Hycomp Air Boosters, Руководство по установке и эксплуатации

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49
COMPRESSOR DISASSEMBLY
WARNING: Before starting work on the compressor,
all pressure must be bled off from both the fi rst and
second stages, suction and discharge.
This is only a general outline of how to disassemble a
Hycomp compressor. Certain speci
fi cs may apply to
your compressor that are not listed here. Contact an
authorized distributor or the factory for assistance on
disassembling your compressor.
C Y L I N D E R H E A D A N D C O M P R E S S I O N
CYLINDER
1. Support the intercooler on two stage models in
such a way that it will not fall, causing it to twist at the
bottom support and possibly bending the tubes, or
damaging the cooling
fi ns. Often it is acceptable to tie
the intercooler to the crosshead cylinder.
2. Detach loadless starting and constant speed
unloader tubing (if supplied) from the compressor.
3. Remove the intercooler cap screws from the
underside of the intercooler flange on two stage
models. Remove the center and outboard head cap
screws from the cylinder head.
4. Remove the cylinder head assembly and head
gasket from the cylinder. The suction and discharge
valve assemblies will remain in the head. Remove the
intercooler gasket from the intercooler
fl ange. Throw
out both gaskets. Be sure the intercooler is securely
held.
5. Unbolt and remove the compression cylinder using
a suitable hoist and chain as necessary, being careful
that the cylinder is lifted vertically until it clears the
pistons, and that it does not cock and thereby damage
the pistons or rings.
6. ‘A’ - ‘E’ & ‘V’ Blocks: Using an adequate heat source
such as a torch, heat the piston rod just below the
compression piston to a temperature just below 400°F.
This will soften the Loctite so that the rod bolt can be
loosened without galling the threads or disturbing the
opposite end rod bolt integrity. Wear gloves so as not
to burn yourself on the piston or rod. Be careful not to
allow the rod to get so hot as to discolor it. A Tempil
stick or other temperature measuring device should
be used to get appropriate temperatures.
While the rod end is hot, use the special rod
clamping tool P/N SA003 to hold the rod while removing
the rod bolt. Remove the piston and store any shims
or thrust washers with the piston. Repeat this process
for the second piston. You may remove the piston rings
from the piston at this point.
‘F’ Block: Use the special rod clamping tool P/N SA003
to hold the piston rod while removing the upper piston
rod nut. Remove piston from the piston rod. Repeat
for the second piston. There are NO shims. You may
remove the piston rings from the piston at this point.
PLENUM CHAMBER
Air boosters and gas compressors incorporate a
‘Plenum’ chamber that sits below the compression
cylinder, and above the crosshead guide cylinder. The
plenum chamber can be removed with the piston rod
packing case still attached, by loosening the bolts that
hold the plenum to the crosshead cylinder, and sliding
the plenum chamber up the rods.
To remove the gas packing case, remove the four
screws per case, and push the case out the bottom
of the plenum. The case is sealed to the plenum with
an O-ring, and may resist removal. If this is the case,
jacking screw ports are provided in the bottom case
fl ange. Use the bolts that were removed from this
fl ange, to jack it out of the plenum case.
CROSSHEAD GUIDE CYLINDER
7. Remove the oil packing box gland (cover) from the
oil packing box. Remove the oil packings. Remove
the oil packing box from the crosshead guide cylinder.
Discard old O-rings.
8. Remove the crosshead guide cylinder cap screws.
Rotate the
fl ywheel so that one crosshead piston is
up and one is down. Lift the crosshead guide cylinder
from the crankcase. Do NOT allow the crosshead
pistons to fall against the side of the crankcase as this
will damage them.
CROSSHEAD PISTONS & CONNECTING RODS
9. Remove the crankcase inspection cover(s).
10. Remove the locknuts from the connecting rod bolts.
It is best to only loosen the locknuts a few turns on both
sides evenly, and to then loosen the connecting rod cap
by blocking the guide piston on top of the crankcase
and rotating the
fl ywheel to cause the crankshaft to
push against the connecting rod cap. This procedure
will keep the connecting rod cap from jamming on the
connecting rod bolts and being damaged.
11. Carefully lift the crosshead piston and connecting
rod assembly out of the crankcase. Keep the
connecting rod cap with the connecting rod/crosshead
assembly. Each cap and connecting rod is marked with
a dot or number on one side so they can be properly