DV Compressor UENA

Installation, Operation, and Maintenance
of
DV Series
COMPRESSORS
Models 7 ½ and 9 ½
Union Engineering North America 14-Apr-15

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DRY COMPRESSORS Model DV 7 ½ x 5
Model DV 9 ½ x 7
TABLE OF CONTENTS
INSTALLATION AND WEAR-IN PROCEDURE
INSTALLATION
Foundation
Erection
Drive and Motor Starter
Piping
Initial Start
Stopping the Unit
WEAR-IN PROCEDURE
OPERATION AND MAINTENANCE
TYPICAL COMPRESSOR CONTROLS

Suction Pressure Switch
High Pressure Switch
Temperature Switches
Water Pressure Switch
Oil Pressure Circuit
Unloaded Starting
CAPACITY CONTROL
Valve Unloading
By-Pass Valve
LUBRICATION
Type and Amount
Lubrication System
Oil Pressure
INTERCOOLER AND AFTERCOOLER

MAINTENANCE
Piston and Rings
Piston Head Clearance
Piston Rod
Valves
Packings
Bearings
Crosshead
Oil Scrapers
TROUBLESHOOTING
SKETCHES AND DRAWINGS
Foundation
Oil Pump Arrangement
Oil Pump Assembly
Capacity Control Assembly
Gas End Assembly
Valve Assemblies
Valve Seat Removal (7 ½ x 5 Model only)
Piston Rod Packing
Crankcase Section Assembly
Starter Circuit Wiring Diagram
PARTS LISTS
Model DV 7 ½ x 5
Model DV 9 ½ x 7

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INSTALLATION AND WEAR-IN PROCEDURE
The DV series compressor is designed to compress CO2 vapor. It is a vertical two cylinder, two
stage unit with a double-acting first stage. The compressor is automatically controlled by
pressure and temperature switches. These switches are set to control proper suction, discharge,
and oil pressures as well as discharge gas temperature. Complete information for vendor
supplied equipment is provided at the back of this manual.
The compressor was carefully inspected and checked before leaving the factory. After break-in,
the unit was tested for required capacity at various suction conditions. The actual capacity was
measured with flowmeters and recorded. Gas temperature (in and out), water temperature, water
volume, flowmeter readings, and electrical load data are on permanent record at the factory. This
is your assurance that Union Engineering has supplied you with the best possible equipment.
Should questions arise regarding the machine, our staff is ready to assist in any way possible.
INSTALLATION
The compressor is normally supplied as a complete package. The control equipment, heat
exchangers, moisture separators, traps, and motor assembly are mounted on a steel base. The
unit is ready to install on a suitable foundation. The compressor flywheel, matched V-belts, and
belt guard have been removed for shipping. The motor starter is normally supplied and shipped
separately for remote mounting.
The compressor should be located in a clean, dry area. There should be sufficient clearance to
perform routine maintenance, as well as pulling the piston rod, removing the crankshaft, or other
major repairs.
Foundation:
It is necessary to provide an adequate foundation to prevent vibration and movement of the

compressor. Reciprocating compressors cannot be completely balanced. They can exert shaking
forces that may destroy an ordinary building foundation. The final responsibility for the success of
the foundation rests with the customer. If two or more compressors are installed adjacently, it is
recommended that their foundations be placed on a common reinforced mat.
Soil bearing pressures for reciprocating machinery are much lower than those permitted by
municipal building ordinances. Test holes should be dug at the proposed site to determine the
nature of the soil and subsoil. If doubt exists about soil suitability, consult a foundation engineer.
The engineer will use the unbalanced forces in Table 1 to analyze a foundation problem.

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TABLE 1 – UNBALANCED FORCES
Model 7 ½ x 5 Model 9 ½ x 7
@ 560 RPM @490 rpm
Vertical Primary 1912 lbs (867 kg) 3912 lbs (1774 kg)
Vertical Secondary 554 lbs (251 kg) 985 lbs (447 kg)
Horizontal Primary 95 lbs (43 kg) 117 lbs (53 kg)
Horizontal Secondary 0 lbs (0 kg) 0 lbs (0 kg)
The foundation plan shows the recommended anchor bolt layout and a cross section view.
Special applications may require a modified foundation drawing that will be included where
applicable. Tubes should be placed around anchor bolts to allow for any misalignment in the
layout. Concrete should be kept out of these tubes when pouring the foundation.
Use ½ inch (13 mm) deformed steel reinforcing bars on 12 inch (305 mm) centers. The bars
should extend vertically and horizontally near all faces of the foundation. The concrete should be
poured 90º from the floor on the flywheel side. This is necessary for flywheel clearance.
Erection:
After the foundation is thoroughly cured, the unit can be lowered onto the anchor bolts. The
compressor must then be carefully leveled both crosswise and lengthwise. To do this, ¾ inch
(19.1 mm) thick wedges should be placed between the bottom of the base and the top of the
foundation. The wedges should be positioned as close to the anchor bolts as possible. This will
prevent excess strain on the unit when the bolts are drawn tight.
A grouting cement (two parts sand and one part cement) should now be poured under the unit.
Work the cement under the base from one side using a board to force it out the opposite side.
While the grouting is still soft, it should be troweled to slope slightly down from the base. Any oil
that may be spilled will then run off instead of soaking under the base.
All wedges should be removed after the grouting has set. This insures that the unit is bearing on
the grouting and not on the wedge. Fill all wedge holes with grouting cement. The finished
foundation should be coated with a good oil and waterproof cement paint.
The inside of the crankcase should be thoroughly cleaned to remove any dust and dirt that may
have entered. Use only clean lint-free rags for cleaning the crankcase. Fragments from waste or
linty rags may clog the oil strainer or passages. The cleaner the crankcase is, the cleaner the
lubricating oil will be.
After cleaning the crankcase, fill it with the recommended lubricating oil (see “LUBRICATION”
section). Add oil until it rises to ¾ of the oil level gauge. Capacities for each model are shown in
Table 2. When starting for the first time or after a long shut-down, pour oil over each main
bearing and connecting rod bearing. Also, lubricate the crosshead guides with a hand oiler.

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TABLE 2 – CRANKCASE CAPACITY
Model Quarts Liters
DV 7 ½ x 5 8 7.5
DV 9 ½ x 7 12 11.3
Assemble the flywheel sheave to its hub. This assembly will be mounted on the crankshaft.
Before mounting the sheave, clean the hub and sheave mating surfaces. Wipe each surface with
a cloth moistened with light machine oil. Mount the flywheel assembly on the shaft. Tighten the
pull-up bolts alternately until each bolt has reached the torque value shown in Table 3. The
sheave type is stamped on the hub. The direction of rotation is clockwise when facing the
flywheel.
TABLE 3 – SEATING TORQUE FOR SHEAVE TO HUB MOUNTING *
Sheave Type Tap Screw Size Torque Value
SD or SDS 1/4” – 20 9 ft-lbs. (1.1 kg-m)

SK 5/8” – 18 15 ft-lbs. (2.1 kg-m)
SF 3/8” – 16 30 ft-lbs. (4.2 kg-m)
E 1/2” – 13 60 ft-lbs. (8.3 kg-m)
F 9/16” – 12 75 ft-lbs. (10.4 kg-m)
J 5/8” – 11 135 ft-lbs. (18.7 kg-m)
*Recommended by Worthington and Wood’s Sons Co.
Drive and Motor Starter:
Install the matched V-belts and align the motor by moving it out to establish proper belt tension.
Refer to vendor bulletins section for proper belt tensioning and alignment procedures. It is
important that the compressor and the motor sheave are aligned. Misalignment will result in
reduced bearing and belt life.
Install the motor starter in the desired location. A fused disconnect switch should be installed on
the line side of the starter. Refer to motor nameplate for motor wiring data and information
required to properly size motor leads and fuses. Install control wiring from the compressor control
panel to the starter. See control circuit wiring diagram.
Piping:
Visually inspect the compressor to be sure that all parts are properly adjusted and in working
order. After a thorough check of the compressor, the following connections can be made:
1. Pipe the cooling water outlet to the drain (or to the return in closed systems).
2. Pipe cooling water to the inlet solenoid valve. This water circulates through the intercooler,
the aftercooler, and the compressor water jacket.
3. Pipe the suction to the compressor from the CO2 supply. The suction line must be blown
clean and thoroughly dried before final connection and start-up.
4. Pipe the discharge of the compressor to the remainder of the CO2 system.
5. Pipe the safety valve outlet and unloader solenoid valve to the outside atmosphere. As an
alternate, the unloader valve discharge may be piped into the suction line upstream of the
CO2 water scrubber.

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Initial Start:
The following steps should be completed before operating the compressor:

1. Tighten the foundation bolts.
2. Clean the suction line to remove rust and dirt.
3. Check the crankcase oil level. The sight glass near the bottom of the crankcase should be
3/4 full.
4. Remove the crankcase covers and hand lubricate the main bearings, crank pin and wrist pin
bearings, and crosshead guides.
5. Rotate the flywheel several revolutions by hand to see that the compressor works freely.
6. Open all needle valves to the gauges. These valves control pulsations to the gauges and
may have to be throttled after start-up.
7. Open water supply valve and make sure water is available to the compressor.
8. Open all suction and discharge line valves.
9. Before closing the electrical disconnect switch, place the “Hand – Off – Auto” switch in the
“Off” position. The “High Discharge Pressure” light will indicate initial power “On” at the
panel. Press the “High Pressure Reset” button (PB-1).
10. The “Hand” position can now be used to job the compressor. Hold in “Hand” position
momentarily. Be sure that the compressor rotation is clockwise when facing the flywheel.
This rotation is necessary for the oil pump to operate properly. Do not pull the system into
vacuum.
11. The compressor is now ready to start. Turn the switch to the “Auto” position. If CO2 is
available and all conditions of the controls are satisfied, the compressor will start and
continue to run.
12. If the compressor fails to start, or stops for an unknown reason, refer to the
“TROUBLESHOOTING” section.
Stopping the Unit:
If it is necessary to stop the compressor, place the “Hand – Off – Auto” switch in the “Off”
position.
WEAR-IN PROCEDURE
The compressor should be monitored closely when operating for the first time. Adjust water
control valves to temperature settings as indicated in the “INTERCOOLER AND
AFTERCOOLER” section. Extensive damage will result if any part of the unit overheats. In
addition to the daily checks outlined in the “MAINTENANCE” section, the following checks should
be made:
After the first 500 hours of operation:

1. Tighten all foundation bolts.
2. Check drive belts for proper tension and alignment.
3. Check all valves.
4. Check the piston rings for excessive wear.
5. Check piston rod packings.
After the first 1000 hours of operation:

1. Check all valves.
2. Check piston rings for wear.
3. Check piston rod packings for wear.
4. Change crankcase oil.
5. Clean crankcase oil strainer.
6. Check oil scraper rings.
7. Tighten foundation bolts.

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OPERATION AND MAINTENANCE
TYPICAL COMPRESSOR CONTROLS
The compressor is designed to operate automatically. Safety controls are also built in to prevent
damage if a malfunction occurs. Refer to compressor wiring diagram.
Suction Pressure Switch:
A pressure switch (PS-2) controls operation from the suction side. This switch should be set to
close and start the compressor at a predetermined operating pressure (for example, 5 psig). The
switch should be set to open and stop the compressor at a desired minimum pressure (for
example 0.50 psig (0.04 kg/cm 2). Therefore, when CO2 vapor is available to the compressor for
collection, the suction pressure will increase and start the compressor. The compressor will
continue to run as long as the CO2 supply is sufficient to maintain pressure above the stop
setting of the switch.
All of the other switches in series with PS-2 are safety controls and must be closed before the
compressor can start.
High Pressure Switch:
The high pressure switch (PS-1) prevents excessive discharge pressure and should be set to
open and stop the compressor at approximately 5 psig (0.4 kg/cm2) above normal operating
pressure. For example, if the system operates normally at 250 psig (17.2 kg/cm 2), the high
pressure switch should be set to stop the compressor at 255 psig (17.6 kg/cm 2). The switch
should then be set to close at 245 psig (16.9 kg/cm 2), allowing the compressor to re-start. Since
control relay (1 TR) is operated by the high pressure switch (PS-1) in a holding circuit, the high
pressure reset button (PB-1) must be pushed to manually reset the circuit after the discharge
pressure drops to the restart pressure setting.
Temperature Switches:
The compressor discharge is controlled by a temperature actuated switch (TS-2). The switch is
set to open and stop the compressor at 300 ºF (149 ºC). The temperature switch should be set to
close and restart the compressor at 275 ºF (135 ºC).
The aftercooler discharge is also controlled by a temperature actuated switch (TS-1). This switch
is set to open and stop the compressor at 140 ºF (60 ºC). It should be set to close and restart the
compressor at 130 ºF (54 ºC).
Water Pressure Switch:
The water supply to the coolers can be adjusted to maintain the gas temperature at the desired
level. To further protect against overheating, a water pressure switch (PS-4) is used. If water
pressure drops below 20 psig (1.4 kg/cm 2), the switch will open and the compressor will stop. It
is set to close and restart the compressor when water pressure rises to 25 psig (1.7 kg/cm 2).

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Oil Pressure Circuit:
The oil failure protection switch (PS-3) contains two separate switches. One switch is pressure
actuated and the other is a heat actuated time delay switch. Both switches are normally closed.
Oil pressure must build up to 20 psig (1.4 kg/cm 2) and open the time delay heater circuit within a
90 second time period. If this does not happen, the heat actuated switch will open and the
compressor will stop. If oil pressure rises to 20 psig (1.4 kg/cm 2) within the delay period, the time
delay heater is de-energized. The heat actuated switch remains closed and the compressor
continues running. If oil pressure drops to 15 psig (1.0 kg/cm 2) during operation, the time delay
heater will be energized. Unless the oil pressure returns to 20 psig (1.4 kg/cm 2) within 90
seconds, the compressor will stop. The control must be manually reset if the oil failure circuit
stops the compressor.
Unloaded Starting:
The compressor starts unloaded by means of the unloader solenoid valve (SOL-2) which is
normally open and relieves pressure from the compressor when it stops. This solenoid is
operated by a timer relay (1TR) which allows the unloader valve to remain open for approximately
5 seconds after the compressor starts. After the time delay, the timer contacts close, energizing
and closing the unloader valve. The discharge pressure then rises to the normal operating
pressure.
CAPACITY CONTROL
The compressor is normally provided with a means of reducing capacity to prevent frequent
starting and stopping of the compressor. Capacity control is achieved by one of the following
methods:
Valve Unloading:
The head end suction valve in the first stage cylinder is automatically unloaded by a pneumatic
diaphragm operator assembly and a three-way solenoid valve (SOL-4). Discharge gas is
reduced to 15 psig (1.0 kg/cm 2) and piped through the three-way solenoid valve to the diaphragm
operator. A 50% capacity reduction takes place when suction pressure decreases to the cut-in
setting of the capacity control pressure switch (PS-5). The three-way solenoid valve is then
energized and allows gas pressure to operate the diaphragm, pushing the capacity control in and
holding the suction valve open. When the three-way solenoid valve is de-energized, it vents the
diaphragm and this suction valve returns to normal operation.
The capacity control pressure switch (PS-5) is set to cut-in and cut-out within the setting of the
suction pressure switch (PS-2). For example, if the suction pressure switch is set to close and
start the compressor at 5 psig (0.4 kg/cm 2), the capacity control switch would be set to open and
load the compressor 100% at 4.5 psig (0.3 kg/cm 2); and with the suction switch set to open and
atop the compressor at 0.5 psig (0.03 kg/cm 2), the capacity control switch would be set to close
and unload the compressor 50% at 1 psig (0.04 kg/cm 2).
By-Pass Valve:
The compressor may be fitted with a diaphragm operated recycle valve to reduce its capacity.
The valve will by-pass discharge gas back to the compressor suction to maintain a constant
suction pressure. The valve is self-operating and, therefore, by sensing suction pressure directly
on the diaphragm, it will automatically open with a decrease in suction pressure. The recycle
valve must be field adjusted to maintain from 50% to 70% of design suction pressure. For
example, if the design suction pressure is 5 psig (0.4 kg/cm 2), the valve should start to open to
maintain 2.5 to 3.5 psig (0.17 to 0.24 kg/cm 2).

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LUBRICATION
Type and Amount:
The life of a machine depends almost entirely upon the effectiveness of lubrication. Therefore,
the selection of the proper lubricants should be given considerable thought. For proper
crankcase lubrication, we recommend turbine type oil with rust and oxidation inhibitors such as
Mobil DTE extra heavy. A quality oil with the following ratings may also be used:
TABLE 4 – OIL SPECIFICATIONS

API Gravity: 28
Pour Point: 25 ºF Maximum
Flash Point: 420 ºF Minimum
SSV Viscosity at 100 ºF: 590 – 610
Color, ASTM: 6.5 Maximum
Viscosity Index: 95 Minutes
Crankcase oil must be maintained at the center of the oil level gauge with the machine operating.
Normal oil pressure should read 30 to 35 psig (2.1 to 2.4 kg/cm 2). The oil circulates rapidly in a
tightly enclosed space and will gradually increase in temperature. Because of this, the crankcase
may become uncomfortably warm to the hand. The case temperature may reach 60 ºF (16 ºC)
above ambient temperature. This is a normal condition and will do no harm. Oil pressure may be
higher than normal until crankcase reaches operating temperature.
Lubrication System:
The frame end of the compressor is lubricated by a force-feed (pressure) system. A gear-type
pump (see oil pump assembly drawing), driven from the crankshaft, draws oil through a
reinforced wire mesh strainer in the sump. It is then forced through drilled holes in the shaft.
From here, the oil is conducted to the main bearings, crankpin bearing, and through a drilled hole
in the connecting rod. Oil is then passed, under pressure, to the inside of the crosshead pin. It
is finally conducted to the sidewalls of the crosshead. The overflow from the pump is piped back
to the crankcase through an oil filter and pressure regulating valve.
The oil head is provided with a piston rod seal. The crankcase oil head is also fitted with a pair of
full metallic oil wiper rings. This completely seals the piston rod and isolates the crankcase. The
seal and rings prevent oil seepage along the piston rod. In addition, the crankcase is separated
from the gas end by a distance piece.
In a new machine, the oil should be examined after the first eight hours of operation. This is
important because the oil will wash out dust and dirt not removed during the initial cleaning.
Carefully examine the oil strainer in the sump of the frame. If it is dirty, it should be removed
immediately and cleaned.
The oil reservoir should be drained every 5,000 hours. Whenever the oil is completely drained,
clean the inside and bottom of the frame and remove any sediment prior to refilling.
Oil Pressure:
The oil pressure regulator valve is on the pump side of the compressor (see diagram). The oil
pressure is set at the factory but, if it is found necessary to adjust the oil pressure, loosen the jam
nut and adjust the screw to proper pressure; then retighten the jam nut. Refer to bulletins for
valve details. Under no circumstances allow the pressure to drop below 20 psig (1.4 kg/cm 2). If
this occurs, shut down the compressor. Investigate the cause and correct before restarting the
compressor.

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INTERCOOLER AND AFTERCOOLER
Heat is produced as the gas is compressed in the first and second stages. This heat is removed
by heat exchangers. An intercooler cools the gas between stages of compression. An
aftercooler cools the gas as it leaves the compressor.
Be certain there is enough cooling water flowing through the cylinder jackets and coolers. The
temperature of the water from the high pressure cylinder head should be about 110 ºF (43 ºC).
The gas temperature exiting the intercooler should be maintained approximately 10-15 ºF (5-8 ºC)
higher than the suction gas temperature. The gas temperature exiting the aftercooler should be
approximately 100 ºF (38 ºC).
Both the intercooler and aftercooler are constructed of stainless steel with removable tube
bundles. The hot gas enters the top of the exchanger’s shell and exits the bottom along with
condensate.
The cooling water flow rate to the coolers and cylinder jacket are maintained by individual self-
powered temperature regulators after initial adjustment. Gas and water temperatures should be
checked on a regular basis and the temperature regulators serviced as required.
MAINTENANCE
A regular inspection and maintenance schedule will extend compressor life and reduce operating
costs. Table 5 is a guide that should be followed by maintenance personnel. Any inspection or
service performed on the compressor should be recorded.
TABLE 5 – MAINTENANCE SCHEDULE
Every 8 hours:  Check oil level.

 Check oil pressure.
 Be sure the compressor is cycling properly.
 Inspect the machine – look and listen for irregularities.
Every 500 hours:  Check oil scraper rings.

 Check piston rod packing for wear.
 Check all valves.
Every 2,000 hours:  Check all valves.

 Check piston rings for wear.
Every 5,000 hours:  Change crankcase oil.

 Clean crankcase oil strainer.
 Tighten foundation bolts.
 Check oil scraper rings.
 Check piston rod packing for wear.

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Piston and Rings:
The compressor piston is made up of several parts with the low pressure and high pressure
sections integrally assembled. See Gas (Upper) End Assembly drawing. The low pressure
section uses two compression rings. The high pressure section uses three compression rings
and one bull ring. The compression rings have a step cut and the bull ring is butt cut.
New rings should be checked for proper end gap. Place the ring squarely in the cylinder bore
and measure the gap. When checking rings for wear, the end gap should not exceed 60% of the
step cut. Roll each ring around in its grooves and make certain that it does not bind at any point.
The piston ring grooves should be checked periodically for taper in the shoulders. A new ring
cannot seat properly in a badly worn groove. Improper seating causes a poor seal which, in turn,
reduces capacity. Table 6 shows the proper ring gap and ring groove clearance.
TABLE 6 – RING CLEARANCES
Model DV 7 ½ x 5 Model DV 9 ½ x 7
COMPONENT FIRST STAGE SECOND STAGE FIRST STAGE SECOND STAGE
Cylinder Bore 7.5” (191mm) 4.375” (111 mm) 9.5” (241 mm) 5.5” (140 mm)
Ring Gap .078” (1.981 mm) .078” (1.981 mm) .078” (1.981 mm) .078” (1.981 mm)
Ring-Groove .013” - .016” .008” - .010” .014” - .018” .011” - .015”

Clearances (.330mm -.406mm) (.203mm -.254mm) (.356mm -.457mm) (.279mm -.381mm)
Piston Head Clearance:
The clearance between the piston and the cylinder head should be checked if the piston is
removed for service. When the cylinders are cold, the clearance must be greater at the upper
end than at the frame end. This difference allows for the expansion of the piston due to heat.
When adjusting or checking the clearance, remove one of the valves on each end of the cylinder.
Insert a piece of 1/8” (3.2 mm) diameter solder between the piston and the head. Then hand
rotate the machine until top dead center has been passed and the solder is crushed. Hand rotate
the machine and check at the opposite end to see that the piston does not bump the head. Also
make sure that the clearance is greater at the top than at the frame end.
The clearances must be measured when the compressor is cold. Refer to the Table on the Gas
(Upper) End Assembly drawing for clearances. The upper clearance (“C”) should never be less
than .070” (1.78 mm). If it is, the piston may strike the head during operation.
To adjust piston clearances, first remove the compressor nameplate. Next, remove the screws
that hold the oil head in place. The oil head can be held out of the way by raising it up along the
piston rod and inserting two rods into the drilled holes provided in the distance piece. These rods
will support the oil head. Loosen the set screw and copper plug and loosen the crosshead nut.
The clearance at the frame end can be set by turning the rod in or out of the crosshead with a
wrench. Never use a wrench that will mar the rod. This will cause damage to the packing.

Page 12 of 48
Piston Rod:
The rod has a ceramic coating in the area of the packing. This coating prevents scoring that
would otherwise be caused by lack of packing lubrication. Care should be exercised, when
handling the rod, to prevent cracking or chipping.
The first stage piston is held in place by the piston rod and nut. The second stage piston is bolted
to the first stage piston. The second stage piston must be removed to gain access to the piston
rod nut. Remove the oil scrapers before removing the piston rod. If the rod is withdrawn through
the scrapers, the lips will be damaged. Examine the lips and reinstall them face down. Table 7
shows the seating torque for piston rod nuts. Table 8 shows the seating torque for piston cap
screws, as well as other screws used on the compressor.
TABLE 7 – PISTON ROD NUT SEATING TORQUE
Rod Size Ft-Lbs. Kilogram-Meters
1” – 14 117 16
1 1/2” – 6 190 26
1 1/2” – 12 275 38
1 3/4” – 12 370 51
2” – 12 480 66
TABLE 8 – SEATING TORQUES FOR VARIOUS SCREWS
Screw Size Ft-Lbs. Kilogram-Meters
UNC 1/4” – 20 5 0.7

UNF 1/4” – 28 7 1.0
UNC 3/8” – 16 17 2.4
UNF 3/8” – 24 19 2.6
UNC 1/2” – 13 38 5.3
UNF 1/2” – 20 40 5.5
UNC 5/8” – 11 60 8.3
UNF 5/8” – 18 70 9.7
UNC 3/4” – 10 85 11.8
UNF 3/4” – 16 95 13.1
If any part of the piston assembly is replaced, the alignment of the entire assembly must be
checked. To do this, place the piston assembly between the centers of a lathe. Measure
eccentricity and squareness at a few points along the length of the assembly. These
measurements should not exceed .005” (0.13 mm) total indicator reading.

Page 13 of 48
Valves:
Valve parts must be in good condition for efficient compressor operation. Capacity can be
affected if these parts are not thoroughly inspected every 500 hours. Inspection may be more or
less frequent according to conditions. See “Valve Assemblies” drawing for parts breakdown of
low and high pressure valves.
The first and second stage valves are stainless steel. A different grade of steel is selected for
each component part. This insures maximum valve durability and efficiency. The valve disc is
guided by replaceable Teflon buttons that reduce wear.
To remove a valve from the cylinder, remove the valve screw cap and loosen the valve screw that
holds down the valve retainer. Next, remove the cover nuts, the cover, and the valve retainer.
The valve assembly may now be lifted out of the valve port. When removing an unloader valve,
remove the diaphragm holder, spring, and unloader nut. Then loosen the valve screw and
remove the valve from the port.
Disassemble the valve completely for cleaning and inspection. The valve guard is held firmly to
the seat by a threaded central post. Never distort a valve by clamping the assembly in a vise. A
stressed valve may later leak or fracture and drop pieces of steel into the cylinder.
The valve guard must be held while removing the seat. Prepare a block of wood as shown in the
drawing “Valve Seat Removal”. Cut the heads off four large nails. Drive the nails into the blocks
so they line up with the slots in the valve guard. The nails hold the guard from turning while the
seat is removed. A special wrench must be used on the DV 7 ½ x 5 second stage valve guards.
Suggested wrench detail can be found in the “Valve Seat Removal” drawing.
If the parts do not come apart easily, soak them in kerosene. Remove the valve discs and
spring. Check the Teflon guide buttons for wear. Carefully scrape and brush all foreign matter
from the parts, making sure the spring socket and valve guides are clean. Valve parts must not
be scratched or gouged. If the contact surfaces are damaged, the valves will leak when re-
assembled.
Examine valve parts thoroughly. Wear marks will be seen where valve parts slide against each
other. The marks are normal unless they are deep or rough. If a good deal of metal has been
worn off, new parts should be installed. If valve discs are worn, replace them. Look for worn or
broken springs and replace them.
If the compressor is equipped with an inlet unloader valve, examine the diaphragm carefully. If
any leakage or rupture is noticed, replace the defective diaphragms. Always keep spare
diaphragms on hand. Ordinary materials are not satisfactory and should not be used.
When reassembling the valve, make sure that the valve discs engage the pin and can be lifted
freely against their springs. The discs must also return squarely to their seats. To test this, insert
a screwdriver through a slot in the seat and push the valve disc off its seat.
Clean all the dirt from the valve seat before reinstalling the valve assembly into the compressor
valve port. When replacing the valve cover, make sure that the valve screw is backed off until the
cover cap screws are tightened.

Page 14 of 48
Packings:
The piston rod stuffing box is of a non-lubricated design. It consists of three sections of annular
case packing which are retained by a gland. Each section consists of one pair of Teflon rings.
The rings float freely and are not adjustable. Garter springs are used to seat the packing against
the rod. This design provides a tight seal even as the rings wear. Refer to “Typical Piston Rod
Packing Arrangement” drawing for a sketch of the packing arrangement.
Packing rings should be replaced when excessive leakage occurs. When installing packing rings,
thoroughly clean the stuffing box and piston rod. Remove any foreign matter from sealing
surfaces. Always inspect the O-ring in the bottom of the stuffing box. Replace the ring if it is
damaged.
Bearings:
The compressor bearings are run in before the compressor leaves the factory. The two main
bearings are double row roller bearings positioned at both ends of the shaft. They are extra large
engine bearings and should last the lift of the machine. The bearings are self-aligning and need
no adjustment. The main bearing on the drive end is locked in position by two plates. It is
important that the two plates are properly installed and the proper thickness gaskets are used on
the drive end bearing housing, as this is what determines the location of the crankshaft journal in
the center of the crosshead guide. The pump end bearing is free to float end wise. This provides
tolerance for any expansion of the frame due to heat.
The connecting rod is fitted with a bushing bearing at the crosshead end. A split bearing is used
at the crankpin end. The running clearance for the split bearing is from .002” to .003” (0.05 mm to
0.08 mm). ANY WORN BEARINGS SHOULD BE REPLACED IMMEDIATELY.
Crosshead:
Each crosshead is tin plated cast iron. They are cast in one piece and precision turned to fit the
guides. Grooves are machined into the crosshead for pressure lubrication. The crosshead
overtravels the guides. This results in uniform, negligible wear even after years of service. The
running clearance for the crosshead is one thousandth per inch of diameter.
The crosshead pin is alloy steel. It is hardened and ground to a precision fit. The pin is retained
by two snap rings that sit in a groove on each end of the pin. A set screw locks the pin and
prevents it from turning.
Oil Scrapers:
The crankcase is fitted with an oil tight cover through which the piston rod travels. There are two
oil scrapers in the cover to prevent oil from traveling up the rod into the gas section. A set of
cartridge seals prevents oil leakage from the crankcase. These seals also prevent contaminants
from entering the crankcase.

Page 15 of 48
TROUBLESHOOTING
If compressor problems occur, the cause may be found in the following troubleshooting chart.
Always begin with simple troubleshooting checks and move toward more complex procedures.
By following this rule, the time you spend repairing the compressor will be minimized.
SYMPTOM PROBABLE CAUSE REMEDY

Compressor will not start Main power supply fuse Check fuses – main and control.
Control circuit fuse
Improper supply voltage Check for correct voltage.
Starter overloads open Reset overloads.
Suction pressure switch Adjust for proper setting.
Discharge temperature or pressure Check temperatures and pressures.

switches Adjust the correct setting.
Reset discharge pressure switch.
Oil pressure switch open Check oil pressure switch. Reset.

Check correct setting.
Water pressure switch open Check switch and water supply.

Adjust correct setting.
Compressor starts; then stops Low oil pressure Check oil pressure regulator.
Check switch setting.
High discharge pressure Check discharge pressure switch

setting. Check valves in line are open.
Check that CO2 condenser is not
frozen.
Compressor stops without apparent Power failure Check power supply.

reason
Starter overloads open Increase setting on overloads to
proper limits. Reset.
Compressor starts and stops CO2 supply to suction inadequate Check CO2 supply from generator or
too frequently fermenters.
Suction pressure switch setting Check switch for proper differential

setting.
Incorrect unloader setting Set unloaders correctly.
Unloader parts worn or dirty Check parts and repair as necessary.
Motor overheats Frequent starts Check suction pressure switch

differential setting.
Check for CO2 supply to be adequate.
Poor ventilation Open necessary vents for proper air

circulation.
High ambient temperature Check for proper air circulation.
Belt tension incorrect Correct belt tension.
Improper supply voltage Check voltage and frequency.
Worn bearings If bearings are worn, replace.
Excessive suction or discharge Check for proper pressures.

pressure

Page 16 of 48
TROUBLESHOOTING (continued)

Compressor overheats Intercooler dirty Clean cooler.
Check water cooling tower.
Check water inlet temperature.
Inadequate cooling water Check pumps and water supply.
Valve gaskets Check that the valve gaskets are not

leaking.
Piston rings Check for worn piston rings.
Valves Check for leaking or broken valves.
Noisy compressor Lubrication problem Lubrication insufficient.
Loose foundation bolts Tighten foundation bolts.
Loose flywheel Check flywheel and hub for tightness.
Piston nut loose Tighten piston nut.
Piston to head clearance Check the head clearance as per

manual.
Worn valves Check valves. Repair or replace.
Valve retainer loose Tighten valve retainer.
Excessive vibration Loose foundation bolts Tighten foundation bolts.
Loose flywheel Tighten flywheel.
Belt alignment Check V-belt alignment.
Piping supports Piping supports are weak and need to

be made stronger.
Improper grouting Grout compressor properly.
Improper belt tension Check belt tension.
Low capacity Belt tension Belts slipping – check tension.
Leak in system Check the piping for leakage.
Safety valves Safety valves are leaking.
Valve assembly Check for leaking valves and valve

gaskets
Piston rod packing Renew packing if leaking.
Piston rings Check rings – renew as necessary.

Page 17 of 48
TROUBLESHOOTING (continued)

High CO2 temperature Water pressure switch Water pressure switch needs
adjustment to a higher pressure.
Check water pump pressure.
Water pressure Raise water pressure; check valves

are open.
Water temperature Check cooling tower.

Check temperature switch.
Low oil pressure Low oil level Fill oil to required level.
Oil strainer clogged Replace element.
Leaks in suction line Repair leaks.
Leaks in pump casing gaskets Replace gasket.
Defective pump Replace pump.
Defective pump drive Replace drive.
Worn bearings Replace bearings.
By-pass relief valve Readjust relief valve for proper

pressure.
High oil pressure Oil viscosity too high Check manual for proper
specifications.
Clogged filter Replace filter.
By-pass relief valve Adjust relief valve for correct pressure.
Valve wear excessive Valves assembled incorrectly Reassemble valves.
Defective unloader Repair or replace unloader.

Check unloader for correct setting.
Contaminated suction gas Check gas for excess moisture.

Check separator.
Ring wear excessive Cylinder scored Replace liner or cylinder.
Contaminated suction gas Check water separator.
High interstage pressure Check for leaking valves.
Piston rod / packing wear excessive Rod scored or worn Replace rod.
Packings broken or worn Replace packing.
High interstage pressure Leaking second stage valves Repair or renew valves.
Check piston rings.

Page 18 of 48
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Page 28 of 48
Page 29 of 48
“DV 7-1/2 X 5” SERIES COMPRESSOR
PARTS LIST
GENERAL:
When ordering spare parts, please specify model number, serial number and sales order
number from “DV” series compressor nameplate, along with spare part item number, part
number, description and quantity of each part required.
ELECTRICAL PARTS:
Original motors, switches and overload heaters are specified by the user according to individual
power source characteristics. Replacements for these items can be ordered by the part
description and electrical rating.
SPARE PARTS:
Union Engineering recommends that each user of a “DV” series compressor keep at least a
small stock of certain spare parts on hand. These parts are identified by (S) in the “QUANTITY”
column of the following list:
CODE/
ITEM NO. DESCRIPTION QTY. STOCK CODE
1-1 Crankcase 1 B0100670

1-2 Crankshaft 1 B0100683
1-3 Main Bearing Housing 1 B0101219
(Drive End)
(Pump End)
1-5 Connecting Rod 1 A0000085
1-6 Crosshead 1 A0000024
1-7 Crosshead Guide 1 B0101116
1-8 Bearing Housing Cover 1 B0100624
(Pump End)
1-9 Counterweight -
1-10 Oil Head 1 B0101161
1-11 Bearing Retainer Ring-Inner 1 B0102451
1-12 Bearing Retainer Ring-Outer 1 B0102452
(Drive End)
1-14 Cover–Blind 1 B0100613
1-15 Cover–Breather 1 B0100621
1-16 Cover-Crankcase Hand Hole 2 B0102162
1-17 Spacer-for Bearing, Drive & 2 B0100432
Pump End
1-18 Connecting Rod Bolt 2 B0060026
1-19 Connecting Rod Bolt Nut 2 B0060028
1-20 Crosshead Pin 1 B0101995
1-21 Crosshead Pin Bushing 1 B0103306
1-22 Crosshead Bushing 1 B0100451
1-23 Shaft End Plate 1 B0102216
Continued:

Page 30 of 48
CODE/
1-24 Cover-Lube Oil Pump 1 B0100642

1-25 Bushing-Lube Oil Pump 1 B0100390
1-26 Cover-Oil Seal Housing 1 B0100647
Piston Rod
1-27 Scraper Ring Retainer 1 B0102419
1-28 Lube Oil Pump 1 B0120137
2-1 Gasket-Covers 2(S) B0130285

2-2 Gasket-Cover Crankcase 2(S) B0130285
Hand Hole
2-3 Gasket-Bearing Housing 2 B0130582
2-4 Gasket-Bearing Housing Cover 2(S) B0130289
2-5 Gasket-Crankcase to Crosshead 2(S) B0130279
Guide & Housing
2-7 Gasket-Lube Oil Pump Cover 1(S) B0130580
2-11 Oil Head “O” Ring 1(S) B0130750
3-1 Socket Head Cap Screw-Gas 8 B0060800

End Housing to Crosshead
Guide to Crankcase
3-2 Socket Head Cap Screw-Bearing 4 B0060725
Retainer to Bearing Housing
3-3 Socket Head Cap Screw-Main 12 B0060704
Bearing Housing to Crankcase
Housing Cover to Main Bearing
Housing
3-6 Socket Head Cap Screw-Shaft 4 B0060750
End Plate to Crankshaft
3-7 Socket Head Cap Screw-Lube 8 B0060771
Oil Pump Cover to Bearing
Housing Cover
Pump to Bearing Housing Cover
3-9 Socket Head Cap Screw-Cover 4 B0060714
to Oil Head
3-10 Socket Head Cap Screw-Oil 4 B0060723
Head to Crosshead Guide
3-11 Socket Head Set Screw- 1 B0060821
Crosshead to Crosshead Pin
3-12 Socket Set Screw-Bushing to 2 B0060849
Crosshead
3-13 Socket Head Set Screw-Plug 2 B0060844
for Lube Oil Pump Cover
3-14 Socket Head Lock Set Screw 1(S) B0060841
(Nylon tip)-Crosshead Nut to
Piston Rod
3-15 Flat Head Cap Screw-Cover 8 B0060056
(Blind Breather) to
Crankcase
3-16 Flat Head Machine Screw- 16 B0060053
Cover, Hand Hole to Crankcase
Continued

Page 31 of 48
CODE/
3-17 Stud-Counterweight to 8 B0060815

Crankshaft
4-1 Plug-Pipe (Square Head) 2 B0070901

for Crankshaft
4-3 Plug-Pipe (Socket Head) 1 B0070886
for Connecting Rod
4-4 Plug-Pipe (Tru-Round) 1 B0070884
for Crosshead Pin
5-1 Roller Bearing Assembly 1 A0000019

5-2 Oil Seal-Crankshaft 1(S) B0131733
5-3 Crank Pin Bearing Shell 2 B0100185
(2 halves)
5-4 External Snap Ring-Crosshead 2 B0060549
Pin
5-5 Oil Scraper Ring-Piston Rod 2(S) B0131628
5-6 Oil Seal (Packing)-Piston Rod
Top - 1(S) B0131404
Center - 1(S) B0131364
Bottom - 1(S) B0131328
7-1 Check Valve 1 B0160369

7-2 Drain Cock with Handle 1 B0160024
7-3 Breather 1 B0100341
7-4 Filter Housing 1 B0140183
7-5 Filter Cartridge 1(S) B0140322
7-6 Oil Level Gauge 1 B0030499
8-1 Bearing Lock Nut-Crankshaft 1 B0060357

(Fixed End)
8-4 “O” Ring-Oil Pump Shaft 1 B0131039
8-5 Pin, Locating-Lube Oil Pump 1 B0060049
and Cover to Bearing Housing
Cover
8-6 Key-Flywheel 1 -
8-7 Pal Nut-Connecting Rod 2 B0060496
8-8 Slotting Taper Pin-Lube Oil 1 -
Pump Bushing to Lube Oil
Pump cover
8-11 Gasket-Oil Head to Crosshead 1 B0130750
Guide
8-12 Nut, Hex-Crosshead 1 B0060973
11-1 Housing-Spacer 1 B0101220

11-2 Cylinder Head-1st Stage 1 B0101144
11-3 Cylinder-1st Stage 1 A0000028
11-4 Cylinder-2nd Stage 1 A0000029
11-5 Cylinder Head-2nd Stage 1 B0101134
11-6 Valve Cover-1st Stage 4 B0100656
Continued

Page 32 of 48
CODE/
11-7 Valve Cover-2nd Stage 2 B0100659

11-8 Valve Retainer-1st Stage 4 B0102433
11-9 Flange-Water Jacket 4 B0100630
11-10 Piston 1st Stage-Inboard 1 B0102064
11-11 Piston 1st Stage-Outboard 1 B0102070
11-12 Piston 2nd Stage 1 B0102052
11-13 Suction & Discharge Flange- 1 B0103106
1st Stage
11-14 Discharge Flange-1st Stage 1 B0100942
11-15 Suction & Discharge Flange- 2 B0100955
2nd Stage
11-16 Cylinder Liner-1st Stage, 1 B0101793
Lower
11-17 Cylinder Liner-2nd Stage, 1 B0101795
Upper
11-18 Cylinder Liner-2nd Stage 1 B0101797
11-19 Piston Rod 1 B0102626
11-20 Bushing-Inboard Piston 1 B0100410
11-21 Bushing-Outboard Piston 1 B0100419
11-22 Piston Rod Nut 1 B0060488
11-23 Piston Rod Packing Ring- 1 B0131506
Bottom
11-24 Piston Rod Packing Ring 2 B0131505
11-25 Piston Rod Packing Flange 1 B0100952
11-26 Valve Screw 6 B0060672
11-27 Valve Screw Cap 6 B0060674
11-28 Valve Pocket Liner-2nd Stage 2 B0101803
11-29 Valve Retainer-2nd Stage 2 B0102395
11-30 Cover Guard-Housing Spacer 2 B0050008
12-1 Gasket-Cylinder 1st Stage to 1(S) B0131863

Cylinder Head 1st Stage
12-2 Gasket-Cylinder 1st Stage to 1(S) B0131864
Cylinder 2nd Stage
12-3 Gasket-Cylinder Head, 2nd 1(S) B0131865
Stage to Cylinder
12-4 Gasket-Valve Cap to Valve 6(S) B0131760
Cover
12-5 Gasket-Valve Cover to 4(S) B0130955
Cylinder, 1st Stage
12-6 Gasket-Valve Cover to 2(S) B0130956
Cylinder, 2nd Stage
12-7 Gasket-Flange, 1st Stage 2(S) B0130890
Suction & Discharge
12-8 Gasket-Flange, 2nd Stage 2(S) B0130280
Suction & Discharge
12-9 Gasket-Flange Cover, Water 4(S) B0130638
Jacket
Continued:

Page 33 of 48
CODE/
12-10 Gasket-Low Pressure Suction 4(S) B0130306

& Discharge Valve
12-11 Gasket-Valve Seat, 2nd Stage 2(S) B0130947
Suction & Discharge
13-1 Socket Head Cap Screw- 8 B0060803

Housing Spacer to 1st Stage
Head & 1st Stage Cylinder
Piston 2nd Stage to Piston
1st Stage
Packing Flange to 1st Stage
Head
2nd Stage Cylinder to 1st
Stage Cylinder
2nd Stage Head to 2nd Stage
Cylinder
Jacket Water Cover to 1st &
2nd Stage Cylinder
13-7 Socket Set Screw-Piston 2nd 1 B0060845
Stage
13-8 Socket Set Screw (Flat Point) 2 B0060826
Cylinder Liner to Cylinder
2nd Stage
13-9 Socket Set Screw (Flat Point) 4 B0060816
Cylinder Pocket Liner to
Cylinder 2nd Stage
13-10 Stud-1st Stage Valve Cover 24 B0060038
13-11 Stud-1st Stage Suction Flange 20 B0060037
& 2nd Stage Valve Cover
13-12 Stud-Suction & Discharge 8 B0060042
Flanges, 2nd Stage
13-13 Hex Nuts with Lockwashers 20 B0060342
13-14 Hex Nuts 8 B0060347
13-15 Hex Nuts with Lockwashers 24 B0060395
13-16 Socket Head Screw (Flat 8 B0060815
Point)-Cover Guard
14-1 Tap Lock Inserts 6 B0060352

14-2 Piston Ring-1st Stage 2(S) B0131457
14-3 Piston Ring-2nd Stage 3(S) B0131459
14-4 Rider Ring-2nd Stage 1(S) B0131587
14-6 Piston Rod Packing 1set B0131316
(3/set)(S)
Continued:

Page 34 of 48
CODE/
15-1 Piston Assembly Complete/ 1 A0000074

Piston Rod
15-3 Low Pressure Suction Valve 2(S) B0160196
Assembly
15-4 Low Pressure Discharge 2(S) B0160190
Valve Assembly
15-7 High Pressure Suction & 2(S) B0160476
Discharge Valve Assembly
16-1 Cotter Pin-Piston Rod Nut 1 B0060506

16-2 “O” Ring 1(S) B0131026
16-3 “O” Ring 2 B0131037
16-4 “O” Ring 1(S) B0131181

Page 35 of 48
PISTON ASSEMBLY
CODE NO. 15-1
PART NUMBER: A0000074
CODE/
11-10 Piston 1st Stage-Inboard 1 B0102064

11-11 Piston 1st Stage-Outboard 1 B0102070
11-12 Piston 2nd Stage 1 B0102052
11-19 Piston Rod 1 B0102626
11-20 Bushing-Inboard Piston 1 B0100410
11-21 Bushing-Outboard Piston 1 B0100419
Piston 2nd Stage, Piston 1st
Stage
13-7 Socket Set Screw-Piston 2nd 1 B0060845
Stage
14-2 Piston Ring-1st Stage 2(S) B0131457
14-3 Piston Ring-2nd Stage 3(S) B0131459
14-4 Rider Ring-2nd Stage 1(S) B0131587
16-1 Cotter Pin-Piston Rod Nut 1 B0060506
3-STEP CAPACITY CONTROL ASSEMBLY

CODE #15-2 – STOCK CODE #A0000006
15-2-1 Operator Top 1(S) B0060494

15-2-2 Spring, 4-8# 1 B0102937
15-2-3 & -4 Plate Kit, Spring – Upper & Lower 1 B0104183
15-2-5 Nut, Gland 1 B0060461
15-2-6 Packing Kit 1(S) B0101398
15-2-7 Diaphragm 1(S) B0100823
15-2-8 Retainer, Valve 1 B0102432
15-2-9 Screw 1 -
15-2-10 Screw, Valve 1 B0060675
15-2-11 Gasket 1 B0130868
15-2-12 Nut 1 B0060455
15-2-13 Fork 1 A0000037
15-2-14 Screw 1 B0060651

Page 36 of 48
CYLINDER ASSEMBLY, 1ST STAGE
CODE/
Cylinder, 1st Stage 1 B0100727

11-16 Cylinder Liner, 1st Stage – Lower 1 B0101793
11-17 Cylinder Liner, 1st Stage – Upper 1 B0101795
Stud – 1st Stage Suction & Discharge 32 B0060037
Flange
Nut, Hex 32 B0060342
16-4 O-Ring (Wire Spacer) 1 B0131181
CYLINDER ASSEMBLY, 2ND STAGE

Cylinder, 2nd Stage 1 B0100739

11-18 Cylinder Liner, 2nd Stage 1 B0101797
11-28 Pocket Liner, 2nd Stage Valve 2 B0101803
Stud, 1st Stage Suction Flange, 2nd 16 B0060037
Stage Valve Cover
Stud, Suction & Discharge Flange 8 B0060042

Page 37 of 48
LOW PRESSURE SUCTION VALVE ASSEMBLY
CODE NO. 15-3, PART NUMBER: B0160196
CODE/
15-3-1 Seat 1 B0102692

15-3-2 Guard 1 B0101091
15-3-3 Socket Head Cap Screw 1 B0060757
15-3-4 Valve Plate (Small) 1(S) B0102191
15-3-5 Valve Plate (Large) 1(S) B0102192
15-3-6 Valve Spring Button 3(S) B0100460
15-3-7 Spring 3(S) B0102920
15-3-8 Dowel Pin, Locating 2 B0060046
LOW PRESSURE DISCHARGE VALVE ASSEMBLY

CODE/
15-4-1 Seat 1 B0102679

15-4-2 Guard 1 B0101082
15-4-7 Spring 3(S) B0102920
HIGH PRESSURE SUCTION & DISCHARGE VALVE ASSEMBLY

CODE/
15-7-1 Seat 1 B0102666

15-7-2 Guard 1 B0101078
15-7-3 Center Stud 1 B0060864
15-7-7 Spring 3(S) B0102935

Page 38 of 48
RECOMMENDED SPARE PARTS LIST
MODEL DV 7-1/2 X 5 CO2 COMPRESSOR
CODE/
Gasket Set 1 A0000115

5-6 Scraper Rings 2 B0131628
14-2 Piston Ring, 1st Stage 2 B0131457
14-3 Piston Ring, 2nd Stage 3 B0131459
14-4 Rider Ring, 2nd Stage 1 B0131587
14-6 Piston Rod Packing 2 set B0131316
(3/set)
For: Suction & Discharge

Valve Assembly, 1st Stage (L.P.)
15-3 Suction Valve (L.P.) 2 B0160196

15-4 Discharge Valve (L.P.) 2 B0160190
15-3-4/15-4-4 Valve Plate (Small) 4 B0102191
15-3-5/15-4-5 Valve Plate (Large) 4 B0102192
15-3-6/15-4-6/
15-5-6/15-6-6 Valve Spring Button 24 B0100460
15-3-7/15-4-7/
15-5-7/15-6-7 Spring 24 B0102920
For: Suction & Discharge

Valve Assembly, 2nd Stage (H.P.)
15-7 Suction & Discharge Valve 2 B0160476

15-7-4 Valve Plate (Small) 2 B0100863
15-7-5 Valve Plate (Large) 2 B0100864
15-7-6 Valve Spring Button 12 B0101113
15-7-7 Springs, Dual 12 B0102935
5-6 Oil Seal (Packing) 1set B0131328

“ “ B0131364
“ “ B0131404
5-2 Oil Seal-Crankshaft 1 B0131733
7-5 Oil Filter Cartridge 1 B0140322
Rubber Ball – 2-1/4” 1 B0100094
Trap 1 B0140300
Thermometer 1 B0031272

Page 39 of 48
GASKET SET
DV 7-1/2 X 5 COMPRESSOR
STOCK CODE #A0000115
QTY. ITEM NO. DESCRIPTION STOCK CODE
2 2-1 Gasket, Crosshead Area Side Cover B0130285
2 2-2 Gasket, Crankcase Access Hole Cover B0130582
2 2-3 Gasket, Bearing Housing B0130289
2 2-4 Gasket, Shaft Oil Guard B0130279
2 2-5 Gasket, Crosshead Guide to Spacer Housing B0130586

& Crankcase
1 2-6 Gasket, Oil Pump (Outer, Plastic Gasket) B0130580
1 2-7 Gasket, Oil Pump (Inner, Fiber Gasket) B0130753
1 2-8 Gasket, Oil Scraper Head B0130750
1 8-4 O-Ring, Oil Pump Shaft B0131039
1 12-1 Gasket, 1st Stage Cylinder to 1st Stage Head B0131863
1 12-2 Gasket, 1st Stage Cylinder to 2nd Stage Cylinder B0131864
1 12-3 Gasket, 2nd Stage Cylinder to 2nd Stage Head B0131865
6 12-4 Gasket, Valve Cover to Cap B0131760
4 12-5 Gasket, 1st Stage Valve Cover B0131955
2 12-6 Gasket, 2nd Stage Valve Cover B0130956
2 12-7 Gasket, 1st Stage Flange (Suction & Discharge) B0130890
2 12-8 Gasket, 2nd Stage Flange (Suction & Discharge) B0130280
4 12-9 Gasket, Water Jacket Cover B0130638
2 12-10 Gasket, 2nd Stage Valve Seat B0130947
4 12-11 Gasket, 1st Stage Valve Seat B0130306
1 16-2 O-Ring, Packing Case B0131026
2 16-3 O-Ring, Valve Pocket Liner B0131037
1 16-4 O-Ring, Cylinder Liner B0131181

Page 40 of 48
“DV 9-1/2 X 7” SERIES COMPRESSOR
PARTS LIST
GENERAL:
When ordering spare parts, please specify model number, serial number, sales order number
from “DV” series compressor nameplate, along with spare part item number, description, quantity
and part number of each part required.
ELECTRICAL PARTS:
Original motors, switches and overload heaters are specified by the user according to individual
power source characteristics. Replacements for these items can be ordered by the part
description and electrical rating.
SPARE PARTS:
Union Engineering recommends that each user of a “DV” series compressor keep at least a
small stock of certain spare parts on hand. These parts are identified by (S) in the “QUANTITY”
column of the following list:
CODE/
ITEM NO. DESCRIPTION QTY. PART NUMBER
1-1 Crankcase 1 B0100669

1-2 Crankshaft 1 B0100681
(Drive End)
(Pump End)
1-5 Connecting Rod 1 A0000084
1-6 Crosshead 1 A0000025
1-7 Crosshead Guide 1 B0101117
(Pump End)
1-9 Counterweight 2 B0104979 (was B0100585)
1-10 Oil Head 1 B0101935
1-11 Bearing Retainer Ring-Inner 1 B0102398
1-12 Bearing Retainer Ring-Outer 1 B0102399
(Drive End)
1-14 Cover-Blind 1 B0100638
1-15 Cover-Breather 1 B0100622
1-16 Cover-Crankcase Hand Hole 2 B0100637
1-17 Spacer-For Bearing, Drive & 2 A0000108
Pump End
1-18 Connecting Rod Bolt 2 B0060025
1-19 Connecting Rod Bolt Nut 2 B0060453
1-20 Crosshead Pin 1 B0101994
1-21 Crosshead Pin Bushing 1 B0100453
1-22 Crosshead Bushing 1 B0100452
1-23 Shaft End Plate 1 B0102217
Continued

Page 41 of 48
CODE/
1-24 Cover-Lube Oil Pump 1 B0100642

1-25 Bushing-For Lube Oil Pump 1 B0100390
1-26 Cover-Oil Seal Housing, 1 B0102664
Piston Rod
1-27 Scraper Ring Retainer 1 B0102421
1-28 Lube Oil Pump 1 B0120137
2-1 Gasket-Covers 2(S) B0130295

2-2 Gasket-Cover Crankcase 2(S) B0130577
Hand Hole
2-3 Gasket-Bearing Housing 2 B0130495
2-4 Gasket-Bearing Housing Cover 2(S) B0130861
2-5 Gasket-Crankcase to Crosshead 2(S) B0130977
Guide & Housing
2-7 Gasket-Lube Oil Pump Cover 1(S) B0130580
2-8 Gasket-Bearing Retainer 1 B0130288
2-11 Oil Head “O” Ring 1(S) B0131029
3-1 Socket Head Cap Screw-Gas 8 B0060743

End Housing to Crosshead
Guide to Crankcase
3-3 Socket Head Cap Screw-Main 28 B0060686
Bearing Housing to Crankcase
Housing Cover to Main Bearing
Housing
3-6 Socket Head Cap Screw-Shaft 4 B0060751
End Plate to Crankshaft
Oil Pump Cover to Bearing
Housing Cover
Pump to Bearing Housing Cover
3-9 Socket Head Cap Screw-Cover 4 B0060782
to Oil Head
3-10 Socket Head Cap Screw-Oil 4 B0060714
Head to Crosshead Guide
3-11 Socket Head Set Screw- 1 B0060778
Crosshead to Crosshead Pin
3-12 Socket Set Screw-Bushing to 2 B0060849
Crosshead
3-13 Socket Head Set Screw-Plug 1 B0060102
for Lube Oil Pump Cover
3-14 Socket Head Lock Set Screw- 1(S) B0060841
(Nylon Tip)-Crosshead Nut to
Piston Rod
3-15 Flat Head Cap Screw-Cover 8 B0060056
(Blind Breather) to Crankcase
3-16 Flat Head Machine Screw-Cover 16 B0060059
Hand Hole to Crankcase
Continued

Page 42 of 48
CODE/
3-17 Stud-Counterweight to 4 B0060865

Crankshaft
3-18 Flat Head Screw-Bearing 6 B0060056
4-1 Pipe Plug (Square Head) for 2 B0070901

Crankshaft
4-3 Plug-Pipe (Socket Head) for 1 B0070886
Connecting Rod
4-4 Plug-Pipe (Tru-Round) for 1 B0070887
Crosshead Pin
5-1 Roller Bearing Assembly 1 A0000018

5-2 Oil Seal-Crankshaft 1(S) B0131729
5-3 Crank Pin Bearing Shell 1 B0102761
(2 Halves)
5-4 External Snap Ring-Crosshead 2 B0060551
Pin
5-5 Oil Scraper Ring-Piston Rod 2(S) B0131482
5-6 Oil Seals (Packing)-Piston 2(S) B0131734
Rod
7-1 Check Valve 1 B0160369
7-2 Drain Cock with Handle 1 B0160024
7-3 Breather 1 B0100341
7-4 Filter Housing 1 B0140183
7-5 Filter Cartridge 1(S) B0140322
7-6 Oil Level Gauge 1 B0030499
8-1 Bearing Lock Nut-Crankshaft 2 B0060356

(Fixed End)
8-2 Lockwasher-Bearing Lock Nut 1 B0060388
8-4 “O” Ring-Oil Pump Shaft 1 B0131039
8-5 Pin, Locating-Lube Oil Pump 2 B0060049
and Cover to Bearing Housing
Cover
8-6 Key-Flywheel 1 -
8-7 Pal Nut-Connecting Rod 2 B0060495
8-8 Slotting Taper Pin-Lube Oil 1 -
Pump Bushing to Lube Oil
Pump Cover
8-9 Lockwasher-Counterweight 4 B0060400
8-10 Allen Nut-Counterweight 4 B0060003
8-11 O-Ring -Oil Head to Crosshead 1 B0131029
Guide
8-12 Nut, Hex-Crosshead 1 B0060492
Continued:

Page 43 of 48
CODE/
11-1 Housing – Spacer 1 B0103551

11-2 Cylinder Head – 1st Stage 1 B0101143
11-3 Cylinder Assembly – 1st Stage 1 A0000030
11-4 Cylinder Assembly – 2nd Stage 1 A0000031
11-5 Cylinder Head – 2nd Stage 1 B0101145
11-6 Valve Cover – 1st Stage 4 B0100659
11-7 Valve Cover – 2nd Stage 2 B0100659
11-8 Valve Retainer – 1st Stage 4 B0102433
11-9 Cover, Flange – Water Jacket 4 B0100630
11-10 Piston, 1st Stage – Inboard 1 B0102063
11-11 Piston, 1st Stage – Outboard 1 B0102071
11-12 Piston, 2nd Stage 1 B0102053
11-13 Suction & Discharge Flange 2 B0103106
1st Stage
11-14 Discharge Flange – 1st Stage - -
11-15 Suction & Discharge Flange 2 B0100938
2nd Stage
11-16 Cylinder Liner – 1st Stage, Lower 1 B0101789
11-17 Cylinder Liner – 1st Stage, Upper 1 B0101794
11-18 Cylinder Liner – 2nd Stage 1 B0101796
11-19 Piston Rod 1 B0102629
11-20 Bushing – Inboard Piston 1 B0100391
11-21 Bushing – Outboard Piston 1 B0100392
11-23 Ring, Piston Rod Packing Cup – Bottom 1 B0102508
11-24 Ring, Piston Rod Packing Cup 3 B0131504
11-25 Piston Rod Packing Flange 1 B0100953
11-26 Valve Screw 6 B0060673
11-27 Valve Screw Cap 6 B0060674
11-28 Valve Pocket Liner – 2nd Stage 2 B0101804
11-29 Valve Retainer – 2nd Stage 2 B0102439
11-30 Cover Guard – Housing Spacer 2 B0050009
12-1 Gasket – Cylinder 1st Stage to 1(S) B0130271

Cylinder Head 1st Stage
For Compressors built as of 1998:
O-ring, Lower 11" ID 1(S) B0131033
O-ring, Water Pass 1-1/2" OD 1(S) B0131035
12-2 Gasket – Cylinder 1st Stage to 1(S) B0130307

Cylinder 2nd Stage
For Compressors as of 2/98:
O-Ring, Upper 14-1/2" OD 1(S) B0131034
O-Ring, Water Pass 1-1/2" OD 2(S) B0131035
12-3 Gasket – Cylinder Head 2nd Stage 1(S) B0130325

to Cylinder
12-4 Gasket – Valve Cap to Valve Cover 6(S) B0131760
12-5 Gasket – Valve Cover to Cylinder 4(S) B0130956
1st Stage
12-6 Gasket – Valve Cover to Cylinder 2(S) B0130956
2nd Stage
12-7 Gasket – Flange, 1st Stage Suction 2(S) B0130890

Page 44 of 48
& Discharge
12-8 Gasket – Flange, 2nd Stage Suction 2(S) B0130639
& Discharge
12-9 Gasket – Flange Cover, Water Jacket 4(S) B0130638
12-10 Gasket – Low Pressure Suction & 4(S) B0130306
Discharge Valve
Continued
CODE/
12-11 Gasket – Valve Seat, 2nd Stage 2(S) B0130306

Suction & Discharge
13-1 Socket Head Cap Screw – Housing 8 B0060742

Spacer to 1st Stage Head & 1st
Stage Cylinder
13-2 Socket Head Cap Screw – Piston 8 B0060685
2nd Stage to Piston 1st Stage
13-3 Socket Head Cap Screw – Packing 4 B0060693
Flange to 1st Stage Head
13-4 Socket Head Cap Screw – 2nd Stage 8 B0060792
Cylinder to 1st Stage Cylinder
13-5 Socket Head Cap Screw – 2nd Stage 6 B0060739
Head to 2nd Stage Cylinder
13-6 Socket Head Cap Screw – Jacket 16 B0060763
Water Cover to 1st & 2nd Stage Cylinder
13-7 Socket Set Screw – Piston, 2nd Stage 1 B0060846
13-8 Tapered Socket Head Screw (Flat Point) - 2 B0060056 was B0060826
Cylinder Liner to Cylinder 2nd Stage
13-9 Socket Set Screw (Flat Point) - 4 B0060816
Cylinder Pocket Liner to Cylinder
2nd Stage
13-10 Stud – 1st Stage Valve Cover 24 B0060037
13-11 Stud – 1st Stage Suction Flange & 20 B0060037
2nd Stage Valve Cover
13-12 Stud – Suction & Discharge Flanges 8 B0060042
2nd Stage
13-13 Hex Nut with Lockwasher 20 B0060327
13-14 Hex Nut 8 B0060334
13-15 Hex Nut with Lockwasher 24 B0060327
13-16 Socket Head Screw (Flat Point) 8 B0060839

14-2 Piston Ring – 1st Stage 2(S) B0131448
14-3 Piston Ring – 2nd Stage 3(S) B0131449
14-4 Rider Ring – 2nd Stage 1(S) B0131586
14-6 Piston Rod Packing 1set(S) B0131315
(4/set)
15-1 Piston Assembly – Complete 1 A0000075

15-2 Capacity Control Valve Assembly 1 A0000004
15-3 L.P. Suction Valve Assembly 2(S) B0160196
15-4 L.P. Discharge Valve Assembly 2(S) B0160190
15-5 H.P. Suction Valve Assembly 1(S) B0160195
15-6 H.P. Discharge Valve Assembly 1(S) B0160189

Page 45 of 48
16-1 Cotter Pin – Piston Rod 1 B0060506
16-2 O-Ring 1(S) B0131036
16-3 O-Ring 2 B0131038
16-4 O-Ring 1 B0131182
Continued:
PISTON ASSEMBLY
CODE/
11-10 Piston, 1st Stage – Inboard 1 B0102063

11-11 Piston, 1st Stage – Outboard 1 B0102071
11-12 Piston, 2nd Stage 1 B0102053
11-19 Piston Rod 1 B0102629
11-20 Bushing – Inboard Piston 1 B0100391
11-21 Bushing – Outboard Piston 1 B0100392
13-2 Socket Head Cap Screw 8 B0060685
13-7 Socket Set Screw 1 B0060846
14-2 Piston Ring – 1st Stage 2(S) B0131448
14-3 Piston Ring – 2nd Stage 3(S) B0131449
14-4 Rider Ring – 2nd Stage 1(S) B0131586
16-1 Cotter Pin 1 B0060506
3-STEP CAPACITY CONTROL ASSEMBLY

15-2-2 Operator Top 1(S) B0060494

15-2-3 Spring 1 B0102937
15-2-4 &
15-2-5 Spring Plate – Upper & Lower 1 B0101740
15-2-6 Gland Nut 1 B0060461
15-2-7 Packing Kit 1(S) B0101398
15-2-8 Diaphragm 1(S) B0100823
15-2-9 Valve Retainer 1 B0102432
15-2-10 Screw 1 -
15-2-11 Valve Screw 1 B0060671
15-2-12 Gasket – Operator to Valve Cover 1 B0130868
15-2-13 Nut 1 B0060455
15-2-14 Fork 1(S) B0100986

Page 46 of 48
LOW PRESSURE SUCTION VALVE ASSEMBLY
CODE #15-3 – STOCK CODE #B0160196
CODE/
15-3-1 Seat 1 B0102692

15-3-2 Guard 1 B0101091
15-3-7 Spring 3(S) B0102920
LOW PRESSURE DISCHARGE VALVE ASSEMBLY

15-4-1 Seat 1 B0102679

15-4-2 Guard 1 B0101082
15-4-7 Spring 3(S) B0102920
HIGH PRESSURE SUCTION VALVE ASSEMBLY

15-5-1 Seat 1 B0102692

15-5-2 Guard 1 B0101091
15-5-7 Spring 3(S) B0102920
HIGH PRESSURE DISCHARGE VALVE ASSEMBLY

15-6-1 Seat 1 B0102679

15-6-2 Guard 1 B0101082
15-6-7 Spring 3(S) B0102977

Page 47 of 48
CYLINDER ASSEMBLY, 1ST STAGE
(REF. DWG. #A23950-5)
CODE #11-3 - STOCK CODE #A0000030
CODE/
Cylinder, 1st Stage 1 B0100732

11-16 Cylinder Liner, 1st Stage 1 B0101789
11-17 Cylinder Liner, 1st Stage 1 B0101794
Stud – 1st Stage Suction & Discharge 32 B0060037
Flange
Stud w/Nuts 8 B0060861
16-4 O-Ring (Wire Spacer) 1 B0131182
CYLINDER ASSEMBLY, 2ND STAGE

(REF. DWG. #A23950-5)
CODE #11-4 - STOCK CODE #A0000031
Cylinder, 2nd Stage 1 B0100733

Pipe Plug (Dry Seal) 4 B0073977
11-28 Pocket Liner, 2nd Stage Valve 2 B0101804
13-10 & -11 Stud, 1st Stage Suction Flange & 12 B0060037
2nd Stage Valve Cover
13-12 Stud, Suction & Discharge Flanges, 8 B0060042
2nd Stage
13-9 Set Screw, Cylinder Pocket Liner to 6 B0060816
Cylinder, 2nd Stage
16-3 O-Ring 2 B0131038
11-18 Cylinder Liner, 2nd Stage 1 B0101796
NOTE: Above assemblies are completely assembled and ready for installation.

Page 48 of 48

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Installation, Operation, and Maintenance

Union Engineering North America 14-Apr-15

INSTALLATION AND WEAR-IN PROCEDURE

OPERATION AND MAINTENANCE

TYPICAL COMPRESSOR CONTROLS

INTERCOOLER AND AFTERCOOLER

SKETCHES AND DRAWINGS

Union Engineering North America 14-Apr-15

It is necessary to provide an adequate foundation to prevent vibration and movement of the

Union Engineering North America 14-Apr-15

Horizontal Primary 95 lbs (43 kg) 117 lbs (53 kg)

Horizontal Secondary 0 lbs (0 kg) 0 lbs (0 kg)

Union Engineering North America 14-Apr-15

Model Quarts Liters

TABLE 3 – SEATING TORQUE FOR SHEAVE TO HUB MOUNTING *

Sheave Type Tap Screw Size Torque Value

SD or SDS 1/4” – 20 9 ft-lbs. (1.1 kg-m)

Drive and Motor Starter:

Union Engineering North America 14-Apr-15

The following steps should be completed before operating the compressor:

Stopping the Unit:

After the first 500 hours of operation:

After the first 1000 hours of operation:

Union Engineering North America 14-Apr-15

TYPICAL COMPRESSOR CONTROLS

Suction Pressure Switch:

High Pressure Switch:

Water Pressure Switch:

Union Engineering North America 14-Apr-15

Union Engineering North America 14-Apr-15

Type and Amount:

TABLE 4 – OIL SPECIFICATIONS

Union Engineering North America 14-Apr-15

TABLE 5 – MAINTENANCE SCHEDULE

Every 8 hours:  Check oil level.

Every 500 hours:  Check oil scraper rings.

Every 2,000 hours:  Check all valves.

Every 5,000 hours:  Change crankcase oil.

Union Engineering North America 14-Apr-15

TABLE 6 – RING CLEARANCES

COMPONENT FIRST STAGE SECOND STAGE FIRST STAGE SECOND STAGE

Ring-Groove .013” - .016” .008” - .010” .014” - .018” .011” - .015”

Piston Head Clearance:

Union Engineering North America 14-Apr-15

TABLE 7 – PISTON ROD NUT SEATING TORQUE

Rod Size Ft-Lbs. Kilogram-Meters

TABLE 8 – SEATING TORQUES FOR VARIOUS SCREWS

Screw Size Ft-Lbs. Kilogram-Meters

UNC 1/4” – 20 5 0.7

Union Engineering North America 14-Apr-15

Union Engineering North America 14-Apr-15

Union Engineering North America 14-Apr-15

SYMPTOM PROBABLE CAUSE REMEDY

Improper supply voltage Check for correct voltage.

Starter overloads open Reset overloads.

Suction pressure switch Adjust for proper setting.

Discharge temperature or pressure Check temperatures and pressures.

Oil pressure switch open Check oil pressure switch. Reset.

Water pressure switch open Check switch and water supply.

High discharge pressure Check discharge pressure switch

Compressor stops without apparent Power failure Check power supply.

Suction pressure switch setting Check switch for proper differential

Incorrect unloader setting Set unloaders correctly.