53
F Blocks: Do not tighten oil packing box bolts.
PLENUM CHAMBER & GAS PACKING CASE
Air and gas boosters require the plenum chamber
installed on top of the crosshead guide.
Pre-assemble the gas packing case(s), ensuring
correct orientation of the gas packings (see diagram
that comes with new gas packings). Install a new
O-ring on the gas packing case, using a minimum of
compatible O-ring lubricant. Insert the case(s) into
the plenum chamber and tighten bolts to speci
fi
ed
torque.
Rotate the crankshaft so one piston rod is at top dead
center (the other will be at bottom dead center). Install
tool PN SA004 (packing install tool) onto the top of the
highest rod. Orient the plenum chamber so the dowel
pins align, and carefully lower the plenum down the
piston rods. Once the
fi
rst set of gas packings is past
the top of the rod, remove the install tool (SA004) and
place on the other rod. Finish lowering the plenum
down to the crosshead cylinder. Tighten bolts to
speci
fi
ed torque.
COMPRESSION CYLINDER AND PISTONS
12. Install compression cylinder over piston rods.
Lower onto crosshead guide cylinder, insuring proper
alignment with dowel pins. Torque cap screws to
proper tightness.
‘A’ - ‘E’ and ‘V’ Blocks:
a. Install pistons into cylinder and tighten piston
bolt or nut to 20 ft-lbs.
b. Measure piston to head (top of head gasket)
clearance at four points on each piston.
Determine necessary head clearance.
c. Remove pistons and place suf
fi
cient .010 inch
thick shims (P/N BA010-010-1) on top of the
piston rod to reduce minimum clearance to
proper amount.
d. Place expander rings onto piston with gaps
180° apart from each other. Place compression
rings over expander rings, with gaps 180° from
expander ring gap. No compression ring gaps
should be aligned. Install rider ring onto pistons.
Install piston into cylinder.
e. Place 4 drops of Loctite (Item # 266) near end of
thread of each of the two bolts. Being careful not
to contaminate Loctite, screw both bolts into rods
and tighten to speci
fi
ed torque. Use piston rod
tool P/N SA003 to keep piston rod from spinning
and loosening lower bolt.
f. Recheck piston to head clearance.
F Blocks:
a. Remove bolts holding oil packing box to
crosshead cylinder. Slide oil packing box up
the piston rods until the crosshead piston is
accessible.
b. Install pistons in cylinder onto piston rod, and
tighten piston nut to specified torque while
holding the piston rod with the P/N SA003 tool.
c. Measure piston to head (top of head gasket)
clearance at 4 points on each cylinder. Determine
proper clearance.
d. Adjust clearance by screwing piston rod into or
out of crosshead piston. Tighten lower piston
rod jam nut to full torque when piston clearance
is properly adjusted.
e. Double check cylinder head (top of head gasket)
to piston clearance. It may change when
tightening the jam nut. Readjust as necessary,
following steps c. and d.
f. Slide oil packing box down onto crosshead guide
cylinder and hand tighten bolts. Torque bolts to
proper tightness.
CYLINDER HEAD
If the valve assemblies must be removed from the
cylinder head, refer to the “Valve Replacement”
section.
13. Place a new head gasket on the compression
cylinder and intercooler. Use compatible gasket
sealant if acceptable. Lower cylinder head down onto
compression cylinder.
14. Center bolts that pass through air passages on
‘B’ - ‘E’ and ‘V’ blocks must have a copper bolt gasket
installed into the bolts.
15. Install center and outer head bolts as well as
intercooler bolts. Tighten head bolts to snug, starting
with center bolts, and working outward. When done,
retighten to one-half
fi
nal torque, and then to full torque.
Tighten intercooler bolts to
fi
nal torque.
16. Rotate the compressor by hand to be certain it
turns freely and the pistons are not hitting the cylinder
head.
17. Follow all procedures listed in the “Compressor
Start-up” section.