ARIELHeavy Duty

Balanced OpposedCompressors

TECHNICAL MANUALFor Models:

JGZ and JGU

ARIEL CORPORATION35 BLACKJACK ROAD, MOUNT VERNON, OHIO 43050

TELEPHONE: 740-397-0311 FAX: 740-397-3856

MORE INFORMATION AND RESOURCES ARE AVAILABLE ON OUR WEB SITE: www.arielcorp.com

REV: 7/09

WHEN THIS SYMBOL APPEARS ON THE COMPRESSOR OR CONTROL PANEL, THIS TECHNICAL MANUAL IS TO BE CON-SULTED FOR SPECIFIC INFORMATION BEFORE PROCEEDING. IF MORE INFORMATION IS NEEDED CONTACT YOUR PACK-AGER AND/OR ARIEL CORPORATION.

CAUTIONGAS COMPRESSOR UNITS ARE COMPLICATED AND DANGEROUS PIECES OFEQUIPMENT. OPERATORS AND MECHANICS MUST BE FULLY TRAINED ANDFAMILIAR WITH THEIR OPERATION.BEFORE STARTING THIS UNIT:FAMILIARIZE YOURSELF WITH THE UNIT.CAREFULLY READ AND STUDY START-UP AND SHUT-DOWN INFORMATIONFOR BOTH PACKAGE AND COMPRESSOR!A GAS/AIR MIXTURE UNDER PRESSURE CAN EXPLODE! YOU CAN BESEVERELY INJURED OR KILLED. MAKE SURE THE COMPRESSOR ISSUFFICIENTLY PURGED OF ANY EXPLOSIVE MIXTURE BEFORE STARTING.AFTER COMPLETING THE ABOVE, BEGIN PROPER STARTING PROCEDURE.

CAUTIONDO NOT ATTEMPT TO START-UP UNIT WITHOUT REFERRING TO THIS MANUALSECTION 3: START-UP. IT IS ALSO ESSENTIAL TO REFER TO THE PACK-AGERS OPERATING MANUAL.

CAUTIONTHIS MANUAL EDITION IS BASED ON THE CURRENT DESIGN AND BUILDPRACTICES. THIS MANUAL MAY NOT BE APPLICABLE TO EQUIPMENT BUILTPRIOR TO THE DATE ON FRONT COVER AND IS SUBJECT TO CHANGEWITHOUT NOTICE. CONTACT ARIEL WITH ANY QUESTIONS. REFER TO LASTPAGE OF THIS MANUAL FOR CONTACT INFORMATION.

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FOR MODELS: JGZ AND JGU TABLE OF CONTENTSTABLE OF CONTENTS

Design Specifications & Data .............................................................. 1-1General ................................................................................................................... 1-1

Opposed Throw - Reciprocating Weight Balancing .......................................... 1-1Specifications ......................................................................................................... 1-4Product Information and Safety Plates ................................................................... 1-6

Important Safety Information ........................................................................... 1-7Clearances ........................................................................................................... 1-13

Piston Ring, Packing Ring & Wearband Side Clearances .............................. 1-14Piston, Piston Ring & Wearband Diametrical & End Gap Clearance .............. 1-15

Fastener Tightening Torque ................................................................................. 1-18Tightening Torque Procedures ........................................................................ 1-22

Ariel Bolting .......................................................................................................... 1-24Main Bearing Temperature Instrumentation - Alarm & Shutdown ........................ 1-25

Thermocouples, Type J (Iron-Constantan) or Type K (Chromel-Alumel) ........ 1-25Resistance Temperature Devices (RTDs) ...................................................... 1-26Main Bearing Temperature Alarm and Shutdown Limits ................................. 1-26

Zone 1 Environment ............................................................................................. 1-27

Compressor Installation ....................................................................... 2-1General ................................................................................................................... 2-1The Skid or Package .............................................................................................. 2-1Lifting the Compressor ........................................................................................... 2-1Setting the Compressor .......................................................................................... 2-2Leveling Limits for Compressors ............................................................................ 2-2

Aligning Main Bearing Bores ............................................................................. 2-3Setting Crosshead Guides ................................................................................ 2-5Setting - Miscellaneous ..................................................................................... 2-6

Alignment - to Driver ............................................................................................... 2-6Cold Alignment .................................................................................................. 2-9Hot Alignment .................................................................................................. 2-10Alignment Methods ......................................................................................... 2-10

Electrical Grounding ............................................................................................. 2-10Pneumatically Actuated Unloaders & Clearance Devices .................................... 2-10Vents and Drains .................................................................................................. 2-11BICERA Type Crankcase Over-Pressure Relief Valves ....................................... 2-11

Distance Piece and Packing Illustrations: ....................................................... 2-12

Start Up .................................................................................................. 3-1General ................................................................................................................... 3-1Start Up Check List ................................................................................................. 3-2

Warranty Notification & Start Up Check Lists JGZ:U Compressors .................. 3-27/09 i

FOR MODELS: JGZ AND JGU TABLE OF CONTENTSMaximum Allowable Working Pressure ................................................................3-12Relief Valve Settings .............................................................................................3-13Filling Sump & Priming a Main Oil Lube Oil System - Before Starting ..................3-14

Filling The Sump ..............................................................................................3-14Priming - Main Lube Oil System ......................................................................3-14

Compressor Prelube .............................................................................................3-14Force Feed Lubricator Adjustment ........................................................................3-14Compressor Re-Application ..................................................................................3-15

Lubrication ............................................................................................ 4-1General ...................................................................................................................4-1Lubrication Functions ..............................................................................................4-1Lubricant Characteristics ........................................................................................4-2

Viscosity ............................................................................................................4-2Viscosity Index ...................................................................................................4-2Pour Point ..........................................................................................................4-3Flash Point .........................................................................................................4-3

Lubricant Base Stock ..............................................................................................4-3Petroleum-Based Lubricants (also referred to as mineral oils) ..........................4-3Synthetic Lubricants ..........................................................................................4-4

Lubricant Formulations ...........................................................................................4-5Compounded Cylinder Oils ................................................................................4-5R&O Oil .............................................................................................................4-5Engine Oil ..........................................................................................................4-5Used Engine Oil .................................................................................................4-6Gear Oil .............................................................................................................4-6

Frame Oil System Components ..............................................................................4-7Oil Strainer .........................................................................................................4-7Oil Pump ............................................................................................................4-7Oil Cooler ...........................................................................................................4-7Oil Temperature Control Valve ..........................................................................4-8Oil Filtration .......................................................................................................4-8Compressor Prelube Pump ...............................................................................4-9Oil Heaters .........................................................................................................4-9Lube Oil Analysis Sampling Point ....................................................................4-10Cold Starting ....................................................................................................4-11Dry Sump .........................................................................................................4-12

Frame Oil Operating Conditions ...........................................................................4-13Compressor Frame Lubricant ..........................................................................4-13Oil Viscosity .....................................................................................................4-14Oil Pressure .....................................................................................................4-14Oil Temperature ...............................................................................................4-14Oil Maintenance ...............................................................................................4-14Oil Sampling ....................................................................................................4-15

Oil System Cleanliness .........................................................................................4-15Cylinder and Packing Lubrication .........................................................................4-16

Common Oil Supply .........................................................................................4-16Independent Oil Supply ...................................................................................4-17ii 7/09

FOR MODELS: JGZ AND JGU TABLE OF CONTENTSGas Inlet Debris Screens to Maintain Lube Performance ............................... 4-18Injection Oil Inlet Filter ..................................................................................... 4-18Oil Dilution ....................................................................................................... 4-18Cylinder Oil Lubrication Examples .................................................................. 4-18Under/Over Lube ............................................................................................. 4-19Inadequate Lubrication Symptoms .................................................................. 4-19Lubrication Quantity - Paper Test Method ...................................................... 4-19Lubricator Cycle Time ..................................................................................... 4-19Cycle Time Indication ...................................................................................... 4-20Force Feed Lubrication System Monitoring: ................................................... 4-20Minimum Requirements .................................................................................. 4-20Devices ........................................................................................................... 4-20Choosing a Lube System Monitor ................................................................... 4-20Break-in Rate .................................................................................................. 4-24Liquids in Gas ................................................................................................. 4-24Lube Type & Rate Recommendations ............................................................ 4-24RATE CALCULATION NOTES ....................................................................... 4-26

Water-Cooled Packing .......................................................................................... 4-28Coolant System Requirements ....................................................................... 4-29

Force Feed Lubrication System - Description ...................................................... 4-29Force Feed Lubricator Adjustment .................................................................. 4-30Blow-Out Fittings, Rupture Disks and Tubing ................................................. 4-31Divider Valves ................................................................................................. 4-32Description ...................................................................................................... 4-32

Divider Valve Block Assembly Instructions ........................................................... 4-33Operation - (see Figure 4-3: and Figure 4-4:) ................................................. 4-33Pressure Testing For Divider Valve By-Passing ............................................. 4-36

Electronic Lubricator Fluid-Flow Monitor/No-Flow Timer Switch - Proflo PF1 ...... 4-37Proflo PF1 Monitor wiring identification & instructions - electronic indication: 4-38Proflo PF1 Button Operation: .......................................................................... 4-39Downloading Proflo PF1 Data: ........................................................................ 4-39Proflo PF1 Setup Alarm Time and Mode: ....................................................... 4-40Proflo PF1 Battery Replacement: .................................................................... 4-41Proflo PF1 Display Errors: ............................................................................... 4-42Proflo PF1 Operation Notes: ........................................................................... 4-43Proflo Normally Open and Normally Closed Definition: .................................. 4-44Proflo PF1 - Using Pulse Output and Alarm Circuit at Same Time: ................ 4-45Proflo PF1 - Using PLC to Calculate Oil Consumption: .................................. 4-46Proflo PF1 Accessories Available: .................................................................. 4-47

Protection of Electronics & the Compressor When Arc Welding .......................... 4-47Electronic-Lubricator Digital No-Flow Timer Switch (DNFT) ................................ 4-47

Replacing the (Field-Replaceable) Battery in the DNFT: ................................ 4-48Oil Head at Lube Points ........................................................................................ 4-49Force Feed Lubrication System and Running Conditions .................................... 4-49

Force Feed Lubrication System ...................................................................... 4-49Running Conditions ......................................................................................... 4-50System Design Considerations and Operating Parameters ............................ 4-50

Force Feed Balance Valves ................................................................................. 4-50Setting and Maintaining Balance Valves ......................................................... 4-507/09 iii

FOR MODELS: JGZ AND JGU TABLE OF CONTENTSChecking/Adjusting Balance Valves on Subsequent Start-up .........................4-51Frame Lubricating System - Description ...............................................................4-52Lube Oil Strainer, Filter & Filter Installation Instructions .......................................4-52

Lube Oil Strainer ..............................................................................................4-52Lube Oil Filter ..................................................................................................4-52Oil Filter Installation for Spin-On Type Filters ..................................................4-53Oil Filter Element Installation for Cartridge Type Filters ..................................4-53

Lube Oil Pump & Lube Oil Pressure .....................................................................4-55Description & Adjustment ................................................................................4-55Lube Oil Pressure Regulating Valve ................................................................4-55

Low Oil Pressure Shutdown ..................................................................................4-56

Maintenance .......................................................................................... 5-1General Introduction ...............................................................................................5-1Positioning a Throw for Maintenance ......................................................................5-2Connecting Rod ......................................................................................................5-2

Checking Connecting Rod (Crank Pin) Bearing Clearances .............................5-3Connecting Rod - Removal ...............................................................................5-5Connecting Rod Bushing Replacement .............................................................5-5Connecting Rod - Installation ............................................................................5-6

Crosshead ...............................................................................................................5-9Crosshead - Removal ........................................................................................5-9Crosshead - Installation ...................................................................................5-12

BICERA Type Crankcase Over-Pressure Relief Valves .......................................5-16Crankshaft .............................................................................................................5-17

Checking Main Bearing Clearances ................................................................5-17Crankshaft - Removal ......................................................................................5-19Crankshaft - Oil Slinger ...................................................................................5-21Crankshaft - Chain Sprockets ..........................................................................5-22Main Bearings - Removal/Installation w/Crankshaft Removed ........................5-23Main Bearings - Removal/Installation w/Crankshaft In Place ..........................5-23Crankshaft - Installation ...................................................................................5-26

Torsional Vibration Detuners - Installation on Crankshaft .....................................5-27Chain Drive System ..............................................................................................5-29

Description .......................................................................................................5-29Chain Adjustment ............................................................................................5-31Chain and Sprocket Replacement ...................................................................5-32Chain Idler Sprockets Replacement - (Eccentric Adjustment Caps) ...............5-33Lube Oil Pump Chain Sprocket Replacement .................................................5-33Force Feed Lubricator Chain Sprocket Replacement .....................................5-34

Piston and Rod - Removal ....................................................................................5-36Piston and Rod - Disassembly and Reassembly ..................................................5-37

Piston and Rod - Disassembly ........................................................................5-37Piston and Rod - Reassembly .........................................................................5-37

Piston and Rod - Installation .................................................................................5-40Piston Rod Run Out ..............................................................................................5-40Piston Rings ..........................................................................................................5-42

Determining Ring Wear: ..................................................................................5-42iv 7/09

FOR MODELS: JGZ AND JGU TABLE OF CONTENTSRemoval: ......................................................................................................... 5-42Wear Bands .......................................................................................................... 5-42

Determining Wear Band Wear: ....................................................................... 5-42Piston Rings - Installation ..................................................................................... 5-43

Special Purpose Piston Rings - High Pressure Face-Cut ............................... 5-43Wear Band - Installation ....................................................................................... 5-43Piston Rod Pressure Packing - Removal & Disassembly ..................................... 5-43Piston Rod Packing - Reassembly ....................................................................... 5-44Types of Piston Rod Packing Rings ..................................................................... 5-46

Type "P" Pressure Breaker ............................................................................. 5-46Type "UP" Pressure Breaker ........................................................................... 5-47Type P1U Pressure Breaker ......................................................................... 5-47Type "BTR" Single Acting Seal Set ................................................................. 5-47Type "BD" Double Acting Seal Set .................................................................. 5-48Type "WAT" Double Acting Seal Set ............................................................... 5-48Type AL Double Acting Seal Set .................................................................. 5-49Type BTU Single Acting Seal Set ................................................................. 5-49Type BTUU Single Acting Seal Set ................................................................. 5-50Type CU Single Acting Seal Set ................................................................... 5-50Type CUU Single Acting Seal Set ................................................................ 5-51Type STU Single Acting Seal Set ................................................................. 5-52Type CR Single Acting Seal Set ................................................................... 5-52Type "3RWS" Oil Wiper Set ............................................................................ 5-52Type RTV Oil Wiper Set ............................................................................... 5-53

Arrangement of Piston Rod Packing Rings .......................................................... 5-54Piston Rod Packing Ring Material ........................................................................ 5-54Water-Cooled Piston Rod Packing ....................................................................... 5-54

Water-Cooled Piston Rod Packing - Re-assembly ......................................... 5-54Water-Cooled Piston Rod Packing - Testing ................................................... 5-55

Valves ................................................................................................................... 5-56Valves - Removal ............................................................................................ 5-56Valves - Maintenance ...................................................................................... 5-57Valves - Reassembly ...................................................................................... 5-57

Tightening Valve Cap Bolting ............................................................................... 5-59VVCP - Head-End Variable Volume Clearance Pocket ........................................ 5-61

VVCP - Removal ............................................................................................. 5-61VVCP - Disassembly ....................................................................................... 5-62VVCP - Maintenance ....................................................................................... 5-62VVCP - Adjustment ......................................................................................... 5-62

Compressor Cylinder Re-Boring and Bore Reconditioning Guidelines ................ 5-63Ethylene Glycol Contamination ............................................................................ 5-65Cleaning, Handling & Thread Lubricants for Non-Lubricated Compr Cylinders ... 5-66BEARING LOG FORM/CONDITIONS AFTER REPLACING BEARINGS ........... 5-68

Maintenance Intervals & Trouble Shooting ........................................ 6-1Recommended Maintenance Intervals ................................................................... 6-1

Daily .................................................................................................................. 6-1Monthly (in addition to Daily Requirements) ..................................................... 6-27/09 v

FOR MODELS: JGZ AND JGU TABLE OF CONTENTSEvery 6 Months or 4000 Hours (plus Daily/Monthly) .........................................6-3Yearly or 8000 Hours (plus Daily/Monthly/6 Months) ........................................6-3Every 2 Years or 16,000 Hours (plus Daily/Monthly/6 Months/Yearly) ..............6-4Every 4 Years or 32,000 Hours (plus Daily/Monthly/6 Months/1 & 2 Years) .....6-4Every 6 Years or 48,000 hours (plus Daily/Monthly/6 Months/1, 2 & 4 Years) ..6-5

Trouble Shooting .....................................................................................................6-5

Appendices ........................................................................................... 7-1Ariel Tools ...............................................................................................................7-1

Ariel Furnished Tools .........................................................................................7-1Ariel Tools - Separately Purchased ...................................................................7-4

Minimum Hand & Commercial Tools Required .......................................................7-8Gas Analysis Common Abbreviations ...................................................................7-12Technical and Service Schools on Ariel Compressors .........................................7-13Ariel Customer Technical Bulletins .......................................................................7-13Vendor Literature ..................................................................................................7-13Ariel Contact Information: .....................................................................................7-14vi 7/09

FOR MODELS: JGZ AND JGU SECTION 1 - DESIGN SPECIFICATIONS & DATASECTION 1 - DESIGN SPECIFICATIONS & DATAGeneralAriel compressors are designed for ease of operation and maintenance. Experience has shown that an Ariel compressor will normally provide years of satisfactory performance with minimal proper maintenance.

While Ariel compressors share many similarities, each model has aspects that are unique to the particular type. If you, as an operator, are familiar with Ariel compressors, it is still impor-tant to review this manual to determine the differences. If you are new to Ariel compressors, it is critical that you become very familiar with this manual prior to operating the compressor.

This manual is designed to provide information on installation, start up, operation and main-tenance of a JGZ or JGU compressor. If you have any questions please contact your pack-ager. If they are unable to provide resolution, they will refer your concerns to Ariel Corporation. If you prefer, you may always contact Ariel directly1.

This manual provides design specifications for standard current production equipment at publication date. Do not exceed information plates ratings for a particular compressor.

The location of the throws and the data shown on the Information Plates is very important when communicating questions concerning an Ariel compressor.

Opposed Throw - Reciprocating Weight BalancingAriel recommends that the reciprocating weight differential between opposing throws be 5.0 pounds (2.3 kg) or less for JGZ and JGU compressors.

If replacing any major reciprocating component, that is; a connecting rod assembly, piston, piston & rod assembly, crosshead-balance nuts or crosshead, weigh component parts on a calibrated scale to 0.1 pounds (0.05 kg), record values for future reference and compare to the Compressor Balancing Record sheet that comes in the parts manual with each compres-sor. If there are weight changes, recalculate opposing throw reciprocating weight differentials1. If not within the recommended limit, new balance nuts and/or crossheads are to be selected to provide the least possible differential.

If it is desirable to exchange opposing throw compressor cylinder locations1, all reciprocat-ing components must be exchanged to the opposite throw, except the connecting rod assemblies. Check the Balancing Record sheet and recalculate reciprocating weight differ-ential, with the connecting rod weights included. If not within the recommended limit, new balance nuts are to be selected to provide the least possible differential.

If opposing throws can not be balanced within the recommended reciprocating weight differ-ential limit, contact your packager and/or Ariel1. When applying or re-applying a different cyl-inder to a throw1, the opposing throw reciprocating weight differential must be re-calculated

1. Contact your Packager or the Ariel Response Center for detailed information. Refer to the last page of this manual for Ariel contact information.7/09 PAGE 1 - 1

FOR MODELS: JGZ AND JGU SECTION 1 - DESIGN SPECIFICATIONS & DATAand new balance nuts or crossheads may be required. The force feed oil distribution system may also need to be resized.

TABLE 1-1 APPROXIMATE COMPONENT WEIGHTSCOMPONENT POUNDS (KILOGRAMS)

Frame Assembly w/o Cylinders See Ariel Electronic Data Booka

a. The Electronic Data Book is available in the Ariel Performance Program.

Main/Connecting Rod Bearing 4 (2)Thrust Plate 12 (5.5)

Top Cover, Drive End Section 70 (32)Top Cover, Center Section 140 (63)

Top Cover, Auxiliary End Section 85 (37)Top Cover Cross/Spacer Bar 100 (45)

Spacer Bar 110 (50)End Cover Drive End 155 (70)

Dust Seal Cover 18 (8)End Cover Auxiliary End 265 (120)

Lube Oil Pump 130 (50)

Crankshaft 2-Throwb

b. Crankshaft weight is without flywheel, vibration or detuner donuts.

2000 (900)

Crankshaft 4-Throw2 2700 (1225)

Crankshaft 6-Throw2 3600 (1630)

Main Journal Caps 85 (39)Connecting Rod 265 (120)

Crosshead Guide 1800 (820)Crosshead Guide Gland 35 (15)

Crosshead See Balancing Record sheetc for Weights

c. Provided by Ariel in the Parts Book for each compressor.

Crosshead Pin 80 (35)Crosshead Guide Large Side Cover 20 (16)Crosshead Guide Small Side Cover 11 (5)

VVCP See Ariel Electronic Data Book1

Cylinder Assembly See Ariel Electronic Data Book1

Piston & Rod Assembly See Ariel Electronic Data Book1PAGE 1 - 2 7/09

FOR MODELS: JGZ AND JGU SECTION 1 - DESIGN SPECIFICATIONS & DATAFIGURE 1-1 COMPRESSOR THROW NUMBERING & INFORMATION PLATE LOCATION

InformationPlate

#2#1

#3

#4

#5

#6

Engine/Motor Drive End

Auxiliary End

Auxiliary End View7/09 PAGE 1 - 3

FOR MODELS: JGZ AND JGU SECTION 1 - DESIGN SPECIFICATIONS & DATASpecifications

Table 1-2 JGZ FRAME SPECIFICATIONSa

a. For more information, see the Electronic Databook available in the Ariel Performance Program.

MODEL JGZ/2 JGZ/4 JGZ/6Stroke, inches (mm) 6.75 (171) 6.75 (171) 6.75 (171)

Speed, RPMb

b. Rated speeds for non-lube, and lubricated process applications may vary. Minimum speed required to provide adequate oil flow to the compressor bearings by the frame driven oil pump.

500 To 1000 500 To 1000 500 To 1000

Piston Speed, FPM (m/s) To 1125 (5.72) To 1125 (5.72) To 1125 (5.72)Number of Throws 2 4 6Horsepower (kW) To 2600 (1939) To 5200 (3878) To 7800 (5816)Height - Bottom to Crankshaft Centerline, Nominal, in. (mm)

24.000(609.6)

24.000(609.6)

24.000(609.6)

Connecting Rod Centerline to Centerline, Nominal, in. (mm)

18.500(469.9)

18.500(469.9)

18.500(469.9)

Maximum Width with Cylinders, in. (m)

186(4.72)

186(4.72)

186(4.72)

Maximum Length, in. (m) 87 (2.21) 135 (3.43) 183 (4.65)Maximum Height, in. (m) 42 (1.07) 42 (1.07) 42 (1.07)Approximate Weight with Cylinders, lb. (kg)

22,500(10 200)

45,000(20 500)

67,000 (30 500)

Oil Pump Flow Rate @ Max. Rated Speed & 180F (82C), GPM (L/s) 35 (2.2) 84 (5.3) 113 (7.1)

Oil Heat Rejection, BTU/hr. (kW) 65,000 (19.1) 130,000 (38.1) 195,000 (57.2)Oil Sump Capacity, US gallons (L) 40 (150) 77 (290) 107 (405)Piston Rod Diameter, Nominal,in. (mm)

2.875(73)

2.875 (73)

2.875(73)

Maximum Internal Rod Load - Double Acting:Compression + Tension, lbf. (kN) 150,000 (667) 150,000 (667) 150,000 (667)Tension, lbf. (kN) 75,000 (334) 75,000 (334) 75,000 (334)Compression, lbf. (kN) 80,000 (356) 80,000 (356) 80,000 (356)

Maximum Internal Rod Load - Single Acting:Tension, lbf. (kN) 75,000 (334) 75,000 (334) 75,000 (334)PAGE 1 - 4 7/09

FOR MODELS: JGZ AND JGU SECTION 1 - DESIGN SPECIFICATIONS & DATATable 1-3 JGU FRAME SPECIFICATIONSa

a. For more information, see the Electronic Databook available in the Ariel Performance Program.

MODEL JGU/2 JGU/4 JGU/6Stroke, inches (mm) 5.75 (146) 5.75 (146) 5.75 (146)

Speed, RPMb

b. Rated speeds for non-lube, and lubricated process applications may vary. Minimum speed required to provide adequate oil flow to the compressor bearings by the frame driven oil pump.

600 To 1200 600 To 1200 600 To 1200

Piston Speed, FPM (m/s) To 1150 (5.84) To 1150 (5.84) To 1150 (5.84)Number of Throws 2 4 6Horsepower (kW) To 2600 (1939) To 5200 (3878) To 7800 (5616)Height - Bottom to Crankshaft Cen-terline, Nominal, in. (mm)

24.000(609.6)

24.000(609.6)

24.000(609.6)

Connecting Rod Centerline to Cen-terline, Nominal, in. (mm)

18.500(469.9)

18.500(469.9)

18.500(469.9)

Maximum Width with Cylinders, in. (m)

186(4.72)

186(4.72)

186(4.72)

Maximum Length, in. (m) 87 (2.21) 135 (3.43) 183 (4.65)Maximum Height, in. (m) 42 (1.07) 42 (1.07) 42 (1.07)Approximate Weight with Cylinders, lb. (kg)

22,500(10 200)

45,000(20 500)

67,000(30 500)

Oil Pump Flow Rate @ Max. Rated Speed & 180F (82C), GPM (L/s) 42 (2.6) 101 (6.4) 135 (8.5)

Oil Heat Rejection, BTU/hr. (kW) 70,000(20.5)140,000(41.0)

210,000(61.6)

Oil Sump Capacity, US gallons (L) 40 (150) 77 (290) 107 (405)Piston Rod Diameter, Nominal, in. (mm)

2.875(73)

2.875(73)

2.875(73)

Maximum Internal Rod Load - Double Acting:Compression + Tension, lbf. (kN) 150,000 (667) 150,000 (667) 150,000 (667)Tension, lbf. (kN) 75,000 (334) 75,000 (334) 75,000 (334)Compression, lbf. (kN) 80,000 (356) 80,000 (356) 80,000 (356)

Maximum Internal Rod Load - Single Acting:Tension, lbf. (kN) 75,000 (334) 75,000 (334) 75,000 (334)7/09 PAGE 1 - 5

FOR MODELS: JGZ AND JGU SECTION 1 - DESIGN SPECIFICATIONS & DATAProduct Information and Safety Plates

FIGURE 1-2 TOP COVER - TYPICAL

Oil Filter Plate with installation instructions.

Frame Information Data Plate: Ariel Frame Model, Frame Serial Number, Stroke, Frame Rated Speed, Minimum Speed - RPM, Maximum Rod Load - Ten-sion and Compression, Ariel Shipping Date, Nor-mal Lube Oil Pressure, Maximum Lube Oil Temperature and Low Oil Pressure Shutdown set-ting. The maximum Unit Speed is the Maximum Name Plate Rated Speed or Cylinder Speed which-ever is the Lessor.

Tapped holes for top cover lifting eyebolts

Top Cover - Drive End Section

Direction of Rotation plate, located at the drive end

Top Cover - Center Section(s)

Top Cover - Auxiliary End Section

ARIEL LOGO NAME PLATE AND WEB SITE ADDRESS: www.arielcorp.com

Breather(s)

Handles

IMPORTANT SAFETY INFORMATION PLATES See Page 1-7

NOTE: USE THE CYLINDER AND FRAME SERIAL NUMBERS IN ALL CORRESPONDENCE.PAGE 1 - 6 7/09

FOR MODELS: JGZ AND JGU SECTION 1 - DESIGN SPECIFICATIONS & DATAImportant Safety Information

CAUTIONSEVERE PERSONAL INJURY AND PROPERTY DAMAGE CAN RESULT IFPRESSURE SYSTEM IS NOT COMPLETELY VENTED BEFORE LOOSENING THECAP SCREWS ON FLANGES, HEADS, VALVE CAPS, OR PACKING. CONSULTARIEL TECHNICAL MANUAL BEFORE PERFORMING ANY MAINTENANCE.

CAUTIONSEVERE PERSONAL INJURY AND/OR PROPERTY DAMAGE WILL RESULT IFSUCTION AND DISCHARGE VALVES ARE NOT INSTALLED IN THEIR PROPERLOCATION.

CAUTIONNOISE GENERATED BY RECIPROCATING MACHINERY CAN BE A SOURCE FORHEARING INJURY. SEE PACKAGERS INFORMATION FOR ANY SPECIFICRECOMMENDATIONS. WEAR HEARING PROTECTION WHEN UNIT IS RUNNING.

CAUTIONHOT GAS TEMPERATURES ESPECIALLY THE CYLINDER DISCHARGE AREAS,190F (88C) OIL AND HIGH FRICTION AREAS CAN BE A SOURCE FOR BURNS.WEAR PROPER INSULATION WHEN WORKING AROUND THESE AREAS. SHUTDOWN THE UNIT AND ALLOW TO COOL BEFORE DOING MAINTENANCE IN THESEAREAS.

CAUTIONDO NOT REMOVE THE PIN FROM THE CROSSHEAD GUIDE TO COMPRESSORCYLINDER MOUNTING FACE. IT IS INSTALLED TO PREVENT THE INSTALLATIONOF MISAPPLIED CYLINDERS AND AVOID PERSONAL INJURY

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FOR MODELS: JGZ AND JGU SECTION 1 - DESIGN SPECIFICATIONS & DATAFIGURE 1-3 HOT & COLD SURFACES - CAUTION SYMBOLS

CAUTION Hot Surfaces CAUTION Cold Surfaces

Where these CAUTION symbols appear on the compressor, the sur-faces are hot or cold when compressor is operating and can cause injury if touched without proper insulated protective clothing. When servicing the compressor, allow these surfaces to cool or warm to safe temperatures or wear protective clothing before proceeding. When applied to compressor cylinders, the temperature CAUTION applies to all connected piping and equipment.PAGE 1 - 8 7/09

FOR MODELS: JGZ AND JGU SECTION 1 - DESIGN SPECIFICATIONS & DATAFIGURE 1-4 FORCE FEED LUBRICATOR DATA PLATES - TYPICAL SINGLE & TWIN PUMPS

Force Feed Lubricator Data Plate for Twin Pumps - Indicator Cycle Time

Force Feed Lubricator Data Plate for Single Pump - Indicator Cycle Time

Data Plate Location

Normal Cycle Time - Seconds per Cycle

Break In Cycle Time - Seconds per Cycle

Throw Numbers

Increase Pump Stroke - CCW

Increase Pump Stroke- CCW

Distribution Block Part Number

Indicator Pin Cycle Time:

Seconds per Cycle

Normal

Break In

Data Plate Location

Top View

Side View

Distribution Block Part Number7/09 PAGE 1 - 9

FOR MODELS: JGZ AND JGU SECTION 1 - DESIGN SPECIFICATIONS & DATAFIGURE 1-5 FORCE FEED LUBRICATOR DATA PLATE - TYPICAL FOUR PUMPS

FIGURE 1-6 FORCE FEED LUBRICATOR DATA PLATE - TYPICAL GERHARDT

Distribution Block Part Numbers

Increase Pump Stroke - CCW

Throw Numbers

Normal Cycle Time - Seconds per Cycle

Break In Cycle Time - Seconds per Cycle

Data Plate Location

Gerhardt Force Feed Lubricator w/up to four pump capacity - Optional for High Pressure CylindersFor more information on the Gerhardt Lubricator, see the Ariel web site under Vendor Literature

Compressor Auxiliary End Cover

Speed Reducer

Unused Drive Shaft - Keep Safety Covers in Place when Compressor is Running

Data Plate Location - See Figure 1-5 for Plate detailsPAGE 1 - 10 7/09

FOR MODELS: JGZ AND JGU SECTION 1 - DESIGN SPECIFICATIONS & DATAThe Force Feed Lubricator provides oil to the piston rod packing and the compressor pis-tons. The Lubricator Data Plate gives directions for adjusting the flow of oil. If this plate is missing, please contact Ariel Corporation for a replacement or specific directions, see Ariel Contact Information: on page 7-14 for contact information.

Cylinder Information Plates appear on each cylinder. The serial number is also stamped on the end of each cylinder. If any plate is missing, please contact Ariel for a replacement or specific directions.

NOTE: USE THE CYLINDER AND FRAME SERIAL NUMBERS IN ALL CORRESPON-DENCE.

FIGURE 1-7 INFORMATION PLATES - TYPICAL

Cylinder Information Plate, See Figure 1-8

Suction Valve Pocket Identification Plate

Frame Serial Number stamped on machined surface above the Mechanical Inspectors Plate. On drive end throw #2 side

VVCP Information and Instruction Plates, See Figure 1-8 - Customer Work Order Number, & Hydrostatic test Pressure are stamped near this plate on top of the VVCP body

Discharge Valve Pocket Identification Plate

Serial Number, MAWP, Part Number, Work Order Number, Hydrostatic Test Pressure, Test Date and Testers Personal Stamp are stamped on the end of each cylinder (cylinder head mounting surface)

F-XXXXX7/09 PAGE 1 - 11

FOR MODELS: JGZ AND JGU SECTION 1 - DESIGN SPECIFICATIONS & DATAFIGURE 1-8 CYLINDER AND VVCP PLATES

VVCP S.N.BASE VOL.

VVCP MAWP

A-0755

VARIABLE VOL.TOTAL TRAV. TURNSOR

ARIEL CORPORATIONCYL. BORE

CYLINDER INFORMATION PLATE:

Nominal Bore Diam-eter - Inches or mm

Stroke - Inches or mm

Class (cylinder model)

Rated Revolutions per Minute (of crankshaft)

Crank End

Head End

Piston End Clearance - Inches or mm

Cylinder Serial NumberMinimum Volumetric Clearance - Percentage

Variable Volume Clearance Pocket Serial Number

HEAD-END VARIABLE VOLUME CLEARANCE POCKET (VVCP) INFOMATION PLATE

Total Travel in Inches or cm

Total Travel in Number of Turns

Base Volume Cubic Inches or cm3 with VVCP Closed

VVCP Maximum Allowable Working Pressure (Maximum Relief Valve Setting) PSIG - Pounds per Square Inch Gauge or barg

Nominal Cylinder Bore Diameter Inches or mm

Maximum Allowable Working Pressure (Maximum Relief Valve Setting) - PSIG - Pounds per Square Inch Gauge or barg

Variable Volume Cubic Inches or cm3

HEAD-END VARIABLE VOLUME CLEARANCE POCKET (VVCP) INSTRUCTION PLATE

Variable Volume Clearance Pocket Serial Number

Fully Closed Dimension A Inches or cm

Fully Open Dimension A Inches or cm

Remove Aluminum Thread Protector Where ApplicablePAGE 1 - 12 7/09

FOR MODELS: JGZ AND JGU SECTION 1 - DESIGN SPECIFICATIONS & DATAClearances

NOTE: MEASURED CLEARANCES WILL NOT NECESSARILY AGREE BECAUSE OF OIL FILMS, ASSEMBLY TOLERANCES, WEAR, ETC. PLASTIGAGES, SOLDER, ETC. ARE NOT TO BE USED.

TABLE 1-4 CLEARANCES

DESCRIPTION CLEARANCE, INCHESCLEARANCE,

(mm)Crankshaft Dust Seal (Feeler Gauge - Centered) 0.010 to 0.014 (0.25 to 0.35)Crankshaft Thrust (End) 0.015 to 0.030 (0.38 to 0.76)Crankshaft Journal Bearing (Jack) 0.0055 to 0.009 (0.14 to 0.23)Crankshaft Pin to Connecting Rod Bearing (Vertical Jack) 0.0055 to 0.009 (0.14 to 0.23)

Connecting Rod Thrust (Side) 0.0115 to 0.0275 (0.29 to 0.70)Connecting Rod Bushing to Crosshead Pin 0.002 to 0.005 (0.05 to 0.13)Crosshead Bushing to Crosshead Pin - Iron Cross-head 0.002 to 0.005 (0.05 to 0.13)

Crosshead to Crosshead Pin - Bronze Crosshead 0.002 to 0.004 (0.05 to 0.10)

Crosshead to Guide - Babbitted Iron (Feeler Gaugea)

a. Crosshead guide to crosshead clearance at the top is to be checked by inserting a standard 0.5 inches (13 mm) wide feeler stock from one side edge of the crosshead across to the opposite side. This is to be done at both ends. The bottom clearance is to be checked with 0.0015 inches (0.04 mm) feeler stock at the four corners. If the feeler can be inserted more that 0.5 inches (13 mm), the assembly is not acceptable.

0.011 to 0.017b

b. With D-4958, D-4959 or D-4960 crosshead, starting 3/07; with older D-3486, D-3513, D-3796 or D-4120 crossheads, clearance is 0.009 to 0.015 in. (0.23 to 0.38 mm).

(0.28 to 0.43)Crosshead to Guide - Babbitted Bronze(Feeler Gauge1)

0.015 to 0.021 (0.38 to 0.53)

Table 1-5 PISTON END CLEARANCESa

a. See Piston and Rod - Installation on page 5-40 for setting instructions.

CYLINDER CLASSCRANK END HEAD END TOTALb

b. If your total piston end clearance is not within table tolerance, contact your Packager or Ariel.

IN. (mm) IN. (mm) IN. (mm)17-7/8, 20-1/8, 22, 24-1/8

& 26-1/2 Z:U 0.060 (1.5) 0.105 to 0.165 (2.7 to 4.2) 0.165 to 0.225 (4.2 to 5.7)

All ZL:UL:ZN:UN 0.300 (7.2) NO SET 0.635 to 0.695 (16.1 to 17.7)All ZM:UM 0.045 (1.1) 0.090 to 0.150 (2.3 to 3.8) 0.135 to 0.195 (3.4 to 4.9)

All Other Z:U 0.045 (1.1) 0.090 to 0.150 (2.3 to 3.8) 0.135 to 0.195 (3.4 to 4.9)7/09 PAGE 1 - 13

FOR MODELS: JGZ AND JGU SECTION 1 - DESIGN SPECIFICATIONS & DATAPiston Ring, Packing Ring & Wearband Side ClearancesThe standard side clearance for JGZ and JGU compressor piston rings, packing rings and wearbands when new are shown in the following tables:

TABLE 1-6 PISTON RING SIDE CLEARANCE, INCHES (mm)NOMINAL

WIDTH ACTUAL GROOVE

WIDTH TEFLON PEEK

5/16 (7.94) 0.312 to 0.314(7.92 to 7.98)

0.006 to 0.010(0.15 to 0.25)

0.005 to 0.008(0.13 to 0.20)

3/8 (9.53) 0.375 to 0.377(9.53 to 9.58)

0.007 to 0.013(0.18 to 0.33)

0.005 to 0.008(0.13 to 0.20)

1/2 (12.70) 0.500 to 0.502(12.70 to 12.75)

0.009 to 0.015(0.23 to 0.38)

0.005 to 0.008(0.13 to 0.20)

5/8 (15.88) 0.625 to 0.627(15.88 to 15.93)

0.011 to 0.016(0.28 to 0.41)

0.006 to 0.009(0.15 to 0.23)

3/4 (19.05) 0.750 to 0.752(19.05 to 19.10)

0.013 to 0.020(0.33 to 0.51)

0.008 to 0.011(0.20 to 0.28)

TABLE 1-7 PACKING RING SIDE CLEARANCE, INCHES (mm)ACTUAL GROOVE

WIDTH

BTUUCUU UP P1U

0.625 to 0.627 (15.86 to 15.93)

0.025 to 0.031 (0.64 to 0.79)

0.019 to 0.023 (0.48 to 0.58)

0.019 to 0.022 (0.48 to 0.56)

TABLE 1-8 WEARBAND SIDE CLEARANCE, INCHES (mm)ACTUAL GROOVE WIDTH TEFLON PEEK2.000 to 2.002 (50.80 to 50.85) 0.024 to 0.034 (0.61 to 0.86) 0.014 to 0.018 (0.36 to 0.46)3.000 to 3.003 (76.20 to 76.28) 0.036 to 0.048 (0.91 to 1.22) 0.021 to 0.025 (0.53 to 0.64)PAGE 1 - 14 7/09

FOR MODELS: JGZ AND JGU SECTION 1 - DESIGN SPECIFICATIONS & DATAPiston, Piston Ring & Wearband Diametrical & End Gap Clear-anceTABLE 1-9 PISTON, PISTON RING & WEARBAND CLEARANCES - NON-PRC, IN.

PISTON TO CYLINDER CLEARANCE

PISTON RING END GAPS - FILLED TEFLONa

WEAR BANDS NEW

BORE CLEARANCE NEW MAXIMUMMINIMUM END

GAP RADIAL PROJECTION

45 704.25 0.071 to 0.079 0.051 to 0.061 0.183 --- 0.136 0.023 to 0.0314.375 0.071 to 0.079 0.053 to 0.063 0.189 --- 0.140 0.026 to 0.0334.625 0.071 to 0.079 0.056 to 0.066 0.198 --- 0.197 0.023 to 0.031

5 0.081 to 0.089 0.050 to 0.060 0.180 0.160 0.213 0.027 to 0.035 5.375 0.081 to 0.089 0.065 to 0.077 0.231 0.172 0.229 0.027 to 0.035 5.875 0.081 to 0.089 0.059 to 0.071 0.213 0.188 0.250 0.027 to 0.035 6.25 0.081 to 0.089 0.063 to 0.138 0.414 0.200 0.266 0.027 to 0.035 6.75 0.087 to 0.096 0.068 to 0.081 0.243 0.216 0.287 0.029 to 0.0377.00 0.087 to 0.096 0.070 to 0.084 0.252 0.224 0.298 0.029 to 0.037 7.25 0.087 to 0.096 0.072 to 0.087 0.261 0.232 0.308 0.029 to 0.037

7.875 0.092 to 0.101 0.079 to 0.095 0.285 0.252 0.335 0.031 to 0.040 8.375 0.092 to 0.101 0.084 to 0.100 0.300 0.268 0.356 0.031 to 0.0408.75 0.090 to 0.098 0.105 to 0.125 0.375 --- 0.280 0.030 to 0.039

9.125 0.096 to 0.105 0.091 to 0.110 0.330 0.292 0.388 0.033 to 0.0429.25 0.090 to 0.098 0.111 to 0.131 0.393 --- 0.296 0.030 to 0.039

9.625 0.096 to 0.105 0.096 to 0.116 0.346 0.308 0.410 0.033 to 0.0429.75 0.090 to 0.098 0.117 to 0.137 0.411 --- 0.312 0.030 to 0.0399.875 0.109 to 0.118 0.099 to 0.119 0.357 0.316 0.420 0.037 to 0.04710.25 0.090 to 0.098 0.110 to 0.132 0.396 --- 0.468 0.033 to 0.040

10.375 0.109 to 0.118 0.104 to 0.125 0.375 0.332 0.442 0.037 to 0.04710.5 0.114 to 0.123 0.105 to 0.126 0.378 0.336 0.447 0.039 to 0.04910.75 0.090 to 0.098 0.110 to 0.132 0.396 --- 0.468 0.033 to 0.040

10.875 0.114 to 0.123 0.108 to 0.130 0.393 0.348 0.463 0.039 to 0.04911 0.114 to 0.123 0.110 to 0.132 0.396 0.352 0.468 0.039 to 0.049

11 (L&M) 0.090 to 0.098 0.110 to 0.132 0.396 --- 0.468 0.033 to 0.04011.25 0.100 to 0.108 0.135 to 0.159 0.477 --- 0.360 0.036 to 0.042

11.375 0.114 to 0.123 0.114 to 0.137 0.411 0.364 0.484 0.039 to 0.04911.75 0.100 to 0.108 0.141 to 0.165 0.495 --- 0.376 0.036 to 0.044

12 0.117 to 0.128 0.120 to 0.144 0.432 0.384 0.511 0.039 to 0.05012.25 0.117 to 0.127 0.123 to 0.147 0.441 0.392 0.521 0.039 to 0.050

12.375 0.100 to 0.108 0.148 to 0.172 0.516 --- 0.376 0.036 to 0.04212.5 0.117 to 0.128 0.125 to 0.150 0.450 0.400 0.532 0.039 to 0.050

13.125 0.126 to 0.137 0.131 to 0.158 0.474 0.420 0.558 0.043 to 0.05313.625 0.126 to 0.137 0.136 to 0.164 0.490 0.436 0.580 0.043 to 0.05314.125 0.126 to 0.137 0.141 to 0.170 0.508 0.452 0.601 0.043 to 0.0537/09 PAGE 1 - 15

FOR MODELS: JGZ AND JGU SECTION 1 - DESIGN SPECIFICATIONS & DATA

14.25 0.126 to 0.137 0.171 to 0.195 0.585 0.456 0.606 0.042 to 0.05215.375 0.127 to 0.138 0.154 to 0.185 0.555 0.492 0.654 0.038 to 0.05015.875 0.127 to 0.138 0.159 to 0.191 0.573 0.508 0.675 0.038 to 0.05017.375 0.179 to 0.191 0.174 to 0.209 0.627 0.556 0.740 0.044 to 0.05717.875 0.181 to 0.193 0.179 to 0.215 0.645 0.572 0.761 0.044 to 0.05719.625 0.187 to 0.199 0.236 to 0.268 0.804 0.628 0.835 0.050 to 0.06320.125 0.185 to 0.197 0.242 to 0.274 0.822 0.644 0.857 0.050 to 0.063

22 0.213 to 0.225 0.264 to 0.304 0.912 0.704 0.936 0.059 to 0.07224.125 0.214 to 0.226 0.290 to 0.330 0.990 0.772 1.027 0.056 to 0.06926.5 0.226 to 0.238 0.320 to 0.360 1.080 0.848 1.128 0.058 to 0.071

a. For PEEK piston ring end gap values, multiply the table values by 0.3.

FIGURE 1-9 WEAR BAND CUT ANGLES

TABLE 1-9 PISTON, PISTON RING & WEARBAND CLEARANCES - NON-PRC, IN.

PISTON TO CYLINDER CLEARANCE

PISTON RING END GAPS - FILLED TEFLONa

WEAR BANDS NEW

BORE CLEARANCE NEW MAXIMUMMINIMUM END

GAP RADIAL PROJECTION

45 70

45

70

End Gap

End GapPAGE 1 - 16 7/09

FOR MODELS: JGZ AND JGU SECTION 1 - DESIGN SPECIFICATIONS & DATATABLE 1-10 PISTON, PISTON RING & WEARBAND CLEARANCES - NON-PRC, (mm)

PISTON TO CYLINDER CLEARANCE

PISTON RING END GAPS - FILLED TEFLONa

WEAR BANDS NEW

BORE (mm) INCHES CLEARANCE NEW MAXIMUM

MINIMUM END GAP RADIAL

PROJECTION45 70

(108) 4.25 (1.80 to 2.01) (1.30 to 1.55) (4.65) --- (3.45) (0.58 to 0.79)(111) 4.375 (1.80 to 2.01) (1.35 to 1.60) (4.80) --- (3.56) (0.66 to 0.84)(117) 4.625 (1.80 to 2.01) (1.42 to 1.68) (5.03) --- (5.00) (0.58 to 0.79)

(127) 5 (2.06 to 2.26) (1.27 to 1.52) (4.57) (4.06) (5.41) (0.69 to 0.89)(137) 5.375 (2.06 to 2.26) (1.65 to 1.96) (4.88) (4.37) (5.82) (0.69 to 0.89)(149) 5.875 (2.06 to 2.26) (1.50 to 1.80) (5.41) (4.78) (6.35) (0.69 to 0.89)(159) 6.25 (2.06 to 2.26) (1.60 to 3.50) (10.52) (5.08) (6.76) (0.69 to 0.89)(171) 6.75 (2.21 to 2.44) (1.73 to 2.06) (6.17) (5.49) (7.29) (0.74 to 0.94)

(178) 7 (2.21 to 2.44) (1.78 to 2.13) (6.40) (5.69) (7.57) (0.74 to 0.94)(184) 7.25 (2.21 to 2.44) (1.83 to 2.21) (6.63) (5.89) (7.82) (0.74 to 0.94)(200) 7.875 (2.34 to 2.57) (2.00 to 2.41) (7.24) (6.40) (8.51) (0.79 to 1.02)(213) 8.375 (2.34 to 2.57) (2.13 to 2.54) (7.62) (6.81) (9.04) (0.79 to 1.02)(222) 8.75 (2.29 to 2.51) (2.67 to 3.18 (9.53) --- (7.11) (0.76 to 0.99)(232) 9.125 (2.44 to 2.67) (2.31 to 2.79) (8.38) (7.42) (9.86) (0.84 to 1.07)(235) 9.25 (2.29 to 2.51) (2.82 to 3.33) (9.98) --- (7.52) (0.76 to 0.99)(244) 9.625 (2.44 to 2.67) (2.44 to 2.95) (8.79) (7.82) (10.41) (0.84 to 1.07)(248) 9.75 (2.29 to 2.51) (2.97 to 3.49) (10.44) --- (7.92) (0.76 to 0.99)(251) 9.875 (2.77 to 3.00) (2.51 to 3.02) (9.07) (8.03) (10.67) (0.94 to 1.19)(260) 10.25 (2.29 to 2.51) (2.79 to 3.35) (10.06) --- (11.89) (0.84 to 1.02)

(264) 10.375 (2.77 to 3.00) (2.64 to 3.18) (9.53) (8.43) (11.23) (0.94 to 1.19)(267) 10.5 (2.90 to 3.12) (2.67 to 3.20) (9.60) (8.53) (11.35) (0.99 to 1.24)(273) 10.75 (2.29 to 2.51) (2.79 to 3.35) (10.06) --- (11.89) (0.84 to 1.02)

(276) 10.875 (2.90 to 3.12) (2.74 to 3.30) (9.98) (8.84) (11.76) (0.99 to 1.24)(279) 11 (2.90 to 3.12) (2.79 to 3.35) (10.06) (8.94) (11.89) (0.99 to 1.24)

(279) 11L & M (2.29 to 2.51) (2.79 to 3.35) (10.06) --- (11.89) (0.84 to 1.02)(286) 11.25 (2.54 to 2.74) (3.42 to 4.04) (12.12) --- (9.14) (0.91 to 1.07)

(289) 11.375 (2.90 to 3.12) (2.90 to 3.48) (10.44) (9.25) (12.29) (0.99 to 1.24)(298) 11.75 (2.54 to 2.74) (3.58 to 4.19) (12.57) --- (9.55) (0.91 to 1.07)

(305) 12 (2.97 to 3.24) (3.05 to 3.66) (10.97) (9.75) (12.98) (0.99 to 1.27)(311) 12.25 (2.97 to 3.23) (3.12 to 3.73) (11.20) (9.96) (13.23) (0.99 to 1.27)

(314) 12.375 (2.54 to 2.74) (3.76 to 4.37) (12.95) --- (9.55) (0.91 to 1.07)(318) 12.5 (2.97 to 3.24) (3.18 to 3.81) (11.43) (10.16) (13.51) (0.99 to 1.27)

(333) 13.125 (3.20 to 3.48) (3.33 to 4.01) (12.04) (10.67) (14.17) (1.09 to 1.35)(346) 13.625 (3.20 to 3.48) (3.45 to 4.17) (12.45) (11.07) (14.73) (1.09 to 1.35)(359) 14.125 (3.20 to 3.48) (3.58 to 4.32) (12.90) (11.48) (15.27) (1.09 to 1.35)(391) 15.375 (3.23 to 3.50) (3.91 to 4.70) (14.10) (12.50) (16.61) (0.97 to 1.27)(403) 15.875 (3.23 to 3.50) (4.04 to 4.85) (14.55) (12.90) (17.15) (0.97 to 1.27)(441) 17.375 (4.55 to 4.85) (4.42 to 5.31) (15.93) (14.12) (18.80) (1.12 to 1.45)7/09 PAGE 1 - 17

FOR MODELS: JGZ AND JGU SECTION 1 - DESIGN SPECIFICATIONS & DATAFastener Tightening TorqueListed in the following tables are fastener tightening torque values, required for proper assembly of an Ariel JGZ/JGU compressor. Refer to the section concerning a subject com-ponent for detailed assembly procedures.

Threads are to be clean and free of burrs.

Torque values are based on the use of petroleum type lubricants on the fastener threads and seating surfaces. Use lubricating oil or Lubriplate 630, except for main bearing-cap cap screws, compressor piston rod nuts, crosshead-balance lock nuts and crosshead threads, stainless steel fasteners and fasteners in forged steel cylinders which use Never-Seez, Regular Grade (by Bostik, www.bostik-us.com, do not substitute for this product), and except where Loctite is specified. Molybdenum disulfide lubricants and Never-Seez are not otherwise to be used for fastener lubrication, unless specified, or excessive stresses can result with the listed values.

(454) 17.875 (4.60 to 4.90) (4.55 to 5.46) (16.38) (14.53) (19.33) (1.12 to 1.45)(498) 19.625 (4.75 to 5.05) (5.99 to 6.81) (20.42) (15.95) (21.21) (1.27 to 1.60)(511) 20.125 (4.70 to 5.00) (6.15 to 6.96) (20.88) (16.36) (21.77) (1.27 to 1.60)

(559) 22 (5.41 to 5.72) (6.71 to 7.72) (23.16) (17.88) (23.77) (1.50 to 1.83)(613) 24.125 (5.44 to 5.74) (7.36 to 8.38) (25.15) (19.61) (26.09) (1.42 to 1.75)(673) 26.5 (5.74 to 6.05) (8.13 to 9.14) (27.43) (21.54) (28.65) (1.47 to 1.80)

a. For PEEK piston ring end gap values, multiply the table values by 0.3.

TABLE 1-11 FASTENER TIGHTENING VALUES

FASTENERNOMINAL

SIZEINCH TPI

TYPE TORQUE, LB X FT (Nm)

Main Bearing-Cap - Cap Screw 1-3/8 6 12 Point - Grade 8 350 (475) + 60 Turna

Connecting Rod-Caps - Cap Screw 1-3/8 12 12 Point - Grade 8350 (475) + 110

Turnb

Torsional Vibration Detuner-Donut Cap Screw 1-1/8 12 12 Point - Grade 8 740 (1010)

Crosshead Pin through Cap Screw - Lock Nut 5/8 18 Hex - Prevailing 125 (169)

TABLE 1-10 PISTON, PISTON RING & WEARBAND CLEARANCES - NON-PRC, (mm)

PISTON TO CYLINDER CLEARANCE

PISTON RING END GAPS - FILLED TEFLONa

WEAR BANDS NEW

BORE (mm) INCHES CLEARANCE NEW MAXIMUM

MINIMUM END GAP RADIAL

PROJECTION45 70PAGE 1 - 18 7/09

FOR MODELS: JGZ AND JGU SECTION 1 - DESIGN SPECIFICATIONS & DATACrosshead Guide to Frame/to Spacer Bar/Frame to Spacer Bar - Cap Screw

1-1/8 1212 Point - Grade 8

685 (930)1-1/8 7 595 (805)

Crosshead Guide to Cylinder; Cross-head Guide to Extension Piece - Cap Screw

7/8 9 12 Point - Grade 8 280 (380)

7/8 14 Hex Stud - Nut 315 (427)

Crosshead Guide to Support - Cap Screw 1-1/4 7 Hex - Grade 8 or 9 770 (1044)

Head End Cylinder Support to Cylin-der

1/2 13Hex - Grade 8

44 (60)5/8 11 88 (120)7/8 9 255 (345)

Eccentric Vernier-Cap - Cap Screw3/8 16

Hex - Grade 8 Hand Wrench Tight5/16 18

Idler Sprocket Through Cap Screw - Lock Nut 5/8 18 Hex - Prevailing 82 (110)

Sprocket Adapter/Flywheel to Crank-shaft - Cap Screw 3/4 16 Hex - Grade 9 215 (290)

Rod Packing - Cap Screw3/4 10

12 Point - Grade 8 or 17-4PH

125 (170)1 14 350 (475)

1-1/4 12 700 (940)Rod Catcher to Packing 5/8 18 12Pt-Gr8/17-4PH 105 (140)Piston Nut 2-1/4 12 Ariel Design Notec

Crosshead-Balance Nut 2-5/8 8 Ariel Design Noted

Lifting Bracket to Frame 1-3/4 8 12 Point - Grade 8 2120 (2870)

Rupture Disk - Blow-Out Fitting Cap 1/4 Nom. Tube Hex - Tube Fitting 40 lb x in. (4.5)

Fenner Drive at FF Lube Sprocket -- Hex 200 lb x in. (23)

Cylinder Mounting Flange to Forged Steel Cylinder

1 14 12 Point - Grade 8 or 17-4PH

485 (655)1-1/4 12 955 (1290)

Hold Down - Stud Nut 1-3/4 5 Hex Stud - Nut 2300e (3100)

TABLE 1-11 FASTENER TIGHTENING VALUES

FASTENERNOMINAL

SIZEINCH TPI

TYPE TORQUE, LB X FT (Nm)7/09 PAGE 1 - 19

FOR MODELS: JGZ AND JGU SECTION 1 - DESIGN SPECIFICATIONS & DATAValve Cap/Cylinder Head/Unloader/Gas Passage Cap/Ariel supplied Companion Flanges, except Pea-nut Dual Nozzle Companion Flanges - Cap Screwf

5/8 11 Hex - Grade 8/9 or12 Point - Grade 8

or 17-4PH

79 (105)3/4 10 140 (190)3/4 16 160 (215)7/8 9 230 (310)7/8 14 260 (355)

1 8 345 (470)1 14 395 (535)

1-1/8 12 560 (760)Peanut Dual Nozzle Companion Flanges 1/2 13

12 Point - Grade 8 or 17-4PH 53 (71)

Tandem Cylinder to Cylinder - Cap Screw6

1/2 13 Hex Grade 8/9 or 12 Point - Grade 8

or 17-4PH

44 (60)5/8 11 88 (120)3/4 10 160 (215)3/4 16 180 (245)

Seating Studs 5/8 11 Dog Point 44 (60)3/4 10 79 (105)3/4 16 90 (120)7/8 9 130 (175)7/8 14 145 (195)

1 & Larger 200 (270)Distribution Block Tie Rod - Nut 1/4 28 Hex 68 lb x in. (7.7)Distribution Block Divider Valve - Cap Screw 1/4 28 Socket Head 75 lb x in. (8.5)

Force Feed Lube Box - Bearing Housing

1-3/8 20 Left Hand Bearing Housing 70 (95)

Force Feed Lube Box -Jam Nut 1 14Hex - Jam

75 (100)1-1/2 12 112 (150)

Grade 5 - Hex Cap Screw 1/4 20 Hex - Grade 5 Hand Wrench Tighta. Separately purchased hydraulic connecting rod/main bearing-caps cap screw torquing tool is required

to achieve the additional 60 turn on the cap screws, see Figure 7-12 on page 7-7.b. See Page 5-6 for complete instructions. Separately purchased hydraulic connecting rod/main bearing-

caps cap screw torquing tool is required to achieve the additional 110 turn on the cap screws, see Fig-ure 7-12 on page 7-7.

c. Use 8700 psig (600 barg) hydraulic pressure and 30 lb-ft (41 Nm) tightening torque on separately pur-chased piston rod tensioning tool G-12644. Tighten, loosen and re-tighten piston nut to be sure of proper tightening. See Piston and Rod - Reassembly on page 5-37. See Ariel Tools - Separately Purchased on page 7-4.

TABLE 1-11 FASTENER TIGHTENING VALUES

FASTENERNOMINAL

SIZEINCH TPI

TYPE TORQUE, LB X FT (Nm)

Dog Point StudPAGE 1 - 20 7/09

FOR MODELS: JGZ AND JGU SECTION 1 - DESIGN SPECIFICATIONS & DATA

d. Use 2000 psig (138 barg) hydraulic pressure on separately purchased crosshead (balance) nut torqu-ing tool G-12645.

e. Minimum torque for recommended 1-3/4 in. 5 TPI hold-down stud size to provide stress in stud of 55,000 psi (380 MPa). Stud must have an ultimate strength of 100,000 psi (690 MPa) or greater. If greater, increase torque, to stress stud to about 55% of the ultimate strength of the stud material, as specified by packager. Or use separately purchased hydraulic hold-down stud tensioner tool (G-12860). See Figure 7-13 on page 7-8.

f. When studs are specified for cylinder applications, tighten stud-nuts to the same values as cap screws in similar applications.

TABLE 1-12 HOERBIGER VALVE ASSEMBLY FASTENERS - TIGHTENING VALUES

FASTENERANOMINAL

SIZEINCH TPI

TYPE TORQUE,LB X FT (Nm)

Center Cap Screwb,c 5/16 24 12 Point - Steel Grade 5,Material Parts: SPL3 & 4

144 lb x in. (16)3/8 24 21 (28)

7/16 20 30 (41)5/16 24 12 Point - Steel Grade 5,

Material Parts: SPL518 (24)

3/8 24 32 (43)7/16 20 50 (68)5/16 24 12 Point - Stainless Steel

Grade B8M,Material Parts: SPL6

120 lb x in. (14)3/8 24 192 lb x in. (22)

7/16 20 24 (33)5/16 24 12 Point - Steel Grade 8 26 (35)3/8 24 45 (61)

7/16 20 62 (83)Center Stud - Drake Lock Nut

1/4 28 Bottom Half 103 lb x in. (12)Top Half 66 lb x in. (8)

5/16 24 Bottom Half 120 lb x in. (14)Top Half 66 lb x in. (8)

3/8 24 Bottom Half 192 lb x in. (22)Top Half 96 lb x in. (11)

1/2 20 Bottom Half 36d (49)Top Half 20 (27)

5/8 18 Bottom Half 73 (99)Top Half 40 (54)

3/4 16 Bottom Half 130 (176)Top Half 70 (95)

Top Half - Locking

Bottom Half7/09 PAGE 1 - 21

FOR MODELS: JGZ AND JGU SECTION 1 - DESIGN SPECIFICATIONS & DATATightening Torque ProceduresListed below are some procedures which make fastener tightening more accurate and will help to be sure that the proper torque is being applied.

1. Be sure that the torque wrench is properly calibrated and used by qualified person-nel to achieve the required fastener tightening torque for all critical parts.

2. Always check to determine over what range the torque wrench is accurate, since most torque wrenches are not accurate over their entire range.

3. Tighten all multi-bolt assemblies in steps (need not apply to Grade 5 cap screws). Tighten each cap screw until snug using an alternating (criss-cross) pattern, refer to Figure 5-49 on page 5-60 for typical pattern sequence. Next, tighten each cap screw to 25% of full torque, moving across from cap screw to cap screw, in an alter-nating (criss-cross) pattern. Repeat this step for 50%, 75%, and 100% of full torque.

Peripheral Cap Screws 10 - 32 Hex Socket Head 25 lb x in. (3)12-28 43 lb x in. (5)

1/4 110 lb x in. (12)5/16 176 lb x in. (20)3/8 21 (28)

a. For Prevailing-Torque Lock Nuts, use Column 40 on page 3 or 4 in the Tool Box Torque Chart (ER-63).

b. 12 Point Cap Screw Center Fasteners in Valve Assemblies not marked SPL (Spiralock Threads), must be cleaned with Loctite Safety Solvent and locked with one or two drops of Loctite #272 thread locking compound. Do not use petroleum lubricants.

c. 12 Point Cap Screws in Valve Assemblies with Spiralock Threads and marked SPL (see Figure 1-10) are lubricated, both threads and seating surfaces, with a petroleum type lubricant only.

d. 29 lb x ft (39 Nm) for 1/2 20 Bottom Half - Drake Lock Nut with non-metallic Plates in Liftwasher Type Valves.

FIGURE 1-10 SPIRALOCK THREADED VALVE ASSEMBLY - MARKED SPL

TABLE 1-12 HOERBIGER VALVE ASSEMBLY FASTENERS - TIGHTENING VALUES

FASTENERANOMINAL

SIZEINCH TPI

TYPE TORQUE,LB X FT (Nm)

Suction GuardDischarge Seat

Bottom ViewsPAGE 1 - 22 7/09

FOR MODELS: JGZ AND JGU SECTION 1 - DESIGN SPECIFICATIONS & DATARepeat the 100% step until there is no fastener rotation. On rod packing fasteners, wait a few minutes, before repeating the 100% step to accommodate for any gasket deformation.

4. Always apply a steady slow force to a torque wrench, and stop force immediately when click is felt, do not jerk the wrench. When a torque wrench is jerked the amount of torque applied can be as much as one and a half times the amount set on the wrench. For example, if a wrench is set at 80 lb x ft (108 Nm) but is jerked, 120 lb x ft (163 Nm) torque can be applied.

5. Always do the final tightening with a torque wrench. Do not tighten the fastener with a ratchet or impact wrench and then "check" the torque with a torque wrench.

6. Do not double tap a torque wrench. Rapidly double tapping a torque wrench will make the torque on the cap screw more than what is set by a significant amount.

7. When checking a tightened fastener torque, set torque wrench to proper required torque value, slowly apply a steady force to torque wrench until click is felt.

8. Always reset the torque wrench to its lowest setting when the job is complete. If the torque wrench is left in a high setting the spring in it is stressed and will become inaccurate with time. If the torque wrench is put back to its lowest setting the spring will relax and retain its accuracy.

9. Do not use a torque wrench to break fasteners loose as it may overload the torque wrench and/or cause loss of calibration.

10. For applications requiring the use of a boxed end or crowfoot adapter with a torque wrench to reach not readily accessible fasteners, the torque wrench setting will not be the actual torque applied to the fastener.1

11. The ratio of actual torque at the fastener with that on the wrench scale is a function of the adapter's length (A) and its position in relation to the torque wrench beam and the location where the force is applied (see Figure 1-11).

Tw = Torque wrench setting, lb x ft or Nm

Ta = Torque required at fastener, lb x ft or Nm

L = Length of wrench, ft or m (from square drive end to center point of force on handle)

A = Length of adapter, ft or m (measured through end of adapter on a line parallel to the center line of the wrench)

These are general guidelines to assist in the proper use of torque wrenches. Con-sult with your torque wrench dealer for more detailed information.

1. The exception is when the adapter is 90 to the torque wrench. The torque will be the same as on the wrench scale (see Figure 1-12).

Tw Ta LL A+------------- =7/09 PAGE 1 - 23

FOR MODELS: JGZ AND JGU SECTION 1 - DESIGN SPECIFICATIONS & DATA12. See the Ariel Web Site, www.arielcorp.com at support, vendor literature, Swagelok, for tube fitting tightening instructions.

Ariel BoltingThe bolting have been selected that meet Ariel's strength, elongation, sealing and locking requirements. Proper bolting must be used and tightened to the values listed in Table 1-11 on page 1-18. Figure 1-13 is provided to assist in the identification of cap screws used in an Ariel compressor.

Connecting rod, detuner donuts, valve cap and suction/discharge nozzle (Ariel supplied spe-cialized companion flange) bolting is modified to prevent fatigue and cannot be replaced with standard cap screws. If attempting to replace other bolting with standard cap screws and there is any question, contact your packager or Ariel. Ariel supplied replacement bolting is recommended.

FIGURE 1-11 TORQUE WRENCH WITH ADAPTER AT ANY ANGLE

FIGURE 1-12 TORQUE WRENCH WITH ADAPTER AT RIGHT ANGLE

FIGURE 1-13 CAP SCREW IDENTIFICATION

FORCE

FORCE

Hex head Grade 8

Hex head Grade 9

Hex head Grade 5

12 Point Grade 8

12 Point Interim Grade 5

12 Point Stainless Steel Grade 17-4PH

Hex Socket Head Grade 8

12 Point Grade 5

17-4PAGE 1 - 24 7/09

FOR MODELS: JGZ AND JGU SECTION 1 - DESIGN SPECIFICATIONS & DATACAUTION: WHEN RE-ASSEMBLING OR REPLACING BOLTING, SEE THE ARIEL PARTS LIST TO DETERMINE THE PROPER FASTENER GRADE, SIZE AND PART NUMBER. DO NOT USE A LESSER OR GREATER MATERIAL GRADE. A PLASTIC GAGE FOR CHECKING BOLTING DIAMETERS AND THREAD SIZES CAN BE FOUND IN THE ARIEL PROVIDED TOOL BOX. ALL SPECIAL FASTENERS AND ALL BOLTING THAT HAS BEEN MADE TO REDUCE THE BODY DIAMETER FOR FATIGUE RESISTANCE, MUST BE REPLACED WITH ARIEL PARTS.

Main Bearing Temperature Instrumentation - Alarm & ShutdownMain bearing temperature sensors are provided as standard from Ariel for JGZ and JGU frames, as thermocouples or RTDs:

Thermocouples, Type J (Iron-Constantan) or Type K (Chromel-Alumel)

A thermocouple is two dissimilar conductors joined together at one end to form a sensor that produces a small self-generated thermoelectric voltage as an accurate function of temperature. When connected to the proper electronics, the thermocouple voltage is interpreted as temperature.

Wire: Must use proper thermocouple wire from sensor to control panel with each lead wire metal matching each conductor metal of sensor.

Sensor Accuracy = 4F (2.2C) or 0.75 percent.

Terminals: Must use proper terminals with metal matching each thermocouple sensor conductor/wire lead metal.7/09 PAGE 1 - 25

FOR MODELS: JGZ AND JGU SECTION 1 - DESIGN SPECIFICATIONS & DATAResistance Temperature Devices (RTDs)

An RTD is a resistor type sensor, in which the electrical resistance accurately varies with temperature change. When connected to the proper electronics, the resistance is interpreted as temperature. When RTDs are ordered for the main bearings, Ariel supplies dual-element RTD instrument assemblies, consisting of two RTDs in each instrument for each main bearing. Each element is a three-wire, 100 ohms (at 0C), Alpha = 0.00385 ohms/ohm/C, platinum thin film type sensors.

Dual element RTDs are provided to allow for rewiring instead of replacing the sensor in the event of an element failure. The advantage of the dual-element RTD assembly is that the redundancy saves time by allowing the operator an opportunity to restore bearing temperature monitoring without entering the crankcase for each RTD failure.

Wire: The dual element RTDs use 24 AWG (American Wire Gage) instrumentation wire from the junction box mounted on the side of the compressor frame to the sensor wiring. An RTD three wire set may be wired using a two, three, or four wire system. More wires increases accuracy. Ariel recommends using standard foil shielded instrumentation cable runs from the compressor frame to the control panel. Shields should be grounded in the control panel.

Sensor Accuracy: 100 + 0.12 ohms at 0C = 1.1F (0.6C), or 0.6 percent.

Terminals: Can use any standard terminals.

For each instrument, a single RTD three-wire set is used to connect to the monitoring circuit. If the connected RTD fails, it can be disconnected and the remaining RTD three-wire set can be used to connect to the circuit. Unused wire ends should be insulated from each other and conduit ground.

RTD's are furnished with two red wires and one white wire for the one element, and two black wires and one green wire for the other element to simplify the wiring requirements.

Main Bearing Temperature Alarm and Shutdown Limits

One of the following, minimum, is to be provided for main bearing temperature alarm and shutdown to Ariel compressors:

1. Main bearing temperature high alarm and shutdown. - The alarm and shutdown should be set as close as practical above the normal operating temperature. Ariel recommends 20F (12C) over normal operating temperature for alarm and 30F (18C) for shutdown. Maximum values of 220F (104C) for alarm and 230F (110C) for shutdown apply. Normal operating temperature is the

White

RedRed

Green

BlackBlack

Element 1

Element 2

FIGURE 1-14 DUAL ELEMENT RTD WIRING DIAGRAMPAGE 1 - 26 7/09

FOR MODELS: JGZ AND JGU SECTION 1 - DESIGN SPECIFICATIONS & DATAaverage of all main bearing temperatures at design load when oil temperature stabilizes and all components are heat soaked.

And/or

2. High main bearing temperature differential alarm and shutdown. - Main bearing differential temperature is defined as the difference between the maximum and minimum of all main bearing temperatures. Ariel recommends the alarm set to 20F (12C) and shutdown at 30F (18C), differential. It is possible after a warm shutdown that main bearing number 1 will cool faster than the others. Provisions should be made such that a cooler number 1 bearing will not prevent a restart.

Zone 1 Environment

A Zone 1 environment requires the installation of proper intrinsically safe or equivalent protection to fulfill the electrical requirements, where applicable.7/09 PAGE 1 - 27

FOR MODELS: JGZ AND JGU SECTION 1 - DESIGN SPECIFICATIONS & DATANOTES:PAGE 1 - 28 7/09

FOR MODELS: JGZ AND JGU SECTION 2 - COMPRESSOR INSTALLATIONSECTION 2 - COMPRESSOR INSTALLATION

GeneralThe installation of the compressor with the associated driver and piping, is to be done with care and precision. This section addresses some of the more critical installation consider-ations and requirements, but does not attempt to address all of the concerns that can arise.

The Skid or PackageThe skid or package is to be manufactured and installed in conformance to Ariel Packagers Standards.

Lifting the CompressorDetermine the weight of the compressor, prior to lifting. For an accurate value, see the Ariel Performance Program to determine frame and cylinder weights or for an approximate weight of the compressor with cylinders see Technical Manual Section 1, Frame Specifica-tions tables. Also account for any extra weight such as a flywheel, etc. Spreader bars should be used to provide for a more vertical pull on the eyebolts or lifting lugs. Be sure that the eyebolts or lifting lugs, lifting tackle, spreader bars and crane capacity are adequate and properly rigged for the load. Keep the compressor level when lifting and setting. Heavier cyl-inders and/or blank throws can significantly affect the center of gravity.

Do not attempt lifting by hooking to a compressor when the compressor is attached to the skid, driver or piping. If you are not experienced in lifting large compressors, the use of qual-ified professional riggers/movers is recommended.

On compressor frames designed for lifting lugs, install the lugs (4) with the proper Grade 8 cap screws and tighten to the torque value given in the Technical Manual Section 1 or the tool box torque chart (the ER-63 chart is also available electronically at the Ariel web site: www.arielcorp.com), for lifting the compressor. If lifting lugs are already installed, recheck fastener tightening torque. JGZ:U/4, KBB:V/4 and all 6-throw compressors have lifting lugs.

When lifting a compressor not designed with lifting lugs, lift by the eyebolts installed by Ariel at the crosshead guides. Eyebolts installed in the crosshead guides by the Ariel Shop are locked with Loctite to help prevent them from turning. Inspect eyebolts to be sure they are free of any visual defects, such as bending, that could affect serviceability. Remove and physically destroy any defective eyebolts. Replacement eyebolts are to be forged steel and meet the requirements of ASME B18.15 latest edition (available at www.asme.org). Clean threads and install a replacement eyebolt with Loctite #262 (available at www.loctite.com) in the same orientation as original eyebolt. Allow Loctite to cure before using a replaced eye-bolt for lifting. For eyebolt load capacity rating and if pulling on an eyebolt in a direction other than along the threaded axis, consult ASME B18.15. 7/09 PAGE 2 - 1

FOR MODELS: JGZ AND JGU SECTION 2 - COMPRESSOR INSTALLATIONThe standard lifting lug and eyebolt materials can fail when subjected to shock loads at low ambient temperature conditions. Follow the guidelines in ASME B18.15. If deemed neces-sary by the customer or lifting professional, eyebolts may be replaced with forged eyebolts of materials more suitable for low temperatures, in accordance with ASME B18.15 and ASTM F541 (available at www.astm.org). Standard lifting lugs and bolting may also be replaced with materials more suitable for low temperatures. Contact Ariel for more informa-tion.

Setting the CompressorThe following procedure is to be used for setting the compressor on the skid:

1. Be sure the skid is level.2. Move the compressor into place on the skid. 3. Level stationary compressors to Table 2-1 on page 2-3 requirements. For com-

pressors subject to transient motion on ships or offshore platforms, level com-pressors to table requirements when at rest. Be sure the pre-grout alignment is relatively close so that the equipment movement will be minimal and within the bolting, foot, push pads or grout box allowance.

4. Grout as required and allow grout to set.With the compressor cylinders mounted but unsupported and with no piping or pulsationdamping bottles attached, tighten the frame foot hold down bolting to skid at full fastenertorque. Refer to Ariel ER-26, Appendix A in the Ariel Packagers Standards for proper framefoot torque values.

Leveling Limits for CompressorsThe limits in Table 2-1 on page 2-3 assume that the running oil level is maintained between one half and two-thirds the height of the sight glass, except for dry sump compressors. Length leveling limits apply axially (parallel to crankshaft) and width limits apply horizontally (parallel to the piston rod) within the length and width of the frame.

CAUTIONWHEN LIFTING A COMPRESSOR DESIGNED FOR LIFTINGLUGS, ONLY USE ARIEL PROVIDED OR APPROVED LUGS.BE SURE THE LUGS ARE HELD IN PLACE WITH THEPROPER GRADE OF CAP SCREWS, AND PROPERLYTIGHTENED. LIFTING CABLE SPREADERS ARE REQUIREDPERPENDICULAR TO CRANKSHAFT AXIS. BE SURE THECRANE CAPACITY IS ADEQUATE.

!PAGE 2 - 2 7/09

FOR MODELS: JGZ AND JGU SECTION 2 - COMPRESSOR INSTALLATIONAligning Main Bearing BoresTo maximize main bearing life expectancy and help avoid crankshaft failures, it is essential that compressor frames be installed and remain in position so that main bearing bores can be maintained in proper alignment. Ariel has established this procedure in an effort to facili-tate the proper installation of compressor frames and provide a means of periodic inspec-tion.

1. The top cover mounting surface of an Ariel compressor frame is manufactured in a flat plane to a close tolerance. This surface is also held to a close tolerance with the main bearing bores and the bottom of the compressor feet. When the frame feet are supported so that the top-cover-mounting surface is flat "in plane", the main bearing bores are in alignment.

2. Top-cover-mounting surface flatness or soft foot check may be used for frame sizes up to and including JGU:Z/2-throw frames to be sure main bearing bores are in proper alignment, except for the JGI which uses only soft foot.

3. On JGU:Z:B:V:KBB:V/4-throw and /6-throw frames the top plane flatness and soft foot checks are both required to be sure the main bearing bores are in proper alignment.

4. Measurements for flatness are to be taken on the top surface of both sides of the frame rails at each anchor bolt or for frames with pairs of anchor bolts between each pair of anchor bolts, with top covers and gaskets removed (see Figure 2-1). Readings between any two adjacent points are to be within 0.002 in. (0.05 mm). The total accumulated out of plane flatness for proper alignment is to be within the flatness tolerances listed in Table 2-2.

TABLE 2-1 MAXIMUM ANGLE FROM A HORIZONTAL PLANE FOR LEVELING COMPRESSORS

FrameMaximum Angle from a horizontal Plane - In/Ft of distance (mm/m) [ ]

1 or 2 Throw 4 Throw 6 ThrowLength Width Length Width Length Width

JGM:N 0.420 (35) [2] 0.500 (42) [2.4] N/AJGP:Q 0.500 (42) [2.4] 0.500 (42) [2.4] N/A

JG 0.460 (38) [2.2] 0.500 (42) [2.4] 0.215 (18) [1.0] 0.500 (42) [2.4] N/AJGA 0.500 (42) [2.4] 0.500 (42) [2.4] 0.310 (26) [1.5] 0.500 (42) [2.4] 0.190 (16) [0.9] 0.500 (42) [2.4]

JGW:R 0.095 (7.9) [0.45] 0.500 (42) [2.4] 0.025 (2.1) [0.1] 0.500 (42) [2.4] N/AJGJ 0.420 (35) [2] 0.500 (42) [2.4] 0.105 (8.7) [0.5] 0.450 (37) [2.1] 0.065 (5.4) [0.3] 0.460 (38) [2.2]JGH 0.375 (31) [2] 0.500 (42) [2.4] 0.160 (13) [0.8] 0.500 (42) [2.4] N/A

JGE:T 0.440 (37) [2.1] 0.500 (42) [2.4] 0.155 (13) [0.7] 0.500 (42) [2.4] 0.090 (7.5) [0.4] 0.310 (26) [1.5]JGK 0.105 (8.7) [0.5] 0.500 (42) [2.4] 0.035 (2.9) [0.2] 0.500 (42) [2.4] 0.020 (1.7) [0.1] 0.310 (26) [1.5]JGC 0.270 (22) [1.3] 0.460 (38) [2.2] 0.100 (8.3) [0.5] 0.460 (38) [2.2] 0.060 (5.0) [0.3] 0.180 (15) [0.9]JGD 0.500 (42) [2.4] 0.460 (38) [2.2] 0.205 (17) [1.0] 0.460 (38) [2.2] 0.125 (10) [0.6] 0.180 (15) [0.9]JGZ 0.500 (42) [2.4] 0.500 (42) [2.4] 0.380 (25) [1.8] 0.500 (42) [2.4] 0.240 (20) [1.1] 0.500 (42) [2.4]JGU 0.500 (42) [2.4] 0.500 (42) [2.4] 0.475 (40) [2.3] 0.500 (42) [2.4] 0.300 (25) [1.4] 0.500 (42) [2.4]JGB N/A 0.250 (21) [1.2] 0.075 (6.2) [0.4] 0.180 (15) [0.9] 0.075 (6.2) [0.4]JGV N/A 0.235 (20) [1.1] 0.075 (6.2) [0.4] 0.150 (12) [0.7] 0.075 (6.2) [0.4]

KBB:V N/A 0.165 (14) [0.8] 0.500 (42) [2.4] 0.120 (10) [0.6] 0.500 (42) [2.4]7/09 PAGE 2 - 3

FOR MODELS: JGZ AND JGU SECTION 2 - COMPRESSOR INSTALLATION5. In preparation for frame plane measurements, be sure that the compressor frame hold down bolting is properly installed and tightened. Either remove or reposition the top cover(s) and gasket(s) to expose the frame's top-cover-mounting surface, be sure that the top-cover-mounting surface is clean. With new unit installations it is recommended that the frame plane be initially checked prior to the guide feet being shimmed and after the initial rough coupling align-ment. On compressors shipped disassembled, the initial check should be car-ried out prior to the guide & cylinder assemblies being installed. Take the appropriate corrective shimming, or other height adjustment, action to have the top-cover-mounting surface fall within the specified plane tolerance. Subsequent readings should be taken and recorded after the guides and cylinders have been fully installed and then again after any vessels have been installed and shimmed. Corrective action is to be taken if guide, cylinder and/or vessel instal-lation results in the frame top rail measurements not meeting the specified toler-ances

6. Refer to Ariel ER-26, Appendix A in the Ariel Packagers Standards for proper frame foot and crosshead guide bolt size and torque values.

7. The top-cover-mounting surface should be measured for flatness and/or soft foot check be done as required:a.When setting a new compressor.b.After reinstalling a compressor frame.c.When loose hold down fasteners are found.

TABLE 2-2 TOP-COVER-MOUNTING SURFACE - FLATNESS TOLERANCE

COMPRESSOR FRAMEa

a. The underlined frames are required to use both top plane flatness and soft foot checks.

TOLERANCE FOR ALIGNMENT

INCHES (mm)

JGM:N:P:Q/1/2, JG:A/2/4, JGR:J/2 0.004 (0.10)JGA/6, JGR/4, JGJ/4/6, JGH:E:K:T/2/4, JGC:D/2/4,

JGU:Z/2/4, JGB:V/4, KBB:V/4 0.006 (0.15)

JGE:K:T/6, JGC:D/6, JGU:Z/6, JGB:V/6, KBB:V/6 0.008 (0.20)

Take Measurements Here

FIGURE 2-1 FLATNESS CHECK LOCATIONS - TYPICALPAGE 2 - 4 7/09

FOR MODELS: JGZ AND JGU SECTION 2 - COMPRESSOR INSTALLATIONd.Every 6 months or 4000 hours as recommended maintenance inspection.8. The Equipment used for flatness measurements should have a published accu-

racy of + 0.001 inches (+ 0.025 mm) over the required distance to measure the entire length of both frame rails.

9. To check soft foot, the compressor frame hold down bolting is to be properly installed and tightened. Loosen each hold down bolt individually while checking the frame foot to skid deflection with a calibrated dial indicator. Correct any hold down position that deflects more than 0.002 inches (0.05 mm) when released. Re-torque the hold down bolt and repeat at each frame to skid bolt.

Setting Crosshead GuidesWith crosshead guides and cylinders unsupported, prior to bottle installation:

1. Measure the clearances between each crosshead guide foot and the guide sup-port. Except for JGZ:U and KBB:V frames when equipped with long two com-partment (L2) crosshead guides, measure clearance at the outboard feet under the guide extension, which are used to support the guide and the feet under the guide are to be unsupported.

2. Completely fill the clearances with shim stock (reference Figure 2-2). 3. Tighten the crosshead guide foot (or long two compartment guide extension

foot) to guide support hold-down bolting to full fastener torque. Refer to Ariel ER-26.

4. Loosen the bolting while checking with a dial indicator to be sure that the clear-ance is completely filled and there is no deflection.

5. Using the information from the current Ariel Performance Program, determine the estimated crosshead guide foot deflection for JGH:E:K:T:C:D:Z:U:KBB:V frames. This calculated value is required to compensate for the deflection or droop of the cantilevered weight of the guide and cylinder. For the JG:A:M:N:P:Q:R:W:J frames, the guide and cylinder weights are not sufficient to deflect the guide.

6. Lift or jack cylinder, just slightly to allow insertion of additional shims based on the calculated value.

7. Re-tighten the crosshead guide hold down bolting to full fastener torque. 8. Repeat for each crosshead guide support.9. Shims may need to be adjusted so that the crosshead to guide top and bottom

clearances, and piston rod run-out measurements are within the tolerance requirements. Reference Section 5 for checking crosshead clearances and pis-ton rod run-out, and Section 1 for tolerance limits.7/09 PAGE 2 - 5

FOR MODELS: JGZ AND JGU SECTION 2 - COMPRESSOR INSTALLATIONFor some applications, head-end cylinder supports may be desirable for larger classes of cylinders (bosses and tapped holes are provided on all K:T:C:D:Z:U:B:V class cylinders). See Ariel cylinder outline drawings for dimensional details. These supports must be adjusted and set when the components are at operating temperature.

Setting - Miscellaneous1. Reference Technical Manual Section 4 for protection of electronic equipment

when arc welding.2. Comply with the Ariel Start Up Check List, see Technical Manual Section 3.

Alignment - to DriverProper alignment to the driver is necessary for satisfactory performance. A flexible coupling will not make up for poor alignment. Misalignment can result in:

High bending moment on the crankshaft. Large axial forces. Excessive bearing wear. And if severe, probable damage to various components.

Procedural Requirements for Aligning a unit:

Check the compressor frame, crosshead guide and drive