bbr-3516 compressor service manual (cp)

5/28/2018 BBR-3516 Compressor Service Manual (CP)

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Compressor Service Manual

Customer :

CompanyAddressCity/StateZIP Code

PhoneFaxEmail Address

Site Location

Product Compressor BBR- 3516 Vol. 2 (J1705)

Model No CO-BBR-3516

Serial No

INTERMECH LTD.88 Leonard Road, Penrose

PO Box 12284, Penrose

Auckland, New Zealand

Ph 64 (9) 525 2220

Fax 64 (9) 579 3900

Email [email protected]
mailto:[email protected]:[email protected]


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Compressor Operation & Maintenance Manual Page 2 of 79

Revisions Record

Revision

No.

Date Description of Revision

August, 2006 First edition

Intermech Ltd. BBR-3516 Compressor Service Manual


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Table of Contents

1 GENERAL.....................................................................................................................................6

1.1 INTRODUCTION

.......................................................................................................................6 2 SAFETY.........................................................................................................................................8

2.1 GENERAL SAFETY ..................................................................................................................8 2.2 MAINTENANCE SAFETY..........................................................................................................9

3 COMPRESSOR SPECIFICATION..........................................................................................11

3.1 MODEL.................................................................................................................................11 3.2 DESIGN SPECIFICATION........................................................................................................11 3.3 MANUFACTURERS PLATE & LABEL INFORMATION.............................................................11

3.3.1 Specification Plate..........................................................................................................113.3.2 Cylinder Identification Plate ..........................................................................................123.3.3 Suction Identification Plate ............................................................................................12

3.3.4 Discharge Identification Plate................................................................ ........................ 123.3.5 Warning Plate.................................................................................................................133.3.6 Rotation Plate ......................................................... ........................................................ 13

3.4 CLEARANCES .......................................................................................................................13 3.4.1 Original Running Clearances.........................................................................................133.4.2 Piston Ring Side Clearances / End Gaps............................................... ......................... 143.4.3 Piston to Cylinder Clearances....................................... ................................................. 163.4.4 Torque Settings ...................................................... ......................................................... 163.4.5 Rhino Compressor Tools ............................................................ .................................... 18

3.5 OPERATING PROCEDURES ....................................................................................................19 3.5.1 Start Up Check List Contents..........................................................................................193.5.2 Package Details.................. ................................................................ ............................ 193.5.3 Prior to Starting.................................................................. ............................................ 20

3.5.4 After Starting .................................................................................................................. 213.5.5 Maximum Allowable Working Pressure ................................................................ .........21

3.6 LUBRICATION.......................................................................................................................22 3.6.1 General Description ............................................................. .......................................... 233.6.2 Oil Specification .......................................................... ................................................... 233.6.3 Before Starting.................................................. .............................................................. 243.6.4 Top Up With Oil .............................................................................................................243.6.5 Primary Starting....................................................... ...................................................... 24

3.6.5.1 Priming the lubrication system using priming pump......... ...................... ...................... ...... 253.6.6 Oil Filter.........................................................................................................................263.6.7 Lube Oil Pressure Adjustment ........................................................ ................................ 263.6.8 Oil Relief Valve Setting...................................................................................................263.6.9 Compression Cylinder Injection Lubrication System .....................................................27

4 MAINTENANCE........................................................................................................................28

4.1 GENERAL .............................................................................................................................28 4.2 OIL PUMP (CRA-357) & OIL PUMP HOUSING (CRA-352-1)................................................29

4.2.1 Oil Pump Housing Drawing (CRA-352-1) .....................................................................294.2.2 Oil Pump Housing (CRA-352-1) Parts List...... .............................................................. 304.2.3 Oil Pump Assembly Drawing (CRA-357) ........................................................... ............314.2.4 Oil Pump Assembly (CRA-357) Parts List......................................................................324.2.5 Oil Pump Relief Valve Drawing (CRA-333)...................................................................334.2.6 Oil Pump Relief Valve (CRA-333) Parts List..................................................................344.2.7 Disassembly Oil Pump Housing ............................................................. ..................... 354.2.8 Disassembly Oil Pump Relief Valve ............................................................... .............354.2.9 Disassembly Oil Pump........................................ ......................................................... 35

4.2.10 Assembly Oil Pump.............................................................. ................................... 364.2.11 ............................................................................................................................................364.2.12 Oil Pump Relief Valve................................................................................................36



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4.2.13 Assembly Oil Pump Housing (CRA-352) ............................................................... .374.3 RHINO CRANKCASE (CRA-3603).........................................................................................38

4.3.1 Rhino Crankcase Drawing (CRA-3603)................................................................ .........384.3.2 Rhino Crankcase Drawing (CRA-3602)................................................................ .........394.3.3 Rhino Crankcase (CRA-3603) Parts List........................................................................ 404.3.4 Rhino Crankcase (CRA-3602) Parts List........................................................................ 40

4.3.5 Taper Lock Bearing Housing Assembly Drawing (CRA-3640)...................................... 414.3.6 Taper Lock Bearing Housing Assembly Parts List (CRA-3640).....................................424.3.7 Rhino Crankcase Filler Bowl Drawing (CRA-820)........................................................ 434.3.8 Rhino Crankcase Filler Bowl (CRA-820) Parts List ...................................................... 444.3.9 Disassembly Crankshaft (CR-3253) ............................................................... .............454.3.10 Assembly Crankcase (CRA-3603)...................... ..................................................... 46

4.4 DRIVE END BEARING HOUSING / MECHANICAL SEAL ASSEMBLY (CRA-356)....................49 4.4.1 Drive End Bearing Housing / Mechanical Seal Drawing (CRA-356 RevB)................... 494.4.2 Mechanical Seal Housing (CRA-356) Parts List ............................................................ 504.4.3 Disassembly / Assembly - Mechanical Seal ........................................................ ............51

4.5 CONNECTING ROD ASSEMBLY .............................................................................................53 4.5.1 Connecting Rod Assembly Drawing (ROA-8525)...........................................................534.5.2 Connecting Rod Assembly Parts List (ROA-8525) ......................................................... 54

4.6 CROSS HEAD CYLINDER/PISTON (CYXA-6003) ..................................................... .............554.6.1 6 Cross Head / Cylinder Drawing (CYXA-6003) ......................................................... 554.6.2 6 Cross Head / Cylinder (CYXA-6003) Parts List........................................................564.6.3 Disassembly - Cross-Head Cylinder/Piston ................................................................... 574.6.4 Assembly - Cross-Head Cylinder/Piston .................................................................. ......57

4.7 1STSTAGE CYLINDER/PISTON / PISTON ROD ASSEMBLY ......................................................59 4.7.1 Cylinder Assembly Drawing (CYA-3500-3)....................................................................594.7.2 Cylinder Assembly (CYA-3500-3) Parts List .................................................................. 604.7.3 Disassembly.............. ................................................................ ...................................... 624.7.4 Assembly............................................................. ............................................................ 62

4.8 ROD SEAL HOUSING ASSEMBLY ..........................................................................................65 4.8.1 Rod Seal Housing Drawing (SEA-3503)......................................................................... 654.8.2 Rod Seal Housing (SEA-3503) Parts List ............................................................... ........664.8.3 Disassembly.............. ................................................................ ...................................... 674.8.4 Assembly............................................................. ............................................................ 67

4.9 2ND/ 3RDSTAGE CYLINDER/PISTON/PISTON ROD ASSEMBLY ................................................68 4.9.1 Cylinder Assembly Drawing (CYA-3216-4)....................................................................684.9.2 3.25x 1.625 Cylinder Assembly (CYA-3216-4) Parts List .......................................... 694.9.3 Piston 3.25 x 1.625 Assembly Drawing (PIA3216-2)............................................... 714.9.4 Piston 3.25 x 1.625 Assembly (PIA3216-2) Parts List ............................................. 724.9.5 Disassembly Final Stage Cylinder / Piston ................................................................. 734.9.6 Disassembly 2nd Stage Cylinder / Piston .................................................................... 734.9.7 Assembly- 2nd / 3rd Stage Cylinder / Piston .................................................................. 74

4.10 ROD SEAL HOUSING ASSEMBLY SEA-3250.........................................................................76 4.10.1 Rod Seal Housing Assembly Drawing (SEA-3250: Sheet 1)................ ...................... 764.10.2 Rod Seal Housing Assembly Drawing (SEA-3250: Sheet 2)................ ...................... 774.10.3 Rod Seal Housing Assembly (SEA-3250) Parts List ..................................................784.10.4 Disassembly .............................................................. ................................................. 784.10.5 Assembly ....................................................... ............................................................. 78

4.11 COMPRESSOR VALVES .........................................................................................................79 4.11.1 Removal ......................................................................................................... ............794.11.2 Installation............................................................... .................................................. 79

Table of Figures

Figure 1 Plan and Elevation of Three-Stage Compressor____________________________________7Figure 2 Specification Plate _________________________________________________________11Figure 3 Cylinder Specification Plate __________________________________________________12

Figure 4 Suction Identification Plate __________________________________________________12Figure 5 Discharge Identification Plate ________________________________________________12Figure 6 Warning Plate_____________________________________________________________13



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Figure 7 Rotation Plate_____________________________________________________________13Figure 8 Compressor Tools__________________________________________________________18Figure 9 Oil Circulation Schematic ___________________________________________________22

Table of Tables

Table 1 Specification Chart__________________________________________________________11Table 2 Original Running Clearance __________________________________________________13Table 3 Piston Ring End Gaps _______________________________________________________14Table 4 Piston Ring Side Clearances __________________________________________________15Table 5 Piston to Cylinder Clearances _________________________________________________16Table 6 Torque Settings_____________________________________________________________17Table 7 The Maximum Allowable Working Pressure ______________________________________21



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1 General

1.1 Introduction

The Rhino compressor has been developed specifically for CNG/NGV with

the following features :

Gas tight pressurised crankcase, up to 40 bar (600 psig).

Hoerbigervalves for specific performance and reliability.

Double row spherical roller main bearings.

Heavy duty crankcase.

High strength crankshaft, 100-80-3 ductile iron, 89mm (3.5" journals.

Full flow, filtered, pressurised lubrication.

Generous integral cross-head piston bearing surface.

Standardized design, 22 - 200 kW (30 - 270 hp), 0.5-30 bar, (8 - 435psig)

inlet pressure.

High quality oil flooded mechanical crankcase seals. Double acting two, three or four stage design.

Exclusive low friction cylinder treatment.



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Figure 1 Plan and Elevation of Three-Stage Compressor



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2 Safety

2.1 General Safety

!!! WARNING !!!

COMPRESSED GAS IS A HIGHLY DANGEROUS

SUBSTANCE

READ AND UNDERSTAND THIS SECTION OF

MANUALS

IT IS ESSENTIAL FOR THE SAFE OPERATION

OF EQUIPMENT

2.1.1. Systems must be entirely vented before repair or maintenance is carried

out.

2.1.2. The installation, operation, maintenance and repair shall be carried out

only by qualified personnel and in accordance with the corresponding

regulations for operation and safety.

2.1.3. No smoking or naked lights within 10m of any gas installation.

2.1.4. Do not adjust, remove or bypass any protective device.

2.1.5. Rotating machine parts represent a special danger. Covers and guards

must not be removed whilst the machine is operating.

2.1.6. Persons operating the compressor should use hearing protection.

2.1.7. Do not store flammable materials e.g. oily rags near the compressor

unit or engine drive.

2.1.8. Supply pipework and other components, which may not be included in

scope of supply, must be suitable for the respective working pressure.

2.1.9. If necessary they have to be tested and protected by a pressure-

unloading device.

2.1.10. Electrical cable must be Flameproof and must not be linked, or allowed

to contact rotating parts.



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2.2 Maintenance Safety

!!! WARNING !!!

COMPRESSED GAS IS A HIGHLYDANGEROUS SUBSTANCE.

BEFORE DISMANTING ANY PART OF

THE COMPRESSOR, ENSURE THAT THE

UNIT IS COMPLETELY DEPRESSURED

2.2.1. Maintenance and repair may be carried out only on the shutdown andentirely vented compressor unit. If necessary isolate all storage

systems and blow-down all condensate traps and heat exchanger

collectors. Open all manual drain valves.

2.2.2. Isolate the equipment electrically by pad-locking the main switch in the

"OFF" position and fixing a corresponding warning sign.

2.2.3. Only use original spare parts and recommended products for

maintenance and repair works on the compressor unit.

2.2.4. Never do work that will produce heat, like welding near oil or gas

systems. Before working on oil or gas tanks empty them and clean

them carefully eg. by a steam jet or purge with nitrogen.

2.2.5. During maintenance and repair work observe strict cleanliness. Keep

impurities away, by covering dismounted parts and free openings with

a clean rag, paper or adhesive tape.

2.2.6. After having finished the works be sure that no tools, loose parts or

cleaning rags have been left on or in the compressor unit, or near the

engine air cleaner.

2.2.7. Do not use easily flammable solving agents for cleaning of parts, until

the unit has cooled thoroughly. After the use of solving agents

carefully rinse the parts and clean them with compressed air.

2.2.8. Be very careful, use eye protection, when working with compressed air

for cleaning equipment.

2.2.9. After modification or repair work on pressure vessels and safety

equipment, such as relief valves, all work must be tested and accepted

by the inspection authority concerned.

2.2.10. The switchboard may be opened only by qualified and authorized

persons. Even if the main switch is set to the "OFF" position, the poles

of the switch and feed cables of the terminal strip are alive. Therefore

do not touch anything on the switchboard, and do not carry out work,with the mains current supply is not disconnected. Before starting

work check if the system is entirely free of power.



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2.2.11. Do not touch bare wires and live (current-carrying) parts, when the

electrical system is energized.

2.2.12. After modification or repair work to compressor, and before power is

supplied to machine, always manually turn compressor over by hand to

ensure compressor is running free.

2.2.13. Intermech takes no responsibility for personal injury or damage on the

unit, caused by the non-observance of the safety precautions during

handling, operation, maintenance or repair of compressor units or other

equipment.



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3 Compressor Specification

3.1 Model

This package utilises the BBR-3516compressor.

First stage 3-1/2 Double Acting cylinder

Second stage 3-1/4 Single Acting cylinder

Final stage 1-5/8 Single Acting cylinder

3.2 Design Specification

DESCRIPTION IMPERIAL UNITS

STROKE 3.25 inchesROD LOAD, COMPRESSION 10,000 lbs

ROD LOAD, TENSION 10,000 lbs

FRAME HORSEPOWER to 270 hp

MAX. INTERNAL PRESSURE 600 psi

WEIGHT, APPROXIMATE 1900 lb

RPM to 1800 rpm

OIL PUMP CAPACITY 6 gpm @ 1600rpm

SUMP CAPACITY 4.5 gallons

Table 1 Specification Chart

3.3 Manufacturers Plate & Label Information

3.3.1 Specification Plate

Figure 2 Specification Plate



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3.3.2 Cylinder Identification Plate

Figure 3 Cylinder Specification Plate

3.3.3 Suction Identification Plate

Figure 4 Suction Identification Plate

3.3.4 Discharge Identification Plate

Figure 5 Discharge Identification Plate



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3.3.5 Warning Plate

Figure 6 Warning Plate

3.3.6 Rotation Plate

Figure 7 Rotation Plate

Note : Rotation direction is anti-clockwise looking at the compressor from the oil

sight glass side.

3.4 Clearances

3.4.1 Original Running Clearances

Original Running Clearances Minimum Maximum

Connecting rod thrust (side clearance) 0.010 0.015

Crankpin bearing (con-rod big end) 0.002 0.004

Connecting rod bushing to wrist pin 0.0015 0.0035

Crosshead to wrist pin 0.0015 0.002

Oil pump impellor assembly end clearance 0.003" 0.005"

Crosshead to guide 0.007 0.010

Drive end metering plate to crankshaft 0.002 0.004

Table 2 Original Running Clearance



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3.4.2 Piston Ring Side Clearances / End Gaps

Min Max Min Max Min Max

Straight Cut 0.004 0.014 0.042 0.052 0.011 0.021

45 Cut 0.003 0.013 0.030 0.040 0.008 0.018

Straight Cut 0.004 0.014 0.046 0.056 0.012 0.022

45 Cut 0.003 0.013 0.032 0.042 0.008 0.018

Straight Cut 0.004 0.014 0.049 0.059 0.013 0.023

45 Cut 0.003 0.013 0.035 0.045 0.009 0.019

Straight Cut 0.006 0.016 0.082 0.092 0.020 0.030

45 Cut 0.004 0.014 0.058 0.068 0.014 0.024Straight Cut 0.006 0.016 0.089 0.099 0.022 0.032

45 Cut 0.004 0.014 0.063 0.073 0.015 0.025

Straight Cut 0.006 0.016 0.096 0.106 0.023 0.033

45 Cut 0.004 0.014 0.068 0.078 0.016 0.026

Straight Cut 0.006 0.016 0.103 0.113 0.025 0.035

45 Cut 0.005 0.015 0.072 0.082 0.017 0.027

Straight Cut 0.007 0.017 0.116 0.126 0.028 0.038

45 Cut 0.005 0.015 0.082 0.092 0.019 0.029

Straight Cut 0.007 0.017 0.123 0.133 0.029 0.039

45 Cut 0.005 0.015 0.087 0.097 0.021 0.031

Straight Cut 0.008 0.018 0.129 0.139 0.031 0.041

45 Cut 0.005 0.015 0.091 0.101 0.022 0.032Straight Cut 0.009 0.019 0.163 0.173 0.038 0.048

45 Cut 0.006 0.016 0.115 0.125 0.027 0.037

Straight Cut 0.010 0.020 0.176 0.186 0.041 0.051

45 Cut 0.007 0.017 0.125 0.135 0.029 0.039

Straight Cut 0.011 0.021 0.216 0.226 0.050 0.060

45 Cut 0.008 0.018 0.153 0.163 0.035 0.045

Straight Cut 0.012 0.022 0.223 0.233 0.052 0.062

45 Cut 0.008 0.018 0.158 0.168 0.036 0.046

Straight Cut 0.012 0.022 0.230 0.240 0.053 0.063

45 Cut 0.008 0.018 0.163 0.173 0.038 0.048

Straight Cut 0.014 0.024 0.270 0.280 0.062 0.072

45 Cut 0.010 0.020 0.191 0.201 0.044 0.054

Ring Gaps

Peek

Ring Material

3.5

Cast Iron

1.5

1.75

ClylinderSize

8.5

3.75

10

6.5

6

4.5

4.75

8

8.25

4.25

1.625

Carbon Teflon *

3.25

3

Table 3 Piston Ring End Gaps



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Side Clearance

Table 4 Piston Ring Side Clearances



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3.4.3 Piston to Cylinder Clearances

Clearances Minimum Maximum

Crosshead piston to guide 0.008" 0.010"

8.0" - 10.0" Dia cylinder 0.035" 0.040"

6.0" - 6.5" Dia cylinder 0.030" 0.035"

5.0" - 5.25" Dia cylinder 0.025" 0.030"

4.125" 4.75" Dia cylinder 0.020" 0.025"

3.5" - 4.0" Dia cylinder 0.018" 0.022"

2.75" 3.25" Dia cylinder 0.015" 0.020"

2.0" 2.5" Dia cylinder 0.013" 0.018"

1.25" - 1.75" Dia cylinder 0.016" 0.025"

Table 5 Piston to Cylinder Clearances

3.4.4 Torque Settings

Torque Settings Size Type Torque ft-lb

Piston Nut (8 to 8-1/2 Piston) 1-1/8 - UNF 150

3" - 3-1/2" Piston 1" UNF - 200

Piston Rod to Crosshead Lock Nut 1" UNF Rod 300Piston Rod to Crosshead 1" UNF - 300

Final Stage Cylinder to C.E.Cylinder " UNC Stud 125

Final Stage Cylinder to C.E.Cylinder " UNF Stud 106

Final Stage Head " UNF Stud 140

Cylinder Head. 10" " UNF Stud 96

Cylinder Head. 6" Thru 8" " UNF Stud 96

Crosshead Cylinder To Crankcase " UNF Stud 105

Compression Cylinder To CrossheadGuide

" UNF Stud 112

Crankcase Inspection Cover 5/8" UNC Cap Screw 92

Valve Lantern Jacking Screw 5/8" - UNF Socket Set Screw 80

Crankcase Mounting Bolts 5/8" - UNC Hex Bolts 80

Cylinder Head. 4-" thru 3-1/2 5/8" - UNC Cap Screw 51

Final Stage Discharge Valve Cover " UNF Cap Screw 50

Cylinder Head. 3-1/4" thru 3 " UNC Cap Screw 51

Valve Covers " UNC Cap Screw 45

Oil Filter Housing " UNC Cap Screw 53

Split Flange Clamps " UNC Bolt 45

Conrod Bearing Cap " - UNF Cap Screw 62

Drive Bearing Housing " UNC Cap Screw 45



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Torque Settings Size Type Torque ft-lb

Oil Pump Housing to Crankcase " UNC Cap Screw 45

Final Stage Piston Retaining Nut " UNF - 30

Rod Seal Housing to Cylinder " UNF Cap Screw 45

Rod Seal Housing to Cylinder 7/16" - UNF Cap Screw 406-1/2 First Stage Piston 7/16" - UNF Cap Screw 27

Tandem Piston (5-1/4") to Crosshead 3/8" UNC Cap Screw 25

Tandem Piston (3" to 3-1/2") to Piston

Rod Lock Bolt3/8" - UNF Cap Screw 27

Split Flange Clamps 3/8" - UNF Cap Screw 20

Gudgeon Pin End-CapRetaining BoltNut

3/8" UNF Bolt / Nut 30

Mechanical Seal Retainer 5/16 " -UNC Cap Screw 15

Bearing Cover Plate 5/16" - UNC Cap Screw 15

Oil Pump Housing Seal Cover 5/16" -UNC Cap Screw 15

Oil Pump Retainer 5/16" UNC Cap Screw 17

Final Stage Piston Retaining Plate 5/16" UNC Cap Screw 22

Piston Power Nut Locking Screw(10 Piston)

5/16 UNF Grub Screw 12

Rod Wiper Retainer Plate 5/16 UNF Cap Screw 18

Piston Rod Balance Nut Lock Screw

(Power Nut type)5/16" UNF Grub Screw 12

Piston Rod Balance Nut Lock Screw

(Standard Balance Nut)" UNF Grub Screw 6

Piston Rod Locking Screw " UNF Grub Screw 6

Table 6 Torque Settings



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3.4.5 Rhino Compressor Tools

Figure 8 Compressor Tools



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3.5 Operating Procedures

!!! WARNING !!!COMPRESSED GAS IS A HIGHLY DANGEROUS

SUBSTANCE.

BEFORE DISMANTLING ANY PART OF THECOMPRESSOR ENSURE THAT THE UNIT IS

COMPLETELY DEPRESSURED

3.5.1 Start Up Check List Contents

3.5.2 Package Details

Compressor Model :

Serial Number :

Motor/Engine Model :

Motor Rated Speed :

Packager :

Package Unit Number :

Date Package Shipped :

Start Up Date :

Commissioning Engineer :

Customer :

Location :

Local Service Agent :

Local Service Agent

Telephone Number:



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3.5.3 Prior to Starting

Yes No

1 Do you have the Intermech Manual(s),

special tools & spares?2 Check the Performance Data Sheet for

design limitations; eg Rod loads, RPM,

discharge temperature.

3 Check the Performance Data Sheet for

optimum running conditions.

4 Set the Fault Switches according to

these conditions.

5 Have all the Intermech Pre Start-up Checks,

as outlined in the Commissioning Procedure,

been carried out?

6 Has the Electrical Pre Start-up Checks, as

outlined in the Commissioning Procedure,

been carried out?

7 Is the Installation complete to the satisfaction

of the Commissioning Engineer?

8 Has the Warranty Document been completed?

9 Are the customer & operators familiar with the

equipment's Operating Instructions?

10 Check that no damage has occurred to the

Package during transportation.

11 Is the correct grade and quantity of oil available

on site (at least 20 litres - 5 imp. gallons)?

12 Check the oil level in the compressor.

13 Has all the lubrication oil pipework been primed

with oil?

14 Is there Methanol or Isopropyl Alcohol available

on site (at least 20 litres - 5 imp. gallons)?

15 Check the coupling bolt torques.

16 Has the compressor coupling alignment been

checked (maximum allowable tolerance 0.005"

(0.127mm)? Record dial indicator readings:

17 Has the gas inlet pipework been cleared of dirt,

slag, rubbish, etc?

18 Check the Cooler Fan for obstructions.

19 Has the Compressor been turned over by hand

prior to initial start-up?

OD

FAC

E

DIAL

ALIGNMENT

RUN OUT



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3.5.4 After Starting

Yes No

1 Did oil pressure come up immediately?2 Are there any strange noises or shaking in

the compressor?

3 Are there any oil leaks?

4 Have all safety/fault functions been tested?

5 If the compressor driver (prime mover) is an

electric motor, check the current draw with the

compressor under full load.

3.5.5 Maximum Allowable Working Pressure

The Maximum Allowable Working Pressure is defined as the maximum

continuous pressure for which the manufacturer has designed the equipment (or

any part to which the term is referred), when handling the specified fluid at the

specified temperature.

All Rhino Compressors Cylinders have a Maximum Allowable Working

Pressure (MAWP), this and the hydrostatic test pressure with test date are

stamped on the end of every cylinder. Any relief valves will be set to operate at

not more than the maximum allowable working pressures but not less than thevalues listed below.

Rated Discharge Pressure Relief Valve Margin

Above Rated

Discharge

Psig Bar Pressure

-14.7 to 150 -1 to 10 15psi (1 bar)

151 to 2500 10+ to 170 10 %

2501 to 3500 170+ to 240 8 %3501 to 5000* 240+ to 345 6 %

Table 7 The Maximum Allowable Working Pressure

* For related discharge pressures above 5000 psig (345 bar), the relief valve setting shall beagreed upon between the purchaser and Intermech Limited.

Rated Discharge Pressure is defined as the highest pressure required to meet the

conditions the purchaser specifies for the intended service. Maximum allowable

working pressure shall exceed the rated discharge pressure by at least 10 percentor 25psi (1.7 bar), whichever is greater.



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3.6 Lubrication

Figure 9 Oil Circulation Schematic



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3.6.1 General Description

The lubricating system is based on a pressurised crankcase with mechanical

seals. Pressurised oil is fed right through the crosshead thrust face.

Oil is picked up via a mesh strainer, through the oil pump, then monitored by a

relief valve, back to the oil pickup, pumped through the oil cooler and then

through a full flow filter. The filter is located within the pressurised crankcase

inside the filter cap. From the filter the oil enters the auxiliary drive end

crankshaft seal cavity.

From the seal cavity the oil then passes into the crankshaft and is fed through to

the crank pin journals. Oil is fed up the con-rod to the gudgeon pin bearing and

into the gudgeon pin itself where it passes into the crosshead bushes and to the

thrust face of the crosshead. Also from the seal cavity oil passes through an

internal pipe to the main drive end where it enters the drive seal cavity, cooling

the mechanical drive seal and then relieving back into the sump.

The main drive bearing is fed from the seal cavity through a close metering

clearance plate. The front bearing is fed from the crankshaft through a small-

metered hole from the oil filter cavity.

3.6.2 Oil Specification

Listed below are some of the INTERMECH approved oils. The customer must

consult INTERMECH during the oil selection process.

SAE 40 Oils ApprovedCaltex RPM 150

Shell Corena H 150

BP Energol RC 150

SAE 30 Oils ApprovedCaltex RPM 100

Shell Corena H 100

BP Energol RC 100

For ambient temperatures above 50degF (10degC), SAE 40 compressor oil

should be used.

For ambient temperatures below 50degF (10degC), SAE 30 compressor oil

should be used.



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Note :

The compressor has a capacity of 3.5 imp gallons (15 litres).

Syntheticoils should notbe used.

3.6.3 Before Starting

1. Check that the oil filter is fitted and tightened using a filter wrench.

2. Ensure that the oil filter housing is securely in place.

3. Check compressor crankcase oil level.

3.6.4 Top Up With Oil

1. Remove the oil cap on top of the crankcase using the oil cap removal tool.

2. Fill the oil filler bowl with the correct oil. The oil filler bowl has a 1.25

litre capacity.

3. Re-instate the oil cap using the oil cap tool.

4. The oil within the filler bowl will drain into the crankcase.

5. After approximately 60 seconds, check the oil level in the sight glass.

6. If necessary, repeat steps 1 through 5 until the oil level in the crankcase

reaches the correct level.

7. The correct oil level is midway up the top sight glass (when the compressor

is stopped).

8. The minimum oil level is midway up the bottom sight glass (when the

compressor is running).

9. Ensure that the oil cap securely in place after topping up crankcase.

3.6.5 Primary Starting

If the compressor package has a built in electric pre-lube pump, oil pressure

builds up automatically before the compressor starts. If there is no electric

prelube pump, a priming pump must be used to prime the compressor

lubrication system before initial start up eg. at time of commissioning. If the

compressor has been shut down for an extended period, the lubrication system

should be primed when restarting.

If the compressor package is supplied without a built in electric pre-lube pump,

a priming pump is supplied as part of the special tools kit.



25/79


3.6.5.1 Priming the lubrication system using priming pump.

Pump oil through until the oil pressure gauge registers approximately 30 psi.

Continue to prime the system for another 15 seconds after oil pressure reaches

30 psi.

IMPORTANT:After replacing the oil filter element or draining any oil from the

oil cooling system, it is important to prime the compressor oil system.



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3.6.6 Oil Filter

Service Period : Oil and oil filter elements should be changed every 1500

hours. If regular quality viscosity checks or oil analyses are done with

satisfactory results, then longer periods of 3000 hours may be justified.

CAUTION:Do not use other than original oil filter element, as this will void all

warranty.

Equivalent oil filters are not necessarily satisfactory and may not have similar

seals, pressure rating or internal valves.

3.6.7 Lube Oil Pressure Adjustment

There are two relief valves in the crankcase. The first is situated in the oil pump

housing and is set at 65psig to protect the oil filter element. The second is

situated in the rear main bearing housing and is set at 50 - 55psig. This is to

relieve the oil from the seal housing and to ensure that the rear seal is cooled.

3.6.8 Oil Relief Valve Setting

Instructions Cautionary Notes

Theory1/. There are two oil pressure relief valves

fitted to the Rhino compressor. One is

located in the oil pump housing the other

in the flywheel bearing housing

(mechanical seal housing).

Both oil pressure relief valves are

adjustable by way of an Allen headed cap

screw located on the bottom edge of these

housings.

The relief valve in the flywheel bearing

housing should lift first to maintain

desired oil pressure.

The oil pressure relief valve in the

flywheel housing must be fitted with a

lighter spring than that used in the relief

valve in the oil pump housing.

This ensures that there is oil pressure at all

parts of the lubrication system, and that

oil flows through the mechanical seal

cavity (aids in cooling)

Setting the Oil Pressure

2/. Screw both oil pressure adjusting screwsin completely and back off about of the



27/79



total adjustment

3/. Start the compressor The Oil Pressure should be high (>65psi)

4/. Unscrew the Oil Pressure adjusting screw

at the oil pump housing until the oil

pressure drops to 65psi

5/. Unscrew the Oil Pressure adjusting screw

at the fly wheel housing until the oil

pressure is 55psi

6/. Monitor the oil pressure Oil Pressure will reduce as the oil

temperature increases.

7/. If the oil pressure drops below 45psi then

adjust both screws up by one full turn

Adjust the oil pump housing first, then the

flywheel housing relief.

8/. Unscrew the flywheel housing relief

screw until the oil pressure is 50psi

3.6.9 Compression Cylinder Injection Lubrication System

1. The function of the injection lubrication system is to lubricate piston rings

on compression pistons.

2. The 2 main components of the injection lubrication system are the

Mechanical lubricator pump and the Oil divider (distribution) block.

3. The compressor crankshaft drives the lubricator pump.

4. Oil from the lubricator pump is delivered to the oil divider (distribution)

block.

5. The function of the divider block is to deliver oil to all stages of

compression and to rod seal housings. .6. The oil is delivered through individual tubes and discharged through check

valves into each compression cylinder and to each rod seal housing.

7. A flow (proximity) switch mounted on the divider block monitors divider

block activity.

8. There is also an orange coloured cycle indicator mounted to the divider

block for visual monitoring of divider block

9. See Fault Repair section of Compressor Package manual for set up and

repair procedure.



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4 Maintenance

!!! WARNING !!!COMPRESSED GAS IS A HIGHLY DANGEROUS

SUBSTANCE.

BEFORE DISMANTLING ANY PART OF THE

COMPRESSOR ENSURE THAT THE UNIT IS

COMPLETELY DEPRESSURED

4.1 General

The major components of the compressor are the crankcase, the crankshaft and

bearings, the connecting rods and wrist pins, the crosshead cylinders and

pistons, the 1st, 2ndand 3rdstage cylinders and pistons and the oil pump.

Drilled oil passages & a fitted oil gallery circulate lubricating oil from the oil

pump to each of the main bearings and crankshaft.

Whenever working on the unit ensure that absolute cleanliness, using lint freecloths, is observed. When the inspection cover is removed and/or the internal

components are exposed, ensure that these parts are kept covered except when

actually working on them. Be sure to protect the exposed mating surfaces from

mechanical damage at all times.

On gas engine powered units remove centre coupling to ensure compressor

cannot turn over during maintenance. On electric motor powered units switch

off & lock out the electric circuit to the motor during maintenance.



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4.2 Oil Pump (CRA-357) & Oil Pump Housing (CRA-352-1)

4.2.1 Oil Pump Housing Drawing (CRA-352-1)



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4.2.2 Oil Pump Housing (CRA-352-1) Parts List

Item Number Part Number Description Quantity

1 CNC-0508 Cap screw 5/16" UNC x 1" 6

2 CR-3554 Seal Cover Cap 1

3 ORN-7151 O-Ring (Nitrile) 1

4 CR-3521 Oil Pump Housing Cover 1

5 8 HP50N 7/8"UNF Plug 3

6 CRA-333 Pressure Relief Valve (refer Item 16 also) 1


8 CR-3611 Sight Glass 2


10 CR-3622 Sight Glass Retainer 2


12 CR-3541 Oil Restrictor Plate 1




16 CR-3336 Spring Pressure Relief Valve (Strong) 1

17 CRA-357 Oil Pump Assembly 1

18 8-10 F5BU 1/2" Tube x 7/8"UNF Straight Connector 1

19 8 FNU 1/2" Blanking Cap - Ferulok 1

20 CR-3524 Wear Plate 1

21 KNC-0404 Cap Screw CSK UNC 1

22 12 F5BU-M 7/8"UNF Straight Tube Connector 2



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4.2.3 Oil Pump Assembly Drawing (CRA-357)



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4.2.4 Oil Pump Assembly (CRA-357) Parts List


1 CR-3571 Hex Drive Key (6mm) 1

2 CR-3582 Thrust Ring 1

3 CR-358 Oil Pump Driven Gear 1

4 CR-357 Oil Pump Driver Gear 1

5 CR-3575 Oil Pump key 1

6 CR-360 Oil Pump Bush 1

7 CR-3591 Oil Pump Retainer 1

8 CNC-0508 Cap screw 5/16"UNC x 1" 1

9 CRA-3579 Oil Pump Impellor Assembly 1



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4.2.5 Oil Pump Relief Valve Drawing (CRA-333)



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4.2.6 Oil Pump Relief Valve (CRA-333) Parts List


1 CR-3335 Valve Plunger 1

2Spring (see CRA-352-1 or CRA- 358 for part

no.)1

3 CR-3333 O-Ring Retainer 1


5 BUN-114 Back-up Ring (Nitrile) 1

6 NNF-08 Nut 1/2"UNF 1

7 CR-3331 Valve Retainer Nut 1

8 CR-3339 Adjustment Screw 1



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4.2.7 Disassembly Oil Pump Housing

1. Refer drawing # CRA-352-1 in section 4.2.1

2. Before dismantling, ensure compressor is completely de-pressured.

3. Drain oil from crankcase.

4. Remove capscrews (15 off) that hold the oil pump housing in place.

5. Carefully remove oil pump housing..

6. Check condition of all o-rings about the oil pump housing sealing face.

7. Check condition of sight glass o-rings. Replace if necessary.

8. Remove seal cover cap (CR-3554) and check condition of oil restrictor plate

(CR-3541) & O' ring (ORN-7228). Replace if necessary.

9. Remove pressure relief valve assembly (CRA-333). See procedure below.

4.2.8 Disassembly Oil Pump Relief Valve

1. Refer drawing # CRA-333 in section 4.2.5.

2. Remove relief valve adjustment screw.

3. Screw UNF Capscrew from special tools into o-ring retainer (CR-3333).

4. Use screw to remove O-Ring retainer.

5. Relief valve plunger and spring will drop out of oil pump housing.

6. Check condition of O-Rings; spring; etc.

4.2.9 Disassembly Oil Pump

1. Refer drawing # CRA-357 in section 4.2.3

2. Remove the oil pump housing from crankcase as described in section 4.2.2

3. Check condition of oil pump drive gear (CR-357) & oil pump drive key

(CR-3575) on crankshaft.

4. Remove oil pump driven gear (CR-356) and hex drive key (CR-3571).

Check condition.

5. Remove oil pump retainer (CR-3591)

6. Check condition of oil pump bush (CR-360) and thrust ring (CR-3582).

7. Remove oil pump impellor assembly (CR-3579) and check for signs of

wear.

8. Remove Wear Plate (CR-3524) and check sign for wear, if necessary

replace with new.



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4.2.10 Assembly Oil Pump


1. Clean and oil all components Refer CRA-352-1 and CRA-357

2. Insert oil pump impeller and rotor into its

pocket.

3. Check clearance between impellor / rotor

assembly and oil pump retainer. See

Clearance chart 3.4.1

Use Plastigauge between impellor

assembly and oil pump retainer to check

clearance.

4. Oil the pump rotor with medium heavy

oil and fit retainer.

Torque cap screws to 17 ft-lb.

5. Fit oil pump driven gear and 6 mm hex

drive key to oil pump and check for ease

of rotation of oil pump. Locate thrust

washer in gear.

6. Rotate driven gear to check freedom of

movement.

4.2.11

4.2.12 Oil Pump Relief Valve


1. Fit new o-ring and back-up ring to oring

retainer.

Apply grease to o-rings

2. Fit oil pressure relief valve plunger,

spring & o-ring retainer.

Take care not to damage o-rings when

inserting retainer.

3. Fit relief valve adjustment screw Adjust spring tension to of full travel of

adjustment screw.

OIL PRESSURE ADJUSTMENT MUST

BE CARRIED OUT AFTEROVERHAUL OF RELIEF VALVE.

Refer sections 3.6.7 & 3.6.8



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4.2.13 Assembly Oil Pump Housing (CRA-352)


1. Fit o-ring (ORN-7228) to bronze restrictor

(CR-3541)

2. Fit bronze restrictor into oil pump housing

3. Fit seal cover cap and torque to17 ft-lb.

4. Fit o-rings to sight glasses. Apply grease to o-rings

5. Fit sight glasses; sight glass retainers and

o-rings.

6. Fit o-rings to oil pump housing. Grease o-rings.

7. Fit oil pump drive gear drive pin intocrankshaft.

8. Slide the oil pump driver gear over the

crankshaft to line up with key.

This will be a firm slide fit.

9. Fit oil pump housing assembly. Ensure that oil restrictor plate remains in

place when carrying out this process.

10. Fit retaining screws and tighten to correct

torque.

See Torque Setting Chart (section 3.4.4)



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4.3 Rhino Crankcase (CRA-3603)

4.3.1 Rhino Crankcase Drawing (CRA-3603)



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4.3.2 Rhino Crankcase Drawing (CRA-3602)



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4.3.3 Rhino Crankcase (CRA-3603) Parts List


1 CR-3603 Taper Locking Bearing Crankcase 12 CRA-3602 Lubrication Assembly 1

3 CR-3253 Crankshaft Rhino 3.25 Stroke 1

4 CRA-356 Drive End Cover Assembly 1

5 CRA-3640 Taper Locking Bearing Housing 1

6BRS-9052-

C4Spherical Roller Bearing 1

7 CRA-328 Filter Cap Assembly 1

8 FIE-Z178 Filter Element 1

9 CR-3311 Spigot Oil Filter 1

10 SSC-0505 Socket Set Screw 5/16 UNC x 5/16 1

11 CR-3254 Main Drive Key 1

12 PNR-M0420 4 x 20 Roll Pin 1

13 CNC-0812 Cap screw 1/2UNC x 1.5 lg 32

14 CNC-0612 Cap screw 3/8UNC x 1.5 lg 8

15 1/8-HHP-S Hollow Hex Plug 1/8 NPT 2

16 1-HHP-S Hollow Hex Plug 1 NPT 4

17 ORN-7114 O-Ring 114 2

18 ORN-7156 O-Ring 156 1

4.3.4 Rhino Crankcase (CRA-3602) Parts List


1 CR-329 3/4" Tube 1

2 ORN-7117 O-ring (Nitrile) 3

3 CRA-820 Oil Filler Bowl Assembly 1

4 CNC-1012 Cap screw 5/8"UNC x 1-1/2" 6

5 CRA-352 Oil Pump Housing Assembly 1

6 PFP-16 1"NPT Dry seal Plug 1

7 CRA-332 Oil Pick-Up Assembly 1



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4.3.5 Taper Lock Bearing Housing Assembly Drawing (CRA-3640)



42/79


4.3.6 Taper Lock Bearing Housing Assembly Parts List (CRA-3640)


1 CR-3641 Bearing Housing 1

2 CR-3642 Taper Locking Wedge Block 1

3 SSF-0608 Set Screw 3/8"UNF x 1" long 4

4 CNF-0412 Capscrew 1/4"UNF x 1.5" Lg. 12



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4.3.7 Rhino Crankcase Filler Bowl Drawing (CRA-820)



44/79


4.3.8 Rhino Crankcase Filler Bowl (CRA-820) Parts List


1 1/4 HP-S 1/4"NPT Plug 1

2 CR-821 Top Plate 1

3 CNC-0628 Capscrew 3/8" x 3-1/2" 4

4 CR-8221 Filler Bowl 1

5 CPE-06 Circlip External 3/8" 1

6 ORN-7010 O-Ring Nitrile 2


8 VAN-073 Seal Teflon 1

9 CR-803 Spring 1

10 CR-805 Regulating Piston 1



13 CR-806 Vent Plug 1

15 CR-807 Spring Seat 1

16 ORN-9151 O-Ring Nitrile 90 1

17 FIE-090 Woven Stainless Steel Mesh 1

18 ORN-7266 O-Ring Nitrile 119 CPE-10E Circlip External 5/8" 1

20 CPI-M72 Circlip Internal 72mm 2



45/79


4.3.9 Disassembly Crankshaft (CR-3253)

1. Before dismantling, ensure compressor is completely de-pressured.

2. Remove the drive coupling.

3. Remove the crankcase top cover.

4. Remove cylinder assemblies as described inthis section.

5. Remove the oil pump housing and oil pump as described in 4.2

6. Remove the mechanical seal assembly as described in 4.4.

7. Remove mechanical seal drive pin from crankshaft.

8. Remove the oil pump end crankshaft main bearing retainer plate.

9. Refer to Taperlock Bearing Housing drawing in section 4.3.5.This showscrankshaft oil pump end Bearing Sleeve arrangement. With crankshaft

installed in crankcase Taperlock Sleeve (item # 2 ) is locked in place over

top of Bearing Housing (item # 1). The bearing is locked inside Bearing

Housing. The Taperlock Sleeve is what locks the bearing in place.

10. To remove the crankshaft, the Taperlock Sleeve must be pushed off the

Bearing Housing. Jacking screws are provided for this purpose.

11. Once the Taperlock Sleeve is free from the Housing the crankshaft bearing

can be slid from the Bearing Housing.

12. The best way to remove the crankshaft from the crankcase is to stand the

crankcase on its end (oil pump end).

13. Carefully lift the crankshaft from the drive end of crankcase.

14. Once the crankshaft is out, remove the crankshaft main bearing retaining

circlip from the drive end bearing housing. Remove the drive end bearing

housing from the crankshaft and bearing.

15. Check the main bearings for wear. Replace if necessary. To remove

bearings use a hydraulic ram puller.



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4.3.10 Assembly Crankcase (CRA-3603)

Crankcase Assembly ProceduresClean inspect and oil all components Ensure 1/8 Dry Seal plugs are fitted into 2

locations on crankshaft.

(*)

I. Fitting Main Bearing to Crankshaft1 Heat bearings for 2 hrs to 110

oC

2 Place 160 internal circlip over drive end

of crankshaft and slide bearing onto this

journal. C3 Type.

Minimum bearing clearance 0.0015

Ensuring that it is hard against the

crankshaft shoulder.

This is best achieved by having the

crankshaft in a vertical position.

3 When the drive end bearing is cool

enough so that it is locked onto thecrankshaft, stand the crankshaft on the

drive end and fit the main bearing to the

oil pump end of crankshaft. C4 Type.

Minimum bearing clearance 0.0015

(*)

II. Assemble Drive End Bearing Housing

1 Fit the O ring (ORN-7240) into the grove

on the bronze metering plate and lightly

lubricate with grease

2 Press metering plate into the metering

plate retainer.

From the side that has the lead in chamfer (*)

3 Assemble oil pressure relief value into itshole, by inserting the shuttle, spring then

retainer (with O ring fitted then backup

ring), locate in place with retaining bolt

and adjust screw.

All items to be lubricated beforeassembly.

USE LIGHT SPRING. CR-3334

(*)

4 Fit plug (8HP50N-S) to bottom drilling

and hollow hex head plug to (6HP50N-S)

into outer seal cover face.

Ensure the Hollow Hex Plug is inserted

below flush.

(*)

5 Tap 1/8 x long roll pin into the hole at

top face of bearing diameter bore.

(*)

6 Place metering plate/retainer assy inside

bore of CR-3531 housing so that the roll

pin locates in the hole in the retainer.

7 Fit this housing assembly to the

crankshaft and locate with circlip, which

is to be fitted to the groove inside CR-

3531 housing.

(*)

III. Install Crankshaft into Crankcase

1 The crankcase is to be clean and inspected

for damage

(*)

2 Insert oil tube into bottom of crankcase.Fitted O ring in recess on end of tube.

Ensuring plastic hose is fitted over thetube between bulkheads and webs of

crankcase.

(*)



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Crankcase Assembly Procedures

3 Fit O rings (ORN-7270 + ORN-7271) into

groove and flywheel housing and corner

of flywheel housing and lightly grease,

and O ring (ORN-7206) into oil reliefvalve recess on face of housing.

(*)

4 Fit both pieces of bearing carrier as one

unit into crank case

Sit on back and lower Crank Case / Drive

housing assembly into crank case

Lower crankcase back onto mounting feet

From inside crankcase tap outer bearing

race fully back towards oil pump end of

crankcase.

Set DTI on outer race of bearing

From outside Tap the outer race of

bearing towards drive end housing.

Note: distance outer race moves.

Shift outer race to center point plus 0.004

further apart.

Tighten cap screws in rear bearing

cover to 3.5 ft-lbs

Tighten Clamp bolts in bearing carrier

to 9.5 Ft/lbsMinimum bearing clearance 0.002

Tighten cap screws in bearing carrier to

12 ft/lbs

Tighten cap screws to 25 Ft-lbs

Tighten cap screws that hold drive

housing in place to 45 Ft-lbs

Once bearing clearance is reduced by

0.001 screw in 4 x SSF0608 set screws

and nip.

Sign as

torqued

Sign as

torqued

Sign as

torqued

Sign as

torqued

Sign as

torqued

5 Check O Rings in recess.

6 Mark cap screws as torqued with a dab of

colored lacquer; or permanent marker.

(*)

7 Check rotation for freedom movement (*)

IV. Fitting Oil Pump Housing assembly

1 Oil Pump Housing assembly to be

assembled as per assembly procedure.

Procedure number: PRA-008

(Oil Pump Housing CRA-352-1

Assembly)

2 Oil pickup filter assembly is fitted from

the inside of the crankcase. Its tube is

passed through from inside the crankcase

to protrude through the recess and be

flush with end of crankcase. This is to be

expanded into the hole so as to lock it

permanently in position.

This needs to be carried out prior to

installing CRA-3640

(*)



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Crankcase Assembly Procedures

3 Fit 2 O-rings to crankcase ORN-7114 Ensure O-rings are fitted to oil pump

bearing housing boss (ORN-7270 &

ORN-7271), and sight glass retains

(ORN-7119) and teflon thrust washer ison the face of oil pump gear.

(*)

4 Fit pin key into crankshaft and slide the

oil pump driver gear over the crankshaft

to line up with key.

This will be a firm slide fit. Ensure that

this gear is correctly located against

restrictor plate.

(*)

5 Fit O rings to end of oil tube & oil pickup

(in recesses provided) and at oil filter feed

drillings on face of crankcase and ease oil

pump housing (CRA-352) over crankshaft

and into is correct position againstcrankcase.

Ensure that the crankshaft does not push

out of its seat, the restrictor inside oil

pump housing.

6 Torque cap screws to 45 ft-lb and mark as

torqued.

(*)

V. Oil Filter Installation

1 Fit socket set screw to left hand side hole

beside oil spigot

Use Loctite 243

2 Insert oil filter spigot and nip to the

bottom of its thread. Lubricate seal on oil

filter with a thin film of grease and screw

onto spigot. Tighten firmly hand tight.

Screw grub screw into filter housing with

Loctite 271

(*)

3 Grease lightly the O-ring on the oil filter

cover and fit to crankcase. Torque cap

screws to 60 ft. lb, and mark as torqued.

Use O-ring 7156 (*)

ASSEMBLED BY:COMMENTS:

SIGNATURE: DATE:



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4.4 Drive End Bearing Housing / Mechanical Seal Assembly (CRA-356)

4.4.1 Drive End Bearing Housing / Mechanical Seal Drawing (CRA-356 RevB)



50/79


4.4.2 Mechanical Seal Housing (CRA-356) Parts List


1 CNC-0510 Cap screw 5/16 UNC x 1-1/4 lg. 6

2 CR-3286 Seal Gland Plate (Burgmann) 1


5SEL-

8010510Lip Seal 1

6 6HP50N-S Hex Plug Dry Seal type 2

7 SEM-H7N/80-00 Mechanical Seal Assembly 1

8 CR-3531 Mechanical Seal and Bearing Housing 1



11 CR-3302 Oil Metering Plate 1


13 CR-3301 Oil Metering Plate Retainer 1

14 BRS-9052 Self Aligning Bearing 1

15 CPI-160 Circlip Internal (160 dia. Groove) 1

16 CRA-333 Pressure Relief Valve assembly 1

17 PNR-0212 Roll Pin 1/8 dia x lg. 1

18 CR-3334 Spring Pressure Relief Valve (Weak) 1


20 4-F5BU-SStraight Thread Tube Connector T x

7/16UNF1

21 4 HP50N-S Hollow Hex Plug 7/16UNF O-Ring seal 1

22 PNR-M0425 Anti-Rotation Pin 4mm dia. x 25mm lg 1

23 CR-3259 Anti-Rotation Pin 1



51/79


4.4.3 Disassembly / Assembly - Mechanical Seal


REMOVAL

1 Remove drive coupling spider.

2 Remove coupling hub from compressor

by firstly removing the flange from the

hub then sliding the hub off the shaft. The

flange will probably need to be jacked off

using jacking screw holes provided on the

flange. Once the flange is removed, thehub will need to be spread a little using a

screwdriver to allow the hub to be slid off

easily.

Before removing the flange, check

the distance between the hub on the

motor and the hub on the

compressor. The distance should be

117.0mm + or 0.15mm. After

installing the new mechanical sealand refitting the coupling hub to the

shaft, the distance between the hubs

should equal this distance (see

coupling hub drawing attached).

3 Remove key from shaft.

4 It is important to protect mechanical seal

faces from damage while removing /

installing. Heavy paper or thin card must

be wrapped around crankshaft before

mechanical seal gland housing (CR-3286)

is removed.

Slide card onto crankshaft through

lip seal cavity up to crankshaft

shoulder.

5 Rotate compressor crankshaft until drivekeyway is at the top.

This ensures that the mechanicalseal drive pin is at the top and

cannot fall out when Spring

Assembly is removed.

6 Remove mechanical seal gland housing

from drive end bearing housing.

7 Remove dynamic part of seal (Silicon

Carbide Ring) along with Spring

Assembly.

To do this, 2 wire pullers should

be hooked behind Spring Assembly

180 deg apart. The Spring

Assembly / Silicon Carbide Ring

can then be removed as an

assembly. Ensure that protectivecard is wrapped around crankshaft

while removing this assembly.

8 Check condition of drive pin (CR-3259) Drive pin can be removed using

pliers. Take care when doing this.

The pin can drop out and fall into

the cavity at the bottom of the

mechanical seal housing.

9 Clean out drive end bearing housing

where mechanical seal is located.

INSTALLATION

1 Slide spring assembly onto the shaft



52/79



ensuring that the drive pin slot at back of

Spring Assembly slides into place over

the drive pin.2 Fit dynamic (rotating) part (Silicon

Carbide Ring) of the mechanical seal into

place against the spring assembly. There

will be resistance from the dynamic ring

o-ring. Lightly oil o-ring. Push dynamic

ring into place using thumbs. Note there

are 2 tabs which locate dynamic ring in

spring assembly.

Take care not to damage the seal

face. Use protective card wrapped

around crankshaft as described

above.

3 Remove protective paper / card from

shaft.

4 Fit the non-rotating part of the seal into

gland housing.

As above, there will be resistance

from the static ring o-ring. Lightlyoil o-ring. Push static ring into

place using thumbs. Drive slot at

back of static ring must locate with

drive pin.

5 Fit the gland housing complete with

bronze ring.

Ensure that the faces of the

mechanical seal parts are dry ie.

free of oil.

6 Tighten gland plate screws.

7 Slide the coupling hub into place on shaft

8 As detailed above, it is most important to

have correct distance between the motorhub and the compressor hub.

9 Lightly clamp the hub to the shaft by

tightening the cap screws on the hub.

This will stop the hub moving when

the flange is fitted.

10 Fit Coupling Flange and tighten cap

screws.

11 Check that distance between coupling hub

flanges is correct.

The distance must be 117mm.

12 Ensure that drive coupling hub locking

bolts are tightened to correct torque.

13 Re-fit coupling spider



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4.5 Connecting Rod Assembly

4.5.1 Connecting Rod Assembly Drawing (ROA-8525)



54/79


4.5.2 Connecting Rod Assembly Parts List (ROA-8525)

Item Number Part No. Title Qty.

1 CNF-0824 Capscrew 1/2"UNF x 3" Lg 42 RO-1252 Bush 2.5" Gudgeon 1

3 RO-85251 Con-Rod 1

4 RO-904 Shell Bearing (Big End) 1

5 RO-905 Pin 3/16" dia x 3/4" lg - Silver Steel 2



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4.6 Cross Head Cylinder/Piston (CYXA-6003)

4.6.1 6 Cross Head / Cylinder Drawing (CYXA-6003)

(CYXA-6003 for Low Pressure side and High Pressure side)



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4.6.2 6 Cross Head / Cylinder (CYXA-6003) Parts List

Item

Number Part Number Description Quantity

1 ROA-8525 Con-rod Assembly 1

2 CYX-6451 X-Head Cylinder 1

3 PIX-6062 6" Cross-head Piston 1

4 RO-2534 Gudgeon Pin 2.5" 1

5 RO-2535 End-plate for Gudgeon Pin 2

6 BNF-0644 Bolt 3/8"UNF x 5-1/4" 1

7 NNF-12 Nut 3/4"UNF 6

8 NNF-C06 Nut 3/8"UNF Cone Lock 1


10 PNR-0405 Roll Pin 1/8" dia. x 5/16" 2

11 STN-1224 Stud 3/4"UNF x 3" 6



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4.6.3 Disassembly - Cross-Head Cylinder/Piston

1. Decompress and degas the compressor.

2. Remove low pressure compression cylinder assembly (ref.4.7)and / or high

pressure cylinder assembly (ref.0)as per procedures detailed in this section.

3. Remove oil filler bowl (CRA-820 section 4.3)assembly from top of

crankcase.

4. Remove big end cap from Conrod.

5. Remove cross head piston assembly complete with Conrod.

6. Remove gudgeon pin end plate (RO-2535) retaining bolt (BNF-0644).

7. Slide Gudgeon pin out of piston and Conrod. Take note of top of Conrod

and top of crosshead piston. (Conrod serial # is always facing the top)

8. If removing both high pressure throw and low pressure throw crosshead

pistons, take note of which crosshead belongs to high pressure throw and

which belongs to low pressure throw. When reassembling, they cannot be

mixed up.

9. Check condition of big-end bearing shells.

10. Remove cross head cylinder from crankcase.

11. Check the condition of the bore, i.e. check for score marks and measure

inside diameter.

4.6.4 Assembly - Cross-Head Cylinder/Piston


1. All components to be cleaned and oiled

before assembly

Check for damage

2. Fit o-ring (ORN-7262) into corner of

cross head cylinder

Lightly grease o-ring

3. Slide cross head cylinder over studs. Orientate so that the radiused cut out on

cross head skirt is adjacent to crankshaft

counterweight.

4. Tighten nuts to correct torque. See Torque

Setting Chart (section 3.4.4))

Check clearance of crankshaft

counterweight on skirt of cylinder.

5. Position the con-rod (ROA-8525) inside

the cross head piston (con-rod serial # to

the top). Align gudgeon pin holes and fit

gudgeon pin.

Ensure that high pressure side cross head

piston is fitted to high pressure throw and

low pressure side cross head piston is

fitted to low pressure throw.

NOTE: Both, the top of the crosshead

piston and the bottom of the cross head

piston have oil retention grooves. In 1

side only, there are oil holes drilled intothe grooves. The side of the piston that



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has oil holes goes to the thrust side of the

crosshead guide i.e. Thrust side on the

high pressure throw is at the top and thrustside on the low pressure throw is at the

bottom.

6. Fit Gudgeon end plates (RO-2535) and

retain with bolt (BNF-0644) and lock nut

(NNF-C06).

Locknut torque = 30 ft-lb

7. Fit big end bearing shells to con-rod and

end-cap.

8. Slide con-rod / cross-head piston

assembly into cross-head cylinder.

Ensure that con-rod serial # faces the top.

Ensure that cross-head piston lubrication

holes face the top for high pressure throw

and face downwards for low pressure

throw.9. Check bearing shell to crankshaft

clearance by placing Plastigauge strip

between end-cap bearing shell and

crankshaft journal then tightening end-cap

bolts to correct torque.

Do not rotate crankshaft with plastic

gauge fitted or faulty readings will result.

10. After checking clearance, lubricate

bearing shells and crankshaft bearing

journal. Then re-fit bearing cap and

tighten retaining bolts to correct torque.

See Torque Setting Chart (section 3.4.4)

11. Check for freedom of rotation

12. If Cross-head piston is new, check cross-head piston to cross-head cylinder

clearances. Check using feeler gauges at

points indicated in sketch.



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4.7 1stStage Cylinder/Piston / Piston Rod Assembly

4.7.1 Cylinder Assembly Drawing (CYA-3500-3)



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4.7.2 Cylinder Assembly (CYA-3500-3) Parts List

Item Part Number Title Quantity

1 CYXA-6003 X-Head Cylinder Assembly Hollow Gudgeon 1

2 CY-3500 Cylinder 3.5" 1

3 PI-3500 3.5" Double Acting Piston 1

4 RIS-3030 Piston Support Ring 1

5 HE-3500-2 Head 3.5" 1

6 ROP-3200 Piston Rod 1

7 RIC-35D438 3-1/2 Sealing & Rider Ring 1

8 Vls-3200 Valve Lantern (Suction) 2

9 VAS-602357-M Suction Valve '60' 2

10 RIC-354532 Compression Ring 3.5 2

11 VLD-3500 Valve Lantern (Discharge) 2

12 GKV-07006530 Gasket Aluminium (60RX) 2

13 HE-3031 Valve Cap 4

14 HE-4553 Cover (Suction Port) 1

15 5151HK-32 2" Split Clamp (Parker) 2

16 HE-4555 Cylinder Stub (Split Flange) 2" - Weld 1

17 HE-4554 Cap (Split Flange) 1

18 ORV-7230 O-Ring (Viton) 5

19 GKV-07006510 Gasket Aluminium (60RX) 2


21 VAD-602357-M Discharge Valve `60 2

22 NNF-12 Nut UNF 6



25 RPN-087 Jam Nut Assembly 0.875 1

26 - - -

27 RPN-100 Jam Nut Assembly 1 1

28 CNC-0812 Cap screw "UNC x 1.5" Lg. 32

29 CNC-0816 Cap screw "UNC x 2" Lg. 8

30 Gkv-10009010 Gasket Aluminium 1

31 CNC-1216 Cap screw "UNF x 2" Lg. 6

32 STN-1224 Stud 3/4"UNF x 3" UNC 6



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Item Part Number Title Quantity

33 SEA-3503 Seal Assembly 3.5 1

34 SEB-3554 Seal Housing Ring for 3.5 D.A. Cylinder 1




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4.7.3 Disassembly

1. Remove inlet filter vessel.

2. Remove 1st stage discharge pipe.

3. Remove first stage cylinder head.

4. Remove first stage piston centre lock nut.

5. Unscrew first stage piston using the special tool provided.

6. CAUTION: When unscrewing the piston, ensure that the piston rings do

not get caught in head end valve pockets. To prevent this occurring, roll

over the machine until first stage piston is approximately in middle of

stroke. Then unscrew the piston.

7. Slide piston complete with piston rings from cylinder.

8. Check condition of the bore, i.e. check for score marks and check bore

diameter.

9. Check condition of piston rings.

10. Remove 3/4" UNF cylinder retaining nuts at crosshead cylinder.

11. Carefully slide cylinder off piston rod.

12. CAUTION: Take care when lifting the cylinder off the piston rod. Rod

Packings are easily damaged. The cylinder must be lifted off the rod

without any force (up; down or sideways) being placed on the rod while

lifting the cylinder off.

13. Inspect piston rod for damage.

14. Before removing piston rod, take note of distance from top of rod to top of

balance nut.

15. Loosen balance nut locking screws.

16. Loosen balance nut (use special tool provided).

17. Remove piston rod.

4.7.4 Assembly


1 Screw balance nut onto piston rod. Set distance between top of rod and

top of balance nut to the same

distance as it was before rod was

removed.

2 Screw piston rod and balance nut

assembly into X-head piston until

balance nut makes contact with top of

X-head piston.



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Tighten balance nut to 300ft-lb Use special tool # TL-0060 (see

section 3.4.5.)

Tighten balance nut locking grub

screws

Tighten until Allen key twists out of

shape.5 Fit o-ring (ORN7268) into groove on

compression cylinder face.

Lightly lubricate o-ring.

8 Fit tapered rod seal guide (special

tool # TL-0061 - see section 3.4.5.)

over end of piston rod.

Lightly oil outside of guide.

9 Slide cylinder assembly over rod and

onto spigot of cross head cylinder.

Tighten retaining nuts to correct

torque (See Torque Setting Chart

section 3.4.4).

Ensure that cylinder is right way up

i.e. Discharge valves towards drive

motor.

Remove rod seal guide from pistonrod.

Fit the piston to piston rod (without

piston rings).

Ensure that piston support ring is

placed in position on rod before

fitting piston.

Tighten piston to 125 ft-lb.

Fit gasket and o-ring to head.

Fit head to cylinder and tighten

retaining screws to correct torque.

Check piston HE and CE clearances

at top and bottom of stroke

respectively.

Use feeler gauges fed through HE &

CE valve pockets to check

clearances.HE clearance should be 2/3 of total

clearance. CE clearance should be

1/3 of total clearance.

If head-end and crank-end clearances

are incorrect. compression cylinder

will need to be removed and piston

rod position changed in X-head

piston

Remove cylinder head and piston.

10 Check that piston ring side clearances

and end-gaps concur with clearances

detailed in Table 3 Piston Ring EndGaps)

11 Fit piston rings to piston. Orientate piston ring end-gaps, 180

deg to each other.

13 Slide piston support ring onto rod.

14 Oil piston rings generously and ease

into cylinder.

Ensure crank is at bottom of throw.

Take care not to damage rings.

15 Screw piston onto rod. Torque to 200

ft lb. using special tool provided

(special tool # TL-0059 - see section

3.4.5.)

Roll over machine until piston is at

top of stroke for final torquing of

piston

Screw piston nut onto rod & torque to130 ft lb.



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16 Tighten grub screws . Use Loctite 222 on grub screws..

17 Fit head to cylinder and tighten

retaining screws to correct torque.

Ensure that bevelled areas of head are

in line with valve pockets (i.e. invertical position).



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4.8 Rod Seal Housing Assembly

4.8.1 Rod Seal Housing Drawing (SEA-3503)



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4.8.2 Rod Seal Housing (SEA-3503) Parts List

ItemNumber

Part Number Description Quantity

1 SEC-3503 3.50 Seal Cup 12 SEB-4625 Seal Block 1

3 CNF-0506 Cap screw 5/16UNF x lg. 8

4 SER-1805-P1U Pressure Breaker 1

5SER-1805-

BTUUBTU Seal 2

6 CNF-0814 Cap screw UNF x 1-3/4 lg. 6



9 SEB-4040-H Seal Block with Hole 1

10 ORMV-706030 O-Ring (Viton) 70x60x3 1


12 SEC-4252-2 3-1/2 x 3-1/4 Wiper Seal Retainer 1

13 SEW-1805-RTV RTV Seal 0.1 Wiper 1

14 SEB-4041 Seal Block Face 1

15 BRB-040 Sealing Plug 4

16 PNR-0204 Roll Pin 1/16 dia. x lg. 2



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4.8.3 Disassembly

1. Remove Wiper Seal Retainer (Item 12), Wiper (Item 13) & Seal Block Face(Item 14)

2. Remove BTU Rod Seals (Item 5), Seal Blocks (Item 2 & 9) and Pressure

Breaker (Item 4).

3. Check condition of all Rod Wipers, Seal Blocks, Rod Seals, Pressure

Breakers, O-Rings, etc.

4. Remove Seal Cup Retaining Screws (Item 6).

5. Remove Seal Cup (Item 1) from compression cylinder.

6. Check condition of O-rings.

4.8.4 Assembly

1. Place Pressure Breaker (Item 4) into Seal Cup.

2. Place Seal Block (Item 2) and first BTU Rod Seal into Seal Cup. Ensure

that Seal Block Alignment Pin (Item 16) locates correctly in hole in Seal

Cup. Ensure that Rod Seal is correct way up.

3. Place Seal Block with hole (Item 9) and second BTU Rod Seal into Seal

Cup. Ensure that Seal Block Alignment Pin (Item 16) locates correctly.

4. Fit O-Ring (Item 10) and Seal Block Face (Item 14).

5. Fit RTV Wiper Seal (Item 13) into Seal Cup.

6. Fit Wiper Retainer (Item 12). Torque cap screws to 18ft/lb.

7. Fit O-rings to Seal Cup. Ensure that O-rings are lubricated.

8. Fit aluminium gasket (part of cylinder assembly) to cylinder then fit Seal

Housing assembly to cylinder. Torque Seal Housing Retaining Screws to

45ft/lb.



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4.9 2nd

/ 3rd

Stage Cylinder/Piston/Piston Rod Assembly

4.9.1 Cylinder Assembly Drawing (CYA-3216-4)



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4.9.2 3.25x 1.625 Cylinder Assembly (CYA-3216-4) Parts List

ItemNumber Part Number Description Quantity

1 CY-3250-2 Cylinder 3.25" D.A. 1

2 CY-2751 Cylinder Final Stage 1

3 CYXA-6003 X-Head Cylinder Assembly, Hollow Gudgeon 1

4 HE-3045 Head Final Stage 1

5 ROPA-3216 Piston Rod Assembly 1

6 SEA-3250 Seal Assembly 1

7 HE-4553 Cover (Suction port) 1

8 HE-3031 Valve Cap 1

9 PIA-3216-2 Piston Assembly (3.25 x 1.625) 1

10 HE-4558 Cylinder Stub (Split Flange) 1-1/2NPT 1

11 Li-1625 Cylinder Liner 1

12 HHP-S Hollow Hex Plug NPT 1

13 VAD-602359-M Discharge Valve 60 1

14 VAS-602359-M Suction Valve `60 1

15 VLD-3201 Valve Lantern (Discharge) 1

16 VLS-3201 Valve

bbr-3516 compressor service manual (cp)

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