guide in Table: Crosshead Guide Support Foot &
Support Foot & Frame Foot Hold-down Frame Foot Hold-down Fasteners are based
Fasteners, the ultimate strength (Su) of the on 100,000 psi ultimate strength material for
stud material must equal or exceed 100,000
psi (690 MPa); higher strength stud material is
preferred. In all cases, torque the nuts to
stress the stud to about 55% of the ultimate
strength of the stud material. Torques shown

JG-JGA Maintenance & Repair Manual – Hold-down Bolting to Resist Shaking Forces and Couples in Recipro- 01/27/2023
cating Compressors
imperial sizes and 830 MPa ultimate strength

material for metric sizes to meet the
minimum clamp load necessary for opera-
tion. Higher strength materials require higher
torques than shown in the tables for added
fastener stretch and preload. Material
strength and torque are directly propor-
tional. Example: for 120,000 psi (830 MPa)
ultimate strength Imperial bolting: 120,000 ÷
100,000 = 1.2 x min. torque for Imperial size
from table = required torque for given nut
size. To use a different stud diameter, consult
Ariel for feasibility and torque.
Table: Crosshead Guide Support Foot & Frame Foot Hold-down Fasteners - Min. Torquesa
Foot Hold- Imperial (basis 100,000 psi) Metric (Class 8.8)c

down Hole
Compressor Min. Nut Recom. Stud Min. Nut
Fastener Diameter
Model Recom. Stud
inch (mm)
Size inch--TPI Torquee lb-ft Sized mm x Torqued lb-ft
Applicationb
(N•m) pitch (N•m)
JG:A Guide 3/4 (19) 5/8 - 11 100 (140) M16x2 125 (170)
Support
JG:A Framef 7/8 (22) 3/4 - 10 175 (235) M18x2.5 175 (235)
M20x2.5 250 (340)
a See #1, "Requirements".

b Crosshead guide support feet and frame feet with counterbored holes are designed to accept 12-point fasteners. To
use hex head fasteners or studs and nuts instead, a washer thick enough to clear the counterbore is required to
provide adequate clearance for the fastener and any tooling used for installation. A washer is also recommended
for feet with holes that are milled flat.
c Ultimate Strength: 830 MPa (120,000 psi); Yield Strength: 660 MPa (95,700 psi).
d Where two sizes appear, the first is the preferred size, and the second is an alternate size.
e For a stud pitch other than those listed above in the same nominal diameter size, use this formula to determine
required torque: Torque = ( fastener torque) x (target fastener root area ÷ fastener root area).
4. Compressor frame foot hold-down studs and NOTE: Fasteners long enough to reach only
crosshead guide support foot hold-down through the compressor foot and a deck plate or
studs listed in Table: Crosshead Guide flange of an I-beam can loosen if not provided
with engineered devices to maintain fastener pre-
Support Foot & Frame Foot Hold-down
load.
Fasteners should be as long as possible. Ariel
recommends a minimum 12 to 1 length to
diameter ratio.

JG-JGA Maintenance & Repair Manual – Hold-down Bolting to Resist Shaking Forces and Couples in Recipro- 01/27/2023
cating Compressors
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
the compressor before flatness adjustment. For 2. Loosen each hold down bolt individually
leveling limits, see Appendix H in the Packagers while checking the frame foot to skid deflec-
Standards Manual. tion with a calibrated dial indicator. If there
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
fabrication. Verify skid level and flatness is 3. Correct any hold down position that deflects
satisfactory on site using the pads. When more than 0.002 inches (0.05 mm) when
documented properly and duplicated, this released. Re-torque the hold down bolt or
practice reduces labor to re-establish major bolts and repeat on each frame foot.
component alignment.
For JG:JGA frames, the soft foot check is Top Plane Flatness Check
required; the top plane flatness measurement is 1. Remove or reposition the top cover(s) and
optional. gasket(s) to expose the frame top cover
mounting surface. Verify it is clean.
Soft foot checks and top plane flatness
measurements are required: 2. Use measurement equipment with a
published accuracy of ±0.001 inches (0.025
• On new installations or if a unit is relocated.
mm) over the distance required to measure
Perform measurements both prior to skid
grouting and at final shaft alignment prior to the entire length of both frame rails. Measure
initial startup. the top surface of both sides of the frame rails
• At 6 months or 4000 hours to ensure skid based on the frame type as shown in figures
stability. If no changes are found, the interval below. For proper alignment, readings
can then be extended to 12 months or 8000 between any two adjacent points must be
hours. within 0.002 in. (0.05 mm).

JG-JGA Maintenance & Repair Manual – Soft Foot and Top Plane Flatness Checks for Proper Main Bearing Bore 01/27/2023
Alignment in Reciprocating Compressors
3. The ER-82 software tool determines if read- 4. Frame temperature can greatly affect flat-
ings meet ER-82 specifications, and if not, ness readings. Factors such as direct sunlight
provides recommendations for shim correc- on a portion of the frame or cooling after unit
tions as well. Contact Ariel Technical Service shut down can cause measurement inaccu-
for the latest version of this tool. racy. Ensure frame temperature is consistent
throughout the measurement process. Ariel
recommends flatness measurement while
the frame is at ambient temperatures to mini-
mize the effects of thermal expansion.
NOTE: If the unit will not be restarted immediately,

re-preserve the unit in a manner appropriate to the
time duration until restart.
Figure: Flatness Measurement Locations for Frames with Single Anchor Bolts
Figure: Flatness Measurement Locations for Frames with Pairs of Anchor Bolts

JG-JGA Maintenance & Repair Manual – Soft Foot and Top Plane Flatness Checks for Proper Main Bearing Bore 01/27/2023
Alignment in Reciprocating Compressors
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, secure unloader tubing or instrumentation lines.
instrumentation, or pipe clamps to any pressure The plug is designed for high pressure and will
containing component. Pressure containing not affect existing Ariel cylinder MAWP in any
components include cylinders, valve caps, application. Also, standard cylinder plugs may be
cylinder heads, unloaders, gas passage caps, and replaced with this plug without a hydrotest.
flanges. DO NOT use pressure containment Packagers may purchase this plug (A-28373)
fasteners to mount brackets or other structural through Ariel Parts Sales.
attachments. These practices can compromise
Newer Ariel cylinder designs include 1/4-20 UNC
the integrity of pressure containing components.
tapped holes to the milled pad that contains the
cylinder indicator port holes (see Figure: Typical
Cylinder Plugs and Tapped Holes). These extra
CAUTION
tapped holes will provide additional
Do not drill holes in any pressure containing accommodation to clamp unloader tubing or
components for any reason.
instrumentation lines.
Figure: Typical Cylinder Plugs and Tapped Holes
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
recommendations to prepare the area for the
1 Standard Plug adhesive. The clamp and unpainted surface can
2 Plug A-28373 be painted after the adhesive cures. This clamp
3 New 1/4-20 UNC Tapped Holes attachment method does not compromise
cylinder integrity.
Ariel offers a 1/2-inch NPT pipe plug with a 1/4-20
UNC tapped hole to accommodate a tubing
clamp or bracket (see Figure: Typical Cylinder
Plugs and Tapped Holes). Installing this plug in
cylinder indicator ports provides locations to

Recommended Maintenance Intervals for Intermittent

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

JG-JGA Maintenance & Repair Manual – Recommended Maintenance Intervals for Intermittent Duty Operation 01/27/2023
4,000-Hour Maintenance 7. Remove valves and valve gaskets:

a. Visually inspect valve pockets for
1. Perform Daily, 400-Hour, and 2,000-Hour damage. Verify all old valve seat gaskets
maintenance. are removed.
2. Verify safety shutdown functionality. b. Have a qualified valve repair shop disas-
3. Inspect crankcase breather filter and clean semble, visually inspect, and refurbish
with suitable solvent. the valves where needed. Provide the
valve repair shop an Ariel torque chart
4. Open force feed lubricator box and visually and valve service guide.
inspect pump followers, cams, and gears for
c. Visually inspect cylinder gas passages and
wear.
clean them of all debris.
5. Pressure test distribution blocks. See
8. Inspect cylinder bores for damage or wear.
“Distribution Block Assembly” for procedure.
Replace the cylinder body or restore the bore
6. Measure, log, and trend the following: if any of the following conditions exist:
a. Main bearing, connecting rod bearing, • Bore surface blemishes or gouges.
and crankshaft jack and thrust clear- • Bore out of round more than 0.001 inch
ances. See "Main Bearing Vertical Jack per inch of bore diameter (0.001 mm/mm)
Clearance Measurement", "Connecting or tapered.
Rod Bearing Vertical Jack Clearance
• Main bore is worn to counterbore diam-
Measurement", and "Crankshaft Thrust
eter or larger.
(End) Clearance Measurement".
NOTE: Clearance trends along with oil analysis and 9. Inspect piston rings:
crankcase visual inspection can indicate the need for • Measure and log piston ring condition,
bearing replacement. Do not disassemble to check end gap, side clearance, and piston ring
clearances. Disassemble only if clearance checks inid- groove width.
cate excessive clearance. Contact Ariel for original • Replace rings that are damaged or
assembly clearances. outside limits listed in Appendix B.
b. Crosshead to guide clearances. See • When replacing rings, re-measure and log
“Crosshead Installation” in Section 4. ring side clearance to check for groove
c. Piston rod runout. See “Piston Rod wear.
Runout” in Section 4. 10. Inspect piston rods for damage and excessive
If any of the above items are outside limits , find wear. Replace rod if any of these conditions
the cause and correct it. It may require part exist (see "Piston Rod Inspection"):
replacement. • Gouges or scratches on the rod
• Under size more than 0.005 inch (0.13
mm)
• In the packing travel length, out of round
more than 0.001 inch (0.03 mm)
• Anywhere in the packing travel area,
tapered more than: 0.002 inch (0.05 mm)

JG-JGA Maintenance & Repair Manual – Recommended Maintenance Intervals for Intermittent Duty Operation 01/27/2023
11. Re-tighten hold down fasteners to proper 16,000-Hour Maintenance

torque. Visually inspect cylinder gas passages
and clean them of all debris. Inspect for frame 1. Perform Daily, 400-Hour, 2,000-Hour, 4,000-
twist or bending to verify main bearing bore Hour, and 8,000-Hour maintenance.
alignment. See Appendix E for flatness and 2. Remove crosshead pins.
soft foot requirements.
a. Measure and log crosshead pin to cross-
12. Perform a coupling alignment (see "Initial head pin bore and connecting rod
Maintenance"). bushing bore clearances.
13. Rebuild piston rod pressure packing cases b. Check the crosshead pin end caps and
and oil wiper cases. See “Piston Rod Packing” through bolt for wear.
in Section 4 for procedure. c. Replace if needed.
14. Re-install valves, retainers, and valve caps 3. Check for bushing wear in the auxiliary end
using new valve gaskets and valve cap o- drive chain tensioner.
rings/seals. Use proper installation
techniques and torque procedures for valve
caps. See “Valve Installation” in Section 4. 32,000-Hour Maintenance
15. Check and re-calibrate all required
1. Perform Daily, 400-Hour, 2,000-Hour, 4,000-
instrumentation.
Hour, 8,000-Hour, and 16,000-Hour
16. Check auxiliary end chain drive for undercut maintenance.
sprocket teeth and chain for excessive
2. Replace lubricator distribution blocks.
stretching. Replace as required. See “Chain
Adjustment” in Section 4 for procedure. 3. Replace crosshead and connecting rod
bushings. See “Crossheads” in Section 4 and
17. Check fastener torques of gas nozzle flange,
head end head, valve cap, piston rod packing,
crosshead pin through bolt, frame hold
down, crosshead guide to cylinder, distance
piece to cylinder, and tandem cylinder to
cylinder.
8,000-Hour or 22,000 Starts

Maintenance (whichever
occurs first)
1. Perform Daily, 400-Hour, 2,000-Hour, and
4,000-Hour maintenance.
2. Replace crankshaft main and connecting rod
bearing shells if no replacement has occurred
in the past 8,000 hours or 22,000 starts.

Latest Manual Revisions
01/27/2023
Topic Change Description
Maintenance 6th ¶: deleted 'NOTE: For intermittent duty service, see ER-8.2.2.' (not
applicable to KB100 manual).
Daily Maintenance Moved 'Daily Maintenance' section from 'Maintenance Intervals' to after
'Initial Maintenance'.
Recommended Maintenance 'Recommended Maintenance Intervals for Continuous Duty Operation' WAS
Intervals for Continuous Duty 'Maintenance Intervals'. For all manuals except KB100 - inserted 'NOTE: For
Operation intermittent duty service, see Appendix x.' For KB100 only - added new
Appendix for “Recommended Maintenance Intervals for Continuous Duty
Operation” with inserted note - 'NOTE: For intermittent duty service, see
Recommended Maintenance Intervals for Intermittent Duty Operation.'
Recommended Maintenance For all manuals except KB100: added new appendix for 'Recommended
Intervals for Intermittent Duty Maintenance Intervals for Intermittent Duty Operation'; inserted 'NOTE: For
Operation continuous duty service, see Recommended Maintenance Intervals for
Intermittent Duty Operation.' For KB100 manuals only: inserted 'NOTE: For
continuous duty service, see Appendix x.'

Ariel JG JGA Manual

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Ariel JG JGA Manual

Uploaded by

Copyright:

Available Formats

JG-JGA Maintenance & Repair Manual 01/27/2023

ARIEL CORPORATION | www.arielcorp.com 1

Four-Year (32,000-Hour) Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

ARIEL CORPORATION | www.arielcorp.com 2

ARIEL CORPORATION | www.arielcorp.com 3

“BTU” Single-Acting Seal Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

ARIEL CORPORATION | www.arielcorp.com 4

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

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 voice mail.

ARIEL CORPORATION | www.arielcorp.com 9

ARIEL CORPORATION | www.arielcorp.com 10

Figure: Optional Furnished Tools for JG:JGA Compressors

Ariel Separately Purchased

ARIEL CORPORATION | www.arielcorp.com 11

Ariel Separately Purchased • 1/2” and 5/8” hex key sockets

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

Main Bearing Temp. Ariel Recommended, but optional.

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)

- Air Not to exceed autoignition temperature of cylinder lubricant at

Cyl. Rod Load Protection Packager

Over Speed Packager 10% over rated speed for shutdown

ARIEL CORPORATION | www.arielcorp.com 14

Notes 7. Install all safety shutdowns, controls, instru-