Compressor Operation & Maintenance Manual

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Company IGL
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City/State INDIA
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Email Address
Site Location INDIA

Product Compressor BBR- 4216 Vol. 1(J1537)

Model No CO-BBR-4216-2
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 sales@intermech.co.nz
 REVISIONS RECORD

Revision Date Changes / Additions Issued

Jan,2006 New edition
 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 MANUFACTURER’S PLATE & LABEL INFORMATION .............................................................11
3.3.1 Specification Plate..........................................................................................................11
3.3.2 Cylinder Identification Plate ..........................................................................................12
3.3.3 Suction Identification Plate ............................................................................................12
3.3.4 Discharge Identification Plate........................................................................................12
3.3.5 Warning Plate.................................................................................................................13
3.3.6 Rotation Plate .................................................................................................................13
3.4 CLEARANCES .......................................................................................................................13
3.4.1 Original Running Clearances.........................................................................................13
3.4.2 Piston Ring Side Clearances / End Gaps........................................................................14
3.4.3 Piston to Cylinder Clearances........................................................................................16
3.4.4 Torque Settings ...............................................................................................................16
3.4.5 Rhino Compressor Tools ................................................................................................18
3.5 OPERATING PROCEDURES ....................................................................................................19
3.5.1 Start Up Check List Contents .........................................................................................19
3.5.2 Package Details..............................................................................................................19
3.5.3 Prior to Starting..............................................................................................................20
3.5.4 After Starting ..................................................................................................................21
3.5.5 Maximum Allowable Working Pressure .........................................................................21
3.6 LUBRICATION .......................................................................................................................22
3.6.1 General Description .......................................................................................................23
3.6.2 Oil Specification .............................................................................................................23
3.6.3 Before Starting................................................................................................................23
3.6.4 Top Up With Oil .............................................................................................................24
3.6.5 Primary Starting .............................................................................................................24
3.6.5.1 Priming the lubrication system using priming pump........................................................... 24
3.6.6 Oil Filter.........................................................................................................................25
3.6.7 Lube Oil Pressure Adjustment ........................................................................................25
3.6.8 Oil Relief Valve Setting...................................................................................................25
3.6.9 ..............................................................................................................................................26
3.6.10 Compression Cylinder & Rod seal. Injection Lubrication System............................26
4 MAINTENANCE........................................................................................................................27
4.1 GENERAL .............................................................................................................................27
4.2 OIL PUMP (CRA-357) & OIL PUMP HOUSING (CRA-352)...................................................28
4.2.1 Oil Pump Housing Drawing (CRA-352-1) .....................................................................28
4.2.2 Oil Pump Housing (CRA-352-1) Parts List ....................................................................29
4.2.3 Oil Pump Assembly Drawing (CRA-357) .......................................................................30
4.2.4 Oil Pump Assembly (CRA-357) Parts List......................................................................31
4.2.5 Oil Pump Relief Valve Drawing (CRA-333)...................................................................32
4.2.6 Oil Pump Relief Valve (CRA-333) Parts List .................................................................33
4.2.7 Disassembly – Oil Pump Housing ..................................................................................34
4.2.8 Disassembly – Oil Pump Relief Valve ............................................................................34
4.2.9 Disassembly – Oil Pump.................................................................................................34
4.2.10 Assembly – Oil Pump .................................................................................................35
4.2.11 Oil Pump Relief Valve................................................................................................35
 4.2.12 Assembly – Oil Pump Housing (CRA-352) ................................................................36
4.3 RHINO CRANKCASE (CRA-3603).........................................................................................37
4.3.1 Rhino Crankcase Drawing (CRA-3603) .........................................................................37
4.3.2 Rhino Crankcase Drawing (CRA-3602) .........................................................................38
4.3.3 Rhino Crankcase (CRA-3603) Parts List........................................................................39
4.3.4 Rhino Crankcase (CRA-3602) Parts List........................................................................39
4.3.5 Rhino Crankcase Filler Bowl Drawing (CRA-820)........................................................40
4.3.6 Rhino Crankcase Filler Bowl (CRA-820) Parts List ......................................................41
4.3.7 Disassembly – Crankshaft (CR-3253) ............................................................................42
4.3.8 Assembly – Crankcase (CRA-3603)................................................................................43
4.4 DRIVE END BEARING HOUSING / MECHANICAL SEAL ASSEMBLY (CRA-356)....................46
4.4.1 Drive End Bearing Housing / Mechanical Seal Drawing (CRA-356) ............................46
4.4.2 Mechanical Seal Housing (CRA-356) Parts List ............................................................47
4.4.3 Disassembly / Assembly - Mechanical Seal ....................................................................48
4.5 CROSS HEAD CYLINDER/PISTON (CYXA-6000) ..................................................................51
4.5.1 6” Cross Head / Cylinder Drawing (CYXA-6000) .........................................................51
4.5.2 6” Cross Head / Cylinder (CYXA-6000) Parts List........................................................52
4.5.3 6” Cross Head / Cylinder Drawing (CYXA-6005) .........................................................53
4.5.4 6” Cross Head / Cylinder (CYXA-6005) Parts List........................................................54
4.5.5 Disassembly - Cross-Head Cylinder/Piston ...................................................................55
4.5.6 Assembly - Cross-Head Cylinder/Piston ........................................................................55
4.6 1ST STAGE CYLINDER/PISTON / PISTON ROD ASSEMBLY ......................................................59
4.6.1 Cylinder Assembly Drawing – X-Section (CYA-4254-2) ................................................59
4.6.2 Cylinder Assembly Drawing – Exploded View (CYA-4254-2)........................................60
4.6.3 Cylinder Assembly (CYA-4254-2) Parts List ..................................................................61
4.6.4 Disassembly – (CYA-4254-2) .........................................................................................62
4.6.5 Assembly – (CYA-4254-2)...............................................................................................63
4.7 ROD SEAL HOUSING ASSEMBLY ..........................................................................................65
4.7.1 4.25” Seal Assembly Drawing (SEA-4250-3).................................................................65
4.7.2 4.25” Seal Assembly (SEA-4250-3) Parts List ...............................................................66
4.7.3 Disassembly ....................................................................................................................67
4.7.4 Assembly .........................................................................................................................67
4.8 2ND / 3RD STAGE CYLINDER/PISTON/PISTON ROD ASSEMBLY ................................................68
4.8.1 Cylinder Assembly Drawing – Exploded View (CYA-3216-3)........................................68
4.8.2 Cylinder Assembly - X-Section (CYA-3216-3)................................................................69
4.8.3 Cylinder Assembly (CYA-3216-3) Parts List ..................................................................70
4.8.4 Piston 3.25” x 1.625” Assembly Drawing (PIA –3216-2)..............................................72
4.8.5 Piston 3.25” x 1.625” Assembly (PIA –3216-2) Parts List ............................................73
4.8.6 Disassembly – Final Stage Cylinder / Piston .................................................................74
4.8.7 Disassembly – 2nd Stage Cylinder / Piston ....................................................................74
4.8.8 Assembly- 2nd / 3rd Stage Cylinder / Piston ..................................................................75
4.8.9 Rod Seal Housing Assembly – (SEA-3250).....................................................................77
4.8.10 Rod Seal Assembly – (SEA-3250) Parts List..............................................................78
4.8.11 Disassembly ...............................................................................................................78
4.8.12 Assembly ....................................................................................................................79
4.9 COMPRESSOR VALVES .........................................................................................................81
4.9.1 Removal ..........................................................................................................................81
4.9.2 Installation......................................................................................................................81

Table of Figures

Figure 1 Plan and Elevation of Three-Stage Compressor____________________________________7

Figure 2 Specification Plate _________________________________________________________11
Figure 3 Cylinder Specification Plate __________________________________________________12
Figure 4 Suction Identification Plate __________________________________________________12
Figure 5 Discharge Identification Plate ________________________________________________12
Figure 6 Warning Plate_____________________________________________________________13
Figure 7 Rotation Plate _____________________________________________________________13
Figure 8 Compressor Tools__________________________________________________________18
Figure 9 Oil Circulation Schematic ___________________________________________________22
 Table of Tables

Table 1 Specification Chart__________________________________________________________11

Table 2 Original Running Clearance __________________________________________________13
Table 3 Piston Ring End Gaps _______________________________________________________14
Table 4 Piston Ring Side Clearances __________________________________________________15
Table 5 Piston to Cylinder Clearances _________________________________________________16
Table 6 Torque Settings_____________________________________________________________17
Table 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).
Hoerbiger valves 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 pipe work 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 HIGHLY
DANGEROUS 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 and
entirely 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 e.g. 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. Only qualified and authorized persons may open the switchboard.
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 4216 compressor.

3.2 Design Specification

DESCRIPTION IMPERIAL UNITS

STROKE 3.25 inches
ROD 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 Manufacturer’s 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

Ring Gaps
Ring Material
Cast Iron Carbon Teflon * Peek
Min Max Min Max Min Max
Straight Cut 0.004 0.014 0.042 0.052 0.011 0.021
1.5
45º 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
1.625
45º 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
1.75
45º 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
3
45º Cut 0.004 0.014 0.058 0.068 0.014 0.024
Straight Cut 0.006 0.016 0.089 0.099 0.022 0.032
3.25
45º 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
3.5
45º 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
3.75
45º Cut 0.005 0.015 0.072 0.082 0.017 0.027
Clylinder Size

Straight Cut 0.007 0.017 0.116 0.126 0.028 0.038

4.25
45º 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
4.5
45º 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
4.75
45º Cut 0.005 0.015 0.091 0.101 0.022 0.032
Straight Cut 0.009 0.019 0.163 0.173 0.038 0.048
6
45º 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
6.5
45º 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
8
45º 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
8.25
45º 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
8.5
45º 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
10
45º Cut 0.010 0.020 0.191 0.201 0.044 0.054

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 300
Piston Rod to Crosshead 1" - UNF - 300
Final Stage Cylinder to C.E.Cylinder ¾" – UNC Stud 125
Final Stage Cylinder to C.E.Cylinder ¾" – UNF Stud 106
Final Stage Head ¾" – UNF Stud 140
Cylinder Head. 10" ¾" - UNF Stud 96
Cylinder Head. 6" Thru 8" ¾" - UNF Stud 96
Crosshead Cylinder To Crankcase ¾" - UNF Stud 105
Compression Cylinder To Crosshead ¾" - UNF Stud 112
Guide
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. 4-½" thru’ 3-1/2” 5/8" - UNC Cap Screw 51
Final Stage Discharge Valve Cover ½" - UNF Cap Screw 50
Cylinder Head. 3-1/4" thru’ 3” ½" - UNC Cap Screw 51
Valve Covers ½" - UNC Cap Screw 45
Oil Filter Housing ½" - UNC Cap Screw 53
Split Flange Clamps ½" - UNC Bolt 45
Conrod Bearing Cap ½ " - UNF Cap Screw 55

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Torque Settings Size Type Torque ft-lb

Drive Bearing Housing ½" - UNC Cap Screw 45
Oil Pump Housing to Crankcase ½" - UNC Cap Screw 45
Final Stage Piston Retaining Nut ½" – UNF - 30
Rod Seal Housing to Cylinder ½" – UNF Cap Screw 45
Rod Seal Housing to Cylinder 7/16" - UNF Cap Screw 40
Tandem Piston (5-1/4") to Crosshead 3/8" – UNC Cap Screw 25
Tandem Piston (3" to 3-1/2") to Piston 3/8" - UNF Cap Screw 27
Rod Lock Bolt
Split Flange Clamps 3/8" - UNF Cap Screw 20
Gudgeon Pin End-CapRetaining Bolt 3/8" UNF Bolt / Nut 30
Nut
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 5/16” - UNF Grub Screw 12
(10” Piston)
Piston Rod Balance Nut Lock Screw 5/16" UNF Grub Screw 12
(Power Nut type)
Piston Rod Balance Nut Lock Screw ¼" UNF Grub Screw 6
(Standard Balance Nut)
Piston Rod Locking Screw ¼" 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 THE

COMPRESSOR 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.
ALIGNMENT 11 Is the correct grade and quantity of oil available
RUN OUT 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
FAC with oil?
E
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:
OD
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
DIAL prior to initial start-up?
INDICATOR

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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 and 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 the
values 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 be
agreed 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 percent
or 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

The oil used in all Rhino compressors must be an SAE 40 compressor oil.
Listed below are some of the INTERMECH approved oils. The customer must
consult INTERMECH during the oil selection process.

SAE 40 Oils Approved

Caltex RPM 150
Shell Corena H 150
BP Energol RC 150

Note:
• The compressor has a capacity of 3.5 imp gallons (15 litres).
• Synthetic oils should not be 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.

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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 e.g. 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.

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

Theory
1/. There are two oil pressure relief valves The oil pressure relief valve in the
fitted to the Rhino compressor. One is flywheel housing must be fitted with a
located in the oil pump housing the other lighter spring than that used in the relief
in the flywheel bearing housing valve in the oil pump 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 This ensures that there is oil pressure at all
housing should lift first to maintain parts of the lubrication system, and that
desired oil pressure. oil flows through the mechanical seal
cavity (aids in cooling)

Setting the Oil Pressure

2/. Screw both oil pressure adjusting screws
in completely and back off about ¼ of the

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Instructions Cautionary Notes

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 the oil pump housing first, then the
adjust both screws up by one full turn flywheel housing relief.

8/. Unscrew the flywheel housing relief

screw until the oil pressure is 50psi

3.6.9

3.6.10 Compression Cylinder & Rod seal. 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
lubricator pump and the oil divider (distribution) blocks.
3. Oil is for the lubricator pump in the tanks situated on each side of the pump,
the oil level in these tanks must be monitored regularly.
4. The pump is serviced & maintained per the Lubricator pump service
manual.
5. Oil from the pump is delivered to the oil divider blocks.
6. The function of the divider blocks, is to deliver oil to the rod seals & all
stages of compression.
7. The oil is delivered through individual tubes and discharged through check
valves into each locaction.
8. A flow switch mounted on the divider block monitors delivery of oil. The
delivery is indicated, by the orange Cycle indicator, on the side of the
divider blocks.

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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, 2nd, and 3rd stage 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 free
cloths, 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)

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
Part Number Description Quantity
Number
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 10 HP50N 7/8"UNF Plug 3
6 CRA-333 Pressure Relief Valve (refer Item 16 also) 1
7 ORN-7117 O-Ring (Nitrile) 2
8 CR-3611 Sight Glass 2
9 ORN-7020 O-Ring (Nitrile) 2
10 CR-3622 Sight Glass Retainer 2
11 ORN-7119 O-Ring (Nitrile) 2
12 CR-3541 Oil Restrictor Plate 1
13 ORN-7228 O-Ring (Nitrile) 1
14 ORN-7271 O-Ring (Nitrile) 1
15 ORN-7272 O-Ring (Nitrile) 1
16 CR-3336 Spring Pressure Relief Valve (Strong) 1
17 CRA-357 Oil Pump Assembly 1
18 8-F5BU 7/8" Tube x 1/2"UNF Straight Connector 1
19 8 FNU 1/2" Blanking Cap - Ferulok 1
20 CR-3524 Wear Plate 1
21 KNC-0404 CSK Cap screw 1/4” UNC 1
22 12 F5BU-M 7/8" 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

Item
Part Number Description Quantity
Number
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" x 1" 1
9 CRA-3578 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

Item
Part Number Description Quantity
Number
1 CR-3335 Valve Plunger 1
2 Spring (see CRA-352 or CRA- 358 for part no.) 1
3 CR-3333 O-Ring Retainer 1
4 ORN-7114 O-Ring (Nitrile) 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 ½” cap screws (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 ½” UNF cap screw 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 4.2.7
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

Instructions Cautionary Notes

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 Use Plastigauge between impellor
assembly and oil pump retainer. See assembly and oil pump retainer to check
Clearance chart 3.4.1 clearance.
4. Oil the pump rotor with medium – heavy
oil and fit retainer.
Torque cap screws to 17 ft-lbs.
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 Oil Pump Relief Valve

Instructions Cautionary Notes

1. Fit new o-ring and back-up ring to o–ring Apply grease to o-rings
retainer.
2. Fit oil pressure relief valve plunger, Take care not to damage o-rings when
spring & o-ring retainer. inserting retainer.
3. Fit relief valve adjustment screw Adjust spring tension to ¾ of full travel of
adjustment screw.
OIL PRESSURE ADJUSTMENT MUST
BE CARRIED OUT AFTER
OVERHAUL OF RELIEF VALVE.
Refer sections 3.6.7 & 3.6.8

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4.2.12 Assembly – Oil Pump Housing (CRA-352)

Instructions Cautionary Notes

1. Clean & Oil all components before

assembly
2. Fit O-Ring (ORN-7228) to bronze
restrictor (CR-3541)
3. Fit bronze restrictor into oil pump housing

4. Fit seal cover cap and torque to17 ft-lbs.

5. Fit O-Rings to sight glasses. Apply grease to o-rings

6. Fit sight glasses; sight glass retainers and

O-Rings.
7. Fit O-Rings to oil pump housing. Grease o-rings.

8. Fit oil pump drive gear drive pin into

crankshaft.
9. Slide the oil pump driver gear over the This will be a firm slide fit.
crankshaft to line up with key.
10. Fit oil pump housing assembly. Ensure that oil restrictor plate remains in
place when carrying out this process.
11. Fit retaining screws and tighten to correct See Torque Setting Chart (section 3.4.4)
torque.

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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

Item
Part Number Description Quantity
Number
1 CR-3603 Taper Locking Bearing Crankcase 1
2 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
6 BRS-9052-C4 Spherical 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 1/2”UNC x 1.5” lg 32
14 CNC-0612 Cap screw 3/8”UNC 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

Item
Part Number Description Quantity
Number
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 Rhino Crankcase Filler Bowl Drawing (CRA-820)

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

Item
Part Number Description Quantity
Number
1 1/4 HP-S 1/4"NPT Plug 1
2 CR-821 Top Plate 1
3 CNC-0628 Cap screw 3/8" x 3-1/2" 4
4 CR-8221 Filler Bowl 1
5 CPE-05 Circlip External 3/8" 1
6 ORN-7010 O-Ring Nitrile 2
7 ORN-7011 O-Ring Nitrile 4
8 VAN-073 Seal Teflon 1
9 CR-803 Spring 1
10 CR-805 Regulating Piston 1
11 ORN-7218 O-Ring Nitrile 1
12 ORN-7137 O-Ring Nitrile 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 Mesh 1
18 ORN-7266 O-Ring Nitrile 1
19 CPE-10E Circlip External 5/8" 1
20 CPE-M72 Circlip Internal 72mm 2

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4.3.7 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 in this section.
5. Remove the oil pump housing and the oil pump as described in 4.2.7
6. Remove the mechanical seal assembly as described in4.4.3.
7. Remove mechanical seal drive pin from crankshaft.
8. Remove the oil pump end crankshaft main bearing retainer plate.
9. Making sure there is support for the crankshaft at both ends and using a
series of increasing length bolt or cap screws screwed in to the jacking
threads in the bearing housing, pull the crankshaft and drive end bearing
housing from the crankcase as one piece.
10. Carefully lift the crankshaft from the drive end of crankcase.
11. 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.
12. Check the main bearings for wear. Replace if necessary. To remove
bearings use a hydraulic ram puller.

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4.3.8 Assembly – Crankcase (CRA-3603)

Crankcase Assembly Procedures

Clean inspect and oil all components Ensure 1/8 Dry Seal plugs are fitted into 2 (*)
locations on crankshaft.

I. Fitting Main Bearing to Crankshaft

1 Heat bearings for 2 hrs to 110oC
2 Place ∅160 internal circlip over drive end Ensuring that it is hard against the
of crankshaft and slide bearing onto this crankshaft shoulder.
journal. C3 Type. This is best achieved by having the
Minimum bearing clearance 0.0015” crankshaft in a vertical position.
3 When the drive end bearing is cool (*)
enough so that it is locked onto the
crankshaft, 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 From the side that has the lead in chamfer (*)
plate retainer.
3 Assemble oil pressure relief value into its All items to be lubricated before (*)
hole, by inserting the shuttle, spring then assembly.
retainer (with O ring fitted then backup USE LIGHT SPRING. CR-3334
ring), locate in place with retaining bolt
and adjust screw.
4 Fit plug (8HP50N-S) to bottom drilling Ensure the Hollow Hex Plug is inserted (*)
and hollow hex head plug to (6HP50N-S) below flush.
into outer seal cover face.
5 Tap 1/8 x ¾”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. Ensuring plastic hose is fitted over the (*)
Fitted O ring in recess on end of tube. tube between bulkheads and webs of
crankcase.

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3 Fit O rings (ORN-7271 + ORN-7272) into (*)

groove and flywheel housing and corner
of flywheel housing and lightly grease,
and O ring (ORN-7206) into oil relief
valve recess on face of housing.
4 Fit both pieces of bearing carrier as one Tighten cap screws to 25 Ft-lbs Sign as
unit into crank case torqued
Sit on back and lower Crank Case / Drive Tighten ½” cap screws that hold drive Sign as
housing assembly into crank case housing in place to 45 Ft-lbs torqued

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 ¼” cap screws in rear bearing Once bearing clearance is reduced by Sign as
cover to 3.5 ft-lbs 0.001” screw in 4 x SSF0608 set screws torqued
Tighten ¼ Clamp bolts in bearing carrier and nip. Sign as
to 9.5 Ft/lbs torqued
Minimum bearing clearance 0.002”
Tighten ¼ cap screws in bearing carrier to Sign as
12 ft/lbs 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 Procedure number: PRA-008
assembled as per assembly procedure. (Oil Pump Housing CRA-352-1
Assembly)
2 Oil pickup filter assembly is fitted from This needs to be carried out prior to (*)
the inside of the crankcase. Its tube is installing CRA-3640
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.
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 is
on the face of oil pump gear.

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4 Fit pin key into crankshaft and slide the This will be a firm slide fit. Ensure that (*)
oil pump driver gear over the crankshaft this gear is correctly located against
to line up with key. restrictor plate.

5 Fit O rings to end of oil tube & oil pickup Ensure that the crankshaft does not push
(in recesses provided) and at oil filter feed out of its seat, the restrictor inside oil
drillings on face of crankcase and ease oil pump housing.
pump housing (CRA-352) over crankshaft
and into is correct position against
crankcase.
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 Use Loctite 243
beside oil spigot
2 Insert oil filter spigot and nip to the Screw grub screw into filter housing with (*)
bottom of its thread. Lubricate seal on oil Loctite 271
filter with a thin film of grease and screw
onto spigot. Tighten firmly hand tight.
3 Grease lightly the O-ring on the oil filter Use O-ring 7156 (*)
cover and fit to crankcase. Torque cap
screws to 60 ft. lb, and mark as torqued.

ASSEMBLIED BY: SIGNATURE: DATE:

COMMENTS:

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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)

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4.4.2 Mechanical Seal Housing (CRA-356) Parts List

Item
Part Number Description Quantity
Number
1 CNC-0510 Cap screw 5/16” UNC x 1-1/4” lg. 6
2 CR-3286 Seal Gland Plate (Burgmann) 1
3 CR-3276 Wear Bush 1
4 ORMN78020 O-Ring (Nitrile) Metric 80x2 1
5 ORN-7246 O-Ring (Nitrile) 1
6 6Hp50N-S Hex Plug 1
7 SEL-8510510 Lip Seal 1
8 ¼ HHP-S Dryseal Plug ¼”NPT 1
9 SEM-H7N/80-00 Mechanical Seal Assembly 1
10 CR-3531 Mechanical Seal and Bearing Housing 1
11 ORN-7271 O-Ring (Nitrile) 1
12 ORN-7270 O-Ring (Nitrile) 1
13 CR-3302 Oil Metering Plate 1
14 ORN-7239 O-Ring (Nitrile) 1
15 CR-3301 Oil Metering Plate Retainer 1
16 BRS-9052 Self Aligning Bearing 1
17 CPI-160 Circlip Internal (160 dia. Groove) 1
18 CRA-333 Pressure Relief Valve assembly 1
19 PNR-F0-43234 Roll Pin 1/8” dia x ¾” lg. 1
20 CR-3334 Spring –Pressure Relief Valve (Weak) 1
21 SSM-305 Socket Set Screw M3 x 5 lg. 3
22 ORN-7206 O-Ring (Nitrile) 1
23 4-F5BU-S Straight Thread Tube Connector ¼” T x 7/16”UNF 1
24 4 HP50N-S Hollow Hex Plug 7/16”UNF O-Ring seal 1
25 CR-3287 Anti-Rotation Pin 1
26 SSF-0506 Grub Screw 5/16”UNF x 3/8” lg. 1
27 CR-3259 Anti-Rotation Pin 1
28 SEM-H7N-SPACER Spacer 1

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4.4.3 Disassembly / Assembly - Mechanical Seal

Instructions Cautionary Notes

REMOVAL

1 Remove drive coupling “spider”.

2 Remove coupling hub from compressor Before removing the flange, check
by firstly removing the flange from the the distance between the hub on the
hub then sliding the hub off the shaft. The motor and the hub on the
flange will probably need to be jacked off compressor. The distance should be
using jacking screw holes provided on the between 116.5mm & 116.8mm.
flange. Once the flange is removed, the After installing the new mechanical
hub will need to be spread a little using a seal and refitting the coupling hub
screwdriver to allow the hub to be slid off to the shaft, the distance between
easily. the hubs should equal this distance
(see coupling hub drawing
attached).
3 Remove key from shaft.
4 Remove wear bush (CR-3276) from shaft. Be careful not to damage the small
o-ring on the inside of this sleeve.
5 It is important to protect mechanical seal Slide card onto crankshaft through
faces from damage while removing / lip seal cavity up to crankshaft
installing. Heavy paper or thin card must shoulder.
be wrapped around crankshaft before
mechanical seal gland housing (CR-3286)
is removed.
6 Rotate compressor crankshaft until drive This ensures that the mechanical
keyway is at the top. seal drive pin is at the top and
cannot fall out when Spring
Assembly is removed.
7 Remove mechanical seal gland housing
from drive end bearing housing.
8 Remove dynamic part of seal (Silicon To do this, 2 “wire pullers” should
Carbide Ring) along with Spring be hooked behind Spring Assembly
Assembly. 180 deg apart. The Spring
Assembly / Silicon Carbide Ring
can then be removed as an
assembly. Ensure that protective
card is wrapped around crankshaft
while removing this assembly.
9 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.

10 Clean out drive end bearing housing

where mechanical seal is located.

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Instructions Cautionary Notes

INSTALLATION

1 Ensure all components are clean and No scratches, dents or chips are
inspected for serviceability. permitted.
Avoid touching the lapped surfaces.
2 Fit mechanical seal spacer onto the
crankshaft with tapered face toward the
compressor.
3 Fit seal drive pin (13.8mm) Ensure a piece of card is placed
underneath the crank to catch the
pin if dropped. This stops pin
dropping into the oil galleries.
4 Fit drive spring of mechanical seal onto This must be correctly and fully
crankshaft. engaged to allow the seal to locate
against the crankshaft shoulder.
5 Slide the carbide rotating face onto the Ensure the O-ring is lightly oiled.
crankshaft and align the drive slots with Wrap a piece of plastic over the
the steps on the drive spring assembly. shaft to protect the carbide.
Press evenly on carbide and locate on step
on shaft.
6 Drive the 4mm roll pin into the seal gland The hole used is the bottom hole
plate so that it protrudes 5-6mm out of the i.e. without scallop.
hole. Fit the ¼ HHPS plug behind.
7 Fit the rotary lip seal to the seal gland Ensure it is pressed in flat.
plate. Fit O-ring 7246 to outside.
8 Place the O rings inside the mechanical The O-ring is supplied with the
seal retaining flange and lubricate. mechanical seal.
9 Carefully insert the bronze stationary face Take care not to mark the seal face.
into the retaining flange.
10 Carefully line up mechanical seal plate Lightly lubricate shaft so lip seal
with bronze face as a set and gently slide slides over shaft without damage.
over shaft and into the drive end bearing Crank keyway must be free of
housing. Use a bit of plastic around crank sharp edges and burrs. Ensure lip-
and fit bottom edge first. seal spring is not caught when
starting lip-seal over crank end.
11 Fit flange retaining cap screws, screw size Must be screwed in progressively to
& type - CNC0510. Torque to 17 ft lbs. avoid wedging and damaging seal
face. Oil hole to topside of housing
pointing to HP side.
12 Slide the coupling hub into place on shaft
13 As detailed above, it is most important to
have correct distance between the motor
hub and the compressor hub. To get the
correct distance the hub should be set at a
distance of 135.75mm from the motor
hub.
14 Lightly clamp the hub to the shaft by This will stop the hub moving when
tightening the cap screws on the hub. the flange is fitted.
15 Fit Coupling Flange and tighten cap
screws.

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Instructions Cautionary Notes

16 Check that distance between coupling hub The distance must be between
“flanges” is correct. 116.9mm & 117.1mm.
17 Ensure that drive coupling hub locking
bolts are tightened to correct torque.
18 Re-fit coupling “spider”

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4.5 Cross Head Cylinder/Piston (CYXA-6000)

4.5.1 6” Cross Head / Cylinder Drawing (CYXA-6000)

(CYXA-6000 for Low Pressure side)

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4.5.2 6” Cross Head / Cylinder (CYXA-6000) Parts List

Item
Part Number Description Quantity
Number
1 BNF-0644 Bolt 3/8"UNF x 5-1/4" 1
2 CYX-6452 X-Head Cylinder 6” 1
3 NNF-12 Nut 3/4"UNF 6
4 NNF-C06 Nut 3/8"UNF Cone Nut 1
5 ORN-7262 O-ring N70 262 (Nitrile) 1
6 PIX-6062 6" Cross-head Piston (CI SDF Coating) 1
7 PNR-0405 Roll Pin 1/8" x 5/16" lg 2
8 RO-2534 Gudgeon Pin 2.5" 1
9 RO-2535 End-plate for 2.5” Gudgeon 2
10 ROA-8525 Con-rod Assembly 1
11 STN-1224 Stud 3/4"UNF x 3" UNC 6

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4.5.3 6” Cross Head / Cylinder Drawing (CYXA-6005)

(CYXA-6005 for High Pressure side)

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4.5.4 6” Cross Head / Cylinder (CYXA-6005) Parts List

Item
Part Number Description Quantity
Number
1 BNF-0644 Bolt 3/8"UNF x 5-1/4" lg 1
2 CYX-6451 X-Head Cylinder 6” 1
3 NNF-12 Nut 3/4"UNF 6
4 NNF-C06 Nut 3/8"UNF Cone Nut 1
5 ORN-7262 O-ring N70 262 (Nitrile) 1
6 PIX-6081 6" Cross-head Piston (Heavy Version) 1
7 PNR-0405 Roll Pin 1/8" x 5/16" lg 2
8 RO-2535 End-plate for 2.5” Gudgeon 2
9 RO-2536 Gudgeon Pin 2.5" Solid c/w RO-2537 Gallery Plug 1
10 ROA-8525 Con-rod Assembly 1
11 STN-1224 Stud 3/4"UNF x 3" UNC 6

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4.5.5 Disassembly - Cross-Head Cylinder/Piston

1. Decompress and degas the compressor.

2. Remove low-pressure compression cylinder assembly (ref.4.6.4) and/or
high pressure cylinder assembly (ref4.8.6)as per procedures detailed in this
section.
3. Remove oil filler bowl (CRA-820 section4.3.5) 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 con-rod. Take note of top of con-rod
and top of crosshead piston. (Con-rod 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. So that 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.

4.5.6 Assembly - Cross-Head Cylinder/Piston

Instructions Cautionary Notes

1. All components to be cleaned and oiled Check for damage

before assembly
2. Fit o-ring (ORN-7262) into corner of Lightly grease o-ring
cross head cylinder
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 Check clearance of crankshaft
Setting Chart (section 3.4.4)) counterweight on skirt of cylinder.
5. Position the con-rod (ROA-8525) inside Ensure that high pressure side cross head
the cross head piston (con-rod serial # to piston is fitted to high pressure throw and
the top). Align gudgeon pin holes and fit low pressure side cross head piston is
gudgeon pin. 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

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Instructions Cautionary Notes

side only, there are oil holes drilled into

the grooves. The side of the piston that
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 thrust
side on the low pressure throw is at the
bottom.
6. Fit Gudgeon end plates (RO-2535) and Locknut torque = 30 ft-lb
retain with bolt (BNF-0644) and lock nut
(NNF-C06).
7. Fit big end bearing shells to con-rod and
end-cap.
8. Slide con-rod / cross-head piston Ensure that con-rod serial # faces the top.
assembly into cross-head cylinder. 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 Do not rotate crankshaft with plastic
clearance by placing Plastigauge strip gauge fitted or faulty readings will result.
between end-cap bearing shell and
crankshaft journal then tightening end-cap
bolts to correct torque.
10. After checking clearance, lubricate See Torque Setting Chart (section 3.4.4)
bearing shells and crankshaft bearing
journal. Then re-fit bearing cap and
tighten retaining bolts to correct torque.
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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Instructions Cautionary Notes

13. With cross head piston at top of stroke, High pressure 1.-
use feeler gauge and record clearances at
corners of skirt as per sketch. 2.-

3.-

4.-

Low pressure 1.-

2.-

3.-

4.-

Acceptable clearance are when are

equal and are equal also.

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4.6 1st Stage Cylinder/Piston / Piston Rod Assembly

4.6.1 Cylinder Assembly Drawing – X-Section (CYA-4254-2)

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4.6.2 Cylinder Assembly Drawing – Exploded View (CYA-4254-2)

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4.6.3 Cylinder Assembly (CYA-4254-2) Parts List

Item Part Number Description Quantity
1 CYXA-6000 Cross-Head Cylinder Assembly 1
2 SEA-4250-3 4.25” Seal Assembly 1
3 CY-4254 4.25” Cylinder 1
4 RIS-4000 Piston Support Ring 1
5 ROP-4000 4.00” – 4.75” Piston Rod 1
6 HE-4250-1 4.25” Head Upper End (35% Clearance) 1
7 PI-4251 4.25” Piston 1
8 RIC-426632 4.25” Compression Ring 4
9 RIR42B231 Rider Ring 1
10 GKV-09108510 Gasket Aluminium (79RX) 4
11 GKV-12311020 Gasket (Aluminium) 1
12 VAS-796719-P Suction Valve ‘79’ 2
13 VAD-796719-P Discharge Valve ‘79’ 2
14 VLS-4002 Valve Lantern (Suction) 2
15 VLD-4002 Valve Lantern (Discharge) 2
16 5151HK-32 Split Flange 2” 2
17 HE-4555 Cylinder Stub (Slit Flange) 2” – Weld 1
18 HE-4557 Thermowell Cap (Split Flange) 1
19 HE-4553 Cover (Suction Port) 1
20 HE-8000 Valve Cap 4
21 CNC-0812 Capscrew 1/2” UNC x 1.5” lg 20
22 CNC-0816 Capscrew 1/2” UNC x 2” lg 8
23 CNC-1016 Capscrew 5/8” UNC x 2” lg 4
24 ORN-7267 O-ring 267 1
25 ORV-7237 O-ring 237 4
26 ORV-7242 O-ring Viton 242 1
27 ORV-7228 O-ring Viton 70 2
28 ORN-7230 O-ring 230 2
29 STN-1224 Stud 3/4” UNF x 3” UNC 6
30 NNF-12 Nut 3/4” UNF 6
31 1/4-HHP-S Hollow Hex Plug 1/4” NPT 3
32 RPN-087 0.875” Jam Nut Assembly 1
33 RPN-100 1” Jam Nut Assembly 1
34 10 HP50N-S Hollow Hex Plug (Incl. O-ring) 1

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4.6.4 Disassembly – (CYA-4254-2)

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 (power nut), by loosening grub
screws then unscrewing power nut and washer.
5. Remove first stage piston.
6. Slide piston complete with piston rings from cylinder.
7. Check condition of the bore, i.e. check for score marks and check bore
diameter.
8. Check condition of piston rings.
9. Remove 3/4" UNF cylinder retaining nuts at crosshead cylinder.
10. Carefully slide cylinder off piston rod.
11. 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.
12. Inspect piston rod for damage.
13. Before removing piston rod, take note of distance from top of rod to top of
piston rod locking (power) nut.
14. Loosen locking nut by loosening grub screws.
15. Remove piston rod.

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4.6.5 Assembly – (CYA-4254-2)

Instructions Cautionary Notes

1 Screw piston rod locking (power) nut Set distance between top of rod and
onto piston rod. top of balance nut to the same
distance as it was before rod was
removed.
2 Screw piston rod and locking nut
assembly into X-head piston until
locking nut makes contact with top of
X-head piston.
Tighten locking (power) nut grub Torque grub screws progressively to
screws 12 ft-lb.
5 Fit o-ring (ORN7267) into groove on Lightly lubricate o-ring.
compression cylinder face.

8 Fit tapered rod seal guide (special Lightly oil outside of guide.
tool # TL-0061 - see section 3.4.5.)
over end of piston rod.
9 Slide cylinder assembly over rod and Ensure that cylinder is right way up
onto spigot of cross head cylinder. i.e. Discharge valves towards drive
Tighten retaining nuts to correct motor.
torque (See Torque Setting Chart
section 3.4.4).
Remove rod seal guide from piston
rod.
Fit the piston to piston rod (without Ensure that piston support ring is
piston rings). placed in position on rod before
fitting piston.
Fit piston locking (power) nut and
tighten grub screws to approximately
6ft/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 Use feeler gauges fed through HE &
at top and bottom of stroke CE valve pockets to check
respectively. 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 End
Gaps)

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Instructions Cautionary Notes

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 Ensure crank is at bottom of throw.
into cylinder. Take care not to damage rings.
15 Fit piston locking (power) nut
16 Tighten locking (power) nut grub Torque grub screws progressively to
screws 12 ft-lb.
17 Fit head to cylinder and tighten Ensure that bevelled areas of head are
retaining screws to correct torque. in line with valve pockets (i.e. in
vertical position).

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4.7 Rod Seal Housing Assembly

4.7.1 4.25” Seal Assembly Drawing (SEA-4250-3)

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4.7.2 4.25” Seal Assembly (SEA-4250-3) Parts List

Item Part Number Description Quantity

1 SEC-4251 4.25” Seal Cup 1

2 SEB-4625 Seal Block 1
3 ORN-7143 O-ring Nitrile 7143 1
4 SEB-4041 Seal Block Face 1
5 CNF-0506 Capscrew 5/16”UNF x 0.75” lg 8
6 ORV-7242 O-ring Viton 242 1
7 SER-1805 P1U Pressure Breaker 1
SER-1805-
8 BTU Seal 2
BTUU
9 SEW-1805-RTV RTV Seal 0.1 Wiper 1
10 CNF-0814 Capscrew ½”UNF x 1.75” lg 8
11 ORN-7106 O-ring Nitrile 70 2
12 ORV-7248 O-ring Viton 7248 1
13 SEC-4252-1 4.25” Wiper Seal Retainer 1
14 SEB-4040-H Seal Block with hole 1
15 BRB-040 Sealing Plug 4
16 PNR-0204 1/16” x 1/4” Roll Pin 2

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4.7.3 Disassembly

1. Remove Wiper Seal Retainer (Item 13), Wiper (Item 9) & Seal Block Face
(Item 4)
2. Remove BTU Rod Seals (Item 8), Seal Blocks (Items 2 & 14) and Pressure
Breaker (Item 7).
3. Check condition of all Rod Wipers, Seal Blocks, Rod Seals, Pressure
Breakers, O-Rings, etc.
4. Remove Seal Cup retaining screws (Item 10).
5. Remove Seal Cup (Item 1) from compression cylinder.
6. Check condition of O-rings.

4.7.4 Assembly

1. Place Pressure Breaker (Item 7) 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 14) and second BTU Rod Seal into Seal
Cup. Ensure that Seal Block Alignment Pin (Item 16) locates correctly.
4. Fit O-Ring (Item 3) and Seal Block Face (Item 4) to Seal Cup.
5. Fit RTV Wiper Seal (Item 9) into Seal Cup.
6. Fit Wiper Retainer (Item 13). Lightly tighten cap screws.
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.
9. Tighten Wiper Retainer cap screws to 18ft/lb.

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4.8 2nd / 3rd Stage Cylinder/Piston/Piston Rod Assembly

4.8.1 Cylinder Assembly Drawing – Exploded View (CYA-3216-3)

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4.8.2 Cylinder Assembly - X-Section (CYA-3216-3)

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4.8.3 Cylinder Assembly (CYA-3216-3) Parts List

Item
Part Number Description Quantity
Number

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

2 CY-2751 Cylinder Final Stage 1
3 CYXA-6005 X-Head Cylinder Assy.Solid Gudgeon 1
4 HE-3045 Head Final Stage 1
5 ROPA-3280 Piston Rod Assembly 1
6 SEA-3250 3.25” Seal Assembly 1
7 HE-4553 Cover (Suction Port) 1
8 HE-3031 Valve Cap 4
9 PIA-3216-2 Piston Assembly (3.25” x 1.625”) 1
10 HE-4555 Cylinder Stub (Split Flange) 2” – weld 1
11 Ll-1625 Cylinder Liner 1
12 1/4-HHP-S Hollow Hex Plug 1/4” 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 Lantern (Suction) 1
17 GKS-7670 Gasket Stepped for 30R1/54C Valve 1
18 GKV-04503511 Gasket Aluminium for VAC-54 Series 1
GKV-07006310-
19 Gasket for VAC-54 Series (Steel) 1
S
20 GKV-07006510 Gasket Aluminium (60RX) 1
21 GKV-07006530 Gasket Aluminium (60RX) 1
22 5151HK-16 1” Split Clamp 2
23 HE-4557 Thermowell Cap (Split Flange) 1
24 HE-1758 Weld Adaptor (For 1” Split Flange) 1
25 ORV-7219 O-ring Viton 70 2
26 ORV-7228 O-ring Viton 70 2
27 ORV-7230 O-ring Viton 70 2
28 ORV-9230 O-ring Viton 9230 4
29 ORV-7232 O-ring Viton 70 1
30 ORV-7236 O-ring Viton 7236 1
31 ORN-7258 O-ring N70 1
32 VAC-545387 Concentric Valve 1
33 5151HK-32 2” Split Clamp (Parker) 2
34 NNF-12 Nut 3/4" UNF 6

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Item
Part Number Description Quantity
Number

35 NNFR-12 Nut Reduced Hex. 3/4” UNF 6

36 CNF-0610 Capscrew 3/8“ UNF x 1.25” lg 8
37 CNC-0816 Capscrew 1/2” UNC x 2” lg 8
38 CNC-0812 Capscrew 1/2” UNC x 1.5” lg 32
39 STN-1274 Stud 3/4” UNC x 3/4” UNF x 9- 1/4” lg 6
40 STN-1224 Stud 3/4” UNF x 3” UNC 6
Seal Housing Ring for Dia 3.25” D.A.
41 SEB-3254 1
Cylinder
42 ORV-7153 O-ring Viton 1

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4.8.4 Piston 3.25” x 1.625” Assembly Drawing (PIA –3216-2)

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4.8.5 Piston 3.25” x 1.625” Assembly (PIA –3216-2) Parts List

Item
Part Number Description Quantity
Number
1 RIC-324432 Compression Ring 3.25” 1
2 RIC-324435 Sealing Ring 3.25” 2
3 RIR-328Q31 Rider Ring 3.25” 1
4 RIR-168L31 1.625” Rider Ring 1
5 RIC-164455 Sealing Ring 1.625” 2
6 RIC-162252 1.625” Compression Ring 3
7 CNC-0508 Cap screw 5/16” UNC x 1” lg 5
8 PI-3250-2 3.25” HP Piston 1
9 RIS-3030 Piston Support Ring 1
10 ROPW-1502 Retaining Plate 1
11 SSF-0404 Socket Set Screw (Grub) 1/4” UNF x 1/2” lg 2

12 PI-1625 1.625” Piston 1

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4.8.6 Disassembly – Final Stage Cylinder / Piston

1. Remove final stage discharge pipe and 2nd stage separator.
2. Remove final stage head (HE-3045)
3. Remove final stage concentric valve.
4. Remove final stage cylinder.
5. Unscrew final stage piston retaining plate screws (CNC-0508).
6. Remove final stage piston.
7. Check condition of final stage piston rings and piston.
8. Check condition of final stage cylinder liner.
9. Check condition of final stage cylinder o-ring (ORV-7232)

4.8.7 Disassembly – 2nd Stage Cylinder / Piston

1. Remove 2nd stage discharge pipe and 1st stage separator.
2. Remove 2nd stage piston locking screw (CNF-0508)
3. Unscrew piston from piston rod using special tool provided (special tool #
TL-0059 - see section3.4.5.).
CAUTION: When unscrewing the piston, ensure that piston rings do not
get caught in head end valve pockets. To prevent this occurring, roll over
the machine until piston is approximately in middle of stroke. Then
unscrew the piston.
4. Remove 2nd stage cylinder retaining nuts.
5. Carefully slide cylinder assembly off piston rod.
CAUTION: Take care when lifting the cylinder off the piston rod. Rod
packings (seals) 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 off.
6. Before removing piston rod, take note of distance from top of rod to top of
balance nut.
7. Loosen balance nut locking screws.
8. Loosen balance nut using special tool provided (TL-0060).
9. Remove piston rod.
10. Check condition of piston rod.

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4.8.8 Assembly- 2nd / 3rd Stage Cylinder / Piston

Instructions Cautionary Notes

1 Fit balance nut to 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 Fit piston rod to X-head piston. Screw rod in until balance nut meets X-
head piston.
3 Tighten balance nut to 300 ft-lbs
using special tool provided. (TL-
0060)
4 Tighten balance nut locking screws. Tighten until allen key twists out of shape.
8 Fit o-ring (ORN-7258) to bottom of
cylinder.
9 Fit tapered rod seal guide (special Lightly oil outside of guide.
tool # TL-0061 - see section 3.4.5.)
special tool) over end of piston rod.
10 Slide cylinder assembly over rod and Ensure that cylinder is right way up i.e.
onto spigot of cross head cylinder. discharge valves towards drive motor.
Tighten retaining nuts 125 ft-lbs
11 Check that 2nd stage piston ring side
clearances and end-gaps concur with
clearances detailed in Table 3 Piston
Ring End Gaps
12 Fit piston rings to piston. Orientate piston ring end-gaps, 180 deg to
each other.
13 Remove rod seal guide from piston
rod.
15 Oil piston rings generously and ease Ensure crank is at bottom of throw. Take
into cylinder. care not to damage rings.
16 Screw piston onto rod. Torque to 180 Roll over machine until piston is at top of
ft lb. using special tool provided. stroke for final torquing of piston
17 Check piston clearance at crank end. Clearance between bottom of piston and
rod seal cup should be between 0.045”-
0.060”.
18 Lock piston in place by tightening
locking screws.
19 Fit final stage piston and lock in Use Loctite on cap screws.
place using retaining plate. Tighten
retaining plate screws to 22 ft-lbs.
20 With retaining plate screws tight, the If piston is tight, bottom “flange” of
final stage piston should be free to piston will need to be lapped.
move (“float”)
21 Check that final stage piston ring side
clearances and end-gaps concur with
clearances detailed in Table 3 Piston
Ring End Gaps)
22 Fit piston rings to piston. Orientate piston ring end-gaps, 180 deg to
each other.

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23 Oil piston rings generously.

24 Fit o-ring (ORV-7236) into groove in Ensure o-ring is greased.
bottom of final stage cylinder.
25 Slide final stage cylinder over piston. Ensure that cylinder is right way up.
26 Fit concentric valve bottom gasket
(GKS-7670) to final stage cylinder.
27 Fit concentric valve top inner gasket
(GKV-04503511) to valve and top
outer gasket (GKV-07006310-S) to
valve recess in final stage head.
28 Fit concentric valve to final stage Ensure that valve gaskets remain in place.
head.
29 Slide final stage head over studs onto
final stage cylinder.
30 Tighten head retaining nuts to 140 ft- Tighten head nuts incrementally starting
lbs at approximately 80 ft-lbs increasing
torque by 10 ft-lbs at a time until full
torque is reached.

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4.8.9 Rod Seal Housing Assembly – (SEA-3250)

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4.8.10 Rod Seal Assembly – (SEA-3250) Parts List

Item Part Number Description Quantity

1 SEC-3250 3.25” Seal Cup 1

2 SEB-4625 Seal Block 1
3 SEB-4041 Seal Block Face 1
4 CNF-0506 Cap Screw 5/16”UNF x 0.75” lg 8
5 ORV-7242 O-ring Viton 242 1
6 SER-1805 P1U Pressure Breaker 1
SER-1805-
7 BTU Seal 2
BTUU
8 SEW-1805-RTV RTV Seal 0.1 Wiper 1
9 CNF-0814 Cap screw ½”UNF x 1.75” lg 6
10 ORN-7106 O-ring Nitrile 70 - 106 2
11 ORV-7238 O-ring Viton 70- 238 1
12 BRB-040 Sealing Plug 4
13 SEB-4040-H Seal Block with hole 1
14 ORMV-706030 O-Ring Viton 70 60 x 3.00 1
15 SEC-4252-2 3.25” - 3.5” Wiper Seal Retainer 1
16 PNR-0204 1/16” x ¼” Roll Pin 2

4.8.11 Disassembly

7. Remove Wiper Seal Retainer (Item 15), Wiper (Item 8) & Seal Block Face
(Item 3)
8. Remove BTU Rod Seals (Item 7), Seal Blocks (Items 2 & 13) and Pressure
Breaker (Item 6).
9. Check condition of all Rod Wipers, Seal Blocks, Rod Seals, Pressure
Breakers, O-Rings, etc.
10. Remove Seal Cup retaining screws (Item 9).
11. Remove Seal Cup (Item 1) from compression cylinder.

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12. Check condition of O-rings.

4.8.12 Assembly

10. Place Pressure Breaker (Item 6) into Seal Cup.

11. 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.
12. Place Seal Block with hole (Item 13) and second BTU Rod Seal into Seal
Cup. Ensure that Seal Block Alignment Pin (Item 16) locates correctly.
13. Fit O-Ring (Item 14) and Seal Block Face (Item 3) to Seal Cup.
14. Fit RTV Wiper Seal (Item 8) into Seal Cup.
15. Fit Wiper Retainer (Item 15). Lightly tighten cap screws.
16. Fit O-rings to Seal Cup. Ensure that O-rings are lubricated.
17. Fit aluminium gasket (part of cylinder assembly) to cylinder then fit Seal
Housing assembly to cylinder. Torque Seal Housing Retaining Screws to
45ft/lb.
18. Tighten Wiper Retainer cap screws to 18ft/lb.

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4.9 Compressor Valves

4.9.1 Removal
1. Decompress and degas the compressor.
2. Loosen valve cap screws.
Note: Do not totally remove the valve cover bolts. Unscrew bolts to a
point where the valve cover can be moved outwards to a position where
the valve cap o-ring seal is clear of the valve pocket. This will allow
residual gas in the valve pocket to escape.
3. Remove valve cap retaining bolts and valve cap.
4. Remove valve lantern ring.
5. Use the valve tool provided to extract the valve.
6. Remove valve gasket.
7. Check condition of valve gasket and valve cap o-ring.
8. Check condition of valve.

4.9.2 Installation
1. Ensure that valve is in good condition before re-installing. Re-kit valve as
required by maintenance schedule. Replace complete valve if required.
2. Fit valve with new gasket. Smear Anti-seize grease on valve gasket before
installing valve.
3. Fit lantern ring. Ensure that valve and lantern are correctly located in valve
pocket.
4. Fit valve cover with new o-ring if required. Ensure that o-ring is greased.
5. Tighten valve cover bolts evenly to the correct torque setting.

INTERMECH Ltd. BBR-4216 Compressor Service Manual