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    KW TP Compressor Operation PDF

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    COMPRESSOR OPERATION INSTRUCTION MANUAL FOR ALL "TP" SERIES COMPRESSORS A CAUTION ai INSTALLING AND OPERATING THIS COMPRESSOR, READ AND UNDERSTAND THE SAFETY NOTICES CONTAINED WITHIN THIS MANUAL. 1111 Bacon Street » Erie, PA 16511 + 814-459-2754 + 800-299-5208 + FAX: 614-455-8493 __ Direction of Rotation TABLE OF CONTENTS ation 1: SAFETY Scetion V: MAINTENANCE (Cont.) Warring Notio= Safety and Maintenance, Selety and Operation Section fl: KNOX WESTERH COMPRESSORS Compressor Features Mode! Identification... Warning Nameplates ‘Compressor Warranty Section Ill: PACKAGING AND INSTALLATION Packaging Riecommended Gil ilRequirements joing Protective Guards... Liquid Separation ... Piping Cleanliness Leveling Coupling Size Coupling Alignment V-Bolt Drive Agent tion IV: START UP wi to Staring Stenting After Starting Section V: MAINTENANCE Valves Valve Function Valve Removal Valve Disassembly ..... Valve Inspection and Flepair Valve Assembly. : Valve Installation Valve Cages. a 8 8 Cylinders ylinder Design ineananeen M4 Piston and Flog Removal... : mar Pision and Rod Installation... i 14615 Piston Rings and Rider Ring Replacement. 18 ‘Adjusting Cylinder Striking Clearance... 16 Clearance Pocket Piston and Rings ve 7 Pressure and Wiper Packing Replacement... a Crankshaft : Removal seinen 9 Installation... 20 it Pump Design and Operation 7 ws V Construction Features vc roneonn 2 Removal and Dissasembly 21 Inspection and installation... 1-22 Adjusting Oil Pressure 2 Frame Crossnead Removal 23 Crosshead Installation vw.rnssecnonn 23 Connecting Rod Removal 24 Connecting Rad installation... 24 Design Variations ‘TP75 (Style) Design Notes TPT5 — Balance Weight Crossheed Removal ‘P75 ~ Balance Weight Guide Removal... ‘TP75 — Balance Weight Crosshead and Guide incialaion 1P75 and TP120 (Sie) Dasign Notes i P75 and TP120 ~ Connecting Rod Removal ‘P75 and TP120 ~ Connecting Rod Installation. “TP400 (Style) Design Notes... . ‘When Installing TP400 Compressor TPag0 Crankshatt Removal... ‘TP400 Crankshaft Installation Section Vi: GENERAL DATA Inspection and Maintenance Chart ‘Troubleshooting... Special Tools Compressor Specifications . - Mechanical Data and Clearances Index. ILLUSTRATIONS . Figure No. Deserintion Page No. Figure No, Deserintion Page Ho, 1 ‘Recommended Oi Figing 6 sleet Compressor Assembly 6 2 CompressorOriver Alignment 7 18 Clearance Pocket ASSEMBIY .nninsnnn 17 Ban ‘Alignment: Anguir.. 7 19 season man PRkng Assembly 7 4 Alignment: Parallel sora 20. ‘Watereronlad Packing Assembly. ate 5 Cunnpressor Package Arrangement orn. 8 3 Frame and Guide Group 8 ‘ Couble-acting Cynder. 8 2 soon CranKshalt GOUD «nn 20 7 woweDauble-Acing Cylinder with Cages 9 ae isereaacrntie aaa ciay 8 nn OrmpresG0K Suction Valve (Series M) 10 Be cena 9 smn Compressor Discharge Valve (Series M) .......10 ‘ ba 10 -nn€ompressor Suction Valve (Series KW)... 10 Ps eee pate 11... Comprassar Discharge Valve (Series KW) ..........10 2 Connecting Rod & Crosshead Group .. ad 12 Single-Acting Tandem Cvlinder ..... ” a vee Grosshead Groun bal 13. Deuble-Aeting Gyinder Cross-Section 12 28 ss TP75 and TPSO Frame & Guide Asem... 25 14 sree PION ANG ROG ABSEMBW ooneesn voces 29... Connacting Rod & Crosshead Balance Group .....28 6... Piston and Rod ASSEMbIY vances 4 30 .Crosshead Group 28 16 Tandem Cylinder Assembly 6 31 CrOSsR62d GIOUP eo runnenennsnannnn 8? 32 cron Frame & Guide Group 28 ” SECTION I: SAFETY Note: this manual mustbe fully understood and carefully observed. Understand too, ‘hat hase safety and caution notices are nat exhauetive, | ‘To reduce the chance of personal injury and/or property damage, the instructions and special safety and caution notices provided in since it would be impossible to warn of every possible consequence from failure to follaw these instructions. Running Characteristics and Safety To insure the safe, reliable functioning of Knox Westem compressors, adhere to the folowing guidelines: Compressor Speed Max. Min, MODELS ‘TF20, TP6O 800RPM 400 RPM ‘TPES, TPH45, ‘TP245, TP4a5.——«1200RPM SSO RPM Te 100, 1P200, Pao 1500 RPM “S50 RPM P75, 1P20, TP120,TP220 1800RPM SSO RPM Working Pressure Maximum allowable working pressure var- ~ igs with cylinder size and design. This infor- «rationis stampedonthe cylinder nameplate ‘and must never be exceeded, Serious or __ fatal injury could occur. ‘elle valves shall be set to operate NO righerthan the maximuin allowable work- ing pressure, but not less than 110 per- cent of the rated discharge pressure, or the rated prassure plus 25 psig, which- everis greater, Pipework and other cornponents which may notbe included in our scoce of supply must bbe sullable forthe respective working pres- sue, and, necessary, must fst be tested andthen protected ftom overioadby @ pres- sure elie device, Termperature Maximum allowable temperature forall stan- dard cyiindere ie 305° F., 350° F, for water cooledcyiinders. Special pistonringandiod packing materials are required for tempera- tures over 275° od Loading Rod or frame load is the total load imposed ‘on the compressor frame by gas pressure acting an the piston fine area. The max imum allowabie value is shown in the com- pressor specification manual and must not be exceeded. Serious damage or injury could occur. in doubt, contact the Knox Western eng neering department for proper sizing or technical assistance. UNDER NO CIRCUMSTANCES SHOULD A KNOX-WESTERN COMPRESSOR BE OPERATED IN A SERVICE OR USE OTHER THAN THAT FOR WHICH ITS SPECIFICALLY DESIGNED. FAILURE TO OBSERVE THIS NOTICE CAN CAUSE SERIOUS MECHANICAL PROBLEMS, AND COULD MAIM OR KILL DANGER COMPRESSED GAS IS POTENTIALLY EXPLOSIVE, MAKING SPECIAL PRECAU- ‘TIONS EXTREMELY IMPORTANT WHEN WORKING WITH THIS EQUIPMENT. BE ‘SURE TO STRICTLY OBSERVE ALL AP- PLICABLE SAFETY REGULATIONS AND PRACTICES. FAILURE TO 00 SO GAN CAUSE SERIOUS MECHANIUAL PHOS LEMS, AND CAN MAIM OR KILL. SAFETY (Cont.) then een NOTE: pat oflessar qual Accordingly, anyone who intends to use a. A WARNING NEVER PERFORM any WoRK CN THE COMPRESSOR WHEN IT IS RUNNING. BEFORE BEGINNING ANY REPAIRS ON OF WITHIN THE COMPRESSOR FRAME OR CYLINDERS, THE FOLLOWING PRE- CAUTIONS MUST BE TAKEN; 4. Refer and strictly adhere to the Packager’s complete instruction ‘anual. 2 Close the main suction (inlet) and scharge (outiet) block vaives to iso- late the compressor package. 3, Turn OFF the main power, DETACH the compressor trom its driver at the ‘coupling, or CLOSE the fuel supply it engine cfiven. Then lack the fuel sup- ply closed or main electric power dis- connect open, 4, Aiter shutting down the engine, take Steps to insure itcannot tum over. A hot engine can fire and rotate the ‘compressor. 5. Relieve any pressure in the com- pressor cyinders), piping, coolers, tc. Purge thoentiresystempriortostartup, alter extended pends of shut dawn and whenever any gas seal, Including valve Cover seals, has been broken. Refer to the packagers instructions for futher information. Do not reverse or install suction ordi charge valves upside down or in the wrongeyiinderport. Severeorapressute ‘may result, causing damageto the equip Ment or personal injury. Proper service and repair are important to the s ‘must frst determine that neither his safety The servica procedures recommended and reseribod in thie manual are proves effective in or ete procedures requie the use of special tealsspeciically designed for the purpose Safety and Maintenance Instaitton, operation, maintenance and re- Dai shail be carried ‘out only by qualified ‘personnel and in accordance withthe eorre- ‘Spondingrequlationstaroneratinn and safety, The compressor must be mainiainedin sale ‘operating condition. Inspection shouid be ‘carried out on a regular Easis, Never perform any work on the compressor when itis running, (Only qualified and authorized personnel are ‘oopen the switchboard, Do not touch anything, or cary out work on the switcnboara, unt the system is entizly fee of power. Note that even if the main ‘switch is setto the “OFF* positon, the poles ofthe switch and the terminal's feed cabies arelive, Electrical equioment andts protection must ‘comply with reguiations as they apply tothe ‘93s being used. Do not touch uninsuilated ar live, current carrying parts when the electical system is energized. Never perform work that produces heat near Gilor gas systems, Always wear eye protection when working ‘on compressors, Before working on olf or gas tanks. empty ‘and clesn them either by steam jet or by urging win nitogen. In the event of oil, gas or coolant leak, 1e- ‘move the lost liquid and repair the leak, Never use flammable solvents forthe clean- ing of parts. After the use of any solvent, Ccarefuly rinse and clean the parts with com. pressed air or clean, ints rags. Observe strict cleanliness practices. Keep Impuriticn from coming w rast on removed ppartsor exposed openingsby coveringthern with a clean rag, paper or adhesive tape. Alter completing repairs, be sure no tools, 'cose parts or cleaning rags have been left Inthe compresser. ave of the service technician andthe sate, reliable operation ofthe comprassor. pat at oo egessary. the part must be replaced wth onaot the same part numberar wiian Graig oo replacement rors cana Pat. service procedure, or ool which is not recommenced by the manufacturer, Nor the safe oper: }etNods of performing service and repair. Some and are described on page 31. ‘Alter work on the compressor, and before ower is Supplied to the machine, always {urn the compressor aver manually by using the flywheel. This ensures that the compres. sori running ree, ‘Aifer cunteting any work on the compres« Sor, be.sure tis tested and accepted by the Inspection authority concemed. Use only the original and recommended spare parts for compressor repair. econ —=— Safety and Operation The compressor is to be operated in stict accordance with its technical specification atall times, Belo ptng te commana opel) tion, be absolutely ceriain that no one is working on the compressor atthe time, Allrotating power transmission products ara otentialy dangerous and mustbe pranerly ‘Quarded forthe speeds and applications for Which they were intended, ‘Take care thetno one can come into contact with pipework orother heat-producing parts Of the Compressor system during Gperation, Never store flammable materials near the compressor, e.g, clly cage. ——— NoTicE: ‘THE MANUFACTURER TAKES NO AE- ‘SPONSIBILITY FOR PERSONAL INJURY OR DAMAGE TO THE UNIT CAUSED BY THE NON-OBSERVANCE OF SAFETY PRECAUTIONS DURING HANDLING, OP- ERATION, MAINTENANCE OR REPAIR OF THE COMPRESSOR, SECTION fl: KNOX WESTERN COMPRESSORS ompressor Features: Knox-Westem comaressors are builtin both single and mutiple-hrow configurations, ut lizing a crossheadstyne design. Frames are cf heavily-ribbad cast iron. The crankshatt, connecting rods, and crossheads are of ductile iron. The main bearings are double~ row spherical roles bearings. The cil pump fend Dearing is allowed i ft, us penile ting shaft expansion. Connectingradbearingsareasteet-backed, bbabbitted insert type. Crosshead pin bush= ingsarecftinized bronze. Lubrication forall bearing surfaces is provided by a splash system on the lower-horsepower units, and byanintegral pressure systemion the higher- horsepower, higher-speed models, Compressor cyiinders are of cast ron, duc- tie ron or forged steel, depending upon the maximum allowable working pressure, Pis- ton rods are of aay steel, hardened in the Packing area for long ite. Tey are provided with both wiper and pressure packings. The standard cylinder construction allows aniy a minute amount of oil to pass through the packing and into the cylinder. When speci- fied, provisions can be made for total non- ube construction, of for tul-gressurized ‘bricatton, Cylinder bores are finely honed and tefion impregnated to reduce break-in time forthe piston rings and riders. Model Identification ‘As shown here, a nameplates permanently attached to every Knox Western compres- ‘sor crankcase assembly. The TYPE and HP ive you the allowabie horsepower for the frame as designed. Use this Serial number ‘when ordering crankcase assembly pars, Frame Assembly Nameplate SERIAL NO, TYPE_____HP KNOX WESTERN Depiciecbetowisacyincernameplate. One is attached to every Knox Western compres: sor cylinder assembly. The SERIAL NUM- SER, BORE DIAMETER, STROKE and MAX- MUM ALLOWABLE WORKING PRESSURE ‘are provided for both reference and safety. Use te serial number when ordering cyiin- er pars. Cylinder Assembly Nameplate SERIAL NO, BORE. MAX PRESS STK, KNOX WESTERN “MAX PRESS" is the maximum aliowable working pressure. See safety precautions. COMPRESSOR WARRANTY Warning Nameplates Depicted below is the Compressor Valve Warning Nameplate. One Is attached 10 each Knox Westem cylinder manufactured after January, 1991. A. DANGER BE ABSOLUTELY CERTAIN THAT THE SUCTION VALVES AND DISCHARGE VALVES ARE NOT INSTALLED UPSIDE DOWN, OF IN THE WRONG CYLINDER PORT. EXCESSIVE INTERNAL CYLINDER, PRESSURE WILL CAUSE CATASTRO- HIG DAMAGE TO THE COMPRESSOR AND/OR FATAL INJURY. The Nameplates shown below are altached to each Knox Westen cylinder to show which is the suction and discharge side of each cylinder. Ensure the correct valve is Used in each side. See safety caution nates, SUCTION DISCHARGE Krnox Wester ("Knox") warrants that the products manufactured by Knox are, in the case of any particular sale, free from defects in material {and workmanship. Under normal use and service for which they ware intended, these products are werranted fora period of 1§ manths from the date of shipment by Knox. if any such defects appear, and notice of such defects's communicated in writing to Knox within tat ime, Knox shall replace or repair the parts at thelr discretion if an inspection proves the claim Labor fs nat covered. Warranty is void tie purchaser fais ‘opropery store, maintain, install or operate the product in 2ccordance with Knox's writen inetructions, Such instructions shall be furnished! to feach purchaser. Tha foregning warranty ces not extend to expendable Rems including valves, pieton ringe, proeaure paoking, and! wiper packing. ‘This warranty is expressly in leu ofall other warranties exoressed or implied Including the warranties of merchantability and finass for use andofalother obigationsor abilities on Knox’s part. Knoxneither assumes, notauthorizes any other personto assume fori, anyother libilly ‘nconnecton with the sale ofthe product. Knox makes no warranty whatsoever in respectto accessories or parts not supplied by t, Noclaim shall be made for proximate damages ofa cifferent amount, normay any recovery be had for incidental er consequential damagesincluding loss of profit. SECTION Ill: PACKAGING ano INSTALLATION Packaging ‘As applied here, the term “packaging” ot “packager” relers o the Knox Westem cus {omer wo incorporates the compressor in toler finished produc However, “installa. lion* recommendations may apply to both ‘he packager and ihe end user, SE sakes sega aa A\WARNING When packaging and installing Knox Western compressors be sure touse the correct ftings and piping. Al fabricating, Dractinas and codes must bo followed, er American Petroleum Institute (API) Spec "11" for compressor packaging. Recommended Oil Piping ‘The correct installation of the compressor ail cooler and thermostatic bypass valve is shawn in Figure 1. Knose Weetorn recom mends using short flexible hose sections between the compressor and piping to ensure NO pipe stress on compressor oil ump housing. Oil Requirements Fergeneralopeatonange iscoaty non: Getergor, super etd Sl wn oe ore oxdaton ihbtor is teconmesced, Ole shoud be ofa nepthenic base, sposticaly compeunded to minimize carbon foray Gis eontlnng animal fis are not ecor mended. For good water separation, use of 2 dispersant sede i nat ecommerce ‘On applications utilizing the Knox Western Ghinder Lubricants oiterely por Seen eso sacese ct aco Suleble asa oyinder ubicaing ot, These Gs ae fermuateg fo mntnze sarson dee poss on efscharge valves and oer cone Ponents which are subjected to high tem- Betas Olscl tise areavaiacle tom Severalalrfners Please contact Knox Western if the 1186 of Syhets tons ended, Temperature Ranges Use te folowing weight ols for tne ambient temperature ranges indicated: ABOVE 80 Fn _-SAE3O Below 60°F. Z wee SAEZO Viscosty ‘hecending to SO Classification -ISO'VG 100 Direction of Rotation ‘When icentiving various compressor com [ponents anc! their dircotion of rotation, refer ence should always be made to the ‘compressor’s drive side, When standing at the chive side and facing the comarassor, rotations are as follows: TPS0, TPE0... counter clockuise Allother medsis clockwise Annan — Protective Guards Protective guards must be furnished and ‘maintained around ail moving parts, Before start-up, be sure the guards are securely in lace and properly aligned, Never operate the compressor with 2 guard removed, Liguid Separation Aswith any postive cispacementcompres- ‘or liquid cary-over into the eyinders can have disastrous results. This can range fom the breakage of valve components and pis- {on rings to bent piston reds, fractured pis- tons, cyinders and heads. For this reason, it is absolutely necessary that adequate quid Sseparatn and removal equipment be in- salle prior othe suction line of each stage. See the packager’ instructors forthe prop- ruse and maintenance of these devices GURE | -ReCoMNDED Ot PW TERE 7a ocoo.es Froncooun Piping Cleanli ert HEELS Te imperance of maintaining clean pines and vessels cannot be over emphasized Clean pipes and vessels wil assure quick Start-up, reduce wear on working pat, and assurslongiie of oyinder pars. Onthecher hand, when not removed, contaminants ike rust, Scale, ct, sand or weld slag wil come torestin the compressor eyinders, causing damage to finely fished parts. Cleaning ot Piping The cleaning of pipes and vessels fs mo~ easily accomplished before compressor Stallion. You should male piping contac tors fuly aware ofthis requirement ‘Taclsen piping, bathmechanicalancichem- ical methods may be requis, tt racom ‘mended that chemical clearing be card ‘ut by service companies specializing in such procedures Leveling A installation, be sure that the compressor package is level, and thatthe base is fuly bedded in and supported. Alpipngmustbe ‘adequately ted down to prevent vibration during operation. ee ee eee SSE PACKAGING ano INSTALLATION (cont, A, WARNING ‘ALL ROTATING POWER TRANSMISSION PRODUCTS AREPOTENTIALLY DANGER US AND MUST BE PROPERLY GUARD- ED FOR THE SPEEDS AND APPLICA- TIONS FOR WHIGH THEY WERE IN. TENDED. ‘ANY COMPRESSOR MUSTAE OPERATED WITHIN ITS DESIGN LIMITS. IF NOT, SE- VERE DAMAGE OR PERSONAL INJURY COULD RESULT. Coupling Size NOT fect drive compressor packages, the alignment of the compressor and ‘driver is very important, Before starting unitafter new insiallation orifany change inposition of compressoror driver, insure alignment meets drive coupling manu- facturer's specifications. Dial Indicator Method Check for Anguiar Misalignment an 4, Resetthepointertozeroancrepeatabove operations 1 and 2when either the criven unitorthe driver is moved during aligning trials. 5, Checktof parallel misalignmentasshown. Move or shim the units so thatthe paralel misalignment is brought wthin the max- imum allowable variations for the coup- ling style. 6, Ine coupling snould ve rotated several revolutions to make sure no "endvise creep in connected shafts s measured, 7, Tighten all locknuts or eapscrews. 8, Re-check and tighten all locknuts or capscrews after several hours of opera- tion Ifthe compressor is connected tothe diver bymeansotatewble coupling, this counting must be sized to handle the horsepower thrust and torsional leads imeosed on it by bof the compressor and ever. Maximum runout or misalignment varies with each cauplng type. Check the packagers in- ‘sructon, and be sure that these speciica- ~ Hans ae flowed prior fo startup. pling Alignment (See Foqures 2, 3nd 4) Proper instalation and aignment will assure long ife and smoot, trouble-free compres- sor sevice, For specific instalation detalls bout a siyie of couping w be insiallen, refer tothe instruction sheet which accom: ‘panies the compressor shipment. \inen instaling coupings, be sure all con- nections are made properly, without mis- alignment tothe compressor frame or cylin- ders, Faure to do so could resut in serious mechanical failure or personel injury. BiaLnercaton sor Seen RATE nesta aeiaporotren Saat RGURE2-COMFRESSORIOANES AUGNMET 4 oure) ‘Adil indicator measures the maximim ton- titucinal variation in hub spacing through @ 360° rotation. 1, Attach thedlalindicatortothehub,aswith ‘hose clamp; rotate the coupling 360" 0 locate the point of minimum reading on the dial: then otatethe bodyor faceot he Indicator so that the zero reading ines up with the pointer. 2, Rotate coupling 360°. Watch the indica- tor for a misalignment reading. 8, Drivar and riven units wil be fined up when the dial indicator reading comes ‘within the maximum allowable variation for that coupling siyle. Refer to the spe- Cc installation instruction sheet for the ‘coupling being installed, ‘Gheck for Parallel Misalignment eure « A dial measures the olsplacement of one ‘shaft center line from the other. FV-be driven, ensure that the correct pul- leys and V-bells are used lo sut the horse- power and RPM requirements. Follow the packager's instructions prior to startup Use the following as guidelines to V-belt peration Check Sheave Alignment - Sheave ad justment should be checked by placing ‘2 straightedge or tight cord across the ‘sheave faces so that it touches all four points of contact General Rules of V-Belt Tensioning 1. Ideal tension ia the lawast tension at whieh the belt wil not sip under peak load conditions. Check tension frequently dung first 24- 48 hours of run-in operation, Over tensioning shortens batt and bear- ing ite, Keep bells free from foreign material which mey cause aip 5. Make V-belt Inspection on a periodic basis, Retighten when slipping SECTION IV: START UP ee ree RNR For specifc star procedures, refer to the package's insiructions as inclu sded with the compressor's shipment. These wil include prestaring Fees wating Sequence, lasing, and operation procedures. Below i an example of a typical engine cven coirprctaor etal oe However, this is not meant fo take the place of the packager's instructions. Prior to Starting (See Figures 1 and 5) 1. Purge entra eystern 20 follows: (@) Open the suction block vaive. (©) Open the by-pass valve. (c) Open the vert valve, (@) Close, thenre-opentheby-passvaive 1 ensure that all air has been ro- ‘moved from the system, (©) Finally, closathe ventvalve,andleave the by-pass open for start-up. 2. Check compressor oil level and engine ‘ll and water levels, 9. For intial start-up: Prime the compressor cil pump by add ing oll tough the top 1/4" NTP hole on the cil pump end-housing. Use a stan- dard oll can and the corect grace af oil Fil the il cooter and al the piping to and lromit. For move information, see page 6, "Oil Requirements," 4, Check all shutdown tate tales to be eure they are armed, 5, Cook he fuel vaive by pushing the lever in the direction of gas fo. 6. Turn the startrun timer to 3-4 minutes, locking out the green-tegged tale ales, Starting 1. Sot the throttle valve per the engine ‘manulacturersinstructions. Tumthe ign tion switch fo the run postion and start the engine. After Starting 1. Once the unit's sunning, retun the star- ‘un timer to the °O" position, this arms all ‘Sensors and protects the system. 2 Check oil pressures to be sure they are Correct. Seethe “OilPump" sectionof his ‘manualforoi pressure adjusiinentproce- dures. rsa cas eae | ute %, WUETeAS wacrass energies Spavion ERLEESS, ‘cance IOUPE 5 - COMPRESSOR PACKAGE APSAANGEMENE 9, Inspect the entire system for vibration, noses, leeks, and oll and coolant levels. Correct any problems, 4, After the engine has warmed up (water temperature of 165° F.), begin loading the unit by opening the discharge block valve while slowly closing Um by-pass valve, Once the by-pass valve is closed, the compressor is online and delivering gas. 5. Reset ail the panel shutdown points as oulfined below: (2) Discharge pressure switches ~ 10% aboveoperating dischargeprassize, Naver execod the eylinder's max ‘mum working pressure, (b) Setthesuctionpressureswitches 20% below the actual suction pressure, but no lower than § pel. This prevents Crating air into the cylinder through the pressure packing. If lower pres Sues are required, special doubie- acting packing is required, (c) Set the temperature switches 1¢ above the expected discharge ter __ erature, up to @ maximum of 325" © F,, or 260° F, if cylinders are water cooled, 6. Check the suction valve covers for any ‘neat bulld-up. This could indicate a mal. functioning valva. Suction valves are lo- Cated closestio the inletconnaction. Ois- charge valves are located closest to the outst connection and are normally hat 7. Check the separators for high liquid iev- ‘ls, per the packagers instructions, 8, Re-check all gauges to be sure they are vwilhin the units operating imi, 8. Begin a log of operating conditions and make entries each time the unit is checked, ” SECTION V: MAINTENANCE VALVES A WARNING BEFORE BEGINNING ANY REPAIRS ON OR WITHIN COMPRESSOR CYLINDERS, ‘THE FOLLOWING PRECAUTIONS MUST 7 | BE TAKEN: 1, Referto thepackagers completeinstruc- tion manuel, as wel asthe “Safety” sec- tion of this manual. 2. Close the main suction and discharge Dock valves to Ksolate the compressor package. 3. Tum OFF the main power and CLOSE {he fuel suppl (i'engine ven) and iock ‘tin ths positon 4, Attershutingdown engine, akesteps to insure it cannot turn over. A hot en- gine can re and otate the compressor. 5, Relieve any pressure in he compressor cyinder(s), ping, coolers, etc. Valve Function ‘ompressor valves are devices placed in 44 0yinder valve port to permit a one-way tlow of gas, ether into or out ofthe cylinder. [The diference in pressure across the valve governs its opening, Springs assist in clos- ing. Knox Western recommends hatno valve be isassembed thatshowsanormal discharge temperature. Any disturbance ofthe valves paris wil affect the seating of the plete and result in both leakage and increased cis- charge temperaiure Valve Removal (Gee Figures 6 and 7 on tis page and Fig- ue 12on page 11) NOTE: Before beginning any repair, read thor- oughly thesaiety precautionsprovidedin this manual ta. Early Design: Atter relieving any re sidual pressure in the oylinder, use a FING" wrench to remove the acom lcknut on the vaive jam screw. With 9/6" hex-bt socket and ratchet, loosen the vaive jam screw. # ean gure 5—DoUBLe ACTING UNDER osc, Teas Se Hage = ‘sw tb, 16, New Design: Same sequence as 1a, except use a 1-1/8" wrench to loosen hex jamnutanda 1/2" socket andratch- et to loosen the valve jam screw. Valve Port Cavers with O-Ring Seals: ‘These covers can be identified by their lack of a center jam screw assembly ‘They are used with a tubular cage to hold the valve in ts seat. After relieving any residual pressure in the cylinder, se a 18/16" socket and ratchet o loos fen the valve cover bolts. Use extreme ‘caution during this procedure, 2s any remaining pressure behind the valve Cover will not be released undl the O- ting seal fs out ofthe vaive port. Never completely ernovethevahecoverbos unt the O-ring is out ofthe valve port ‘and you are absolutely cartam there is ‘no pressure behind the cover. Removal ofthe valve cover usually mustbe done by inserting two (2) fla-blede screv- vers, 180" apart, between the valve cover and thecyinderheed. Gentlyand evenly, pry the valve cover away fem the oyinder head. Ne LR A VALVES (cont,) . 2. Slowly loosen the four (4) valve cover ‘retaining nuts witha 15/16 box wrench Donat completely remove the nuts unt you are cenain there is no remaining Pressure in te cyinder. (See Figures 6 and 7) 3. Remove the valve cover nuts and the valve cover. Unless your compressoris Gesignad using vaive cages (ses note ‘below), the discharge valves onthe bot- tom of the cylinder will drop aut as the valve coveris lowered. (Seo Figures 6 and 7) 4, Remove the suction valve with a pair of eedle-nose piers, Flemove valve seat gasket. NOTE: IF THE CYLINDER 1S FITTED WITH FINGER TYPE VALVE CAGES, a cam- lo¢ screw is used to lock the discharge valve cage to the valve part. Once the discharge valve coveris removed, locate the serew end rotate ita 1/2-turnunti the valve cage comes loose. Remove the cage, valve, and valve gasket as an assemhly. Screw a 5/18016 threaded rod inte the center hole of the case for ease on handling. (See Figure 7on page 8, and Figure 13 on page 12) Valve Disassembly knox Westem compresscr valvesaresimp 2plece, guard and seat assemblies. 1/6! ameter through a dlamoter valves are cix- assembled by holding one half of the valve ‘and turning the other half ing counter-clock Wise direction. This can usually be accom. plished by using anty your hands, However. due to the effecisof ioral operation, some: times it becomes necessary to clam one half in sof jaw vise, and ingen wo (2) pins 180 apartinto two diiled holes in ths valve Insert a pry bar between the pins and rotate Ing counterclockwise Uirecton, 45° diameter and larger valves are held together using a center stud and lacknut. Use a9/16"socketand ratchet oremove the Jocknut. The valve halves can then be sepa fated. in the evant the center stud is re- moved along with the ocknut, after seperat- ing the vale halves, clamp the shoulder potion of he stud ina vise, then remave the leckrut from tho otud. Inallvele sizes, be sure toncte valve soring ‘quantties and iocationsandrecordhese fot ‘ference when reassembling the valves Check he condition ofailvalvecomponents Valve Inspection and Repair (See Figures 8 and 9 for M Series) (See Figures 10 andi 11 far KW Series) 5 2 Sr BS29 vite nar wali tlce i a CFS vavesepng ue io B ia = Nowueraue Re avenue RE Boo Se a vawvensevetr upern i oeoace ave 7 eoune. coneese0n ose Valve EMS ND ES So os0y CBE VALVE SAIC. = VALVE PLATE — mse wooed rn Rutan) Ne Sa wallets URE - COMPRESSOR DSESARGE VALVE SERES MD Valve Lift Valve lit should be mainteined between 0.050" 100.080". Refer tothe “Specifications section ofthis iar ua eee SUCTION YALE Serre | QURE 10 COMPRESSOR SUCTION VALVE (ERS Ki) Seats To prevent gas leakage Its important that the seat face i lat and free of any traces of Wear. If any damage to the seat face is 2p- parent. it wil be necessary to ooneentric grind and lap the seat surface. The total thickness ofthe seat should not ke reducer! ‘more than 0.080", Guards Valve guards need vary tle maintenance. However, the mating surfaces of tho valve guard seat should be ground flat. These Surfaces must seal yghty when valve is as- sembled, Gulife Pins (Series K-W vatves only) Guide pins are mountedin he quardto guide the plates when operating, When they be ‘come won, they should be replace, Valve Plates Valve plates should be replaced when they have worn as much as 0.015". They should ‘never be tumed over for contiued use. The slendard plates are 060" thick, ype 41088, hardened to 366-985 Brinell. Also used for ‘many applications are non-metalic (plastic) valve plates. In wet hydrogen or H2S applications, i is Suggested that plates having less hanes be used. Brinell 255-283 ls recommenced. ‘These wil wear fester but wil better with: stand the effects of gases, Consult with Knox Western's engineering department if you need assistance, Springs From protracted workin, springs may lose thei elasticity or even breaie They may iso rub against the wal of the spring pocket reducing their elastic propertes. vw VALVES (Cont.) 00d method for determining spring con sions to keep a spare set for comparison, IReanbe seenatonce ifthe length ofa spring is less than R was originaly. When valve plates crack or break, te causes often not in the plate, but the springs, Gaskets When making repairs, itis acvsable to use new valve eect and vaWe cover gaskets. Remember, a leaky gasket means another shutdown and repairjob. Valve Assembly A compressor valve's function is to control the iniake and discharge of gas in the comm pressor cylinder. To operate properly, each Component must meet all the criteria de- scribed under “inspection and Repair Pro- cedures", and be assembled correctly. Knox Wester valves generally fall into two categories: (1) an individual plate type, and (2) 2 portad plate type. Assembly proce- ures for each are sirilar, hence bath types are covered by these procedures: 1. Work Arn —Salect a claan, weighted area with an unobstructed, fat work sur face. 2. Tools - Only a few tools are required for assembly. They are: = 23/16" hex allen wrench for the valva stud, ~~ aball peen hammer for rol pin instal lation. = a 11S2thiok x 1/2'nide steel strip to depress the plates and straightedge. ~ Locktitetolock the guidepinsin place. ~ For 4.5" diameter and iergar valves, a 9/16" socket and ratchet. 3. Cleanliness ~ Prior to assembly, be sure all parts are clean and dry. The presence Of any foreign material can damage the sealing surfaces, 4, Handling - Remember, the compressor valve is an expensive, precisionmade ‘component. Carelesshandling can cause damage which may render the valve un- acceptable for service, 5. Assembly ~(See Figures 8, 9, 10nd 11) A. 2 diameter through 4° diameter ‘Values: Pasian the valve seat, center hole up, end install the cantor stud ‘The cone point end must be instaled into the seat. Tighten the stuc lightly with, a 3/16" allen-wrench, This Stud is cdplve ater assembly; excessive torque is unnecessary. 45° diameter and larger valves: Post tion the valve half (suction guard andi ischarge seat) center threaded hole Up. Placo a crop of Loctite #270 on the short-hveaded end of the center ‘stud and turn this end of the stud into the threaded hole until the stud shoul- der betioms, B. On valves using ported type plates ‘hosition the valve guard (soring poc! ts up) and locate the 1/1" diameter hole for the indexing pin. Install she YMG" clesmeter ro pin in this locaion, . lnsertone springineach spring pocket or as recorded during disassembly. Ported-piate type valves oflaraer size (2-1/2 diameter and up) may require ewer springs in low-pressure appl cations. Valve spring buttons are sometimes ‘customer specified. This part fis be- N SOG Lowenertune soe RETR RCERs POURS 12-SNOLE-ACTING TANDEM CYUNDER cranwna Ns EX LD debe. cuehate oxer nee 1. VALVES (Cont,) tween the spring and the plate, The ‘smaller diameter fis inside the spring andprovidesa quidesurlace, Useone bbuttan per spring. Valve spring caps are used in some applications, The ‘caps are to be installed over the lop of ‘the spring, This will prevent the valve ‘spring fremeoming interest contact with the valve plate, Please nota that valves originally installed with spring ‘caps use valve springs and valve ‘guards that are unique to this appl Cation. They cannct bs interchanged with standard M-Series valves. Also, before assembling the valve halves, install the required number of valve springs and their caps into the sping packets. Depress each sering and cap into the spring pocket. Be Certain that the cap does not bind in the spring pocket. Itany cap sticks in the spring pocket, investigate to find the cause. If no apparent cause is noted, use a new cap. Place the valve plate(s)ontheneialens valve springs, Ported plates have a sali hole for the indexing pin, Be sure the hole and pin are aligned. This siyle plate is guided on the LO. only Algneachvalvepiateusingthe center guide and guide pins. Dapress the valve plata(s) with the steel straight- edge (On 2 ciareter through 4 diameter valves, hala the plates down and turn the vaive seat (with center stud) in a clockwise direction into the valve ‘Quard. When the seat makes contact with the streightedge, withoraw the straightedge slowlyand carefully, Fn ish tightening the assembly by hand, taking care to keep the valve plate(s) in their proper positon, On 45° diameter and larger valves, ccheck to make sure the valve plate index hale is instald over the index pin. Lower the valve seat onto the valve guara assembly, taking care not to change the indexing of the valve plate. install anew selelocking ‘Aut on the center stud and tighten ut using a 9/16" socket and ralchet. . Using ablunt object, such ase dowel (ed, depress each valve plate to oe sure each moves freely. In operation, {gas must flow through the seat, nast the opened plates, and exit through the guard passages. The plates must depress in this direction, away fram the seat F. Fill he vaive seat with a clean, non- flammable solvent and check for any leaks. A properly assembled valve should hol this liquid for atleast ane minute, G. Aller assembly and testing are com- leted, the valve should bs sprayedor sipped with a suitable rust inhibitor. Valve Installation (See Figures 6,7 and 12 on pages 8 ant iD NOTE: Before beginning eny repairs, read thor- ‘oughly the safety procedures providedin this manual. For installation, reverse the procedures for “Valve Removal” using the following guide- lines. Note the separate instructions where valve cages are employed, 1 A. Be certain the valve seat gactc ia in lacein the cylinder suction valve pen, The seat gaskets for the discharge valves should be instalec on the charge valve belorereinstalaton, Figures 7 and 8) 7% 2. cece Stes ee te Teo ee HENCeSS ovonasior serous} j \ aces come case Sea. ‘Cruncen STRING CLEARANCE TWN FAGURE 18 -DOUBLE.AGTING GrUNDEA CADSESECTION eve SOC Va Vest cer SNR SiS ES runner exo oisciicevaLve DISCHARGE VALVE CAGE k pooganet vasve coe ee EEy oa.” J VALVES (Cont.) B. Gaskets generally adhere to suriace Adjacent fo the gasket seam, Itis ad- visable to insiall seat gasket with the seam facing the valve. 2, The discharge vaive must be installed 2s an assembly in conjunction withthe valve cover. (Note: If a vaive cage is being Used, see the special instructions.) Piace the valve cover gasketanthe valve cover. \With te fecating pininsertedinto the howe can ty end uf te jt screw, plow Ue siischarge valve on the jam screw, Tho locating pin wil match up with the small hole at the center of the diacharge valve guard 3. Withthe valve cover gasket and the valve seat gasket in place, insert the entire -gsserbly into the bottom of the cylinder. Be certain the valve isin ts seat before tightening the valve cover nuts. 4, The valve Jam screw must remain loose Untilthe valve caver nuts are tightened to 504. Ibs. Early Design Jam Screw ‘This type requires 2 3/6" hex bit socket ‘nd torque wrench for tightening. Torque specication is 60 ft. Ibs. A soft stes| sealing washer and acom nut complete tne assembly, Me acorn nuts igntenes to 60 ft. fos. using a 1-1/6" socket and — torque wrench, ew Design Jam Screw This ype requires. 1/2", or 12 pt socket and torque wrench fortightening. Torque specifications 60. Ibs. Arubber thread seal, bevel washer (beveled or counter- Sunk face of washer installed facing the thread seal), and hex jam nut complete the assembly, Lubricate the thread seal vith silicone grease before installation onthejamscrew. Thejam nutis tightened to 80 ft Ibs. using a 1-1/8" socket anc torque wrench, DANGER BE ABSOLUTELY CERTAIN THAT THE SUCTION VALVES AND DISCHARGE VALVES ARE NOT INSTALLED UPSIDE DOWN, OR IN THE WRONG CYLINDER PORT, EXCESSIVE INTERNAL CYLINDER PRESSUREWILL CAUSECATASTROPHIC DAMAGE TO THE COMPRESSOR ANO/ ‘OR FATAL INJURY. 5. Follow these procedures to ensure cor rect valve installation: A, Install the discharge valves (normally on the bottom side of the cylincer) valve seat first. Reach through the ‘pen suction port with a dowel and depress the discharge valve plates. B. Install the suction valves next, valve uard first. Depress the valve plale to be certain that gas can flow in the oylinder Valve Gages - Finger Type ‘When valve cages are used, the flowing additional procedures should be employed (See Figure 7 on page 9 and Figure 13 on page 1) 4. On discharge valves, install the valve cage, valve, and valve seal gasket as an assembly into he discharge valve por. Be sure the valve is properly sested and installed seat side st. 2. Ones the valve is seated, lock the vahe ‘cage into place using a minimum of torque on the cam-lok Screw located on the edge of the valve cage. Fit the valve cover and gasket leaving valve Jam screw loose, Tighten valve cover nutsto COR bs, 3. On suction valves, insert the valve cage ‘on top of the valve. Be certain the cage fingersengage he ace slotsonine valve Fitthe gasketand valve cover and torque the nuts to 60 ft Ib. 4, Torque the jam screw to 60 ft. Ibs. and replace the jam screw gasket and lack: ut Valve Gages - Tubular Type 1, Tubuiar-ype valve cages are used wih valve port cavers utlzng an O-ring seal Before begining the insalaton proce- dure, check tne conelon of the O-1"g, ‘and on high pressure eppications, the Cconditgn athe teflon back-up rings. Fe- place if necessary. 2. Lubrcatethe valve portcover Oxing with slioone grease. 3. Install vales in discharge vahe ports first. On neatly all appicatons, the dis- cchaige valves are installed in the better ofthe cylinder and are usuelly more dif jou to Insta. Its helpful to have an Unrestricted viewthroush the suction valve ors tocheck for properinsialston otha Gischarge valves, Install the valve seat gasket on the seat sideof the valve, using a small amcunt of silicone grease cn the gasket iohelp hold itin place. Place the vaive, valve cage, and valve port cover into the valve pert. Check to make sure the cover is started Correctly ints the valve port “Then, using both hands, apply fim, even pressure on the cover to force it into the vale port. Take extreme care not 10 damage the O-ing, ithe cover does nat move completely into its final positon, use one hand to suppor the valve port ‘cover assembly and start the valve port cover nuts or boils. Use @ socket and ratchet to rotate the fasteners tra uuck- wise direction, Use a criss-cross pattern fo insure even movernent of the cover. During this procedure, ile or no resis- tance should be felt when rotating the Valve port cover fasteners until the vane isfuly seatedin its port, Underno crcum- stances should the fasteners be torqued totheir final spec. unl you are certain the valve is correcly sested. A ook into the suction valve port dawn tothe discharge valve port wil help #0 confirm proper seating of the valve, ‘When instaling suction valves, install the valve seat gasket fst, Then install the valve, valve cage, and valve cover. Fol ‘ow the precautions detailed in the cis- charge valve installation instructions ‘when instaling the valve port cover. Allfasteners for valve port covers itzing (O-ring seals are to be tightened to 50 ft lbs. in a criss-cross patter, Any over- tightening of these fasteners can result in deformation of the valve cages, mek- ing removal ofthe cages very cific. 13. CYLINDERS A.WARNING CAUTION: BEFORE BEGINNING ANY REPAIRS ON OR WITHIN COMPRESSOR CYLINDERS, THE FOLLOWING PRECAU- TIONS MUST BE TAKEN: 1. Reier to the package's complete in- struction manual, as well as the Safety" section ofthis manual 2. Close the main suction and discharge block valves to isolate the compres- sor package. 8, Tum OFFthemain powerand CLOSE the fuel supaly (if engine driven) and lock it in this poston 4, After shutting down the engine, take stops to insure it cannot tum aver. A. hhot engine can fire and rotate the ‘compressor. 5, Relieve any pressure in the compros- sor cylinder(s), piping, coolers, etc. Cylinder Design Standard Knox Westem compressor eylin= ars ate air-cooled, use nen-metalic piston fings, and have min-iube cylinder bores. All cylinders are hydro-ested before going into senice, ————S SE Piston and Rott Removal (See Figure 6 on page 9, and Figures 14, 15, 16 and 17) NOTE: Before beginning any repairs, read thor- ‘ugh the safety procedures pravidedin this manual 1. Relieve all pressure trom inside the coytinderis). 2, Remove inlet and discharge fange con- Aections to the high pressure (outboard) oylinder (tandems only) 3. Remove the suction valves from both cylincers, 4. A. Support the high-pressure (autboard) oyinder with a sling or jack (tandems only). (See Figure 17 on page 16) 8. Steel block-ype tandem cylinders ut lize a separate head which contains a suction and discharge valve and is ‘machined forint and discharge pipe connections. After removal of pipe flange bolts and hex socket head bola (use 1/2" hes bit sucks) when ‘r8 used 10 retain the head to the PSION AND ROO ASSEMBLY cylinder, the head can be removed from the cylinder. Be very careful when removing the eyinder heads a they are quite heavy. The head to ceylinder connection is a slip ft with an (Ging seal. No special to0!s are re- uired for removal of the head. Do net Use excessive force to remove the head or allow it to cock as itis re- Moved, as this may damage the O- ring seaiing surfaces, Once the head is removed, remove the hex socket head bots (with a 2" hax hit sariet and ratchet) which re tain tne high-pressure outboard cylin- der tothe inboard low-pressure cylin- der. The eyinder to cyinder connec: tion is a lig fit with an O-ring seal, Follow the same precautions when removing the cylinder as detailed for removal of the cylinder head, 5. Remove the nuts holding the outboard eylinder to the inaoare eylincer & A, For tandems only. Carefully move the outboard cylinder away from the in board cyinder. The cylinder must not beallowes to droponceitis ree ofthe inboard cylinder, as the weight of the cylinder resting on the pistonirod as- ‘sembly will bend the piston and rod. 6. B. Remove head-end or clearance pocket on double-acting cylinders. 7. Remove bath covers from the crosshead ‘guide. (See Figure 17 on page 16) 8, Remove the packing vent tube, (See Fig- ue 17) 8. Loosen and remave the two (2) set SScrewewiich lock the piston rod balance hut to the crosshead, (See Figure 14) 10. Using a spanner wrench (special tool, part 8800400001) and two (2) 3/8-18x1* bolts (1b. and 2b, nuts), 918-161-112" (31, nut) or 318-16x2" bot (4b. nut), attach the tool tothe face ofthe balance ‘Aut, The two (2) holes {.295* diameter) riled through the spanner tool must be aligned with two (2).correspending difled and tapped holes on the face af the balance nut that are on, or closest to, the horizontal centertne of the rut. This is necessary to allow free move ‘ment of the tool when used with a 1/2" ‘drive ratchet o loosen the balance nut, Be certain that belore attempting to loosen the balance nu, thatthe spar Net tool is not positioned within the (rosshead guide bore area. Rotate the crankshaft 38 required to move the balance ut spanner toal ut of this Dortion ofthe crosshead guide. Rotate the balance nut in & counter Clockwise direction (as viewed facing lowards the crankcase center} to loos. fen, Remove the spanner tool from the biance nuts. 114, Tur the piston/fod essamibly counter- Clockwise outof the ceneshaad, 12, Remove the belence nutira the piston fod. On multiple twwow units, it's very important to maintain the original loca tion of the balance nuts. There are four (4) diferent balance nuts (140, 2-0. S-Ib,, and 4b) which may be utlized tomaintain balance of the machine. 13, Bofore removing the pistonitoc assem- Dy from the cyinder. wran alertrcal lepe over the piston rod threads. The tape will pravent demage to the pres- Sure and wiper packing while the 1 threads are moving through the pac. ing. (See Figure 15) 14, Remove the pistonifod assembly from the eylinder. (See Figure 16) ‘couRESSoN Aber me RE agence ose see 1 a FTGUME 16—ISTON 4 ROD ASSENLY Piston and Rod Installation (See Figures 15, 16 and 17) NOTE: Before beginning any repairs, read thor. oughly the safely precautions provided [inthis manual 1. Place the entering sieeve tool (PIN {800200101} overthe pistonradthveads, Wap a .002" shim stock over any re- mainingexposedihreads, Tucktheshim stock between the entering sleeve anc! the piston od. (See Figure 15) 2. Rotate thecrankshalttomave the cross <7 head away trom the cylinder. ial Install the pistonfiod assembly into the cylinder. Use both hands to comoress CYLINDERS (cont ons ae ff the piston and rider rings as you push the assembly inward. Use extreme caution during this step to prevent damaging pieton and rider rings. (See Figure 16) 4: Aftertnepistonrodtireadshavecleared the packing assembly, remove the er- tering sieeve and shim stock 5, Before proceeding eny further fe any high spots on the locking surface of the crosshead. The high spols are formed when the balance nut locking screws: ae tightened against the crosshead. Groeghead clearance aroblems wil sult if these high spots are not filed down beiare tightening the balance nut. Take care to keep any flings from falling into any critical areas of the com- pressor. (See Figure 17) 6 Repace the ence ron he piston ra 7. Tum the piston rod into the crosshead guide approximately Sto 4 tun, 8. On tandem cylinders only, check that the O-ring or gaskets in place, then it the high-pressure oylincer with a sing ar jack. Align tre oyinder bore with the high-pressure piston. Begintomove the ayinderontothe piston. (See Figure 16) 8. Use one hand 19 compress the piston and rider rings, the other to gently push tne Gye turer ent the rston fod, Baga SCAN Valve PLUG ‘GLEARANGE POCKET FIGURE = TANDEACYUNDER ASSENELY Do not use excessive force in pushing the cylinder on, as damage to the rings will occur. Use some oil on the piston andrings. Be sure that tering joints are staggered. Install nuts on the high-pressure tolow- pressure cylinder studs. Square the cy! Inder with the suction and discharge piping. Torque the nuts to 150 it fos. (Tandems anty.) |. Rotate the fiywhee! by hand to check the piston’s striking clearance through the cylinder. Ifthe machine rotates ree- ly through one revolution, begin prace- ures to set the clearance. ifnot, use a piston rod wiench to rotate the piston od unti an adequate end clearance is obtained. 2. Reler to page 18, "Adjusting Oyinder ‘Strking Clearance” to setthe end clear- ances cfthe pistonto the cylinder head. 3. Install the packing vent tube, Install the crosshead guide covers. Install the low-pressure and high-pres- ‘sure suction vaives and valve covers. Rler to page 9. (Sse Figures 6 ard 7) . Connectthe piping tothe cylinder, mak- ing sure flange gaskets are correctly. (Tandems only). stalled szpyapro0 Piston Rings and Rider Ring Replacement (See Figures 6, 14, 15, 16 and 17) NOTE: Before beginning any repairs, read thor- ‘oughly the safety precautions provided In this manual. a 1. Follow the instructions for removal of the pistonod assembly. The low-pressure {nboard) cylinder need not be removed ‘on tandem cyinder assemblies. 2. Remove the wom rings and discara. ‘Thoroughly clean the piston ring groaves wilh a non-flammable solvent 3, Carefully Inspect the piston ring grooves {or nicks or itregularties. Also inspect he ‘cylinder bore ior regularities. 4, Usingthecylinder boreas.agauge, check the piston rng end gap. The gap should be 0.026" times the cylinder bore diam ter, 5, Install new rings on the piston, Check the piston and piston sing clearances with feeler gauges. The corect side clear- ance is 0,005" i 0.006" 6. See page 14 for instructions on reinstal- lation of the pistorvrod assembly. CYLINDE! Adjusting Cylinder Striking Clearance (See Figure 12 on page 11 and Figure 17 beiow) A. WARNING Thre uylinder sinking cearance must be checked and reset alter any procedure which involves loosening or separating the piston rad from the crosshead, Thefollowing procedures are recommended for obtaining the proper sirking clearance: 1. Remove both the head end and crank ‘end suction valvea on deuble-acting cylinders. On tandem cylinder arrange- ents, remove the suction valves on both the low-pressure and high-pres- sure cylinders. 2. Insert 0.120" diameter piece of solder between the piston facs and the cylin. der face, Then push the wire through the crank end suction valve pert to the top of the piston rod. (See Figures 13 and 17) 3. Rollthe tywhealoverby hand until mini mum clearance is obtained between the piston and cylinder face, 4. Rollthe ywhealto permitremoval ofthe solder. Remove the solder from the oy. inder and, using a 0,000" to 1.000 mi- Ccrometer of cial caliper, messure the Solder wire at the minimis point of is Compression between the piston and) the cylinder face. Record this measure- ment. 5. Rlepeat his procedure on the head end of the double-acting or high-pressure endem cyinder, whichever Is appl- cable, 6. Add the two clearance measurements. This sum represents the total strking clearance. ‘Theesseing for ne crank end, piston-to-head Clearances one-third (1/9) this figure. The Femining Wwo thirds (28 represenisthehead fend piston-to-head clearance. 7 Use a piston rod wrench or, f possible, ‘umthe piston rod byhand in theappro: priate rection to obtzin the proper Clearances, Use the solder and micro ‘meter measurement method to vely proper clearence, Affer the proper clearances are ob- tained, tighten the balanes nut finger. tight against the crosshead, Recneck the final cyinder clearances, (See Fig: ue 17>below) instal spanner tool (asd talledon page 13, step 1of*Piston and Rod Removal") Use a torque wrench (12 chive, 0-260 lb. range) with the Spanner tcol to tighien the balance nut 10200 ft. tbs. Remove the spanner tool Install two (2) nev $/8'-16xT* cone point Set strewn 180" apart, on or asest fo the horizontal center line ofthe aut) in the balance nut. Use a 3/16" nex bit socket and 1/4" drive ratchet to tighten the balancenutlocking screws. Tighten the set sorews in three to four steps, altemating from side to side, to 25 fl. tis important to ighten the lock ing scvews in steps in order to minimiza Uneven loading ‘an the piston rod fo crosshead joint. 10. Install the packing vent tube 11 Install the crosshead guide covers, taro, ie noah” ego 27, %, ote Fs: cae oi Cosgiap cune ean [GURE 17 -coMnESson asSeNLY CYLINDERS (Cont,) “Jearance Pocket Piston and Rings (See Figure 18) NOT: Before beginning any repalrs, read thor- ‘oughly the safety precautions provided inthis manual, ‘Some Knox Westem compressor models mre Uesiy md ad bull wil lea ane puck 25 to reguiate compression, They may De fied to ether the crank or headend of the compressor cyinders, but are all basically the samen construction and operation. Ac Justments should be made by qualified, au- thorized personnel only. (See Figures 6, 7 and 16) ‘The clearance pocket piston can be fitted ‘win two atterentypes oF piston angs. Spe Gal care must be laken in instaling these tings. fing Ais astendard spit buit-cut, carbon- filed, tetoncistonringtnatissippedavertne piston and fited ino the piston ring groove. (SeeFigure 16)Thisringis designed tohave no end clearance when instales. fing "8" uses a sol ring with a back-up O- fing Ton soiling over he pation, heat “the Seal ing for fveto ten minutes in boiling ater. This expands the ring and permits -88y instalation on top of the O-ring, previ ‘usly installed in the groove. Once the ring isin the ring groove, use a pistonring compressor to compress he ring down ntotharing groove, Take care, this is not done correctly, the rng wil not fit into the clearance pocket bore. (See Figure 18) | seageezrocete esse SSeS EET PEGE SG stot ana Steaw souenven a 4s CAUTION Underno creumstances shouldany clear ance pocket adustments be made while the compressor is operating. Pressure and Wiper Packing Replacement (See Figures 13, 16, 17 and 19) NOTE: Below Leyling ay repairs, read thor oughly the safety precautions provided in this manual, Removal 4. Follow the procedures for removal of the high pressure (outboard) cyinder and pistonvrod assembiy. (See Figure 16) 2 Memove the 1/4" packing vent tbe. 3. On water-cooled pressure packing (See Figure 20) assembles, close inlet and ‘oulet valves on water sunply piping ta the packing case. Bleed all water pres- sure from the packing case by loosen- ing tubing connections tothe case. This rust be done before loosening or re- moving the packing case retaining bolt. 4, Remove ihe packing case retaining bolts with 2 9/8 hex bit socket 5, Remove the packing assembly rom the cylinder. On water-cooled assembles, the fst and lest packing cases are fited with O-rings on the outside ciameter. These O-ings can make it dificult to re. mave he packing case assembly. Apply Gentle, even pressure with two (2) screw. Grivers atthe tree and nine otlock posi tions on the packing flange (between the flange and the cylinder) to ain removal from the cylinder 6. Carefullycisassemblethe packing flange and the packing ring cases. On new design packing cases, twa (2) tie rods fare uted ta hold the cages together. Use 25/16" wrench to remove the te od nuts before attempting to separate he pack- ing ring cases. 7. Note the positoning of packing rings as ‘you disassemble the packing cases to {ensure reassembly in same order. Inspection and Repair 1, Thoroughly clean the packing cases before instaling the packing rings. Note that packing cases machined for ie rods ‘canonly be assembled in onectientation

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